Jeep Wrangler TJ Manual

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Content

Lubrication and Maintenance
Suspension
Differential and Driveline
Brakes
Clutch
Cooling System
Battery
Starting Systems
Charging System
Ignition System
Instrument Panel Systems
Instrument Panel Systems
Audio Systems
Horn Systems
Speed Control System
Turn Signal and Hazard Warning Systems
Wiper and Washer Systems
Lamps














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Introduction






                






Introduction

Lamps
Passive Restraint Systems
Electrically Heated System
Power Distribution System
Vehicle Theft/Security Systems
Chime/Buzzer Warning Systems
Wiring Diagrams
Engine
Exhaust System and Intake Manifold
Frame and Bumpers
Frame and Bumpers
Fuel System
Fuel System
Steering
Transmission and Transfer Case
Tires and Wheels
Body
Heating and Air Conditioning
Emission Control Systems
Emission Control Systems

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INTRODUCTION
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GENERAL INFORMATION

VEHICLE
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POSITION

INTERPRETATION

CODE = DESCRIPTION

1

Country of Origin

1 = United States

2

Make

J = Jeep

3

Vehicle Type

4 = MPV

4

Gross Vehicle Weight Rating

E = 3001-4000 lbs.
F = 4001-5000 lbs.

5

Vehicle Line

Y = Wrangler 4X4

6

Series

1 = Sport
2 = SE
4 = Sahara

7

Body Style

9 = Open Body

8

Engine

P = 2.5L Unleaded-Gasoline
S = 4.0L Unleaded-Gasoline

9

Check Digit

10

Model Year

X = 1999

11

Assembly Plant

P = Toledo #2

12 thru 17

Vehicle Build Sequence



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Fig. 5 Thread Notation Chart – SAE and Metric

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9

INTRODUCTION
˜™›š œašžœŸ
page

page

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GENERAL INFORMATION

• ß>×1ÝÍ ß>×7Ï_Ñ_ê
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VEHICLE
ËjÌ@ÍaÎDÍPÌIDENTIFICATION
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POSITION

INTERPRETATION

CODE = DESCRIPTION

1

Country of Origin

1 = United States

2

Make

J = Jeep

3

Vehicle Type

4 = MPV

4

Gross Vehicle Weight Rating

E = 3001-4000 lbs.
F = 4001-5000 lbs.

5

Vehicle Line

Y = Wrangler 4X4

6

Series

1 = Sport
2 = SE
4 = Sahara

7

Body Style

9 = Open Body

8

Engine

P = 2.5L Gasoline
S = 4.0L Gasoline

9

Check Digit

10

Model Year

X = 1999

11

Assembly Plant

P = Toledo #2

12 thru 17

Vehicle Build Sequence

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Fig. 1 Vehicle Safety Certification Label—Typical

VEHICLE
SAFETY CERTIFICATION LABEL
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Fig. 2 Body Code Plate Location

BODY CODE PLATE
LOCATION
AND DECODING
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LQ?3=%VJSMb‘NžBS@bi=%hiDCGJLR=@[8¢AYTz=ME£J—8¤J—8¥J—8GJT3b"¦ GJP=%T3S@L~3EH=Mb
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Fig. 3 Body Code Plate Decoding

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GENERAL INFORMATION
CLASSIFICATION OF LUBRICANTS . . . . . . . . . . . 1
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INTERNATIONAL SYMBOLS . . . . . . . . . . . . . . . . 1
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9,000 Miles (14 000 km)
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36,000 Miles (58 000 km)
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39,000 Miles (62 000 km)
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51,000 Miles (82 000 km)
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54,000 Miles (86 000 km)
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57,000 Miles (91 000 km)
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60,000 Miles (96 000 km)
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63,000 Miles (101 000 km)
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66,000 Miles (106 000 km)
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69,000 Miles (110 000 km)
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72,000 Miles (115 000 km)
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75,000 Miles (120 000 km)
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78,000 Miles (125 000 km)
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81,000 Miles (134 000 km)
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84,000 Miles (134 000 km)
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87,000 Miles (139 000 km)
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90,000 Miles (144 000 km)
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93,000 Miles (149 000 km)
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96,000 Miles (154 000 km)
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99,000 Miles (158 000 km)
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102,000 Miles (163 000 km)
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105,000 Miles (168 000 km)
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111,000 Miles (178 000 km)
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117,000 Miles (187 000 km)
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JUMP STARTING, HOISTING AND TOWING
I2J6K6LNM
page

page

SERVICE PROCEDURES
EMERGENCY TOW HOOKS . . . . . . . . . . . . . . . . 10
HOISTING RECOMMENDATIONS . . . . . . . . . . . 10
JUMP STARTING PROCEDURE . . . . . . . . . . . . . . 8

RECREATIONAL TOWING . . . . . . . . . . . . . . . . . 10
TOWING RECOMMENDATIONS . . . . . . . . . . . . . . 9
VEHICLE TOWING . . . . . . . . . . . . . . . . . . . . . . . . 9

SERVICE PROCEDURES
JUMP STARTING PROCEDURE
WARNING: REVIEW ALL SAFETY PRECAUTIONS
AND WARNINGS IN GROUP 8A, BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS.
DO NOT JUMP START A FROZEN BATTERY, PERSONAL INJURY CAN RESULT.
DO NOT JUMP START WHEN BATTERY INDICATOR DOT IS YELLOW OR BRIGHT COLOR. BATTERY CAN EXPLODE.
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 ACCIDENTAL
ARCHING OF BATTERY CURRENT.
WHEN USING A HIGH OUTPUT BOOSTING
DEVICE, DO NOT ALLOW DISABLED VEHICLE’S
BATTERY TO EXCEED 16 VOLTS. PERSONAL
INJURY OR DAMAGE TO ELECTRICAL SYSTEM
CAN RESULT.

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”
CAUTION: Do not crank starter motor on disabled
vehicle for more than 15 seconds, starter will overheat and could fail.

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CAUTION: When using another vehicle as a
booster, do not allow vehicles to touch. Electrical
systems can be damaged on either vehicle.

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CAUTION: If the cause of starting problem on disabled vehicle is severe, damage to booster vehicle
charging system can result.

Fig. 1 Jumper Cable Clamp Connections

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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 (AUTOMATIC TRANSMISSION) OR A FORWARD DRIVE
GEAR (MANUAL TRANSMISSION).
DO NOT ATTACH SLING-TYPE TOWING EQUIPMENT TO THE REAR OF A TJ.

Fig. 3 Towing With Tow Dollies

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CAUTION: DO NOT use emergency tow hooks for
tow truck hook-up or highway towing.

HOISTING
í&îïAîðñ2ò’ñ/óRECOMMENDATIONS
î’ô~õö îð÷ øPù=úö ûúüLï ò
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Fig. 4 T-Hook Attachment

Fig. 6 Vehicle Lifting Locations
Fig. 5 Safety Chain Attachment

CAUTION: Do not attempt to lift a Jeep vehicle with
a floor jack positioned under:

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s†'v:Š‹#š1{‚T‹=z›‘=†'„ ŒTzš*€t€„ƒ!{…~

NOTE: When a frame-contact type hoist is used,
verify that the lifting pads are positioned properly.

zdzt‡„*tz-€ †g{†'v:tƒ!Š„*ƒ!ƒ
„€ t€ „x‹#v:t~
zdŽ1|z x{…v:tˆ~
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‹=ztƒ!„*€ tv=†'Š~
‘†'v:tƒ
Ž*z†`‰'v=ƒ!z~

NOTE: Use the correct sub-frame rail or frame rail
lifting locations only.
’T“” •%–
s—ŒTz „‰'xz-‰'v:t}:z-x„Ž1{z˜<„{™






ƒ!„#zdƒ
„xx~

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s{˜<„tš1‹=€ƒ
{›‘‰6v=ƒ!ƒ
„ƒ<€ „ƒ
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WARNING: THE HOISTING AND JACK LIFTING
POINTS PROVIDED ARE FOR A COMPLETE VEHICLE. WHEN A CHASSIS OR DRIVETRAIN COMPONENT 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.

R1S

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SUSPENSION
Ä-ÅRÆdÇ ÈgÆ,ÇgÉ

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ALIGNMENT
Ì*ÎàÐá

page

page

DESCRIPTION AND OPERATION
WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING
SUSPENSION AND STEERING SYSTEM . . . . . . . 3
SERVICE PROCEDURES
PRE-ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . 4

WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . 4
SPECIFICATIONS
ALIGNMENT SPECIFICATIONS . . . . . . . . . . . . . . 5

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DESCRIPTION AND OPERATION
WHEEL
ALIGNMENT
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CAUTION: Never attempt to modify suspension or
steering components by heating or bending.

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NOTE: Periodic lubrication of the front suspension/
steering system components may be required. Rubber bushings must never be lubricated. Refer to
Group 0, Lubrication And Maintenance for the recommended maintenance schedule.

a&b$a cVd[cVeGfZg[c9h i[g
lmnop&qsrt quwvyxvzl{uwrmpxt quwv}|~oG€G'‚€9ƒG„G…G†

Fig. 1 Wheel Alignment Measurements

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‡1ˆ

‰VŠH‰V‹9ŒZ[‰GŽ [

DIAGNOSIS AND TESTING
SUSPENSION AND STEERING SYSTEM
CONDITION
FRONT END NOISE

EXCESSIVE PLAY IN
STEERING

FRONT WHEELS SHIMMY

VEHICLE INSTABILITY

EXCESSIVE STEERING
EFFORT

VEHICLE PULLS TO ONE
SIDE

POSSIBLE CAUSES

CORRECTION

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.

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.

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.

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.

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.

1. Tire pressure.

1. Adjust tire pressure.

2. Alignment.

2. Align vehicle to specifications.

3. Loose or worn steering or
suspension components.

3. Tighten or replace components as
necessary.

4. Radial tire lead.

4. Rotate or replace tire as necessary.

5. Brake pull.

5. Repair brake as necessary.

6. Weak or broken spring.

6. Replace spring.

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132

SERVICE PROCEDURES
PRE-ALIGNMENT
“F”K•s–K—7”{˜Q™Lš—I™(›œ?Ÿž) ?”K”'¡¢š¡›£œ¥¤ ”Kœ?™L¦§™( ¥”¨•–'¡¡s–(ž)›œ?

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¾$›š £œ?–'˜Q›˜)¿F ?š —7™A•s–K—-š ¬O¬›™(›–Kœ¥š¡F›sœ¥•–K—7¤)š™L›–Kœ?¶
ÀIÁ´à œ?˜M©O”'ª7™A™(›—7”'˜)•–K—˜Q›ÄZ”wš œ?¬´™(—7”'š ¬Åž-”Kš — ¶
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WHEEL
“F”K•s–K—7”ÍALIGNMENT
”'š ª7 Õš ¡s›œ?¤ ”Kœ?™ —7”'š¬›sœ¥Ö™L ?”wËʔ' ?›ª7¡”͘M ?–K²?¡¬

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³ ²?¤ ©O”'— š ™4™L ?”ª7”'œ?™L”K—)š œ?¬×'–K²¥œ?ª7”™L ?”1ËʔK ¥›sªI¡s”²¥©š œ?¬
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š ¬L×'²¥˜Q™Lš ³¡”wš œ?¬´ª7šœ¥œ?–K™A³ ”wš ¡™(”'—7”K¬O¶
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 ~û 

 


NOTE: Changing caster angle will also change the
front propeller shaft angle. The propeller shaft
angle has priority over caster. Refer to Group 3, Differential and Driveline for additional information.

å¥ê4á¸ëêGä@ì åì ê4í
NOTE: The wheel toe position adjustment is the
final adjustment. This adjustment must be performed with the engine running, if the vehicle is
equipped with power steering.

Fig. 3 Drag Link and Tie Rod Clamp

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£¥¤¥¦l§_¨R©C¤«ª¥¦C¬•©C¤¥­C®•¦“¤¥£°¯©C±+²+³N´µ²+¶+·+¸+¹

˜'™Y˜'š/›-œ(˜+ ž(œ

Ÿ" ¢¡

46587:9<;>=-?@BACAEDFGHFJI6ALKMDFNFJG$AEONFPON@BQHA>QRONSTKMQHA>DUA>DFA>QHF
V@BON];`:W/F_XYXL? Va$SZbdc6A>egDfhFP@BGHONFJ@BFEQH[\AEQHFONS?S]A>@iQHGMAEDAEDF FGHQHFNjkI6DACAlKMKMDDFNFNFJFJGMGHW3QH@^mnON]@BA_QHA>AEQHOJDS F
A>DF"opGH]`:PrqONGHAE@]@@8DOEKMS46sQRjtW/V u87:]S;rA>QRjtDA>FJSAEO_vw
f<x `h4Rvy^IRAEW/GHq@BW 7W/zT{|}~N€ }‚ƒ }‚„}~N}‚‚… †n‡‰ˆn„}~
† „‚lŠƒ {† ‡}Tˆ€ … † ‡rŠ‹Œ{"Ž‰‚… ‡ƒ ‚}† … † ‡
4687:‘dF QHI ’A>DF QRjtDA“A>ONF@BPFJopQHI6QHop]A>QRONS@”]S;A>? V S‰ONI6I
A>DF•FJSjtQRSV FJW V
SPECIFICATIONS
ALIGNMENT SPECIFICATIONS
NOTE: Alignment specifications are in degrees.

Fig. 4 Steering Linkage

ADJUSTMENT

PREFERRED

RANGE

MAX RT/LT DIFFERENCE

CASTER



6 1.0°

0.65°

CAMBER
(fixed angle)

− 0.25°

6 0.63°

1.0°

TOE-IN
(each front wheel)

0.15°

6 0.07°

0.05°

THRUST ANGLE 0° 6 0.25°

Z[\

]_^`]_acbed`]gf h`d

i)j
FRONT SUSPENSION

ºR»+¼+½J¾
page

page

DESCRIPTION AND OPERATION
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . 6
DIAGNOSIS AND TESTING
SHOCK DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . 6
SERVICE PROCEDURES
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REMOVAL AND INSTALLATION
COIL SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FRONT AXLE BUSHING . . . . . . . . . . . . . . . . . . . . 8
HUB BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . 10
LOWER SUSPENSION ARM . . . . . . . . . . . . . . . . 8

SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . . 7
STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . . 9
STEERING KNUCKLE . . . . . . . . . . . . . . . . . . . . . 8
TRACK BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
UPPER SUSPENSION ARM . . . . . . . . . . . . . . . . . 8
WHEEL MOUNTING STUDS . . . . . . . . . . . . . . . . 11
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 11
SPECIAL TOOLS
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . 12

DESCRIPTION AND OPERATION

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of
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õ_ö‡õ_÷gøeù`õcú û`ù

üýžþ

SERVICE PROCEDURES
LUBRICATION
§

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REMOVAL AND INSTALLATION
SHOCK ABSORBER

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µ6á>·„Ùz¿Ê>½-Ã=Ì$Ìc½-¾¹&ÀÉ=ÉX¹(‚ÇLÂ!» ºº¹(½Ã=¿ƄÂ!¹ ½/Ã,Ä$¿¹ š» ¿V½-¾¹
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COIL SPRING

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µ6á>·„è9Ã=Â!ӎÃ,¿Æ¡ÆXÄ$Ê>Ë!»(¿¿#¹(Ë!½½-¾¹OÈ6Â!» ¿½ÉXÂ!» ÉX¹(Ì$Ì$¹ Ê>¾Ã=ÈK½
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µ6ß>·„êÄ$Ê>Ë!»(¿¿#¹(Ë!½9½/¾¹ÅÊ3½-Ã,Ñ=Ä$Ì$Ä$ëe¹(ÂOÑ,Ã,ÂOÌKÄ$¿ÓʖÃ,¿ÆxÊ3¾» Ë!Ó
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µ6ì>·„êÄ$Ê>Ë!»(¿¿#¹(Ë!½9½/¾#¹W½-Â!Ã=˕ÓÑ,Ã,ÂOÈ6Â!» ºí½/¾#¹WÈ6•Ã=º¹ÅÂ!Ã,ÄKÌ
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µ6ã>·„êÄ$Ê>Ë!»(¿¿#¹(Ë!½½-¾¹‹Æ=Â!Ã,Ç9Ì$Ä$¿ӄÈ6Â!» º¤½-¾¹ÉXÄ$½/ºÃ,¿OÃ=Â!ºÎ
µ6Û>·„zÐ5¹ €½-¾¹‚Ã3ґÌK¹‚À¿½-Ä$Ì ½-¾¹šÊ>ÉXÂ!Ä$¿ÇÄ$Ê)ÈKÂ!¹(¹‚È6Â!» º£½-¾¹
ÀÉXÉ=¹(‚º»(À¿#½€Ã=¿#ÆOÂ!¹ º»z¼‘¹0½-¾¹&Ê>ÉXÂ!Ä$¿ÇLÎ
NOTE: Left coil spring has a retainer and bolt
which must be removed from the axle pad.

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NOTE: Install retainer and bolt on the left spring
and tighten to 22 N·m (16 ft. lbs.).

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ÞÀßhà ádâãádäåeæãáÝç èãæ
ëìí‚îïmðñ›ðòóõôòö÷ãðññð÷
ôîòøùúûüýûþÿ
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STEERING
79465T62?A9MO462?)_5'`+Q1*2)N+-2?246C'OBaDO'*MOT6DO.02:,;'*A
] 548)N24^L=C0T62:KNUCKLE

b ,;..dce5?C0'*+-)&462?32?4`+-5gfh465?MO7jilkmC332?462'*+-C0,/.0)onS'OAjkh4PC Lqp
2?.0C0'*2>

LOWER SUSPENSION ARM

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+-1*2462?,;&4 Lower
Aƒ'OM*+83C0'*BW2?4:Arms
+-C0B„1O+Q2'*>
b 5?.0+8,;'*Suspension
!i$#&%('*)$+-,/.0. b 5?.0+Ž-TP,/F b 5.+J,;'*A'O2(Rˆ'OM*+J3C0'*B„24h+QC0BW1*+Q2'
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,;46D~)N>
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!"$#
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UPPER SUSPENSION ARM

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5(L=2K+-21*Cam
2K.05QRKBolt
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346,;F
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,;46F€! ] C0B„>’iN#>
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b 46,;T6DO2+8,;'*A&346,;F
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NOTE: Small holes in the side of the arm face
inboard.

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FRONT AXLE BUSHING

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NOTE: On 4x2 vehicle and right side of 4x4 vehicle,
leave Spacer 7932-3 in position for bushing installation.

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SPECIFICATIONS
TORQUE CHART

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SPECIAL TOOLS
FRONT SUSPENSION

Bolt, Special 7604

Remover/Installer Suspension Bushing 7932

Remover C-4150A

Nut, Long 7603

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Æ_ÇwÆRÈÉ(ÊwÆË ÌwÊ

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REAR SUSPENSION
 

page
DESCRIPTION AND OPERATION
REAR SUSPENSION . . . . . . . .
DIAGNOSIS AND TESTING
SHOCK DIAGNOSIS . . . . . . . . .
REMOVAL AND INSTALLATION
COIL SPRING . . . . . . . . . . . . . .
LOWER SUSPENSION ARM . . .

. . . . . . . . . . . . . 13
. . . . . . . . . . . . . 13
. . . . . . . . . . . . . 14
. . . . . . . . . . . . . 14

DESCRIPTION AND OPERATION
REAR
SUSPENSION
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page
SHOCK ABSORBER . . . . . .
STABILIZER BAR . . . . . . . .
TRACK BAR . . . . . . . . . . . .
UPPER SUSPENSION ARM
SPECIFICATIONS
TORQUE CHART . . . . . . . .

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14
15
16
15

. . . . . . . . . . . . . . . . 16

CAUTION: Suspension components with rubber/
urethane bushings (except stabilizer bar) should be
tightened with the vehicle at normal ride height. It is
important to have the springs supporting the weight
of the vehicle when the fasteners are torqued. This
will maintain vehicle ride comfort and prevent premature bushing wear.

DIAGNOSIS AND TESTING
SHOCK
–0—j˜™(šDIAGNOSIS
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"!$#&%('&) *'

REMOVAL AND INSTALLATION
SHOCK ABSORBER

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+-,

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Ø Ú2üÝï/çæ9ß àWæ9çßÞæ9ÜðÝê"Ý Dß åhðÜådê"Ý"àöjÞ rÞçä éöZÜ-ðÞä åð 

ß åÞAÜàákæ9åÜéö;ðÜ-å,æ@ähÞãß éYÝôÝß(ákæ@ä(å -âß ì
LOWER SUSPENSION ARM

ÑÒÓÔÕbÖ×
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Fig. 1 Shock Absorber

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Ø Ú2üÝï/çæ9ß à:æ@çßdê"ä@óAß å,àâæcæ9ä;Ù `ý„þ îiØ ÿôæ@ìKêðÞì ÚYì


Fig. 2 Upper & Lower Suspension Arms

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COIL SPRING

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Ú täaóAß(åcæ9çß,Üëbêß,âàæ@Ý"êIæ9çß,ÞãåÝ"àï2Ý"ބô7åß ß,ô7åä(îÀæ9çß
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÷7ø_ùtúxÖf×× ÖúF÷ Ôø
NOTE: Springs can be install with either end up.

ØYÙqÚ
tä ÞÝæ9Ý"ä à\æ9çß}éä Ý"êtÞãåÝ"àïAä à\æ9çß}Üë_ê"ß}ãÜádÝ"Þä ê"Üæ@ä(å*ì
Ø7íÚkۉÜÝ"Þ߸æ9çß~Üëbê"߸Ý"àæ9ä¸ãä(ÞÝ"æ9Ýä(à€âàæ9Ý"êdæ@ç߸Þã-åÝ"àï
Þß Üæ@ÞAä(àæ9çßhâãã-ß å,ÝÞä ê"Üæ9ä å*ì

Fig. 3 Upper & Lower Suspension Arms

YØ ÙqÚ
tä ÞÝ"æ9Ý"ä àWæ9çßê"ä@óAß åhÞâÞã-ß àÞÝ"ä àWÜåî Ý"àWæ@çßÜë_ê"ß
ðåÜéöß(æcÜàákô7åÜî2ßhåÜ-Ý"êîAä âàæ9ì
Ø7íÚkûaàÞæ9Ü-ê"êAæ9çßZî2ä(âàæ9Ý"àïOð-ä(ê"æ@Þ:Üàáƒô7Ý"àï/ß å%æ@Ý"ï/çæ@ß(à
æ9çßhàâæ9Þì

¤|¥

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±²´³[µ;¶l·¸¹·ºƒ»{¼Tºƒ½´¾·¸&¸&·¾R¼TµƒºÀ¿ÂÁÃ&Ä&Å(ÆmÄ&Ç&È&É&Ê
./0
132547698"2;:=<>2;?@BAA65CD:E?7FG>H
I69J72(CK:=<>2L8"2(<>MNI25O
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13254R6E8"2Š:=<>2p?:EFcMIMT™š2(CVcFCVC25:=FMG>25C[c6(I:E?œFG>H
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UPPER SUSPENSION ARM
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P0DO

Fig. 5 Stabilizer Bar Link

Fig. 4 Parking Brake Cable/Bracket And Wiring
Bracket
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Fig. 6 Stabilizer Bar
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FG>H
MTGB?:=FITI3:E<>2;C2(:EFMG>2(C?7FGBHˆc65I:=?O

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:=<>2K@>AA25CL?@>?A25G>?M65G
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G>@>:n:=6;\”

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NOTE: Ensure the bar is centered with equal spacing on both sides and is positioned above the differential housing (Fig. 6).
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]n^ 4 .P`‰aT:EO

Ic?O 0DO

STABILIZER BAR
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aCF4R24R65@>GB:E?O"‘9G>?:=FII—:=<>2c6(I:E?LFG>HG>@>:=?LaMG>S€2(Cn:EMSU<>:EO
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VWYX[Z]\^_`^acbedfacgYhL^_O_O^hidfZcakjmlnOoOpQq/oOrOsOtOu

TU
SPECIFICATIONS

TRACK BAR
Ë&ÌBÍ-Î&ÏjÐlÑ
ÒDÓmÔ
Õ3Ö×ØÙ;ÖÚ>Û
ØÜ>ÝÝÞ5ßànà=á>ÙLâ"Ù(á>×ãäÙ5å
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èßÖãêBÙ(ànÒë†×ì€åbíÔDå
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Õ3Ù5ç7Þ9â"كà=á>ٝèÞ(äTàLéTßÞ5ç„àEá>كÖï"äكèßÖãêsÙ5àLÒTë ×ì€åíÔ
ÖÚ>Û
ßÙ5çRÞEâ"Ù;à=á>Ù;àEßÖãêvèÖߛå

Fig. 7 Rear Track Bar
ðñ"ò†ó€ÐÑBÑ5ÐBóbð Î-ñ
ÒDÓmÔ
ô9Ú>Øà=Öääà=á>Ù[à=ßÖãêqèÖß
×Úà=á>Ù[ÖïjäTÙõèßÖãDêBÙ(àÖÚ>Û
×Ú>ØàEÖää&à=á>Ù;èÞ(äànäÞ5Þ5ØÙ5ä ö å
ÒæÔ
ô9Ú>Øà=Öäälà=á>ÙWàEßÖãê[èÖßX×ڜà=á>ÙWéßÖçRÙWßÖ×TäèßÖãêsÙ5à
ÖÚ>Û
äTÞ(Þ5ØÙ5ä ö[×Ú>Øà=Öää&àEáBكèÞ(äTà´ÖÚBۈÚ>ÜBàEå

NOTE: It may be necessary to pry the axle assembly over to install the track bar.
ÒîÔ
Õ3Ù5ç7Þ9â"Ù;ØÜ>ÝÝÞ(ßà=ØRÖÚ>Û
äÞ9÷KÙ5߁àEá>ÙLâjÙ5á>×ãäÙ5å
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Óüü–ýLþ ç„ÒTíøéà=åbäèØå ÔDå

TORQUE CHART

 
 


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DIFFERENTIAL AND DRIVELINE
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~ "ŽyO‚
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‘ ” % • ” ‡"†"†"‡"“–—%„ ˜Š–™ˆ"ˆ"ˆŠˆ"ˆ"ˆ"ˆ"ˆ"ˆ"ˆ"ˆ"ˆ"ˆŠˆ"ˆ"ˆ"ˆ"ˆ"ˆ"ˆ"ˆ"ˆD~

PROPELLER SHAFTS

ƒfšO›O‡ …
page
GENERAL INFORMATION
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . .
PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . .
PROPELLER SHAFT JOINT ANGLE . . . . . . . .
PROPELLER SHAFT JOINTS . . . . . . . . . . . . .
PROPELLER SHAFTS . . . . . . . . . . . . . . . . . .
DIAGNOSIS AND TESTING
RUNOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNBALANCE . . . . . . . . . . . . . . . . . . . . . . . . .
VIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE PROCEDURES
DRIVELINE ANGLE MEASUREMENT
PREPARATION . . . . . . . . . . . . . . . . . . . . . .
PROPELLER SHAFT ANGLE MEASUREMENT

.
.
.
.
.

.
.
.
.
.

.
.
.
.
.

2
3
2
1
1

... 5
... 4
... 3

... 6
... 6

GENERAL INFORMATION
PROPELLER
SHAFTS
œ"žŸf ¡¢ £C¤f¥Q¡¦
¥QŸG§©¨&ª>¥

¨&žQ«f«¬žQª®­¯§9Ÿf£‹¤f­°£C¥£Cª §¡­¯±i¤¬£
¨&¥³²´ž ª‰Ÿ;ª ¥ ±µ¥ ¡ž¶¨&¥ ¤¬¡£·£C¥¸§¡¥Q£³"ž ªº¹‹œž¸­¯§Ÿ;£·¤¬­
»&žQ­¼¤¬½A¡"ž »y£³¥¾­¯ž ¡»y£C¥ ª ¿ ž¾Ÿ;ª ¥Q±À£Cž¾£Cª §¡­¼±i¤¬­¯­¼¤¬¥ ¡§¡»
£Cª §¡­¼Ÿfž ª0¢>§9­¯ž]£³¥]£Cž]»&ª ¤ Á%ž]§¯Â%«¬žQ­iÃfĤ¬½A¹)Å/Æ>¹
œ"žÇ¨&ª ¥ ¨9ž «¬«¬ž ª`­¼"§9Ÿf£È±i ­¯£È¥ ¨9ž ª §£CžÇ£³"ª ¥  ½#É¢>¥ ¡Ê
­¯£³§¡£C« ËÈ¢ §¡½A¤¬¡½[ª žQ«¬§9£C¤ Á%ž‹§¡½#«fžQ­ÍÌž £Î²´žQž ¡Ï£Cž‹£³ª>§9¡"­¼Ê
±i¤¬­¼­¯¤¬¥ ¡G§¡»]§¼ÂЫ¬ž ¹ÐÑÒ£O±i ­¯£Ó§«¬­¼¥Ìž¢ §¨&§Ì«¬ž¥QŸ¢ §¡½#¤f¡"½
«¬ž ¡½#£³i²´¤¬«¬ž´£³ª §¡­¯±i¤¬£³£C¤¬¡½c£C¥Qª ¿9 "ž ¹9œ"ži§¯Â%«¬ž´ª ¤¬»&ž ­­¼ "­¼Ê
¨&žQ¡»&žQ»Ô̼Ë7­¼¨&ª>¤f¡"½A­¤¬¡Í§]Ÿ;«¬¥ §£C¤f¡"½|±i¥ £C¤¬¥ ¡¹Aœž0¨&ª ¥Q¨&ž «¬«¬ž ª
­¯§Ÿ;£±´ ­¼£ ̞ԧ̫fžc£C¥Ô¢ §¡½#žÔ¥ ¨9ž ª §£C¤f¡"½Í§¡½A«¬ž ­Y²´žQ¡
½A¥Q¤¬¡½e¥ÒÁ%žQªÕÁЧ9ª ¤¬¥Q ­¸ª ¥ §»Ö­¼ ª>Ÿ;§¢ ž ­¯¹×œ"¤f­¸¤¬­¸»&¥Q¡ž
£Cª ¥  "½A® ¡¤ Á%žQª ­¼§«&ØQ¥Q¤f¡"£³­¯Ù²0¤¬¢ ®¨&ž ª ±´¤f££³"žG¨&ª ¥Q¨&ž «¬«¬ž ª
­¯§Ÿ;£4£³¥¥Q¨&ž ª §£Cž§£4»&¤¬Ÿ;Ÿfž ª žQ¡£4§¡½A«¬ž ­¯¹6œž­¯«¬¤¬¨4ØÚ¥ ¤¬¡£C­Ãf¥ ª
Ë%¥Qۊž ­ºÆ¨&žQª ±i¤¬£¢ ¥ ¡"£³ª §¢ £C¤¬¥ ¡¾¥ ªžÒÂ%¨9§9¡"­¼¤¬¥ ¡¾Ã;Ä
¤¬½A¹YÅ/Æ>¹
œ€ "Ì9 «¬§ª0¨&ª>¥ ¨&žQ«¬«fžQª0­¼"§9Ÿf£³­´§ª žç«¬§9¡"¢ ž »D̯Ë[£³ž]±i§¡Ê
 Ÿf§9¢ £C ª žQª²0¤f£Cc²´ž ¤¬½#£³­´­¯¨&¥ £€²´ž «¬»&žQ»D£C¥]£Cž]£³ ÌžQ¹

page
REMOVAL AND INSTALLATION
FRONT PROPELLER SHAFT . . . . . . . . . . . . . . . . 8
REAR PROPELLER SHAFT . . . . . . . . . . . . . . . . . 8
DISASSEMBLY AND ASSEMBLY
DOUBLE CARDAN JOINT . . . . . . . . . . . . . . . . . 10
SINGLE CARDAN UNIVERSAL JOINT . . . . . . . . . 9
CLEANING AND INSPECTION
SINGLE AND DOUBLE CARDAN JOINT . . . . . . . 13
ADJUSTMENTS
AXLE PINION ANGLE ADJUSTMENT . . . . . . . . . 13
SPECIFICATIONS
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SPECIAL TOOLS
PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . 14

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Ë%¥QÛ"ž0«¬ ½#­¤¬¡7«¬¤¬¡ž²0¤f£CÍž §¢ Í¥ £CžQª4²´"¤f¢>7¤¬­¢ §«¬«¬ž »ÔÝڞ ª ¥
¨&§­¯¤¬¡½A¹Aœ¤¬­»9ž ­¯¤f½#¡Í¨9ª ¥ »& ¢>ž ­ £³"ž0­¯±i¥ ¥Q£³"ž ­¼£Óª  "¡¡¤¬¡½
¢ ¥ ¡"»&¤¬£³¤¬¥Q¡Ù§9¡Þ¥  £CÊ;¥QŸ;Ê;¨&"§9­¯ž®­¯§Ÿ;£Ü¢ §¡©¢ § ­¼ž×§“ÁФf̪ §Ê
£C¤f¥Q¡¹
ß)à&áCâã6àyäåæà9ã#çâè"é>êºåëè“ìLà&íêºçîïà&ðémíàyñã6âñ
à&îïî/à9ã
íò è"á³é)èåæ¾émíàÔóô õAâêºåé òò íâäîïæ¾öàÔçâ6ì€à&ã6à&æ¾âé)ñã6à&ô
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êºémêºâå`èåæÞæ
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ìLêºö%ã#è"é>êºâ"å÷
CAUTION: Use original equipment replacement
parts for attaching the propeller shafts. The specified torque must always be applied when tightening
the fasteners.

PROPELLER
œ"²0¥È»&¤¬ŸfŸ;ž ª žQ¡SHAFT
£¾£ÎË%¨&žQ­øJOINTS
¥QŸÍ¨9ª ¥ ¨&žQ«¬«fžQª°­¯§Ÿ;£ØQ¥

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  ­¯ž »Í¤¬¡]œùÜÁ%ž "¤f¢>«fžQ­0Ã;Ä
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Ìž]ª ž ¨&«¬§¢ ž »7§­´§Í¢ ¥Q±i¨&«¬ž £Cž]§9­¯­¼žQ±iÌ« Ë6¹

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“7”

Fig. 1 Propeller Shafts

Fig. 2 Single Cardan U-Joint

PROPELLER
 "!$#&%')SHAFT
(+*,-%/.0#1$JOINT
&2#43542)ANGLE
467(+8(9.0#1&1&#4:4#4;2<

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G@)&BA(D6H3567-)&(+)35BA<I-)&BA(+603567-)&(+1&#J)8#*K(+)3LJ)M
BA(+6N(+.0.04BA60(+2;A#4O(D?P?.04BA60(+2;A#4O#*Q-)E:4#4;A)2FG@);A%
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LUBRICATION
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Fig. 3 Double Cardan U-Joint

Fig. 4 Maximum Angles And Engine Speed

PRECAUTIONS
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CAUTION: Do not allow the propeller shaft to drop
or hang from any propeller shaft joint during
removal. Attach the propeller shaft to the vehicle
underside with wire to prevent damage to the joints.

Fig. 5 Reference Marks on Yokes

DIAGNOSIS AND TESTING
VIBRATION
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Drive Condition
Propeller Shaft Noise

Universal Joint Noise

Possible Cause

Correction

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 180°,
test, and evaluate.

10) Excessive drive pinion gear
shaft runout.

10) Re-index propeller shaft 180°
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.

1) Loose U-joint clamp screws.

1) Install new clamps and screws
and tighten to proper torque.

2) Lack of lubrication.

2) Lubricate U-joint and evaluate.
Replace as necessary.

UNBALANCE
NOTE: Removing and re-indexing the propeller
shaft 180° relative to the yoke may eliminate some
vibrations.
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Fig. 7 Two Clamp Screws At The Same Position
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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)

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.

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SERVICE PROCEDURES
DRIVELINE ANGLE MEASUREMENT
PREPARATION
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PROPELLER
SHAFT
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Fig. 9 Front (Output) Angle Measurement (A)

Fig. 10 Propeller Shaft Angle Measurement (C)

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Fig. 11 Rear (Input) Angle Measurement (B)

Fig. 12 Universal Joint Angle Example



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REMOVAL AND INSTALLATION
FRONT PROPELLER SHAFT
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Fig. 14 Reference Marks on Yokes

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Fig. 13 Front Propeller Shaft

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REAR PROPELLER SHAFT
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Fig. 15 Dust Boot Clamp




   
  



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Fig. 16 Rear Propeller Shaft

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Fig. 18 Remove Snap Ring

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Fig. 17 Crimping Dust Boot Clamp

DISASSEMBLY AND ASSEMBLY
SINGLE CARDAN UNIVERSAL JOINT
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Fig. 19 Press Out Bearing

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CAUTION: If the cross or bearing cap are not
straight during installation, the bearing cap will
score the walls of the yoke bore and damage can
occur.

Fig. 21 Install Cross In Yoke

Fig. 20 Press Out Remaining Bearing
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Fig. 22 Install Bearing On Trunnion

DOUBLE CARDAN JOINT
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 åWüã+ßõî\ðrö

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Fig. 23 Remove Snap Rings
ßøJáùtãWé‚éhêRãúåWî\ïRébî
ïªçUïªçUíZëgåAí1òíZãWóJó_åWí„ætî
óJã8û‚î\éhêªç
óJåWñZüãWéû‚êRåAópãýî\ïRópî\þãýþî\çUä8ãWéhãWíôî\ó.è\çgíZðrã°ãAïRåWÿRðrê

éhå

íZãAñZãWî æjãnéhêRãnëUãWçUíZî\ïRð)ñZçUò“òåWóJî\éPî\åAïRãWþ“ëUãWïvãWçUéPêìéhêRãnè\î\ïRü
 åAüãWö
ßJá‡è
çUñZã«ç

ópåAñZüãWé¢ûbî\éPê

çUï

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Fig. 25 Remove Bearing From Yoke
ßJáõ‡è
î\òuçUópóJãWä8ëUè 
çUïRþuíZãWògãWçUé8ùtéPãAòuø›ùtéPãAò›çUïRþ
ùtéPãAò
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çUïRþópògíZî\ïRð_ßõî\ðrö

÷
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íZåWä
éhêRãnåWÿvéPëUåWçUíZþ“óJî
þgãnåéhêRãnè\î\ïRü  åAüvãnãAïRåAÿRðxêìéhånðxíZçUópò
éhêRãëUãWçUíZî\ïRðwñZçUò_ûbî
éhêsæjî\ópã#úçJû‚ó1ßõ‡î\ðxö

÷ øJá…ö
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íZãAä8åMæjã+ðríZãWçUópã 
î
éhéhî
ïvðxó‚éhêRçUéî
ïvéPãAí ãWí…ã„ûbî\éPêíZãWä8åPæjçUè\ö

Fig. 26 Remove Centering Kit
ßJá‡íZãWóJóéhêRã‚íZãAä8çUî
ïvî
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ãWïvþ)åéhêRãè\î\ïRü
éhêRã+þî\ópçUóJópãWä‚ëgè  ö

Fig. 24 Press Out Bearing

 åAüvãçUó1þãWóJñZíZî\ëUãWþ|çgëUåMætãéPåñZåAä8òè\ãWéhã

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WYX*X[Z\^]Y_a`
bdcfehgjifkmlnnoqprts u&vCo#ifncfehoxwzyfl{w|wzyfoxlsRgRk{ifpo#ifw
pl{eh}Yn~iKwzyfo€sgji*}‚u
u

~{}*o‚l{ifƒ…„Yeh~{„Yo#ssRoqe†nyfl‡aw

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‰MŠR‹ŒŽ#q ’‘a“/”–• ‘—‘9#•M‘˜™˜›š{• ‘9‰œžq‹ ŸŽ¡ ¢*¡ £6¡¥¤a¡-£¦• §¨#‘IŠ
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”–·{‘|#• © #‘‘•9˜™·§ ° ”0 ©± ‘|‰´ ® «¸¡

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Fig. 29 Press In Bearing Cap
‰˛‹´Y ® x”a·{‘Í#• © #
 ‘‘•A˜™·{§ ° ” ©± ‘§ ¯ ¨
®"¯ ˜™”–§q ”–·{‘
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˜ ¯ §q• ®¯ «9‰´ ® «¸¡Èº̛‹M¡

Fig. 27 Install Cross In Yoke
‰º›‹Y"§µ ‘m§»²‘§• ® ¯ «¼µM§q
‘ •¾”a·{‘m”a•Mš ¯{¯{®©¯
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Fig. 30 Press In Bearing Cap
‰¹›‹´ ® ”­”–·{‘͏ ®¯{±  
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Fig. 28 Install Bearing Cap

W‚
”3•B–˜—™–˜–˜š˜›>œY=žŸ—™ X”Ÿ—™–˜–˜š˜›œ™=ž¢¡*£™¤¥¦ §¨¥©ª«¬

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Fig. 33 Install Remaining Cross

Fig. 31 Install Link Yoke

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Fig. 34 Press In Bearing Cap

CLEANING AND INSPECTION
SINGLE
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Fig. 35 Seat Snap Rings In Groove

Fig. 37 Adjustment Cam

SPECIFICATIONS
TORQUE

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SPECIAL TOOLS
PROPELLER SHAFT

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Fig. 36 Check Assembly

Inclinometer—7663

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181 FBI AXLE

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page
GENERAL INFORMATION
181 FBI AXLE . . . . . . . . . . . . . . . .
LUBRICANT SPECIFICATIONS . . .
DESCRIPTION AND OPERATION
STANDARD DIFFERENTIAL . . . . .
DIAGNOSIS AND TESTING
BEARING NOISE . . . . . . . . . . . . .
DRIVELINE SNAP . . . . . . . . . . . .
FRONT AXLES . . . . . . . . . . . . . . .
GEAR NOISE . . . . . . . . . . . . . . . .
GENERAL INFORMATION . . . . . .
LOW SPEED KNOCK . . . . . . . . . .
VIBRATION . . . . . . . . . . . . . . . . .
SERVICE PROCEDURES
LUBRICANT CHANGE . . . . . . . . .
REMOVAL AND INSTALLATION
AXLE BUSHING REPLACEMENT .
AXLE SHAFT OIL SEAL . . . . . . . .
AXLE SHAFT—CARDAN U-JOINT
COLLAPSIBLE SPACER . . . . . . . .
DIFFERENTIAL . . . . . . . . . . . . . .
DIFFERENTIAL SIDE BEARINGS .

. . . . . . . . . . . 15
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17
17
18
16
16
17
17

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27
31
21
23
27
30

GENERAL INFORMATION
181
FBI,/.0AXLE
')(+*,214365&798;:<*>=@?BADCE*>FHGJIK7-LM365&7-ND14:<LJOP=HQSRJ*UT65>79A

F/G"F/8VFW5>XP=YT6=ZF/8G"35&7[C@GJXDXD*>36*&798VGJ=ZR\(95&]9F/GJ79I_^BGJ8`(a=/QbRJ*
F/(9=ZXD8c8V]9dZ*&Fe*MQb8V*>79CEGJ79IfXD35&?a*&GJ8V(9*&3 F/GJCE*&gK'c(9*h8V]9dZ*&F=Z36*
i 36*>FHF/*&CPGJ798V5j8V(9*
CEGJXDX"*&36*>798VG"=ZR(+5&]9F/GJ79I\=Z79Ck^B*>RJCE*&C@g
')(+*lGJ798`*>IK36=ZRm8on i *l(95>]9FHGJ79Iqp<(&n i 5>G"CrIq*&=Z3BCE*>FHGJIK7s(9=ZF
8V(9*\T6*>798`*>36RJGJ79*\5&X8V(9* i GJ79GJ5&7UFH*>8dZ*&RJ5`^t8`(+*\T6*&798V*>36R"GJ79*
5&Xm8V(9*
36GJ79I;IK*&=Z3g
')(+*u=/QbRJ*v(9=ZFw=YXDGJ8V8`GJ79IxXD5>3y=wzb*>798(95>FH*v]9FH*>C{8V5
36*>R"GJ*`zb*PG"7+8`*>3679=ZR i 36*&F/FH]+36*|T6=Z]9F/*&C}dHnWRJ]9dZ36GJT6=Z798~zb= i 5&3A
GJ€=Z8`GJ5>7=Z79CPGJ798`*>3679=ZR*`Q i =Z79F/G"5>79g
')(+*x=HQSRJ*&Fv=Z36*x*&Z]9G iEi *&Cu^BGJ8V(‚F/*&?kGJƒZXDRJ5&=Z8VGJ79I„=HQSRJ*
F/(9=ZXD8`F/p…?k*>=@7+G"7+I;8V(9=Z8RJ5&=ZCEFh=Z36*fFH] i@i 5&368V*&C†d/ns8V(9*f(9]9d
dZ*&=Z36GJ79IKF/g@'c(9*k=/QbRJ*BFH(9=ZX"8`F‡=Z36*k36*>8`=ZGJ79*>C\d/n27+]98`F‡=Z8)8`(9*
(9]9d-dZ*&=Z36GJ79IqFHg'c(9*W(9]+dxdZ*>=@36GJ79IqF_=Z36*wd@5>RJ8`*>Cˆ8V5W8V(9*
F/8`*>*&36GJ79Ik‰+7+]9T6‰ŠR"*=Z8m8`(+*h5>]98`dZ5>=@3Cl*&7+Cl5>X‹8V(9*=HQSRJ*h8V]9dZ*
nb5>‰Š*&g+'c(9*
(9]9d†dZ*>=@36GJ79IqFB=@3*jF/*&3ŒzSGJT6*&CP=@FB=Z72=ZFHF/*&?kdZR nqg
15>3yzS*&(9GJT6RJ*&Fw^hGJ8`(YŽe:<dZ36=Z‰Š*&F/p28V(9*yŽe:<‘^h(9*&*>R
F i *&*>CYF/*&79F/5&36F_=Z36*’=Z8V8`=ZT6(9*>CY8V5’8V(9*W‰+7+]9T6‰ŠR"*W=ZFHF/*&?kA
dZRJG"*>FHgE'c(9*f8V5&7+*f36GJ79IKFXD5>3‡8`(+*mŽe:<F“nbF/8`*>?”=@3* i 36*>FHF/*&C
5&7+8`5ˆ8V(9*ˆ=/QSR"*ˆF/(9=ZXD8Vg†•–‚—…–9˜w™š9›\š9œ+WžŸ~ ˜–9—…
¡P¢ E@£–+¤f˜ ¢ ;¥>E—…¥&–+¤ ¡P¢ E—}¤¦E›\–¦§©¨“—…œPš¦ª©£Œ;¥ ¢ š9«V˜¥>¬

page
DRIVE AXLE ASSEMBLY . . . . . . . . . . . . .
HUB BEARING AND AXLE SHAFT . . . . . .
PINION GEAR . . . . . . . . . . . . . . . . . . . . .
PINION SHAFT SEAL . . . . . . . . . . . . . . . .
RING GEAR . . . . . . . . . . . . . . . . . . . . . . .
STEERING KNUCKLE AND BALL STUDS .
DISASSEMBLY AND ASSEMBLY
FINAL ASSEMBLY . . . . . . . . . . . . . . . . . .
STANDARD DIFFERENTIAL . . . . . . . . . .
CLEANING AND INSPECTION
AXLE COMPONENTS . . . . . . . . . . . . . . . .
CARDAN U-JOINT . . . . . . . . . . . . . . . . . .
ADJUSTMENTS
DIFFERENTIAL BEARING PRELOAD AND
GEAR BACKLASH . . . . . . . . . . . . . . . . .
GEAR CONTACT PATTERN ANALYSIS . . .
PINION GEAR DEPTH . . . . . . . . . . . . . . .
SPECIFICATIONS
181 FBI AXLE . . . . . . . . . . . . . . . . . . . . . .
181 FBI AXLE . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS
181 FBI AXLE . . . . . . . . . . . . . . . . . . . . . .

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20
25
32
22
31
27

. . . . . 36
. . . . . 36
. . . . . 37
. . . . . 37

. . . . . 38
. . . . . 43
. . . . . 37
. . . . . 45
. . . . . 45
. . . . . 45

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GJ79F i *&T68VGJ5&72=Z79C|F/*&3ŒzSGJT6G"7+I\8V(9*
CEGJXDX"*&36*>798VG"=ZRJg
')(+*w,H.0,\1:<L
=/QbRJ*r(9=ZF†8V(9*r=ZFHF/*&?kdZR n i =Z368f7+]9?kdZ*&3
=Z79C\IK*>=@336=Z8`GJ5kRJGJFH8V*&C\5>7|=;8V=@IqgE'c(9*k8`=ZIjGJF=Z8`8V=ZT6(9*>C†8V5
8V(9*l(95>]9FHGJ79I†T5Mzb*>3BdHnU=PT65MzS*&3BdZ5&RJ8Vg<:<]9GJRJCrCE=Z8V*lGJCE*&7+8`GJA
XDGJT6=Z8VG"5>7WT65&CE*>F†=Z36*rFH8V=Z? i *&C_5>7W8`(9*rT5Mzb*>3\F/GJCE*r5&X‡8V(9*
=/QbRJ*
FH(9=ZX"8 8`]9dZ*>g
')(+*CEGJXDXD*>36*&798VGJ=ZRT6=ZFH*GJFe=f5&79*>ƒ i G"*>T6*CE*>FHGJIK79gq')(+*CEGJXDA
XD*>36*&798VGJ=ZR i GJ79GJ5>7Y?k=@8V*yF/(9=ZXD8PGJF}36*>8`=ZGJ79*>CU^BGJ8`(Y=v365&RJR
i GJ79g…¯~GJXDX"*&36*>798`GJ=ZR<d@*>=@3G"7+I i 36*&RJ5>=@CP=Z79CP3G"7+I;IK*&=Z3dZ=ZT6‰+A
RJ=ZFH(xGJFs=ZCV°]9F/8`*>Cud/nY8V(9*U]9FH*U5>X
F/(9GJ?kFNDF/*&RJ*&T68;8`(9GJT6‰ŠA
79*>FHF“OgE'c(9*kFH(+G"?BF=@36*kRJ5>T6=@8V*&C\dZ*&8±^B*>*&7|8V(9*kCEGJXDXD*>36*&798VGJ=ZR
dZ*&=Z36GJ79I
T65&79*>F=Z79C;T6=ZFH*>g4²GJ79GJ5>7|dZ*&=Z36GJ79I i 36*&RJ5>=@C;GJF‡FH*&8
=Z79CP?k=@GJ798V=ZGJ79*&CPd/ns8`(9*
]9F/*
5&Xm=†T65>R"RJ= i F/GJd@RJ*
F i =ZT6*&3g
LUBRICANT
³x´kµ9¶J·V¸J¹@º@µ9»6SPECIFICATIONS
ºE¼>½H¾&¿…À¦Ábº@¼&¸JÂPÃK¾>Ä@»¶Jµ9ÅZ»6¸JÆ6ÄZÇ9·©ÈBÀ9¸JÆ6À2Æ6¼>Ç9É

Ê ¼>»6´k½j·V¼\·VÀ9¾ Ê ¼&¶J¶J¼MÈh¸"Ç+Ã|½Hº@¾&Æ6¸ Ê ¸JÆ6ÄZ·V¸"¼>Ç9½j½/À9¼>µ9¶JÂÅ@¾;µ9½/¾&ÂEË
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ÃK¾>•ÄZ»h¶Jµ9ÅZ»6¸JÆ6ÄZÇ9·`Ë

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CAUTION: If axle is submerged in water, lubricant
must be replaced immediately to avoid possible
premature axle failure.

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DESCRIPTION AND OPERATION
STANDARD DIFFERENTIAL

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Fig. 2 Differential Operation—On Turns

DIAGNOSIS AND TESTING
GENERAL
INFORMATION
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• w jGo=m\h=h=e;oYq_fgo=‚ƒdFgr„Gy
• w
b cdFe[ke\gh_lh=m;fdFe;no=m\jGpSiFqDiVm\jGrgh=e[sGrsGgdFd tuq„GeQh=e;rsGdFq
m;xVv
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w
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• w
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w‚h`dje^`bTz† †d^Zvh`‰™acbed¨acvh`¬gted¨h`dE]‰ikjelsMvhyikjenƒa{]guk²
uk]ga{ikvEj‘h`dEsMdh`dEje^`dEz
XM´ƒ[
µnƒikjel ¶Wvuk‰dEh·›g¸gšg´®acv±bevuk‰¡acbed±mijTivEj}v_dE‡
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XM¸ƒ[
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h`dE<v€”d1acbed1mikjeikvj6}vE_Td1X˜iklRz¦›„[@z

Fig. 7 Pinion Seal Installation

MX ‹ƒ[
Œ€jenƒac]uku }xv_d™vjŽacbed™mikjeikvEj•l’d]gh+wyika{bŽŒ€jenƒac]ukukdh
»‘²ZYƒ›‹gˆgÀÁ‡U—†tTm~´¿Yƒ½g¸‡¦]jT‰~¶WvEu‰dh+›¸gšg´XM˜PiklRzU´ƒ[Zz

Fig. 8 Pinion Yoke Installation
CAUTION: Do not exceed the minimum tightening
torque when installing the pinion yoke retaining nut
at this point. Damage to collapsible spacer or bearings may result.

Fig. 6 Pinion Yoke Removal

ZX Yƒ½ƒ[
µnƒd•] nƒteikac]fgukd•mh}¾a{vEvu¨vh«]£nƒuik‰dŽbe]g<<dh
<vEtejeacd‰
n„^`h`d{wºa{v1h`dE<v€”d1acbed1mikjeikvjŠn„dE]guz

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Œ€jenƒac]ukuacbed+mijTivEj‚wy]gn„bedEh]gje‰6]Âjed€w¡jetea vj%acbed
mikjeikvEjÃlRdE]ghrzoÄ-ÅrÆTǦÈZÉÊËÈZÇÉÌÊ¦Í¦È ÎeÊ¦Ï Ð>ÉʦÎeͦÆTÇÑÈ@Î
Ò ÉÓ%ÎÕÔÉ
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n„bT]sa'tenƒijTl1]¨XMikjez¿ukfnƒz [a{vEh`¬gted
wyh`dEje^`bezP †vEa{]gacikjel6acvEh`¬tTd<nƒbevtTu‰ofgd<dE¬gte]u¦a{vya{bTd<h`dE]g‰²
ikjeloh`dE^`vh`‰d‰
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COLLAPSIBLE SPACER

Fig. 9 Check Pinion Rotation Torque
CAUTION: If the maximum tightening torque is
reached prior to reaching the required rotating
torque, the collapsible spacer may have been damaged. Replace the collapsible spacer.

Fig. 10 Tightening Pinion Shaft Nut—Typical
 
  !"#$% #$"&$('
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, #$! , -#./* %-(0213!)*405  6 , #$! , ""#
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Fig. 11 Pinion Yoke Removal

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ç Ù$ØÖ×:èé“ê;Ù$Ðå*ÓÒ/éUæ Ø"Ù^×VÙ$Ø×VÓ"Ù^×VÙ$Ø"ÝDÓ"ÕVÖÙDÓ"Ò/ß
Ì ë Î:ìPÐ Ù$å4ÚÛÓ× Ù$Ø"×VÓÞÞ-ÓÙ:Ò/ÛÐæ-ÚPÐÔÕ‘× Ñ-Ô*Ñ-ØÔGí3Øå*Ó(æ Ø"Ù
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Fig. 13 Collapsible Preload Spacer

Fig. 14 Pinion Seal Installation
Ì è Î LÔÒ ÚÐ ÞÞí3Ø"åNÓMâ]ÑÚÛ
LÔÒ ÚÐÞÞÓ"Ù¡ýò¶Í/îàò=éUû;Ö×FóÿÍ ú öé
ÐÔÕ:ÛØ"ÞÕVÓÙYîöèóFÌmÑ-ï>ß¨Í è ÎDß
Ì î
Î Læ¨ÚÛÓOØ"Ù$ÑïÑÔÐÞ× ÑÔÑØ"Ô{ã ÓÐÙ$ÑÔïҌÐÙ$ÓOãÓ"ÑÔï+ÖÒ Ó"ÕVé
ÑÔÒ/ÚÐÞÞUÕ Ñæ æ ÓÙ$Ó"ÔÚÑРގÐÒ/Ò Ó"á
ãÞ í+ÐÔÕPÐ õgÞ-Ó^Ò/ÛÐæ ÚÒ éÿÑæ“Ô*Ó"Ý$ÓÒ/ò
Ò/ÐÙ|í ß
Fig. 12 Remove Pinion Gear
É ÊĒÅ*Å"Ä“É ÂdÊ
ÌDÍr
Î LÔÒ ÚÐ ÞޓÐPÔÓâÝ$ØÞ-ÞÐ×VÒ Ñ-ãÞÓ]×VÙ$Ó"ÞØÐ Õ6Ò/× Ð Ý$ÓÙdØÔ+×VÑÔò
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Ì ä
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Ì ë
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ÐÔÕ:øÐÔÕ Þ-ÓZû;ò-ëmÍ ðÿÍ]Ì mÑïß¨Í ë ÎDéUÑ-æ¡ÔÓÝ$Ó"Ò Ò/ÐÙ|í ß

NOTE: If new pinion bearings were installed, do not
install the differential assembly and axle shafts until
after the pinion bearing preload and rotating torque
are set.
Ì ð
Î LÔÒ ÚÐ ÞގÚÛÓ^× Ñ-Ô*Ñ-ØÔYâ]ÐÒ/ÛÓÙMÐÔՌÐBÔÓLâuÔÖÚØ"ÔOÚÛ*Ó
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• ·
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Fig. 15 Pinion Yoke Installation
CAUTION: Never loosen pinion gear nut to
decrease pinion gear bearing rotating torque and
never exceed specified preload torque. If preload
torque is exceeded, a new collapsible spacer must
be installed. The torque sequence will then have to
be repeated.
ijlk mnlo6pq rsct7uwvscxy*u$z {}|}~}j€}py€€‚s$z&ƒ*„u…†z‡ucpˆ‡v
nlu$K}K‰}~}‰.Š‹ ŒiŽ}{*‚‘x6’}n“‘ k&”=ˆ‡z‡„n“v
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i|lk žxs˜…†x rŸ‚o6q v‚u$p¡˜vuwp„Oo6p¢{}‘ j€ŠB‹ Œ£i~¤‚‘Bx’}nl‘ k
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Fig. 17 Check Pinion Gear Rotation Torque—Typical

u$}n“„z&u–˜vu–z‡s$‚}˜o6pqT˜scz‡ƒ}„u–z‡ucƒ}„u$p‚x rw‚s–l©s$o6y s˜©ucz
«

i&œ$œdk ¼ªpn“‚}xxAy*ou$z&u$p‚o6*xA}n“nlu$Œ†’*x r }py–l½x6u¾nlv}‚n“”o6

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pucˆ‡u$nln“}zµr‘
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•z‡sc•u$x6x6ucz°n“v*B}py—o6pnl‚*x6xY•*z‡s$•ucx6x6u$z°nlv}‚‘
i&œl‰lk ¼ªpnl˜}x6xM’*z‡}t7u§z‡sc˜scz‡n¥}py²ˆ‡}x6o6•ucz‡n“‘
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Â

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Å „’*z&oˆ‡}p°ž•ucˆ‡oo6ˆ‡*‚o6s$pnsc‚vo6nnlu$ˆ‡‚o6s$p¤s$zOx„’*z&oˆ‡}p
z‡u$ƒ}„o6z‡ucŒ u$p‚nl‘
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i&œl{lk
Å

s˜…†u$zZ©ucvo6ˆ‡x6u$‘

HUB
BEARING AND AXLE SHAFT
¼ªŸ‚vuÆl½žxuÀn“v}Ç}pyVv„’È’}u$}z‡o6pqÉ}z‡uÀ’*uco6pq
z‡ucŒ sª©ucy¦o6p€s$z‡y*u$zT‚s nlu$zµ©žoˆ‡u }ps$‚vu$zTˆ&s$Œ •scpu$p˜”Z‚vu
l½x6uÊnlv}.}py¢v„’¡’}u$}z‡o6pqˈ&*p´’}uÊz‡ucŒ sª©žu$y¢}nw}p
}n“nlu$Œ ’}x r›‘
ÌYÍÎÏYОÑÒ
i&œdk Á®}o6n“uO}py n“„••*s$z‡B‚vu©ucvo6ˆ‡x6u$‘
iŽlk Á®u$Œ s˜©uO‚vu…†vucu$xY}py ‚oz&uT}nln“ucŒ ’*x r‘
i‰lk Á®u$Œ s˜©uM˜vu¦’}z‡}tuMˆ‡}xo6•ucz—}py¡z‡sc˜scz(‘Á®u$u$z—‚s
z‡sc„• ~*”¸®z‡}tucn“”!s$zI•z‡s$•*u$zI•z‡s$ˆ&u$y„z&u$n“‘
Â

iÃlk Á®u$Œ s˜©u¿¸®™…†vucu$xBnl•ucu$y¦n“ucpn“scz(”o6pucˆ‡u$nln“}zµr‘

Fig. 16 Tightening Pinion Nut

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˜vu™ˆ‡sc˜‚u$z•o6p”Kp„–z‡u$‚}o6pu$zd”K*py¤l½x6u
v„’.p„Bišo6q ‘Kœljlk&”!o6@pucˆ‡u$nln“}zµr‘

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Fig. 18 Hub, Knuckle and Axle Shaft

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Fig. 21 Steering Knuckle Removal/Installation

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Fig. 22 Upper Ball Stud Remove/Install

Fig. 23 Lower Ball Stud Remove/Install

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¦ÀŒ» ˆŠV•â£¥—»
…‡†Ýˆ½¿‘¥Œ˜¦¦/´¥—´¥£¥ÀÀ—V˜–•Ž‘¥¨ÆŒ³˜–‘µ™¯˜Þ0¦—Œ´¥˜«
Œ»

CAUTION: Do not spread over 0.50 mm (0.020 in). If
the housing is over-spread, it could be distorted or
damaged.

ï7ð9ñ%ò

‡kˆ{‡+‰

Šp‹-ŒYŒ++Žpp‘I‹ ’”“k’ajŠxŠpŽp‹ •”+“Y‹ j

–—

˜™›š…œ)žŸxž ~¡£¢. ~¤›¥pžŸŸžf¥h¢.œ~ §¦¨©ª«¬ ª­®¯°

Fig. 28 Differential Case Removal

Fig. 30 Differential Bearing Cap Reference Letters

Fig. 29 Install Axle Housing Spreader

DIFFERENTIAL SIDE BEARINGS

  "!$#&%')(+*-,.,/"012435*.6879168:;),/01#"!<6;='7-)>4#"?4:;*-24@BA
/C; "!$#&%')35>4)D8"6801*-24@E:$,/01#"!<35>4)(+*-,/,."01243F*-6879168:;
*
HI?47-7-"0/J5HK01":;:ML N/C8O8P8N/HQSRTL N/C8O8P8N/P8OUQS(+68V+35"0
G 35>
7
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1
9
Y
X
;
:
Z
R
6824([HK7-?4@]\'HKN/P8C8^8O_/`K*.@EAZPa A
W
b/c'dKeBf"eZb c
g ,01V+7-6891"!h243h(i*-,/,/01"2435*-6i7j:;*-(+[D8"6801*-24@E:k#"0l(i*.,.,/0N
"23F*-687 9168:;m6i01mD8*.2@l*.2:n35687.7-(+Ro(i*.,.,/"012435*-6i7p:n*-(+mD86i0N
*-24@q:;>4*-!r01s8?4*-01"!h243F:t!$6nuv91>6i2@B"Ak ",."0w3F#x35>4
y *-,/,."012435*.687 W "6801*-24@lHI017-#"68(6824(_z{"680 W 6891XY7-68:n>|Vi01#"N
91(+?401:$*.2|35>4*-:$:n9135*.#2|3F#)(i"35"01!h*-24)35>4)V+01#V+0}:;>4*-!
:;"7-"9135*-#"24A

Fig. 31 Differential Bearing Removal

   g 24:;356i7-7(+*-,/,."01243F*-687:n*-(+)D8"6801*-24@k:;>4*-!h:$#"2435#~(i*.,.N

,/01"2435*-6879168:n)>4?4D8:;A
/C;S:;*-24@ g 24:;3F687-7-"0L N/P8€a;iN Q‚6824(„ƒ6i2(+7-…L N/†a;€anR
*-24:n35687-7(+*-,/,."01243F*-687:;*-(+)Di6801*.2@B:$/`K*-@BAZP8C;A
/P; g 24:;356i7-7(i*.,.,/"0"2435*-6i7 *.2|6;='7-)>4#"?:n*-24@BA


!#"%$'&)(*#+*#,.-0/
,.1%2*#++*324/
&.,6587#9:;=<>:?@AB



  
    

Fig. 32 Differential Side Bearing Installation

Fig. 33 Axle Seal Installation



AXLE SHAFT OIL SEAL
±²³´µ¶·
¸¹ º» 8
¼ ½-¾n¿)¼8À4Á¾nÂ4ÃiÃ+Ä"Å1ÆpÇ¿"È4½-É1Ê-¿"Ë
¸/Ì;º» "
¿ Í$Ä&Ç'¿)Á+½-Î.Î/¿"Å1¿À4Æ5½.¼8ʼ8¾;¾n¿ÍhÏiÊ ÐÑË
¸/Ò;º» "
¿ Í$Ä&Ç'¿[ÆFÈ¿Ó½-À4À4¿Å]¼nÔÊ-¿Ó¾;È4¼8Î/Æh¾n¿"¼8Ê-¾}Õ$½-ÆFÈÖ¼×ÃiÅØÐ
Ï8¼;ÐEË
Ù/Ú'ÛKÜB¶f··"¶ÜZÙ ´Ú
¸¹ º» ¿"Í$Ä&Ç'¿Ý¼8ÀÑÐÞ¾n¿¼8Ê.¿ÅßÅ¿"Íh¼8½-À4½-À4àáÎ/Å1Ä"ÍUÄ"Ž.àE½.À¼iÊ
¾;¿"¼8Ê-¾nË
¸/Ì;º» ¿"Í$Ä&Ç'¿~¾n¿¼iÊ-¿Å$Î/Å1Ä"Ív¼;Ô'Ê-¿~ÆFÂ4Ï8¿~ÆFÄ~È4Ä"Â4¾;½-À4à{âÂ4À4É1ã
Æ5½-Ä"À4äZ½-ΔÀ4¿É1¿"¾;¾n¼8ÅØÐÑË
¸/Ò;ºå&À4¾;Æ5¼iÊ-ÊÓÄ"½-ÊÓ¾n¿¼8Ê.¾æÕ$½-Æ5Ȃç{½-¾nɾéèa¹"¹;êݼiÀÁìëZÂ4Å1Àã
Ï8Â4É1íYÊ-¿hî8ï8ðiïl¸/ñK½-àBËKÒ8ÒnºËi딽-àBÈÆF¿À[Æ5Ä"Ä"ÊZÂ4ÀÆF½-ÊZÁ+½-¾nÉÏ8ÄÆFÆ5Ä"Íh¾
½-ÀòÈÄ"Â4¾;½-À4àBË
¸/ó;ºå&À4¾;Æ5¼iÊ-ÊÁi½.Î.Î/¿"Å¿"À4Æ5½-¼iÊ ¼i¾;¾n¿ÍhÏ8Ê ÐÑË

Fig. 34 Ring Gear Removal

Ù/Ú'ÛKÜB¶f··"¶ÜZÙ ´Ú

RING
GEAR
ëÈ¿}Ž.Ààm¼8À4Á~Ã+½-À4½-Ä"ÀkàB¿¼8Å1¾S¼iÅ1¿¾;¿"ÅØǽ.É1¿½-Àk¼)Íh¼8ÆFÉ1È¿"Á
¾;¿"Æ5˛ç{Ä|ÀÄ"ÆmÅ1¿"ÃiÊ.¼8É1¿ÓÆFÈ¿|Å1½-À4à…àB¿"¼8Å}Õ}½.Æ5È4ÄÂ4ÆmÅ1¿"Ã+Ê-¼8É1½-À4à
Æ5È4¿)Ã+½-À4½-Ä"À|àB¿¼iÅ Ë

CAUTION: Do not reuse the bolts that held the ring
gear to the differential case. The bolts can fracture
causing extensive damage.

±²³´µ¶·

¸¹ ºå&ÀÑÇ¿"Å1Æ}Æ5È4¿_Á+½-Î/Î.¿"Å1¿À4ÆF½-¼8ʛÉ1¼8¾;¿¼8À4Á…¾;ÆF¼8Å1Æ}ÆúÕ$Ä_Å1½-À4à
àB¿¼8ÅæÏ8ÄÊ.Æ5¾;˛ëfÈ4½-¾_Õ}½.Ê-Ê)Ã+Å1ÄFÇ'½-Á+¿ÖÉ1¼8¾;¿"ã/Æ5Äã/Å1½-À4àöàB¿¼8ŅÏiÄÊ-Æ
È4ÄÊ.¿)¼8Ê-½-àBÀ4Íh¿À4Æ5Ë
¸/Ì;ºå&ÀÑÇ¿"Å1ÆjÆ5È4¿)Á+½-Î/Î.¿"Å1¿À4ÆF½-¼8ÊÉ1¼8¾;¿~½-À|ÆFÈ¿SÇ'½-¾n¿Ë
¸/Ò;ºå&À4¾;Æ5¼iÊ-ÊæÀ4¿FÕûÅ1½-À4àüàB¿"¼8ÅxÏ8ÄÊ.Æ5¾ß¼iÀÁv¼8Ê-ÆF¿Å1À4¼8ÆF¿Ê Ð
Æ5½.àEÈ4Æ5¿"ÀéÆ5Äæðiý8þa¹;ÌiÌÖÿ Í
¸/ï8êiþ8ð8ê„Î.ÆFËÊ-Ïi¾;Ë ºÆFÄÅ Â4¿æ¸/ñK½.àEË
Ò8ý;ºË
¸/ó;ºå&À4¾;Æ5¼iÊ-Ê}Ái½.Î.Î/¿"Å1¿À4Æ5½-¼iÊ}½-Àt¼;Ô'Ê-¿…È4Ä"Â4¾;½-À4à÷¼iÀÁòÇ'¿Å1½-Î Ð
àB¿¼8Å}Íh¿¾nÈ|¼iÀÁ[É1ÄÀ4Æ5¼iÉ1ƛÃ+¼8ÆFÆ5¿"Å1ÀË

¸¹ º» ¿"Í$Ä&Ç'¿)Á+½-Î.Î/¿"Å1¿À4Æ5½.¼8ÊÎ.Å1Ä"Í<¼nÔÊ-¿~ÈÄ"Â4¾;½-À4àBË
¸/Ì;ºôKÊ.¼8É1¿|Á+½-Î/Î/¿Å1¿"ÀÆF½-¼8ÊõÉ1¼i¾;¿ò½-Àö¼÷¾;Â4½-ÆF¼8Ï8Ê-¿lÇ'½-¾;¿lÕ}½.Æ5È
¾;Ä"Î/ÆjÍh¿Æ5¼iÊB␼;Õ<ÃiÅ1Ä"Æ5¿"É1Æ5Ä"Å1¾;ËZ¸.ñI½-àBËoÒió;º
¸/Ò;º» ¿"Í$Ä&Ç'¿ÓÏ8Ä"Ê-Æ5¾_È4Ä"Ê-Á+½-À4à…Å1½-À4à…àB¿¼8ÅkÆ5ÄÓÁ+½-Î/Î/¿Å1¿"À4Æ5½-¼8Ê
É1¼8¾n¿Ë
¸/ó;ºøS¾;½-À4à]¼_¾;Ä"Î/ƛÈ4¼iÍ$Íh¿"ÅùäoÁ+Å1½ Ç'¿)Å1½-À4à]àE¿"¼8Å}Î.Å1Ä"Í<Á+½-Î/ã
Î/¿Å1¿"À4Æ5½-¼8ÊÉ1¼8¾n¿)¸/ñK½-àBËZÒ8ó;ºË





¬­l¬ ® ¯°T±± ² ³²´µ° ¶·¶©´¯¯³° ¸² ·° ´²
»#¼%½'¾)¿À#ÁÀ#Â.Ã0Ä
Â.Å%ÆÀ#ÁÁÀ3Æ4Ä
¾.Â6Ç8È#ÉÊË=Ì>ÊÍÎÏÐ

¹tº

Fig. 37 Pinion Yoke Removal

y ™ |~} E _ Ud\Eo`dDFER ITKQITUXKLjEXMOG•MOKQPŽ^JUXgTgTMhRhY[I ƒ gTEY[RhMO^JEXG
€GJU _ DQU=nQY‚I
KFL y
  ITLjc  œ | c%¡£Mh`a^JD˜`dDQEŽR ITKQITU=K'kmI
`aDi„UXnFG
DQMOKQP~`dU)RhGJE\E=KQ`IT`€GJU _ €
MhgTgTITKQLoMOKQP ƒ E=I
KFLPhM _ MOLWEXP c
Fig. 35 Ring Gear Bolt Installation

PINION
CDFEHGJI
GEAR
KFLNMOKQPSR ITKQITU=KVLWEXMOGJYZMOGJEHY[E=G]\IT^JEXPSMOYZM

_ OM `a^JDQEXPbY[E=`dceUfKFUX`GJEXRhgTMh^JE.`aDQE.R ITKQITUXKiLjEXMOGlkmIT`dDQU=nQ`
GJE=R gTMh^JITKQLo`aDQE)GJITKQLoLjE=MhG>c
pqFrtsuwvx
y{z>|~} E _ U\E'PhI
€
€E=GJEXKQ`aITMhg#MOY[Y‚E _4ƒ g „…€GJU _ M‚†wg
E'DFUXnQY‚‡
ITKQLjc
yˆ‚|~‰ MhGJŠ6R ITKQITUXK‹„U=ŠFESMOKQPŒRhGJUXR E=gTg
E=GY‚DQMO€`Z€
UXG
ITKQY‚`dMOgTgTMh`aITUXKŽMOg
ITLWK _ EXKQ`ac
y‚| elITY‚^JUXKQKFEX^J`R GJU=R EXgTgTE=G‘Y[DFMh€
`€GJU _ R ITKQITUXK…„U=ŠFE=c
’Y‚ITKQLfY‚nQIT`aM ƒ gTE%k“ITGJEX”`aITE•RhGJUXR E=gTg
E=GY‚DQMO€`l`aU•nQKFP EXG ƒ U=P„Wc
y–‚| ’Y‚ITKQL˜—tUXgTP E=Gi™Ošh›Oœ`dUž`dDFEŸDQU=g
P„UXŠE=”“GJE _ U\wE
`aDQE)R ITKQITUXKŽKQnQ`MOKQP4k“MOY‚DQEXG y  ITLWc  ™ | c
y › | ’Y‚ITKQL } E _ U\wEXGZ¡£¢ – › ˆ MOKQP0—tUXgTP EXGZ¡£‡ Oˆ œ z ”
GJE _ U\E)`aDQE)R ITKQITUXK.„U=ŠFE)€
GJU _ R ITKQITUXKŽY[DQMO€
` y  ITLWc O¤[| c

Fig. 38 Remove Pinion Gear

Fig. 36 Pinion Yoke Holder—Typical

y ¤‚|~} E _ Ud\E`aDQE€GJU=KQ`mR ITKQITU=K ƒ E=MhGJITKQL¥^JnFR ” ƒ EXMOGJITKQLW”
UXITgY‚g
ITKQLWEXG¦”wI
€§EX¨OnQITR RhEXP ”MOKQP.R ITKQITUXKY[E=Mhg kmI
`aD } E _ U\wEXG
¡£‡ –OO– ›MOKQPb—tMOKQP gTE)¡£¢ –©z[¤©z“y
  ITLjc  š | c
y œ |~} E _ Ud\Eo`dDFEGJE=MOG•R ITKQITUXK ƒ E=MOGJITKQLb^JnFRi€GJU _ M‚†gTE
DQU=nQY[ITKQL y  ITLjc –Oª‚| ct’Y[E } E _ U\E=G¥e‡ z‚– š‘MOKQP—tMOKQP gTE
¡£¢ –«z‚¤©z c
y š |~} E _ Ud\E#`aDQE#P E=R `aDY‚DQI _ Y€GJU _ GJE=MOGR ITKQITU=K ƒ EXMOG8‡
ITKQL.^{nQR ƒ UXGJE“ITKbM‚†gTE“DQUXnFY[ITKQLjc } E=^JUXGJPo`dDFE4`aDQIT^JŠKQEXY‚Y#U=€
`aDQE)P EXRh`dDŽY[DFI _ Y‚c

9;:

<>=@?+?+ACB>AED>F
= GIHG0DJ<K<>B>= LMA+H+= DJA

N!OPN+N

QRSUTWVPXYKXZ\[^]@Z\_`>XYIYIX5`]@T\Zba#cdIeIfhgieIjIkIlIm

Fig. 39 Front Bearing Cup Removal

Fig. 41 Collapsible Spacer

NOTE: The pinion depth shims can be very thin.
Verify that all shims have been removed before proceeding.

Fig. 42 Inner Bearing Removal
,.-0/
13254 42 16, 78-

Fig. 40 Rear Bearing Cup Removal

{Ñ Ò‚Ó‚Ô~Õ£ÖX×4ØdÙÖÛÚaÜQÖÛÝJØ=ÞTÞ
ßOà á‚âTãOÞ
֝à äJÖXÞTØ=ßhåæá‚à ßOÝJÖXäŸç
äJØX×
à âTèQâTØ=èiéWÖXßOämсê«âTéjëíì©Ò>Ô{ë
Ñ{Ò=Ò¦Ô~Õ£Ö=×4ØÙwÖ)ÚdÜFÖ)äJÖXßOä#à âTèQâTØXèŽãOÖ=ßhäJâTèQéfçäJØX×îÚaÜQÖ)à âTèQï
âTØXèñð“âTÚaÜóò«ôQÞTÞTÖXä]õ¦òä{ÖXá[á÷ö£øOùOúOûhï
òXü ßOèQåýüåhßhàhÚdÖ=äJá
ö£øOùOúhûOøOûOúсê«â
éWëíìOù‚Ô{ë
þ3ÿ  

©ÿ 
 
 
!"
#$%'&(") "+*

NOTE: Pinion depth shims are placed between the
rear pinion bearing cup and axle housing to achieve
proper ring and pinion gear mesh. If the factory
installed ring and pinion gears are reused, the pinion depth shim should not require replacement.
Refer to Pinion Gear Depth to select the proper
thickness shim before installing pinion gear.

Ï!ОÏ+Ñ

Ò>ÓÔCÔ+Õ+Ö>ÕE×>Ø
Ó ÙMÚ!Ù%×JÒKÒ>Ö>Ó ÛMÕ+ÚCÓ ×JÕ

Ü8Ý

ÞßàUáWâPãäKãå\æ^ç@å\èé>ãäIäIã5éç@á\åbê#ëìIíIîhïiíIðIñIòIó
noiprq
s@tuwvWxywzx+vhy{}|~uw€Cvh‚‚„ƒvx+{…|)‚|~†‡~)ywvtyx+~ˆ

n.´p’“x+xs ”µtUs~Š3|{£uwzt{}~Š)zh 8Š³vtysŒ‰yw~uwt{„zh²{…|v

~z)‰vtyw~Š‹uwŒxr‰zhywvW~{…|vWtŽ0svW|zŒ‚~Š3

s~xz x+~~z!‚vhts0¢± ‚{…ts@s
‚vts+¤„~{…|¢±‚{…tssvy©™ˆ.­¶«‘ˆ ’

n.‘p’“x+xs ”–•zx+ty
zzhy!˜™t‚vhšzy‹v›Œ~ œtsvh{}šž‚{…~uw€
t —
sŒ‰yw~uwt{r{…zŸzŒ{…‚~@ƒvŸ‚Œ yw .tuwvŸz \ywvhtyUx~@ ~@zh¡‰vtyw~Š

tƒr§;tƒs@vW©™ª¥%o«
o„n@¬
~Š3¥´p#

ˆo¥¦\tƒ
—
yw~ œvy¨§;tƒs@v©™ª¥%o«%on@¬
~Š3;¥­p#5®™vyw~  ”¡uwŒx–~‚uwzy#ˆ

—

uwŒx
¢}‚{…tss6{…|v£‰vhtyw~@ ŠWuwŒx;¤„~{}|r¢}‚{…tss@vhy
ywvhuw{}s ”U‚vht{}vhƒ+

Fig. 45 Pinion Seal Installation

n.¦pr¢±‚{…tssP{}|v‹ywvty·x+~~z‰vtyw~Š$tƒzh~sž‚s@~Š³vy(š
~ Pvh›Œ~xx+vƒš™zhU{…|vx~@ ~@zhUŠ3vhtyž¤„~{}|¢±‚{…tss@vhyž¸Uˆ@‘¦‘
tƒrt‚| zxrx+ywv‚‚„n.¬
~@Š³6¥¦p

Fig. 43 Rear Pinion Bearing Cup Installation

zzhy!˜™t‚vhšzy‹v›Œ~ œtsvh{}šž‚{…~uw€
t —
sŒ‰yw~uwt{{…zUzŒ{…‚~@ƒvU‚Œ yw .tuwvUz „ @ywz{\x+~~z¯‰vtyw~Š
n.­p’“x+xs ”–•zx+ty

uwŒx
¢}‚{…tss6{…|v£‰vhtyw~@ ŠWuwŒx;¤„~{}|r¢}‚{…tss@vhy
§8tƒ+svW©™ª¥%o«%o„n.¬
~Š36¥¥p

—

ˆo­°\tƒ

Fig. 46 Rear Pinion Bearing Installation

n.«pr¢±‚{…tss6tv}¤¹uwzsstx+‚~@‰sv„x+ywvszhtƒ‹‚xtuwvhy8zrx+~ˆ
~z‚|t .{5tƒ~‚{…tssx+~~zŠ3vty“~|zŒ‚~Š·n.¬
~Š³%¥«p
n.ºpr¢±‚{…tss”0zh€ vJ¤„~{}|)¢}‚{…tss@vhy5¸Uˆ#o¦‘ˆ.»™š©™Œxrº%o°¶š
tƒr§;zhsƒ+vy¦¶´ºn@¬
~Š3¥ºp

Fig. 44 Pinion Outer Bearing Cup Installation

n.¥pr¢±‚{…tssJ .ywzh{x~@ ~@zh²‰vtyw~Š3šPtƒz~sJ‚s~Š³vy(šP~ 
v›Œ~xx+vƒ+

n.¶pr¢±‚{…tss
{…|vx~@ ~@zh£¤„t‚|vhyJtƒ\t·v±¤¼Œ{Iz!{}| v
x+~~zrŠ3vhtyi+½I~Š3|{…vh${}| vŒ {ž{…z‘%o¦¾“¿ †Àno¦° .{…
s@‰‚ p
†~~†Œ†JÁ8ÂÄÃÂŋÂ'Æ>Ç+È'ÉhÅÊ(Ë ÌÅÇÃÍJ•‹tŽ0~†Œ†^{}zhyw›Œv
~‚„­´‘¾J¿ †În.‘¦° .{…6s‰‚ p#

d\e

fhgi-i-j2khjmlhnog pbqpLlAfRfhkhg rsj-q-g lAj

tvuWt-w

xzyS{}|M~Wz€RzK‚„ƒK…S†hz€b€b‡†0ƒ|K‰ˆ7Šz‹bŒbŽŒbb‘b’b“

Fig. 47 Collapsible Preload Spacer

Fig. 49 Tightening Pinion Nut

ôõ&÷
NO1P% wúûüQwþ$ …úûüQ…þ 
„ú+$R ûKúû
,+þû…þ STû>¨ô!4
ú@ü5#U
ö÷(#-VW>J…þ ·ûùù X/
…þKþ$ $M$M,+úûúþû)ü; ùþÿ+
%Y



ÿ+%ù# ÷(#

wúü³ú@û> ÿ\[O wúûü3ù]
Z

õ
}þ


AB

=_[O wú@û ü3ùT]`…þM
 ‡ôõ&
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úû#6ÿ+%ù&# ÷7#



Fig. 48 Pinion Yoke Installation
CAUTION: Never loosen pinion gear nut to
decrease pinion gear bearing rotating torque and
never exceed specified preload torque. If preload
torque is exceeded a new collapsible spacer must
be installed. The torque sequence will then have to
be repeated.
ôõö÷rø“ùú@û üý8þhÿ 

û…þ ûô@ù 

 Îô! ö"!$#6ÿ%ù&# ÷.÷(') ù*þÿÿ+ ,ùú+%ÿ+\ù&,-  û}úÿ
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,+ÿ+ &/Uúù0$ 12û3,$ô4
úü5#)6 ÷7#

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8ÿþ9£ÿ /:…úü;$û<=>)ûWúû? # @AB^ô!
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úû0û…ùCû…ú@ÿD$Ewþ$ }úûüF…þ 

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ADJUSTMENTS
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Fig. 54 Typical Housing Cover With Sealant
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Y 63=ÁN{6)638Š=@Gr64?A8:?A038ŠG:6)?b]uG:= Y QA03KJyO;78rFO=[G:6;>D Y 03D Y ;>D
N{?A=[G=@G:6’9<KJ030)=@6)D Y QA0)KJyk;>]d;>?A8:9S==[G:6’47?b8r?b0)8G:63?A]dGr= Y Qb0)KJy
_ao?A]dRpg>ŽShiR>¿»G:638
=@G:6F?A;>Qf47DJ0 Y 6KJ0)8:=[;7KJ=[9l=[G:6;7D Y 0)D Y ;>Dvn
=[G:6´F?A;>QŠ403?A8:=[6)D¶N?AQbQŠ=[^:DJ8ˆKJQA03K$y3N?b9<63Rx³1DJ?A8:]ÂF7?b;>Q
40)?b8r=@6)D Y ;>KJyª=[0 ½ 63DJ0»;>]d;>?A8:9S=
=[G:6»;>D Y 03D Y ;>Dvn’F0»8:0)=
=[^:DJ8ZF?A;>QB;>KJ63Rµ/1038r=@?A8:^:6{250@Hp?A8:]\=[G:6{F?A;>Q4D$0 Y 6{=@0{=[G:6
KJDJ6)9S=¾0)Bf=@G:6;>D Y 03D Y ;>D€;>8:FDJ6)KJ03DJF=[G:6G:?A]dG:6)9S=DJ63;>F?A8:]dR
j Bf=@G:6F?A;>Qc?b8rF?AKJ;>=@0)D€KJ;>88:03=¾;>KJG:?A6MH6=[G:6 ½ 63DJ0DJ63;>F?A8:]un
=[G:6{DJ6);>D Y 63;>DJ?A8:]\KJ^:4k03DU=[G:64?A8:?A038F634=[GZ]u;>^:]d69S63=V?A9
8:0)=€?b8r9S=[;>QbQA6)F`KJ0)DJDJ63KJ=[Q ”–R
_°<hZ¬63QA63KJ=l;†9<G:?A2´63“>^:;>QV=@0k=@G:6kF?A;>Q ?A8:F?AKJ;>=[03D5DJ6);7F7t
?A8:]{4QA^:9=@G:6lFDJ? Hp6’47?b8r?b0)8]d63;>DmF6)4=[GHp;>DJ?A;78rKJ6’8:^:2 Y 63D
63=[KJG:6)FX?A8W=[G:6†B;>KJ6‰0)B=[G:6‰47?A8:?A038W]u63;>D
_ao?A]dRe>e<h$Rac0)D
6M§;>254QA63n?AB=[G:6
F7634=[GH;7DJ?A;>8:KJ6?b9\‹>>n¾;>FF‰:Ž>R Ž>Ž>‰?A8:R
=[0=[G:6\F?A;>Q?A8:F?AKJ;>=[03DDJ63;>F?A8:]uR

NOTE: If an oil slinger is used behind the inner pinion bearing, deduct the thickness of the slinger
from the dial indicator reading and use that total for
shim selection.

DIFFERENTIAL BEARING PRELOAD AND GEAR
BACKLASH

˜™p£pšl›¢Ãc˜ šl™
}m?ABBb63DJ6)8:=@?A;>Qc9<?AF6 Y 63;>DJ?A8:]547DJ63QA03;>F;>8:F]d6);>D Y ;>KJyzQA;79<G
?A9;>KJGr?b6@Hp6)F Y ”X9<63QA63KJ=[? Hp69SGr?b259\40)9S?A=[?A038:6)F Y 63G:?A8:F‰=[G:6
F?ABBb63DJ6)8:=@?A;>Qx9S?AF76 Y 63;>DJ?A8:]´K$038:6)9SRTVG:6¨47DJ0346)D©9SGr?b2
=[G:?AKJyr8r639<9XKJ;>8 Y 6WF6)=@6)DJ25?A8:6)F¦^r9S?A8:]ª9<Qb?A4tbB?A=‰F^r252”
Y 63;>DJ?A8:]d9{}mt¯>®>¸Z?A84QA;>KJ60)BV=@G:6\F?ABB6)DJ638:=[?A;>Q¾9<?AF6 Y 63;>Dit
?A8:]d9
;>8:F¹;sF7?b;>QU?A8:F?AKJ;>=[03D/1tb¯>¯7¯>°>Rm³163Bb03DJ6`4DJ03K$6363F7?b8r]
N{?A=[G»=[G:6F?ABB6)DJ638:=[?A;>Q Y 6);>DJ?b8r]`4D$63QA03;>F;>8:F‰]d6);7D Y ;>KJyzt
QA;>9SGW2{63;>9S^:DJ6)25638r=@9<n2563;>9<^:DJ6‰=[G:6†4?A8:?A038O]d6);7DF6347=@G

GIH

JLKMMN'OLNQPLR,K S"TUSVPWJXJLOLK YZNTK PWN

[
\[]

^`_`a"bdcWefhgideckjl`m"n"oQpqn"r"s"t"u
132542760498":<;>=@?>:<13AB9CD;=E25;>40F>:

Fig. 58 Pinion Height Block—Typical

Fig. 57 Pinion Gear Depth Gauge Tools—Typical

ç>è:é»êëJì3ê7ç>ëJì†í[î:ì`êïAè:ïAð)èOñuì3ç>ëòbð3ëkïbèróSí[ç7ôAôAç>í[ïbð)è:õmö1ó<í@ç>÷>ø
ôAïAóSî:ïAè:ñ5ê7ëJð3êì)ëêïAè:ïAð3è
ñuì3ç>ëéì3êí[î
ïAóUì)óSó<ì3è:í[ïAç7ôoí[ðì3ó<í@ç>÷>ø
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û òí[ì3ëí[î:ìðMüpì)ëJç>ôbôóSî:ïAýí@î:ïAùJúzè:ì)óSó5í[ðí@ç>úzìþ:ê†é7ïAòòì)ëJì3è:ø
í[ïAç7ôÿóSïAéìÂê7ôbç ïAó´ý5ì)ç>óSþ:ëJì)é Ší@î:ìÂê7ïAè:ïAð3è‡ñdì)ç7ëïAó
ïAè:ó<í@ç>ôAôAì3é ç>è:éqí@î:ì¹ñuì3ç>ë‰÷7ç>ùJúzôAç>óSî¶óSîrïbý í[î:ïAùJúzè:ì3ó<ó ïAó
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í[ïAð3èZç7é7éì3éí[ð3ñdì)í@îrì3ëvõ  î:ì{ñdì)ç>ël÷>ç>ùJúrôAç>ó<î`ý5ì)ç7ó<þ:ëJì)ý5ì3è:í

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óSîrïbýPí@î:ïAùJúzè:ì)óSólç7èréóSì)ôAì3ùJíVí@îrç7íVç>ý5ð3þ:èrí òbð3ëUí[î:ì{ê7ïbèrïbð)è
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ô oïAñd
õ
$
õ  ïbòbòì3ëJì)è:í[ïAç7ô
óSîrïbý ý5ì)ç>óSþ:ëJì)ý5ì3è:í[óEç>ëJì ê7ì3ëJòð)ëJý5ì3
é ïAí@î ç pôAì
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ë ø 7ø ŠëJì)ý5ðMüpì)éõ
 "! #$%'&(%*),+-! .0/

NOTE: It is difficult to salvage the differential side
bearings during the removal procedure. Install
replacement bearings if necessary.

Ç
È>ÉÊ

ËL̆Í'ÍÎÏLÎQÐLÑ,Ì ÒZÓ
ÒÔÐWËXËLÏLÌ ÕZÎÓ'Ì ÐWÎ

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{*Š(‹€ƒ†Ž"—‰˜{ˆ™
v šxzy<{*|~}€V{h… —‰‹Œ}*‡œ›ƒ†ŠD‹€Ž†Ž†{*@˜žDƒ†|~Ÿ… ‡‰}ˆ| „ƒ…… {*‡{*ŠD•
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v ±xz¢£ŠD‹Œ„Ž†Ž"„ƒ…… {*‡{*ŠD‹Œƒ†„Ž<—‰„{dƒ†Šh²VŽ†{džD}ˆ­D˜ƒ†ŠD‘¨™
v ³xz¢£ŠD‹Œ„Ž†Ž‹ŒžD{I|~‡‰´'{*d„{ˆ‡‰ƒ†ŠD‘~—„ª„3ƒ†Šµ‹ŒžD{*ƒ†‡—}*‡‰‡‰{ˆ—‰‹
ª}ˆ˜ƒ†‹Œƒ}ˆŠD™-¢£ŠD‹€Ž†Ž"ŠDz˜Š(­D‘
‹ŒžD{d}*Ž†‹ŒEv ¶ƒ‘¨™-³šx™

Fig. 59 Gauge Tools In Housing—Typical

Fig. 62 Tighten Bolts Holding Bearing Caps

v ·xz¸3ƒ†ŠD‘
z{ˆ„„• Ž†}£¹º‹5›Vª{|~Ž†Ž†{*‹Œ»L{*‹3‹ŒžD{ƒ†… …{*‡–•
{*Š(‹€ƒ†Ž-­D|E|›©{*‡‰ƒ†ŠD‘¨`‹Œ}E{*—‰žz˜ƒ†{E}*…L‹ŒžD{E˜²Ž†{~ž(}*­D•
ƒ†ŠD‘µv ¶ƒ‘¨™-³¡x`ŠDzv ¶ƒ†‘’™-³«x™

Fig. 60 Pinion Gear Depth Measurement—Typical

Fig. 63 Seat Pinion Gear Side Differential Dummy
Side Bearing

Fig. 61 Axle Adjustment Shim Locations

v °x~¼ žD‡‰{*$‘’­(ƒ„{˜‹Œ­D$½<•¡„š°°• ¾¿ƒ†ŠD‹€}À‡‰{*‡@—‰}£{*‡
}*Ž†‹WžD}ˆŽ{d{ˆŽ}€¹º‡ƒŠ(‘
‘¨{*‡®v¶,ƒ†‘’™¬³„±x™
v Áx~Â3‹Œ‹€—‰žÀ@ƒ†Ž®ƒ†ŠDƒ†—‰‹Œ}*‡z½<• ¡¡„¡Á@‹Œ}ђ­Dƒ†„{‚‹Œ­D™
Ä }*˜ƒ†‹Œƒ†}*ŠÅ‹€žD{Uƒ†Žƒ†ŠDƒ†—‰‹€}ˆ‡ªŽ†­DŠ(‘’{*‡d}*ŠÆh…Ž‹®­D‡‰… —‰{
{*‹5¹E{ˆ{*Š©‹€žD{d‡‰ƒ†ŠD‘µ‘’{ˆ‡®}*Ž†‹WžD{ˆEv ¶ƒ‘¨™-³±x™

EGF

H+IJ,J,KML+KON+PQI RTSURVNCHWH+L+I XYK,S,I NCK

Z\[^],_

`?a?bTc=dCe0f:g0h=e0dji
k?lTmTnOopmTqTrTsTt

Fig. 64 Seat Ring Gear Side Differential Dummy
Side Bearing

Fig. 66 Hold Differential Case and Zero Dial
Indicator

Fig. 67 Hold Differential Case and Read Dial
Indicator

Fig. 65 Differential Side play Measurement

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Fig. 68 Hold Differential Case and Zero Dial
Indicator

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Fig. 69 Hold Differential Case and Read Dial
Indicator

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Fig. 70 Ring Gear Backlash Measurement

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Fig. 71 Backlash Shim Adjustment

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t xv

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Fig. 72 Gear Tooth Contact Patterns

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SPECIFICATIONS
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SPECIAL TOOLS
181 FBI AXLE
Puller—C-452

Puller—C-293-PA

Wrench—C-3281

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Cup—8109

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Pilot Stud—C-3288-B

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194 RBI AXLE
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page
GENERAL INFORMATION
194 RBI AXLE . . . . . . . . . . . . . . . .
LUBRICANT SPECIFICATIONS . . . .
DESCRIPTION AND OPERATION
STANDARD DIFFERENTIAL . . . . . .
TRAC-LOK OPERATION . . . . . . . . .
DIAGNOSIS AND TESTING
BEARING NOISE . . . . . . . . . . . . . .
DRIVELINE SNAP . . . . . . . . . . . . .
GEAR NOISE . . . . . . . . . . . . . . . . .
GENERAL INFORMATION . . . . . . .
LOW SPEED KNOCK . . . . . . . . . . .
TRAC–LOK DIFFERENTIAL NOISE
TRAC–LOK TEST . . . . . . . . . . . . .
VIBRATION . . . . . . . . . . . . . . . . . .
SERVICE PROCEDURES
LUBRICANT CHANGE . . . . . . . . . .
REMOVAL AND INSTALLATION
AXLE SHAFT . . . . . . . . . . . . . . . . .
AXLE SHAFT SEAL AND BEARING
COLLAPSIBLE SPACER . . . . . . . . .
DIFFERENTIAL . . . . . . . . . . . . . . .

. . . . . . . . . . 49
. . . . . . . . . . 49
. . . . . . . . . . 50
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GENERAL INFORMATION
194
RBI AXLE
‚Eƒ…„
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š›Žœ+˜?ž‹ŒŒš Ÿˆ¡@¢„ƒ£œ¤…”–•˜£—
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ƒ£œ+¤£”–•˜£—§¨œ"¬œŽ¼?œ+˜£„‘º©•„¦„"ˆ¡@¢„"ƒ£œ¤£”ˆ•˜£—™¶
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§¨ƒ£„
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page
DIFFERENTIAL SIDE BEARINGS . . . . . . .
FINAL ASSEMBLY . . . . . . . . . . . . . . . . . .
PINION GEAR . . . . . . . . . . . . . . . . . . . . .
PINION SHAFT SEAL . . . . . . . . . . . . . . . .
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . .
RING GEAR . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLY AND ASSEMBLY
STANDARD DIFFERENTIAL . . . . . . . . . .
TRAC-LOK DIFFERENTIAL . . . . . . . . . . .
CLEANING AND INSPECTION
AXLE COMPONENTS . . . . . . . . . . . . . . . .
TRAC-LOK . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTMENTS
DIFFERENTIAL BEARING PRELOAD AND
GEAR BACKLASH . . . . . . . . . . . . . . . . .
GEAR CONTACT PATTERN ANALYSIS . . .
PINION GEAR DEPTH . . . . . . . . . . . . . . .
SPECIFICATIONS
194 RBI AXLE . . . . . . . . . . . . . . . . . . . . .
194 RBI AXLE . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS
194 RBI AXLE . . . . . . . . . . . . . . . . . . . . .

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. . . . . 68
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. . . . . 75
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. . . . . 79
. . . . . 79

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Fig. 2 Differential Operation—Straight Ahead Driving

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DIFFERENTIAL
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TRAC–LOK TEST
WARNING: WHEN SERVICING VEHICLES WITH A
TRAC–LOK DIFFERENTIAL DO NOT USE THE
ENGINE TO TURN THE AXLE AND WHEELS. BOTH
REAR WHEELS MUST BE RAISED AND THE VEHICLE SUPPORTED. A TRAC–LOK AXLE CAN EXERT
ENOUGH FORCE IF ONE WHEEL IS IN CONTACT
WITH A SURFACE TO CAUSE THE VEHICLE TO
MOVE.


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CAUTION: Overfilling the differential can result in
lubricant foaming and overheating.

Fig. 5 Trac-lok Test —Typical

SERVICE PROCEDURES
LUBRICANT
!#"%$'&)("%*,CHANGE
+!&)-,./.1032546487,(:9;(7,$'<5='(3>

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Fig. 6 Apply Sealant

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48(32*,03$'&)(<50A.1='"%$'*,4E>

REMOVAL AND INSTALLATION
REAR AXLE

¶·F¸d¹ºT»½¼
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?@!¾”03&)$'48$'03*¿"U&)-F$ 48"%H%= (ª='$ I 4E$'*,KŽ+1(C9T$ <5(ª-,*,+1(2À4E7F(
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îï;ð”ñaò²óFó3òFñtî ôdï
NOTE: The weight of the vehicle must be supported by the springs before suspension arms and
track bar fasteners can be tightened. If the springs
are not at their normal ride position, vehicle ride
height and handling could be affected.

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PINION SHAFT SEAL
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Fig. 7 Pinion Yoke Removal

Fig. 8 Pinion Seal Installation

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CAUTION: Do not exceed the minimum tightening
torque when installing the pinion yoke at this point.
Damage to the collapsible spacer or bearings may
result.

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Fig. 10 Check Pinion Rotation Torque
Fig. 9 Pinion Yoke Installation
CAUTION: Never loosen pinion gear nut to
decrease pinion gear bearing rotating torque and
never exceed specified preload torque. If preload
torque or rotating torque is exceeded a new collapsible spacer must be installed. The torque
sequence will then have to be repeated.

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CAUTION: If the maximum tightening torque is
reached prior to reaching the required rotating
torque, the collapsible spacer may have been damaged. Replace the collapsible spacer.

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Fig. 11 Tightening Pinion Shaft Nut

COLLAPSIBLE SPACER
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ã µ»W¸³(ÙHѺ½ Á ½º Á ¸½ Á ½º-Õ¸¾À!½¸³Ç
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› 13 Remove Pinion Gear
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›z‘P’=Yoke
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-xq1y103254167P9LbdA'X<ZYeA?B
fd«OiFGFjR]F7:@©l[BWA'7:nWKIfd«OpFjF.¬qwV
BWA'X<ZYSAHJK:AN687:68<?7QS<'TPA‚BW<?X N687:68<?7[4wK:]F‚H^-/st689­a q1jw0"a
-xq'qƒ03bdA'X<ZYeALHJK:A¨N687:68<'7}9uA']FBª‚/Bx<?X®KP<?\:41687:9-st689ua
q1p10xa fd]FH~nWKH~K:AN687:68<'7‡_`68HJK‡QS<'\:BK:]F7:@©H~<NBWAZYeA?7:HŽ68H
‚/BW<'X¯‚]O>8>8687:9†]F7:@…{FA'67P9@O]OX`]O9­A?@a
-xq1j103bdA?X<~YSAnW<?>8>8]FN416{F>8A4wNO]OnWA'B‰‚BW<?X N687:68<?7[4wK:]F‚H~a

/- p103ŠZ7:41HJFig.
]O>8>NO1467P6Collapsible
<'7‡‚BW<?7:H {OA']OPreload
Bx67P9uV‹68‚²Spacer
7:A?nWA'4w41]FB|Q­a
-/i10³5NNO> Q]
>8689uK:H‰nW<?]FH~687:9[<'‚=9­A?]FB>8\:{FBW68nW]F7:H`<'7DHJK:A
>868N<?‚N687:68<?74wA']O>8aSŠZ7P4wHJ]F>>t41A?]F>_`68HJK„ŠZ7:41HJ]O>8>8A?B fdh/pFEO¡FjFh ³
]F7:@3;ˆ]F7:@O>Afd«Fi¬q1¡rq`-st689uavq1Gw0"a

BDC
[]\^/_a`&b]cTb]d(egfd(hiGb]c5c5b2i f_(dkjml]n5o5pqro5s5t5u5v

EGFHIHIJLKGJNMGOPF Q5R+QSM ETEGKGF UVJIRIF M J

WX&YIZ

Û/ö1
Ý 5à1é8ß:û„äSå'æUç‡ê:å'ã÷Oç?í„ùFöFÜFîªâFß:÷ªâªáJå?í Oó:çè`íWç'ß:ìWê
àwç'á âFá  
 ÿ ÛFÜOõ†ý/áJüã8þOà1ü ÝxñtìWíWó:àwêìWå'ãã8âFôà1é8þOã8çŽà1ôâFìWç?í
ó:ß:áJé8ãþFç?âFíWé8ß:û†ç?ß:÷3ôã8â1ä
é8àáJâFæUç?ß[ó:ô3Û/úté8û­ü ï wÝ"ü
NOTE: If more than 474 N·m (350 ft. lbs.) of torque
is necessary to remove the bearing end play, the
collapsible spacer is defective and must be
replaced.

Ûxï1õ1Ý3ëSã8å~è`ã äDáJé8ûuê:áJç?߀á~êPç„ß:óPá‰é8߀ùOü 
î
 ÿ ÛÜ[ý/áJü²ã8þOà1ü Ý
é8ß:ìWíWç'ÿç?ß:áJàmó:ß:áJéãŒáJê:çcíWå?áJâFá~é8ß:û¤áJå?íFó:çcéàmâFìWê:é8çeç?÷ü
ç Fó:ç?ß:áJã ä‡áJåŽâ Så?é8÷„å Sç'í
 ç'âFàwó:íWçá~êPçŽíWå?áJâFá~é8ß:ûá~å'í Fó:çŽý/íW
ìWíWó:à1ê:é8ß:û†á~êPçìxå?ã8ã8âOôOàwé8þFã8çà1ôâFìWç?í Û/úré8ûuü ï1î1Ýxü

/Û Ü1Ý3ÞZß:à1áJâOã8Fig.
ãäeå?15
æUçPinion
è`é8á~ê¨ëSSeal
ìxíWçZèInstallation
îrï'ï1ðOñ^òdó:ôî¬ï1õFöOñ^âOßP÷
ø å?ã8÷ç'í‰ùFöFÜFî„Û/úréû­ü ï1ù1Ýxü

/Û ù1Ý3ÞZý áJê:çFig.
å?íWé8ûu16é8ß:âFPinion
ãôé8ß:é8å?Yoke
߀þFç?âFInstallation
íWé8ß:ûuàâFíWçþFç?é8ß:û…ó:à1ç?÷ñ
é8ß:à1á~âFã8ã÷Oé8ý/ý/ç'íWç?ß:áJé8âFãâFà1àwç?ÿ`þOã ä…âFß:÷âeãç àwê:âFýá~à1ñ¬é8ý‹ßPç?ìWç'à
à1âOí|ä ü
NOTE: If new pinion bearings were installed, do not
install the differential assembly and axle shafts until
after the pinion bearing preload and rotating torque
are set.
Û 1Ý3ÞZß:à1áJâOã8ãáJê:çˆäSå?æUçˆè`âFàwêPç?íâFß:÷â…ß:ç~è£ß:ó:á=å'ߌáJê:ç
ôé8ß:é8å'߆ûuç'âFíƒü²é8û­ê:á~ç'߆áJê:ç=ôé8ß:é8å?ßß:ó:ádó:ß:áJé8ã¬áJê:ç?íWç=é8à ¾ç'íWå
þFç?âFíWé8ß:û†ç?ß:
÷ /ôã8â1ä­ü
Û/î1 Ý éû­ê:áJç?ß[á~êPçßPó:á^á~å ð ¬ï
 ÿ Û/ðFõFõ„ý/áJü‹ã8þFàwü Ýxü

CAUTION: Never loosen pinion gear nut to
decrease pinion gear bearing rotating torque and
never exceed specified preload torque. If preload
torque or rotating torque is exceeded a new collapsible spacer must be installed. The torque
sequence will then have to be repeated.

Fig. 17 Tightening Pinion Nut
xÛ ï?ï(Ý3òdêPç?ìWæ
íWå?áJâFá~é8ß:û3áJå?íFó:ç è`é8á~êŒâÛ/é8ß:üã8þFàwü Ý`á~å'íOóPç
è`íWç'ß:ìWê
Û/úré8ûuü5ï1î1Ýxü!êPçá~å'íFó:çß:ç'ìWç?à1àwâFí|ä€áJåíWå?áJâFá~çáJê:ç
ôé8ß:é8å?ß[ûuç'âFí‰à1ê:å?ó:ã8÷3þFç#"
íWé8û­éßPâO&ã %dç?âFíWé8ß:û­(à ')ê:ç†íWç?âF÷é8ß:û…íWç'ìWå?íW÷Oç?÷‡÷óPí 
é8ß:û• íW$ ç?ÿå SâFã8ñôã8ó:à‰âFß[âF÷÷OéáJé8å?ß:âFãdõFü ÜFù
 ÿ ÛÜé8ß:üã8þFàwü Ýxü
5ç~*
è %dç'âFíWéßPûuà ' ð„áJå+
Ü
 ÿ Ûxï1܄áJ(å F܄é8ß:ü‹ã8þFà1ü Ý"ü

Ûxï1ð1Ý3ÞZß:à1á~âFã8ãˆ÷Oéýý/ç?íWç'ß:áJé8âOã=âOà1àwç'ÿþFã äLâOß:÷ªâ Sã8ç[à1ê:âFý/áJàwñ
é8ý²ß:ç?ìWç'àwà1âOí|ä ü
Ûxï 1 Ý ,5ã8éû­ß ÿâFíWæPà¨ÿâO÷OçôíWç Sé8å?ó:à1ã ä£å?ßmäeå?æUçâFß:÷
ôíWå'ôç?ã8ã8ç'í‰àwêPâOýá^âFß:÷…é8ß:à1áJâOã8ãôOíWå?ôç'ã8ã8ç?í‰à1ê:âFý/áJü
Ûxï 1Ý3ÞZß:à1á~âFã8ã‰íWç'âOí3þFíWâFæPç
÷íWóPÿàwü -ç'ý/ç'í…áJ/
å .víWå?óPôzÜFñ
%díWâFæPç'àwñý/å?í ôíWå'ôç?í ôíWå'ìWç?÷óPíWç?à1ü
Ûxï1Ü1 Ý ,5÷÷ ûuç'âOíMã8ó:þFíWé8ìWâFß:á~ñŒé8ýß:ç?ìWç'àwà1âOí|ä 0
ü -ç'ý/ç'ícáJå
1 ó:þOíxéìWâFß:á‰ëeôç'ìWéýé8ìWâOáJé8å?ßPà†å'ý5áJê:é8à†à1ç?ìWáJé8å?ß©ý/å?íãóPþOíxéìWâFß:á
íW#ç Fó:é8íWç'ÿç?ß:áJà1ü
Ûxï1ù1Ý3ÞZß:à1á~âFã8ãSè`êPç?ç?ãdâOßP÷…áJé8íWçâOà1àwç'ÿþFã8éç'àwü
Ûxï 1Ý 1 å~è`ç?2í Sç'ê:é8ìWã8ç?ü

AXLE SHAFT
35476985:<;&=
-

Ûxï(Ý dâFé8àwçIâFß:÷kà1ó:ôôå'íW>
á eç?ê:é8ìWã8ç?ü?dß:à1ó:íWçIáJê:âFáDáJê:ç
áJíWâOßPàwÿé8à1àwé8å?ß[é8à`éß[ß:ç'ó:áJíWâOã8ü
Û/ð1
Ý -dç?ÿå Sç5è`êPç?ç?ãdâOßP÷…áJé8íWçâOà1àwç'ÿþFã ä­ü
Û 1
Ý -dç?ÿå Sç`þFíWâFæUç`÷íWó:ÿ@ü -dç?ý/ç'í=áJå.víWå'ó:ô†ÜFñA%díWâFæUç?à1ñ
ý/å'í‰ôíxå?ôç'í‰ôíxå?ìWç?÷Oó:íWç?ü

ÞߘàIá

âGã~äLäIåIæGåNçGèPã éVêé@ç âTâGæGã ëVåIêLã ç å

ì9í



î]ïð/ñaò&ó]ôTó]õ(ög÷õ(øùGó]ô5ô5ó2ù ÷ñ(õkúmû]ü5ý5þÿrý

Fig. 20 Axle Shaft C–Clip Lock

w³yÀ!¦I}Ž‰ Ÿ<{~}(‹! ‚‰ }# {5‚ƒ#„›{~}
¨L †‡}aƒ„›I ˆ  †‡}
w²ºyÀ!¦I}#Ž‰D„ƒ{{~}„œ•
} „…~€!†¤Žƒ€!‰  Ž‰DŒ7„‚ Ž}ƒ€ÄŸS{~}
‹7
‚‰ž‚ƒ„>…†½€!ƒ#‚ • „…~€!}#{~{~…~€!†‡¾9†‡ {~{…~€!†Å €!¦I…~‰Š‰ …~€!†½DÂ
 €Æ¥ƒ#‚›‰Š‹!}#}¶Žƒ#€!
…~‰ …~ƒ#€7¤}ŸS…~‰ ¾ ‰ ‹7}¶Ÿ<{~}/‹! ‚‰( €!Ç¢ƒ#„
• }# „…~€!†ž €!¤}# {5ˆ Œ7‰ • }a„}#¦
{ Ž}I

Fig. 18 Check Pinion Gear Rotation Torque

wxyz|{~}# € {~{9‚ƒ„}#…~†‡€ˆ
‰Š}#„…~ {9‚„ƒˆg‹!ƒŒ!…~€!†/Žƒ<}#„
 „}# 
w‘y’Aƒ#ƒ#}#€“‹!ƒ#Œ!…~€!†”Žƒ S}„–• ƒ#{~‰ >—˜„ …~€™{~Œ!• „…~Ž €!‰
‚„ƒˆš‰ ‹!}›‹7ƒ#Œ!…€7†œ
€7žŸ<{}›‹! ‚‰2‰ŠŒ!• }#@ |}ˆ ƒ<}›‹!ƒ#Œ!¡
…~€!†žŽƒ<}#„¢
w£y |ƒ#‰Š ‰Š}–I…~‚‚}„}#€7‰ …~ {¤Ž }–ƒ¥‰ ‹7
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ŽŽ}#…~• {} |}#ˆ ƒ S}š{~ƒŽ¨
Ž„}©¬ €!­¦I…~€!…~ƒ#€®ˆ  ‰ }/†‡} „¤‹! ‚‰¯‚„ƒˆ°
…‚‚}#„}#€!‰Š…~
{
Ž }aw±P…~†‡˜²³y

ÈÉSÊAˇÌ2Í7Í#Ì7Ë¹È Î9É
w²ry’AŒ!• „…Ž ‰Š}¤•
}
„…€7†/• ƒ#„}¤ €!Ï}# {{~…~¦©…~‰Š‹­†½}# „
{~Œ!• „…~Ž €!‰ ¯Ã€!}#„‰0ŸS{~}¥‹! ‚‰0‰Š‹!„ƒŒ!†‡‹”} {¾¯• }# „…~€!†‡¾
 €!}#€!†½
†½}a…‰ …~€!‰Šƒa…~
}(†½}# „›¦I{~…~€!}#

NOTE: Use care to prevent shaft splines from damaging axle shaft seal lip. Also, exercise care not to
damage the wheel speed sensor on vehicles
equipped with ABS brakes
w¸yÀ!}#„‰žz|· Ž{~…~¦Ð{~ƒ#Ž¨®…€¥}#€!ƒ#‚ ŸS{~}0‹! ‚‰ŠDµAŒ!‹
ŸS{~}a‹! ‚‰ ƒ#Œ!‰Ñ© „‰ ƒa}# ‰ z|· Ž{~…¦{~ƒ#Ž¨>…~€…~I}a†½}# „¢
wÒyÀ!}#„‰ ¦I…~€!…~ƒ#€­ˆ  ‰Š}>‹! ‚‰œ…~€!‰Šƒ>
…‚‚}„}#€!‰Š…~
{Ž }
 €!‰ ‹!„ƒ#Œ!†½‹¶‰Š‹!„Œ!‰G© ‹7}#„ €!¦I…~€!…~ƒ#€†‡}
„
wxy ¿{~…~†‡€¤‹!ƒ{}…€¤‹! ‚‰P©…~‰ ‹¤‹7ƒ#{~} …~€¤‰Š‹!} I…~‚‚}#„}€!‰Š… {
Ž }T
€7”…~€!‰Š {~{{~ƒ#Ž¨*Ž„}©Ó©›…‰Š‹Ô’Aƒ#Ž‰Š…~‰ }
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t ‚‰Š9{~•
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{~{2Žƒ S}#„ €! I>‚{~Œ!…~I| |}‚}#„‰ ƒ¯’AŒ!• „…~Ž
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{~Œ!• „…~Ž €!‰ „}#À Œ!…~„}ˆ }#€!‰Š
w£yÀ!‰Š
{~{˜• „ ¨L}I„Œ!ˆ 5 |}#‚}„a‰Šƒؘ„ƒŒ!¦¶‘
¾5Á|„ ¨7}¾
‚ƒ„›¦I„ƒ#¦I}„›¦I„ƒ#Ž}#
Œ!„}#
w´yÀ!‰Š
{~{S©›‹!}#}{5 €!‰ …~„}#
w»y’Aƒ©}„&<}#‹!…~Ž{~}#

Fig. 19 Mate Shaft Lock Screw

w ´yµAŒ!‹0ŸS{~}ž‹! ‚‰9…€#© „¶ €!„}ˆ ƒS}žŸS{~}ž‹7
‚‰
z|· Ž{~…¦{~ƒ#Ž¨¤‚„ƒ#ˆ*‰Š‹!}aŸ<{}a‹! ‚‰ w±A…~†‡¹¸ ºy
w»y |}#ˆƒS}]Ÿ<{}D‹! ‚‰Š<¼}]Ž
„}D‰ ƒ]¦
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‰Šƒ¯Ÿ<{}¯‹! ‚‰9• }# „…~€!†+ €!>}
{~¾<©›‹!…~Ž‹©›…~{{V„}#ˆ  …~€0…~€
ŸS{~}›‹! ‚‰V‰ŠŒ!• }#N¿9{~ƒ#¾S} ŸS}#„Ž…}›Ž „}]€!ƒ#‰V‰Šƒ›

ˆ  †‡}]‰Š‹!}
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Œ!…~¦
¦I}#©›…~‰ ‹¤¿Á|Â
• „ ¨7}

AXLE SHAFT SEAL AND BEARING
Ù5Ú7Û9Î5Ü<Ì&Í
w²ry |}#ˆ ƒ S}a‰Š‹!}aŸS{~}a‹! ‚‰Š
w¸y |}#ˆ ƒ S} ‰Š‹!} ŸS{~} ‹! ‚‰˜}# {¹‚„ƒ#ˆ”‰Š‹!} }#€7ƒ#‚|‰Š‹!}
ŸS{~}a‹! ‚‰ ‰ Œ!• }©…~‰Š‹¶ˆ  {~{5¦I„ÝÆ/•  „¢

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°{±M²D²D³©´{³ƒµ{¶G± ·¸N·µH°¹°{´{± ºŽ³D¸D± µH³

»6¼½D¾

NOTE: The seal and bearing can be removed at the
same time with the bearing removal tool.

 
   ! #"%$# #&(')*+"&(,-  
 .$# 0/'132
#&(')*4
#65798 ,;:#7< =>.?')*
@BA #CD &FEG,H:#I< =KJMLNE7'*PORQI<STO

Fig. 22 Axle Shaft Seal Installation

Fig. 21 Axle Shaft Bearing Removal

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#) A $K.?&(&(OZ
[1 \K)? W(  #&^]_O
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~ s  q_€{p\nykZp,mTqs^sq‚kZuƒ„puDq?sS}
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DIFFERENTIAL

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T<S
#' \#) A .CKCD&({ 'W( O
Q 
 ”1? +.$#&('W(K)? "'Y ”CD.*;"M&(•
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 31 A '"" ,&( )'#–?. 'M)?*„W( &>#) A
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)ˆ $# ,K&T'M)?*+W(#CDš#) A . ')*+KW(?'M)? A  #')*
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:  œ7 )‚ A '"" ,&( )'#$# #&(')*%W(#C$#O

Fig. 23 Bearing Cap Identification

 Œ  ž7'')Ÿ8CK&(  A ,& …!‹7< Q#¡#‹K2
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CKCD '1 † ' A †"§ †.?')*!E7'*POBQ#L 6#) A £ƒ &(†
') A 'W(#&yO
CAUTION: Do not spread over 0.38 mm (0.015 in). If
the housing is over–spread, it could be distorted or
damaged.

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" ,&( )'#6W(# 0"&(,¬ ;. ')*PO\­% ,#.&( ;1 A 'J
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T< = 
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&(  \ A '""M &( )?1'#$# #&(')*%W(#C$#,M#) A W(#CDO

1,2-3 4

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FHG

IKJMLONQP'RKSDRKTVUXW*TVYMZ/RKS[S[RZ\W*NVT]_^K`[a[bdcea[f[g[h[i

Fig. 24 Install Axle Housing Spreader

Fig. 26 Spread Axle Housing

Fig. 25 Install Dial Indicator

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æ úçÛ àÝé?êâåëPìfô%æ#ä(õ”Ý,ä™ßæ#ë†ßàÛ áDâããMÛä(Û,åßâMæ#çHï(æ#ê Û ðDä(Ûû
çÝæ#á9êà?âMÜ[ê™ßÝNâåáDâï(æ#ßÛöàâï(à”êâáDÛNÝ,ãBßàÛNáDâãMãÛä(Û,åßâMæ#ç
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Fig. 27 Differential Case Removal

Ò²Ó

Ô/Õ*Ö Ö ×8Ø/×<Ù/Ú>Õ Û[ÜەÙCÔDÔ/Ø/Õ ÝA× Ü Õ ÙC×

Þ,ß'à Þ

áKâMãOäQå'æKçDæKèVéXê*èVëMì/æKç[ç[æì\ê*äVèí_îKï[ð[ñdòeð[ó[ô[õ[ö

Fig. 29 Differential Bearing Cap Reference Letters

Fig. 28 Install Axle Housing Spreader
CAUTION: Do not spread over 0.38 mm (0.015 in). If
the housing is over–spread, it could be distorted or
damaged.

jlknmoqp rtsuvOwyxzsxz{d|z}+~"z€sdz{|€x‚wy{~*}+wyuƒ*ƒ-wyxzs„tu}+s
~"…wyxzsxz{|z}n~"z€†M‡&su}+|rtswyxzsv ~"}+wyuz„tsVˆ‰~*wyx…wyxzsv ~"uƒ
~"zv ~"„tuwy{rKjlŠ>~"€‹†ŒŽ+m_†
jlnm s‘’{”“•sQwyxzsQv ~"uƒ[~"zv ~"„tuw–{dr—†
jl˜nm™”z}nwyuƒ"ƒ[v ~"šlš*srtsdzwy~*uƒ[„tu}+sQ~"›wyxzsVxz{d|z}n~*€†œ z}n|zrts
wyxzuwHwyxzs&v ~"šlš*srtsdzw–~"uƒsdurt~"z€,„t|zp }žrtsd‘\u~*O~"Op {d}+~"wy~*{d
{Ÿwyxzs v ~"šlšlsdrtszwy~"uƒ¡sdurt~"z€}uzv¢wyxzuwwyxzs p rtsƒ"{duv
}nxz~"‘\}›rtsd‘\u~" sw£ˆ’sds wyxzs¤šlu„ts¤{š\wyxzssdurt~"z€¥„t|zp
uzv›wyxzs)xz{d|z}+~"z€‹†•¦/upw–xzs)v ~"šlš*srtsdzw–~"uƒ'„tu}+s)wy{,sdz}+|zr§s
wyxzs,surt~"z€‹}V„t|zp }Quzv›}+x~*‘\}Qurts,šl|zƒ"ƒ ¨¥}nsuwysv›~"wyxzs
xz{d|z}+~"z€‹†
jlŽnm™”z}nwyuƒ"ƒMwyxzssurt~"z€„tup})uw’wyxzsd~*rV{drt~"€~"zuƒMƒ*{d„tu©
wy~"{z}’jlŠ~"€†Œªnm§†
jl«nm¬{{}nsƒ ¨O~"z}+wyuƒ"ƒ[v ~"šlš*srtsdzw–~"uƒ[surt~"z€)„tup¡{dƒ"w–}n†
jl­nm s‘’{”“•sQun®•ƒ"sQxz{d|z}+~"z€)}+prtsuv sdr—†
jlªnm\¦[~*€‹xzwyswyxzsžsdurt~"z€V„tup{dƒ"w–}Kw–{\««,¯±° ‘Ÿj*˜«)šlwy†
ƒ"}+† m²w–{drt³|zs†
j§´nµnm™”z}nw–uƒ"ƒ[wyxzsQun®•ƒ"sQ}+xzušlwy}n†

Fig. 30 Differential Bearing Removal

DIFFERENTIAL SIDE BEARINGS
¶[·¸H¹[ºq»'¼
j§´em s‘’{”“•sQv ~"š*šlsrtsdzwy~*uƒ[š*rt{‘½u+®qƒ"sVx{|z}n~"z€†
jlŒnm s‘’{”“•sQwyxzsQsurt~"z€‹}’šlrt{‘½wyxzsQv ~"šlš*srtsdzw–~"uƒ[„tu}ns
ˆ’~"wyx¿¾>|zƒ"ƒ"srÁÀ—¾rts}n} Â ©lŒªk©l¾dñġ ©lŒªk©lkªÅ ƒ"{„tÆ8}nÄ¡uzv
¾ƒ*|€,oq¾>©*kŒ­ªj*Š>~"€†Çkµnm§†

ÈlɕÊË»¼¼»ËÈ ¹HÉ
j§´em̱}n~"z€Íwy{{ƒŸÂ ©lk«B´nŽ© ÃΈ’~"wyxÏxzuzv ƒ"sР©lB´n«B´+Ä
~"z}nw–uƒ"ƒ[v ~"šlš*srtsdzw–~"uƒ[}n~"v sQsdurt~*€}’jlŠ~"€†kB´em§†
jlŒnm™”z}nwyuƒ"ƒ[v~*š*šlsr§szwy~"uƒ ~*un®•ƒ"sQxz{|}+~"z€†
RING
¦'xs‰rtGEAR
~"z€\uzvVp ~"z~"{,€sdurt}HurtsK}nsrÁ“q~*„tsK~",uQ‘\uw–„txsv
}+sdwy†MÑ-{{wžrtspƒ*u„tsw–xsrt~"z€O€sur‰ˆ‰~*wyxz{d|zwžrtsp ƒ"u„t~"z€
wyxzsQp ~"z~"{€sdure†

–H—|˜™

š{›œŠœž{?Ÿ{ B› ¡’¢H¡Ÿ<šbš{ž{› £’¢Š› Ÿ<

¤X¥

¦§M¨G©ªr«¬b«­%®”¯­%°M±{«¬¬«^±=¯©%­²Ž³´µ¶·µ¸¹º»

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Fig. 31 Install Differential Side Bearings

÷[øùHú[ûqü'ý
þ§ÿ 

 "!#%$&'()*,+
þ-)./01
&2304()567()'289
()9:;$
()<=4,>?):
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Fig. 33 Ring Gear Bolt Installation

PINION
GEAR
]r$&sS&*t
u@v*P(wd("x
0
uy
=20S$
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 2$&%)! $'("*P+
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þC)z|()0&0\@@_("$&4\‚@ƒe ~&+

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8
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Fig. 32 Ring Gear Removal

üýýü&WRT úXU

TU V/W

CAUTION: Do not reuse the bolts that held the ring
gear to the differential case. The bolts can fracture
causing extensive damage.

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8:9<;>=@?6A:B0A:CEDGF#CEH<I!A:B.B.AIJF#=ECLKNM:O.P.QRSP.T.U.V.W

Fig. 34 Pinion Yoke Removal

Fig. 36 Front Bearing Cup Removal

Fig. 35 Remove Pinion Gear

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¼S½)ã)¿ÀÁÂ=Ã2Ä Á;ÅÆÁ;ÇÁÈÇKÉÁÈ4ÇÊË̄ÐÇSËÅÆÁ;ÏÊËÊÃË=ä;ÊÅÆ
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Fig. 37 Rear Bearing Cup Removal

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Fig. 38 Collapsible Spacer

Fig. 40 Pinion Rear Bearing Cup Installation

Fig. 41 Pinion Front Bearing Cup Installation

Fig. 39 Rear Bearing Removal
NOTE: Pinion depth shims are placed between the
rear pinion bearing cone and pinion gear to achieve
proper ring and pinion gear mesh. If the factory
installed ring and pinion gears are reused, the pinion depth shim should not require replacement. If
required, refer to Pinion Gear Depth to select the
proper thickness shim before installing rear pinion
bearing.

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g$lmoflmj owv`^hx
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X•[Zz{ofp[be^i]m]’^Šof`‰–_aj ]m]m^g$p[l#~]m`—g$ha` ]mj^irkpqgi^i_a`h˜j og$lmofŒ
lmj opqdf^ƒb^ofrŠlmofpqbe^]m]™g$lmoflmj ov` ^hšlmodfj …fp[lmofv›X+lmvœx‘i‘[Z”x
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yž[Ÿi•‚’^ofrdfj]#ri` h:i•¥yXlmvx’‘¥[Z”x
X”ž[Ž[Zz{ofp[b^]m]’bedf`¦ jn`¦‰—^p[df` hš^ior^Eof`{‰§of…fb6jocbedf`
g$lmoflmj o¨v`^h:^ofrblmvdb`owbedf`›g$lmoflmj o¨of…fb<…foblm]¤bedf` ha`›lmp
© ` haj@~`^ihalmofvk`ofr$Œgi]#^[ ªx
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!"# $&%'$()* +,% )

-/.102

Fig. 42 Pinion Seal Installation

Fig. 44 Collapsible Preload Spacer

Fig. 43 Shaft Rear Bearing Installation
CAUTION: Never loosen pinion gear nut to
decrease pinion gear bearing rotating torque and
never exceed specified preload torque. If preload
torque or rotating torque is exceeded a new collapsible spacer must be installed. The torque
sequence will then have to be repeated.

ԔÕ[Ö[×ؚÙ[Ú#ÛÜJÝÞ ß'àkáfÞâmã$à äJåæçiècéÛfãwé¨êeÞ äaëìfà:í†äaà Ûfîaá
Ù[à ê<éê<ÖïÖðšñ òóÔôçiõköêe÷™âmøÙq÷ הù+îaäaìfÙqá¨îaÞâ#âméú$Ù[Úmøiâmà›Ù[ú$éîaà ä
ìfÛfêeÚmâ.øà éäaÚmÛfÜkà Ûãcú$âmé[Ý>Úmٗêéß'à ÛwìfúÔû+Úmܜ÷’Öåq×N÷
NOTE: If the spacer requires more than 474 N·m
(350 ft. lbs.) torque to crush, the collapsible spacer
is defective and must be replaced.

Fig. 45 Pinion Yoke Installation

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Fig. 46 Tightening Pinion Nut

Fig. 48 Typical Housing Cover With Sealant

DISASSEMBLY AND ASSEMBLY
STANDARD DIFFERENTIAL

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Fig. 47 Check Pinion Gear Rotating Torque

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CAUTION: Overfilling the differential can result in
lubricant foaming and overheating.

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Gear Mate Shaft Lock Screw
ƒ ‡eŠ Fig.
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ícî#îDï¬ðsñcògFig.
ó 50 Pinion Mate Gear Removal
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Fig. 51 Trac–lok Differential Components

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Fig. 54 Mate Shaft Removal

Fig. 52 Differential Case Holding Tool

Fig. 53 Mate Shaft Lock Screw

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Fig. 55 Step Plate Tool Installation

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NOTE: The clutch discs are replaceable as complete sets only. If one clutch disc pack is damaged,
both packs must be replaced.

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Fig. 56 Threaded Adapter Installation

Fig. 57 Tighten Belleville Spring Compressor Tool

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Fig. 58 Remove Pinion Gear Thrust Washer

Fig. 59 Pinion Gear Removal

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Fig. 60 Side Gear & Clutch Disc Removal

Fig. 61 Clutch Disc Pack

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Fig. 62 Clutch Discs & Lower Side Gear Installation

Fig. 63 Upper Side Gear & Clutch Disc Pack
Installation

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CLEANING AND INSPECTION

ADJUSTMENTS

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Fig. 65 Shim Locations

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Fig. 66 Pinion Gear Depth Gauge Tools—Typical

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Fig. 67 Pinion Height Block—Typical

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Fig. 69 Pinion Gear Depth Measurement—Typical

DIFFERENTIAL BEARING PRELOAD AND GEAR
BACKLASH
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Fig. 68 Gauge Tools In Housing—Typical

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Fig. 70 Axle Adjustment Shim Locations

NOTE: It is difficult to salvage the differential side
bearings during the removal procedure. Install
replacement bearings if necessary.

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SPECIFICATIONS
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ü ÐÃdÌË × Ëöç,Ð ÙÙ ÌÅ Ù ÊzÈ Ù Å ÐÕ ÉÉÉÉÉYÞÉ äXå6Ë.Ë é ÞÉ Þô%Þ.ÌNÒÉ ì

194 RBI AXLE
¶·¸Y¹-º`»¼X½`»¾¿
½`¾oºcýoþ·
ñ,Ï ÄÑ(î ï ÌðNðÉ5ç,Ï"ÿdÅ Ù ÉÉÉÉÉÉ[ÉÉÉÉÉÉÉYæå6ù`ú Ë éNê Þ ðNÑÉ5Ä Ø ëÉ ì
ñ,Ï ÄÑ(î5ñ,ÅÐ Ù ÌÒ5Ó$ç,ÐÈÉÉÉÉÉ[ÉÉÉÉÉÉÉYãã ù`ú Ë é ä%ã ðNÑÉ5Ä Ø ëÉ ì
ù × Ñî5òXÌÒ5ÌÏ Ò ÉÉÉÉÉÉÉYôãXåÍæã%æ.ù`ú Ë é ôÞÞÍ ê äÞ ðÑ(É5Ä Ø ëÉ ì
ÊdÚ Ù Å"áî5òXÌÒ5ÌÏ Ò ü ÐÑ(ÅoÊdÜ5ÐðÑ Ö Ï Úõ ÉÉÉÉ[ÉÉÉÉåèÉ ôä ù`ú Ë
é åô.ðÑÉÄ Ø ëÉ ì
ñ,Ï ÄÑ(î5í,ÌÒ5Ó$óÅÐ Ù ÉÉÉÉÉ[ÉÉ]àäÍåôô ù`ú Ë é ãÞ%ÍàÞ ðÑ(É5Ä Ø ëÉ ì
ñ,Ï ÄÑ(îÂ`ñ,ÊFÊzÅÒ5ëÏ Ù ÉÉÉÉÉÉÉÉ[ÉÉÉÉÉYÝ ù`ú Ë é ã%Þ ÌÒ5É5Ä Ø ëÉ ì

Adapter—C-293-39

Adapter—C-293-40

SPECIAL TOOLS
Plug—SP-3289

194 RBI AXLE

Puller—C-293-PA

Puller—C-452

 

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4656768:9<;>=?6@A@A=4CBD8>EFGIHJFKLMN

132

Cup—8109
Wrench—C-3281

Installer—C-3972-A

Handle—C-4171

Spanner—6958

Driver—C-3716-A

Installer Screw—8112

Installer—D-130

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Installer—D-146

QRS S T UTVWR XYXVQQUR ZT Y R VT

Installer—6436

Remover—C-4345

Installer—6437

Remover—D-149

Disc, Axle Arbor—6732

Installer—W-262

Gauge Block—6735

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Tool Set, Pinion Depth—6774
Spreader—W-129-B

Trac-lok Tool Set—6960
Adapter Kit—6987

Holder—6965
Guide Pin—C-3288-B

Starting Point Shim—8107
Bearing Remover Tool Set—6310

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Hub Puller—6790

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Dial Indicator—C-3339

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216 RBI REAR AXLE

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page
GENERAL INFORMATION
216 RBI AXLE . . . . . . . . . . . . . . . .
LUBRICANT SPECIFICATIONS . . . .
DESCRIPTION AND OPERATION
STANDARD DIFFERENTIAL . . . . . .
TRAC-LOK OPERATION . . . . . . . . .
DIAGNOSIS AND TESTING
BEARING NOISE . . . . . . . . . . . . . .
DRIVELINE SNAP . . . . . . . . . . . . .
GEAR NOISE . . . . . . . . . . . . . . . . .
GENERAL INFORMATION . . . . . . .
LOW SPEED KNOCK . . . . . . . . . . .
TRAC–LOK DIFFERENTIAL NOISE
TRAC–LOK TEST . . . . . . . . . . . . .
VIBRATION . . . . . . . . . . . . . . . . . .
SERVICE PROCEDURES
LUBRICANT CHANGE . . . . . . . . . .
REMOVAL AND INSTALLATION
AXLE BEARING AND SEAL . . . . . .
AXLE SHAFT . . . . . . . . . . . . . . . . .
DIFFERENTIAL . . . . . . . . . . . . . . .
DIFFERENTIAL SIDE BEARINGS . .

. . . . . . . . . . 84
. . . . . . . . . . 84
. . . . . . . . . . 85
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93
92
94
95

GENERAL INFORMATION
216
º»½¼¿RBI
¾/ÀÂÁAAXLE
Ãļ¹ÅÇÆ6Èļ¹ÅÇÉËÊ<Ì ¼IÍÏÎ(ÐÒÑÓÔÆÖÕIÑ×<ÃÄÈÄÓÙØ6ÅÂÚÛ(¼>»ÜչݽÍÏÎ(ÑÜÐ

»ÜÅÇÍ>ÅÇÑÞÎ(ÆÖÕIÑÞßÖ¼IÑÜàá¼¹ÆßDÅâÍÂàãÎ(ÑÜÐä×Ì Î(å<å<¼IÆÖ¼¹ÑÜàáÎ(ÅÇÛ»ÜչݽÍÏÎ(ÑÜÐÖØÄæ¿Îàá»
ÅÂÚÛ(¼çÍÏ»ÜÅÇåàèàãÝÜéǼIÍê¼ÔÚàá¼¹Ñ½Ì Î(ÑÜÐëå<ÆÖÕ¹Éì¼¹Î(àá»Ü¼¹ÆíÍÏÎ(Ì ¼Iîïºð»Ü¼
àáÝÜéǼ¹ÍñÅÇÆÖ¼èòâÆÖ¼¹ÍÂÍϼIÌêÅÇÑÜÌóæô¼¹Û(Ì ¼IÌêÎ(ÑÜàáÕõà㻽¼èÌâÎåå<¼IÆÖ¼¹ÑÜàáÎ(ÅâÛ
»ÜÕIÝÜÍÏÎ(ÑÜÐ:àáÕAå<Õ¹ÆÖÉöÅÕIÑܼ¹Ê<òâÎ(¼¹ßÖ¼AÅÂÚÛ(¼A»ÜÕ¹ÝÜÍÂÎ(ÑÜÐÒî
º»½¼÷Î(ÑÜàã¼IÐÒÆÖÅÇÛàÙøùò ¼÷»ÜÕIÝÜÍÏÎ(ÑÜÐûúÄ»¹øò ÕIÎÌÞÐû¼¹ÅÇÆôÌ ¼IÍÏÎ(ÐÒÑü»ÜÅÇÍ
àá»Ü¼¿ßÖ¼¹ÑÜàá¼¹ÆÛ(Î(Ñܼ¿Õ¹åýà㻽¼ôòâÎ(ÑÜÎ(Õ¹ÑÍϼ¹àéâ¼IÛ(ÕÔæþà㻽¼ôßÖ¼IÑÜàá¼¹ÆÛÎ(Ñܼ
Õ¹åàá»Ü¼AÆÖÎ(ÑÜÐ:ÐÒ¼¹ÅÇÆÿî
º»½¼ÅÏÚùÛ¼»½ÅâÍä
Å ¼¹Ñ½à>»ÜչͼàãÕÆÖ¼IÛ(Î(¼ ¼Î(ÑÜàá¼¹ÆÖѽÅâÛò ÆÖ¼¹ÍÂÊ
ÍÂÝÜÆÖ¼óßÖÅâݽÍϼ¹Ì éÂøçÛ(ÝÜéÇÆÖÎ(ßÖÅÇÑÜ
à ÅÇò ÕIÆÖÎ ÅÇàãÎ(Õ¹ÑêÅÇÑÜÌíÎ(ÑÜàá¼¹ÆDÑÜÅÇÛ
¼ÔÚùò ÅÇÑÜÍÂÎÕIÑÜî
º»½¼çÅÏÚùÛ¼IÍêÅÇÆÖ¼ç¼ ÇÝÜÎ(ò ò ¼IÌ æ¿Î(àã» ÍϼIÉËÎ(Ê<å<Û(ÕIÅâàáÎ(ÑÜÐëÅÂÚÛ(¼
Í»ÜÅÇå<àãÍÂî º»Ü
¼ ù¼¹»ÜÎ(ßÖÛ(¼Aæô¼IÎ(ÐÒ»ÜàËÎÍÍÏÝÜòâò Õ¹ÆÖàá¼¹Ì éÂø àá»Ü¼ÞÅÂÚÛ(¼
Í»ÜÅÇå<àôÅÇÑÜÌñéǼ¹ÅÇÆÖÎ(ÑÜÐûÍÏî º»½¼ ÅÂÚÛ(¼ Í»ÜÅâåàãÍ÷ÅÇÆÖ¼ ÆÖ¼¹àáÅÇÎ(Ñܼ¹ÌñéÂø
ò Û(ÅÇàá¼¹ÍôéÇÕ¹Û(àá¼¹Ì àãÕAàá»Ü¼A¼¹ÑÜÌ å<Û(ÅÇÑÜÐû¼¹ÍôÕ¹åàá»Ü¼AÅÏÚùÛ(¼äàáÝÜéǼIÍÏî
º»½¼>ßÖÕ ¼IÆ6ò ÆÖÕ Î(Ì ¼IÍ ÅËÉ˼¹ÅÇÑÜÍå<ÕIÆ6ÍϼI Æ Î(ßÖÎ(ÑÜÐôàá»Ü¼>ÌâÎ(å<å<¼IÆDÊ
¼¹Ñ½àãÎ(ÅÇÛæôÎ(àá»ÜÕIÝÜàÆÖ¼¹ÉËÕ Î(ÑÜÐ:àá»Ü¼AÅÏÚùÛ¼A»½Õ¹ÝÜÍÂÎѽÐÒî

ÕI Æ ù¼¹»ÜÎ(ßÖÛ(¼¹Í÷ ¼ ÇÝÜÎ(ò ò ¼IÌæ¿Îàá
»
È èéÇÆÖÅ ½¼IÍÏúà㻽¼ ÅÂÚùÛ¼IÍ
»ÜÅ ¼óÅ àáÕIÑܼ ÆÖÎ(ÑÜÐ òâÆÖ¼¹ÍÂÍϼIÌíÕ¹ÑÜàáÕ àá»Ü¼óÅÏÚùÛ(¼ ÍÏ»½Åâåàã
î  ͼ
ßÖÅÇÆÖ¼÷濻ܼ¹Ñ ÆÖ¼IÉËÕ ùÎ(ÑÜÐóÅÂÚÛ(¼ Í»ÜÅÇå<àáÍ àáÕ ¼IÑÜÍÏݽÆÖ¼ àá»ÜÅÇàäàá»Ü¼
àáÕ¹ÑܼÆÖÎ(ÑÜÐôÕIÆ6àá»Ü¼æô»Ü¼I¼¹Û/ÍÏò ¼I¼¹ÌAÍϼIÑÜÍÂÕ¹Æ#ÅâÆÖ¼ÑÜÕIàÌ ÅÇÉËÅÇÐÒ¼IÌ î
º»½¼Þ¾/ÀÂÁñÃÄÈÄÓAÅÂÚÛ(¼ »ÜÅÇÍàã»Ü¼ ÅÇÍÏͼ¹ÉËéÇÛ ø ò ÅÇÆÖàËÑÜÝÜÉËéǼ¹Æ
ÅÇÑÜÌÐÒ¼IÅâÆ3ÆÖÅÇàáÎÕËÛ(Î(ÍÏàá¼IÌÕIÑ Å:àáÅâÐûî ºð»Ü¼ËàáÅâÐäÎ(Í>ÅÇàáàãÅÇßֻܼIÌàáÕ

page
FINAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 100
PINION GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . 97
PINION SHAFT SEAL . . . . . . . . . . . . . . . . . . . . . 91
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
RING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
DISASSEMBLY AND ASSEMBLY
STANDARD DIFFERENTIAL . . . . . . . . . . . . . . 101
TRAC-LOK DIFFERENTIAL . . . . . . . . . . . . . . . . 101
CLEANING AND INSPECTION
AXLE COMPONENTS . . . . . . . . . . . . . . . . . . . . 105
TRAC-LOK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
ADJUSTMENTS
DIFFERENTIAL BEARING PRELOAD AND
GEAR BACKLASH . . . . . . . . . . . . . . . . . . . . . 108
GEAR CONTACT PATTERN ANALYSIS . . . . . . . 111
PINION GEAR DEPTH . . . . . . . . . . . . . . . . . . . 106
SPECIFICATIONS
216 RBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . 113
216 RBI TORQUE . . . . . . . . . . . . . . . . . . . . . . . 113
SPECIAL TOOLS
216 RBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . 113

àá»Ü¼ Ì Î(å<å<¼IÆÖ¼¹ÑÜàáÎ(ÅÇÛ»ÜչݽÍÏÎ(ÑÜÐñéÂø Å ßDÕ¼IÆéÇÕ¹Û(àáîÈÄÝÜÎ(Û(ÌèÌâÅâàá¼
Î(Ì ¼¹Ñ½àãÎ(å<Î(ßÖÅÇàáÎ(Õ¹Ñ ßÖÕ¹Ìâ¼¹ÍËÅÇÆÖ¼äÍÂàáÅâÉËòâ¼¹Ì ÕIÑüàá»Ü¼AßÖÕ¼IÆ¿ÍÏÎ(Ì ¼äÕIå
ÅÇÑ ÅÂÚÛ(¼AÍ»ÜÅÇå<ààáÝÜéǼ¹î
º»½¼ËÌâÎåå<¼¹ÆÖ¼IÑÜàáÎ(ÅâÛýßÖÅÇͼËÎ(ÍÅ÷չѽ¼¹Ê<òâμIßÖ¼ôÌ ¼¹ÍÂÎ(ÐÒÑÜîâºð»Ü¼ôÌ Î(å<Ê
å<¼IÆÖ¼¹ÑÜàáÎ(ÅÇÛ¿ò Î(ÑÜÎ(Õ¹ÑíÉËÅâàá¼üÍÏ»ÜÅÇå<à÷Î(ÍÞÆÖ¼¹àáÅÇÎѽ¼¹Ì æôÎ(àã»íÅèÆÖÕ¹Û(Û(Ê
ò Î(ÑÜî Îåå<¼¹ÆD¼¹ÑÜàáÎ(ÅâÛ ÍÂÎ(Ì ¼ éâ¼IÅÇÆÖÎѽÐüò ÆD¼¹Û(Õ¹ÅÇÌ ÅÇÑÜÌóÆÖÎ(ÑÜÐüÐû¼¹ÅÇÆ
éÇÅÇß ½Û(ÅÇÍÏ»Î(Í ÅÇÌ ÝÜÍÏàá¼IÌäéÏø Í»ÜÎ(ÉËÍ ò ÕIÍÏÎ(àáÎ(Õ¹ÑܼIÌäéǼ¹à æô¼¹¼IÑà㻽¼
ÍÏÎ(Ìâ¼ÞéǼ¹ÅÇÆÖÎ(ÑÜÐüßÖչѽ¼ÞÅÇÑÜÌ Ì Î(å<å<¼IÆÖ¼¹Ñ½àãÎ(ÅÇÛ3ßDÅâͼ¹î Î(ÑÜÎ(ÕIÑ ÐÒ¼¹ÅÇÆ
Ì ¼Iò àá»êÎ(Í ÅÇÌ ÝÜÍÏàá¼IÌ éÂøÍ»ÜÎ(ÉËÍ ò ÕIÍÏÎ(àãÎ(ÕIÑܼ¹Ì éǼ¹à æô¼I¼¹Ñ àá»Ü¼
ÅÂÚÛ(¼»½Õ¹ÝÜÍÂÎ(ÑÜÐ ÅÇÑÜÌ àá»Ü¼:Î(ÑÜÑܼ¹ÆËò Î(ÑÜÎ(Õ¹ÑóéǼIÅâÆÖÎ(ÑÜÐ ßÖÝÜò î  Î(ÑÜÊ
Î(Õ¹Ñ éǼ¹ÅÇÆÖÎ(ÑÜÐ ò ÆÖ¼¹Û(ÕIÅâÌþÎ(Í ÉËÅÇÎѽàãÅÇÎ(Ñܼ¹ÌþéÂø Í»ÜÎ(ÉËÍ ò ÕIÍÏÎ(Ê
àáÎÕIÑܼ¹Ì éǼIàÙ濼¹¼¹Ñ àá»Ü¼ñò Î(ÑÜÎ(ÕIÑêÐû¼¹ÅÇÆ ÍÏ»ÜÅÇå<à÷ÍÏ»ÜÕIÝÜÛ(Ì ¼¹Æ ÅÇÑÜÌ
àá»Ü¼AÕ¹ÝÜàá¼¹Æ>éǼ¹ÅÇÆÖÎ(ÑÜÐ:ßÖÕ¹ÑܼIîý×
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LUBRICANT
 "!$#%&('()*!$+)-SPECIFICATIONS
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Fig. 1 Axle Adjustment Shims

[ƒ „$…†‡(ˆS‰-Š$‹EŒ†Ž‰05‘’R‡Š$‹‘Š$“*‘ “”Œ(†Ž•$‘‰–9—5˜“*„B‹™—š†
‹†‰‡(‘ †F‹›œ„$’‘8‡’ŽŸžd ¢¡-£¤¦¥[§¨©¦Mª¬«­¯®  5­±°²¢³9‘ ‰-†
„$…†‡ˆ‰Š$‹´
­¬†‰-ˆS˜µT“*‡Œ(Œ‘†‘ Š$‹‡(‰’I†‘¶„$‡†‘Ž‹•$‘Ž‰“*“*‡‹‡( Š· Œd¨h¸{´
Œ[Œ†‡ˆ‹‡( ŠI¹" “*‡Œ‡‘†‹º‹•$‘ ‰05‘º„$…†‡ˆ‰-ŠB‹´4­±•$‘º»^§¼"½¾°
‰M‘ „$…†‡ˆ‰Š$‹¿ˆ‰À*‰ˆ‡(‹g—Á‡’§0´ ÃăÆŨ´ ©ÇÀ-‹’´ Èɋ‹‰(Ê
‡Š$ˆ„$“*‡Š$³I‹•$‘Œ†‡ˆ‹‡Š8¹"“*‡Œ(‡(‘ †‡Œ@Š$‘ˆ‘ ’0’‰† —Ÿ´


CAUTION: If axle is submerged in water, lubricant
must be replaced immediately to avoid possible
premature axle failure.

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Fig. 2 Differential Operation—Straight Ahead Driving

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‹†‰0–5‘"‰É³Ÿ†‘‰‹‘ †8“*‡’0‹‰Š$ˆ‘T‹•$‰ŠO‹•$‘¦‡(ŠB’0‡“*‘Ž›•$‘‘ ;‹
ˆ¹AÀ*‘‹‘‰‹„$†ŠB´9­±•$‘“*‡ŒŒ(‘†‘ Š$ˆ‘¹"„$’‹@…‘ˆ ¹"À*‘ŠB’0‰‹‘“
Œ †Ž‹HÀ*†‘–M‘Š$‹E‹•$‘h‹‡†‘’GŒ† ¹Ô’0ˆ„$Œ(Œ‡Š$³T‰Š$“U’µw‡(“-“*‡Š$³
‹•$†„B³9•¢‹„B†Š$’0´­Q”‰ˆˆ¹"À-‡(’•¢‹•B‡(’Ê‹•$‘”“-‡(Œ(Œ‘†‘ Š$‹‡‰-
‰Õ (›A’d‹•$‘‰05‘’•$‰Œ‹’d‹‹„$†ŠF‰‹@„$Š$‘¶„$‰Q’À*‘ ‘“*’dÅÒ[‡³9´
ÈS´±°Š¿‹•$‡’‡Š$’0‹‰Š$ˆ‘ ʱ‹•$‘f‡Š$À*„$‹‹†S¶-„B‘Ž‰À*À-‡(‘ “h‹f‹•$‘
À*‡Š$‡Š8³9‘ ‰-†’A‡’AŠ$‹“*‡ –M‡“-‘“G‘ ¶„$‰( —4´B­¯•B‘EÀ*‡Š$‡ ŠH³9‘ ‰†’
Š$›Ö†‹‰‹‘E‰† „$Š$“G‹•$‘EÀ*‡Š$‡ ŠH¹"‰-‹‘E’•$‰Œ‹d‡ŠH À*À* ’0‡‹‘
“*‡†‘ ˆ‹‡ Š$’0´Q­¯•$‡’F‰(›A’F‹•$‘G’0‡“*‘G³Ÿ‘‰†I‰Š$“¦‰M‘G’0•$‰Œ‹
‰‹‹‰ˆ•$‘ “U‹H‹•$‘H„$‹’0‡“-‘I›A•$‘ ‘‹h†‹‰‹‘H‰-‹E‰¿Œ‰’0‹‘†
’0À-‘‘ “*´

DESCRIPTION AND OPERATION
STANDARD DIFFERENTIAL

­¯•B‘Ë“*‡ŒŒ(‘†‘ Š$‹‡(‰R³9‘ ‰†É’Ì—5’0‹‘¹Í“-‡ –5‡(“-‘’W‹•B‘Ë‹†¶„$‘
…‘‹g›A‘ ‘ŠC‹•$‘I‰M‘I’•$‰Œ‹’0´°‹º‰›A’;‹•$‘‰05‘I’0•$‰Œ(‹’‹
† ‹‰‹‘E‰‹“-‡(Œ(Œ‘†S‘Š$‹’À*‘‘ “*’›A•$‘ Š8‹„$†ŠB‡(ŠB³Fˆ †Š$‘ †’0´
 ‰ˆ•Ë“*‡ŒŒ(‘†‘ Š$‹‡‰;’0‡“-‘¿³9‘ ‰†H‡’C’À*‡Š$‘“W‹T‰ŠË‰M‘
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Fig. 3 Differential Operation—On Turns

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Fig. 4 Trac-lok Limited Slip Differential Operation

DIAGNOSIS AND TESTING
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DRIVELINE
SNAP


ÒEÓNÔÕ

þBóøk ÷ >ô7ù7ó%÷ Eð økõBðGÿn÷2ôoð ù7ñ >/
õ õB÷5ï<økóù7ð9õlò9óúó2îAó2ô-;
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gð9ï<øWóDîAþ>óûcó5þ>ï;
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ï<øk÷2ñ<ðGî;ï<õ>öwîAþBóøW%÷ Bô7ù7ó %÷ ¢ðlõ>÷5ï<øW%ó


TRAC–LOK
LNMOPRQ%S.TNUDIFFERENTIAL
Q%PPRQ%VXWYQ Z[O P]\NOISE
SG^_UM/^T0TO Y@VQ%\SOa`bM/O%V

T0c/YV/\V/dXU-Q%YV/O YSefO gKQ%YOhYO%PRQiC\V/dX^jL
Y^UkK[Q%l8c/V\BT@gKQ Y
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nY^\BVm
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\gK\O%ns[c/ZY\BU^V/T0eutO gKO%YvT0Q&wxc/ZY\U^V/TJUM/^V/d4O&\VyT0M/\S
z YQ c/We
{ UQ V/T^\V/O YjQ ga|uQ W^Y L
Y^UkK[Q%l8wxcZY\U^V/T@}KgKY\UT0\Q%V
PRQ%n\gK\O%YF~SMQ%c/[nhZOb^nnO%tnh^gBTO Y YO W^\Y S.O%YFiA\BUObQ Y ncY-k
\V/du^[c/ZY\U^VT€UM/^V/d4O e
{ gKT0O%Y@UM/^V/d4\V/d_T0M/OR[c/ZY\U^VTmnY\ iCORT0M/OiCO M/\U[Oj^V/n
PR^l#Oƒ‚.„pT0Qƒ‚.…pS.[BQ`amgK\d4cYO%kKO \d4M/T@T0c/YV/S.eALNM\BSjPR^V/O c/k
iCO YR`\[[bWc/PRWv[c/ZY\U^V/ThT0M/YQ c/d4M†TM/O8U[c/TU-M/O%S.eqL‡M/\S
`\[[UQ%YYO UTuTM/OJUQ%Vn\T\Q Vˆ\VˆPRQ%S.TE\V/S.T0^VUO%S.eG‰3gjT0M/O
UM/^T0TO YbWO%YS.\BS.T0Sm
U[c/T0UMon^PR^d4OUQ%c[BnXM/^.iCOQ UUc/YYO ne

TRAC–LOK TEST
WARNING: WHEN SERVICING VEHICLES WITH A
TRAC–LOK DIFFERENTIAL DO NOT USE THE
ENGINE TO TURN THE AXLE AND WHEELS. BOTH
REAR WHEELS MUST BE RAISED AND THE VEHICLE SUPPORTED. A TRAC–LOK AXLE CAN EXERT
ENOUGH FORCE IF ONE WHEEL IS IN CONTACT
WITH A SURFACE TO CAUSE THE VEHICLE TO
MOVE.

ŠN‹ŒGŽBBKŒ%-Œ%‘/’0Ž“”I•-“‘h–ŒG’0Œ%—.’0Œ%€˜Ž’‹™%š/’Œ ›R™3œAŽB‘’0‹/Œ
ŽKBŒ%Œ ‘/’Ž“”•“—.Œ–.ž8›RŒ%“—.š/Ž‘/h™%’0“’Ž‘/h’0™%Ÿš/Œ   ¡u“¢#Œ
—šŒƒ–“¢Œ —9“Œ8‘/™%’_“4?ŽB‘£š/Ž‘/¤’‹ŽB—p›RŒ%“—.š/Œ%¥
›RŒ%‘’ 
¦-§"¨X© ”B“•Œª–”™%•-¢—£ŽB‘«K™%‘’o“‘/¬Œ “¤™ E–™%’0‹sK™ ‘/’
˜‹Œ%Œ%”—. 
¦K­.¨X® “Ž—Œ™ ‘/ŒŒ “ ˜‹/Œ Œ%”aš/‘/’0Ž”Ž’=ŽB—_•™%›R¯”Œ%’0Œ%” ž°™ K
’0‹/Œ4™ š/‘/ 
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Ž‘/u–“¢#Œ™%BK 
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˜‹Œ%Œ%”“‘pŒ “X™ ’“’0Ž‘/u’™ ŸšŒ ¦B¾ Ž4  ».¨  
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”–—  ¨ ™%›R™%Œ8’0‹/“‘ ­ ¸ §pÀ€Á › ¦B­ ººÂB’ €”B–—.  ¨ ™ ‘†Œ%Ž’0‹/Œ%
˜‹Œ%Œ%”’‹/Œš/‘ŽB’—‹/™ š/”p–Œ—Œ FœCŽ•Œ  

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pãsuÎك…„
Þ „‡vx‹‡äxŒƒ*åæ~
wz——{*„‡{…}†‰wzvxŒy¬ÆvçÍx€vx}†“wz†4¨èƒ*—
ʃ*
vx„
Þ „‡v‚‹‡äxŒzƒ…åéŒz€–x„‡wz‹‡vx}†êp—„‡wz‹‡†‰wzƒ…}"2ƒ…~
wz—wz{*„Àsr¬šƒ…„
{…Íx€w Š¡v‚tŒz{*}†“¬>€y|†–‚{Ðvx~
~
{*~’v‚—†“{*„„‡{*
vxwz„y{…„ÀŠTwz‹‡{Ѓ*„v
Œz€–x„‡wz‹‡v‚}”†S‹‡ˆvx}™­{*ÇtC{*—{…„£†‰ƒ•†‰ˆ{’ëـ–x„‡wz‹‡v‚}”†
‚{…‹‡wz—wz‹‡vxÌ
†‰wƒ*}y8y{…‹‡†‰wzƒ…}uƒ*—†‰ˆwzy8™­„‡ƒ*€—ƒ*„:†“ˆ{Ç͂€”v‚}”†“wz†4¨Ð}Ë {*‹‡{…yy|vx„À¨¥
pìsuÎÙwŒzŒŸ~
wz——{*„‡{…}†‰wzvxŒ•ª2wz†‰ˆ›Êƒ*
vx„
¨T‚ƒ…wz~éî>{…vx„
t ƒ…—
í †‰ˆ{<—wzŒzŒ2‚Œ€”™
ëـ–‚„rw‹‡vx}†‰¬
ƒ…„Å{…Íx€w ŠTvxŒz{…}†‰¬
†“ƒ<–xƒ…†‰†‰ƒ…é
ˆƒ*Œ{*CtC{*—{…„2†‰ƒB†“ˆ{Bëـ–x„‡wz‹‡vx}†
‚{…‹‡wz—wz‹‡vx†‰wƒ*}y˜y{…‹‡†‰wzƒ…}—
Ë ‹‡{…yy|vx„À¨Õ
†‰ˆwzy2™­„‡ƒ…€”Å—ƒ…„†“ˆ{Íx€vx}†‰wz†©¨ï}{*

Fig. 5 Trac-lok Test —Typical

SERVICE PROCEDURES
LUBRICANT
CHANGE
prq+sutCvxwzy|{vx}~uy|€‚
ƒ…„‡†U†‰ˆ{:ŠT{*ˆwz‹‡Œz{…

p ŽsutC{…2ƒ‘ŠT{’†“ˆ”{•Œz€–x„‡wz‹‡v‚}”†u—wzŒzŒ˜ˆƒ…Œz{’
Œz€™š—„‡ƒ…›†‰ˆ{
~
wz——{…„‡{*}†‰wvxŒ'ˆ”ƒ…€yw}”™‹‡ƒ“ŠT{*„œ
psutC{…2ƒ‘ŠT{ž†“ˆ{ž~
wz——{*„‡{…}†‰wzvxŒŸˆ”ƒ…€yw}”™ ‹‡ƒ‘Š¡{…„¢vx}~
~
„‡vxwz}£†“ˆ{Œz€–x„‡wz‹‡vx}†U—„‡ƒ*¤†‰ˆ{ˆƒ*€y|wz}™¥
p¦su§CŒz{…vx}Ÿ†‰ˆ{<ˆƒ…€”y|wz}™•‹‡vŠTwz†©¨•ª2wz†‰ˆŸv«—Œz€yˆwz}™•ƒ…wzŒz¬
Œzwz™­ˆ†'{…}™¥w}”{ƒ…wzŒz¬Tƒ*„Œwz}†'—„‡{*{‹‡Œzƒ…†‰ˆ¡®
¯S°±¯”²>³±´…µ
¶S·²rµ‚¸‡¹
´…²$µ
·”ºS¹±»Pµ‚¸¥¯”´…µ
°±µ‚¹¼¯¸B½”·´…¯¾À¿œ°±µuÁ‰¯¸BÂx¾Àµ
·°±¿œ°±½”Ã
pďsutC{…2ƒ‘ŠT{ņ‰ˆ{Ń*„‡wz™­wz}vxŒ:y{…vxŒzvx}†—„‡ƒ*Æ†“ˆ{uˆƒ…€ywz}™
vx}~u‹‡ƒ‘Š¡{…„Çy€„‡—v‚‹‡{*y|
pȏsÉ:
‚Œ ¨’v£–x{*v‚~£ƒ…—ÊBƒ…‚v‚„
wzŒwz‹‡ƒ*}{tC€”–‚–x{…„
{*v‚ŒzÌ
Ë ™‹‡ƒ‘Š¡{…„pÎPwz™¥¼Èsr Ë
vx}†‰¬¼ƒ…„{…Íx€w ŠTvxŒz{…}”†“¬±†“ƒ†‰ˆ{ˆƒ…€”ty|wz}

Fig. 6 Apply Sealant

Ï °±´…²$·¾À¾Ð²$ѱµÒѱ¯³±´…¿+°±½ÓÂx¯ÕÔ¼µ
¸’¶u¿œ²$ѱ¿œ°×ÖÒº¿œ°±³±²$µ
´
·Á‰²rµ‚¸B·ØÙØP¾ Ú¿œ°±½£²$ѱµÅ´*µ
·¾À·°±²$Ã
pۏsuܑ}y†‰v‚ŒzŒÅ†‰ˆ{Ÿ‹‡ƒ“ŠT{*„švx}~vx}Õ¨¤wz~
{…}”†“wz—wz‹‡vx†‰wƒ*}݆“vx™­
Þ w™¥ˆ†‰{…}u†“ˆ”{‹‡ƒ“ŠT{*„
–xƒ…Œz†‰y8†“ƒ2¦q8ß:à ápxâB—†‰ÙŒz–xy| sU†‰ƒ…„‡Íx€{…

CAUTION: Overfilling the differential can result in
lubricant foaming and overheating.
prqâsuܑ}y†“vxŒzŒÙ†“ˆ{8—wzŒzŒÙˆƒ…Œz{‚Œz€™vx}~ Œzƒ‘ªÇ{…„†‰ˆ{ŠT{…ˆ”w‹‡Œz{*
prq…q+s Þ „‡vx‹‡äxŒzƒ…åð~
wz——{…„‡{*}†“wzvxŒñ{*͂€”w‚
{…~ŠT{*ˆwz‹‡Œz{…y˜y|ˆ”ƒ…€Œz~
–x{„‡ƒ…vx~ð†‰{…y†‰{…~£–|¨’vxåMw}”™•qâІ‰ƒïq|ŽÐyŒzƒ‘ª—wz™­€”„‡{…Ì{*wz™­ˆ†
†‰€„‡}y Þ ˆwzy v‚}”{…€ÕŠ¡{…„Óª2wzŒŒê
€ò†‰ˆ{óŒz€–x„‡wz‹‡v‚}”†
†‰ˆ„‡ƒ…€”™­ˆÅ†‰ˆ{‹rŒ€”†“‹‡ˆu~
wzy|‹‡y8†“ƒ2{…Œzwzwz}vx†‰{vB
ƒ*y|yw–xŒz{‹rˆv‚†‰Ì
†‰{…„}ƒ…wzy|{‹‡ƒ*
Œzvxwz}†“

REMOVAL AND INSTALLATION
REAR AXLE
ô'õ”ö
÷'ø¡ù[ú
prq+sutCvxwzy|{vx}~uy|€
‚ƒ…„‡†U†‰ˆ{:ŠT{*ˆwz‹‡Œz{…
pŽsuûك…y|wz†‰wzƒ…}üv¢y|€”w†‰vx–xŒ{êŒzw—†“wz}™Ó~
{‘Š¡w‹‡{ê€}~
{*„V†“ˆ”{
výTŒz{…
ps
{…‹‡€„‡{výTŒz{†‰ƒ ~‚{‘Š¡w‹‡{*
p¦suËtC{…ƒ“ŠT{†‰ˆ{:ª2ˆ{*{…Œzy2vx}~ņ‰wz„‡{…y
pďsutC{…ƒ“ŠT{†“ˆ{–‚„‡vxåM{S~
„r€yB—„rƒ…ü†‰ˆ{SvýTŒz{…tC{…—{…„
†‰ƒ î[„‡ƒ…€uÄx¬¼þC„‡vxåM{…y¬¼—ƒ*„ǁ
„rƒ…
{*„ǁ
„rƒ…‹‡{…~‚€„‡{…y
pȏsuÿ>wzy‹‡ƒ…}}”{…‹‡†:
vx„‡åMwz}™S–x„‡vxåM{B‹‡vx–xŒz{…y—„‡ƒ*–x„‡vx‹‡å”{*†‰y
vx}~uŒ{“ŠT{*„œ
pۏsutC{…ƒ“ŠT{ݪLj{…{*Œ y
{…{*~
y|{*}y|ƒ*„‡y|¬ wz— }{…‹‡{*y|yvx„À¨¥
tC{…—{…„†“ƒî>„‡ƒ*€uÄx¬¼þC„‡vxå”{*y|¬±—ƒ…„
„‡ƒ*
{…„
„‡ƒ*‹‡{…~
€”„‡{…y
pãsuÿ>wzy‹‡ƒ…}}”{…‹‡†:†‰ˆ{B–x„‡vxåM{Bˆƒ*y|{ vx†
†‰ˆ{ výTŒz{  €}‹‡†‰wzƒ…}
–xŒzƒ…‹‡åMPÿ>ƒ˜}ƒ*†~‚wy‹‡ƒ…}”}{…‹‡†>†‰ˆ{˜–x„‡vxå”{ˆÕ¨T~‚„‡v‚€”Œwz‹8Œzwz}{…yvx†
†‰ˆ{Sª2ˆ{*{…Œ2‹À¨TŒzwz}~
{*„‡y|8tC{…—{…„І“ƒ<î>„‡ƒ…€” ì8þC„‡vxå”{*y|¬8—ƒ*„

„‡ƒ*
{…„
„‡ƒ*‹‡{…~‚€„‡{…y
pìsuÿ>wzy‹‡ƒ…}}”{…‹‡†B†‰ˆ{ŠT{*}†Bˆƒ*y|{ï—„‡ƒ*é†‰ˆ{ïvýTŒz{ïy|ˆvx—†
†‰€–x{…
prqâsuÊvx„‡åu†‰ˆ{‚„‡ƒ…
{*ŒzŒ{*„
y|ˆvx—†[vx}~ǨTƒ…åM{*y—ƒ…„
wz}y†“vxŒzÌ
Œzvx†“wzƒ…}£vxŒzw™¥}{…}”†U„‡{…—{…„‡{*}‹‡{…
prq…q+sutC{*ƒ‘Š¡{ ‚„‡ƒ…
{*ŒzŒz{…„Çyˆvx—†‰
prqŽsuÿ>wzy|‹‡ƒ*}}{*‹‡†Uy|†‰vx–xwŒzw {…„–xv‚„Œzwz}å”y
prqsuÿ>wzy|‹‡ƒ*}}{*‹‡†Uy|ˆ”ƒ…‹‡åÐvx–xy|ƒ*„‡–‚{*„‡y2—„‡ƒ*¤výTŒz{*
prq¦suÿ>wzy|‹‡ƒ*}}{*‹‡†U†‰„‡v‚‹‡åŖ‚vx„œ
prqÄsuÿ>wzy|‹‡ƒ*}}{*‹‡†Ç€‚
{…„vx}~ïŒzƒ‘ª2{*„ y€y
{…}ywzƒ…}’vx„‡y
—„‡ƒ*¤†‰ˆ{výTŒz{–x„‡v‚‹‡åM{*†“y
prqÈs
{*
vx„‡vx†“{†‰ˆ{výTŒz{—„‡ƒ…¢†‰ˆ{:ŠT{…ˆ”w‹‡Œz{*
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NOTE: The weight of the vehicle must be supported by the springs before suspension arms and
track bar fasteners can be tightened. If the springs
are not at their normal ride position, vehicle ride
height and handling could be affected.

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Fig. 7 Pinion Yoke Removal
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PINION SHAFT SEAL
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Fig. 8 Pinion Seal Installation
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AXLE SHAFT
Fig. 9 Pinion Yoke Installation
CAUTION: Do not exceed the minimum tightening
torque when installing the pinion yoke retaining nut
at this point. Damage to the pinion bearings may
result.



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Fig. 13 Cut Retaining Ring

Fig. 14 Axle Bearing and Seal Remove

Fig. 12 Drill Retaining Ring

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ÓEÌE¹Ë
·5ÌE¹ á ÀÊGÆOÇ8ÏO¾G½+Å ÊGÅ(¾ÆOÇJ»ÈÛÚ{ÇJ½h  Á(ɾGÆ
ÂÅ(ÅQ
¿ VÅQ¾GÆOÇJ»È
 ÆOÅ(¾G¼>Å(чÁQÆ:ÅQãGÀÇ æ…¾G¿JÅQ»½+Ë  ÇJÉÅ@ÅTÄwÏOÅQ¼E¼ tÈYÆO ÅQ¾G¼EÅ@Ð5ÆOÁQÖ ÁQÀ½+ä
¼>ÇJÃŨÁ(КÊÅ(¾GÆOÇ8»
ÈYË
·5ÒE¹%âw¿8ÇJÃÅcÊGÅQ¾GÆOÇJ»ÈöÁQ»½+Ád¾>Äw¿JÅc¼E¾GÐ5½àÚ{ÇJ½+‰ÈYÆOÁ(ÁTæwÅcÇJ»
ÁQÀ
½hÅ(ÆÛ¼EÀÆOÐ5¾GÏOÅ:½+ÁTÚ{¾GÆOÃ%¼>Å(¾G¿j·5ò0Ç8ȁË
ÓEÌE¹Ë
·5ÙE¹%ïW¼EÇJ»È ºT»¼E½h¾G¿J¿JÅQÆóÙGå<ÓEð€¾G»Ã×¼EÂÁQɀÉÆOÅQ¼E¼>ÑÉÆÅQ¼>¼
ÊGÅQ¾GÆOÇJ»ÈÁQ»½+Á:¾Eą¿JÅ:¼>¾GÐ5½
·5òÇJȁË
ÓEÒ>¹Ë
·5ÝE¹%ïW¼EÇJ»ȨºT»¼E½h¾G¿J¿JÅQÆ\ÙGå0ÓEð ¾»Ã!¼EÂÁ(É@ÉÆOÅQ¼E¼>Ñ0ÉÆOÅ(¼>¼ ¼EÁQÐ5½
Ö7ÅQ½+¾G¿jÆOÅ(½h¾GÇJ»ÇJ»ÈÆOÇJ»ÈÁQ»½+Á:¾Eą¿JÅ:¼>¾GÐ5½B·8òÇJÈYËZÓ>ÙE¹Ë
·5åE¹%ºT»¼E½+¾¿J¿j¾Eą¿JÅ:ÇJ» æwÅQÂÇJÏO¿JÅ(Ë

¹ Ÿ
º »¼
½ ¾a¿¿ÀÁ À Ã¾ ÄŠĐ½½ Á ¾ ÆÀž ÂÀ
É%Ê'Ë)Ì+Í"Î%ÏÎ%Ð0Ñ2Ò
Ð0Ó'Ô Î%ÏÏÎ5Ô6Ò
Ì0Ð8Õ:Ö%×ØÙ?Ú@ØÛÜÝÞ

ÇJÈ

Fig. 15 Axle Bearing and Seal Components

Fig. 17 Press Bearing Retaining Ring On Axle

Fig. 16 Press Bearing On Axle

DIFFERENTIAL

EFHGJIKML"N
OQP@RTSVUXWZY\[U+]_^`aU+bdcH]fe
ghb_i
Okj_RTlmY?ghUnghcHUoY?prq
U?stgu]fguqaYXsvYXewguctUnq
sHbdgu]x`
`a]xguq
Y?syprU?ekUXp:z
UXsH{rU`aUXgughU?prb|b_gh]xW6}U?~)YXsguctU€xU?]fprqast‚{r]f}fb|]xst~)ctYXƒHbdz
qast„W6]x{rctqastUX~Tb_UX]x`aq
sH b_ƒtprek]x{rU+Ok…†qa‡i'P_ˆ_RQi
Ok‰_RTSVUXWZY\[U+guctU+~qaeke
UXprUXsHghqa]x`€xUX]xprqast„{r]x}b_i
OkŠ_RT‹†YXb_q
guqaYXs|Œ}fprUX]x~U?pŽP_jx‘fx’„“Zqaghc|ghcHUguYXY?`~Yh“ZUX`
}qastbZb_UX]xguUX~Tq
s”guctU+`aYX{r]xguq
sH ctY?`aUXbZOk…†qa‡i'P_‘_RQi
Ok•_RT–\stb_gu]f`a`mghctU—cHYX`a~~Y\“˜s™{Q`
]xW6}fb]fsH~šguqa‡ctguU?s™guctU
guYXY?`ghƒHprst€xƒt{r›`
U+e
q
sH‡UXprxguqa‡ctgui
Okœ_RT–\stb_gu]f`a`]|žŸƒHq
~fU6‹†qas‚ Vzk‰xjxˆfˆxz
’¡]fg"guctUZ`
U?ekg"b_q
~fU6Y?e
guctU¢~qaekekU?prUXstguqa]x`¡ctYXƒHbdqast‡i+£mgugu]f{rc¤~qa]x`¡qast~qa{r]xghY?p¥guY
ctY?ƒtbdqast8}qa`aYXg¦b_ghƒH~i¨§Y?]x~©guctUªqast~qa{r]xghY?p«}`aƒtsH‡UXp

Fig. 18 Bearing Cap Identification

]x‡]xqastbdg5guctU˜Y?}}Y?bdqaghU˜b_qa~U˜YXeghcHU˜ctYXƒtb_qastwOk…qa¬iP_‘dR']xst~
­ UXprY+guctU+qast~qa{r]xguYXp®i
Ok¯_RTŒM}prUX]x~TguctU+ctYXƒHbdqast„UXstY?ƒt‡c”guY+prUXW6Yh[U+guctU+{r]xbdU
ekprY?W°guctU˜ctY?ƒtbdqast¬i±„U?]fb_ƒtprU%ghctU%~qabdgu]xst{rU"“˜qaghcguctU%~qa]x`
qast~qa{r]xguYXp˜O
…qa‡iŸP_‘dR:i
CAUTION: Do not spread over 0.50 mm (0.020 in). If
the housing is over-spread, it could be distorted or
damaged.

Okˆ_RTSVUXW6Yh[U+guctU+~qa]x`qast~qa{r]xghY?p®i
Ok‘_RT‹†p³²vguctU”~qaeke
UXprU?stguq
]x`{r]xb_U”`
Y?YXb_U”ekprYXW2guctU”ctYXƒtb_z
qast‡i ´Yµ}prUh[U?stg0~]xW6]x‡U?¶m}q [MYXg0Y?s·cHYXƒtb_qast“Zqaguc·guctU
UXsH~‚Y?e5guctU+}p³²)€x]xp˜]x‡]xqastb_gbd}pQUX]x~UXp%Ok…†qa‡ijx¸_RQi

SUT

VXW.Y4Y4Z%[XZ]\X^_W `<ab`\;VcVX[XW deZ4a4W \;Z

fMgGh4i

jPkmlon1pGqPrcqPsutwv.suxmyXqPr<r<q
y'v.nus{zQ|P}<~<€~<‚<ƒ<„<…

ëxó‡ëxñaòtìdè5èuétä˜æ?ùùæ?ìdñaèhä˜ì_ñaüä˜æXíèhéHä˜étæXðtì_ñaòtówß!ñaó¬ôàdâ'ëxòtü
5 äXîræ+èuétä+ñaòtüñaêrëxèuæXî®ô
ß ,_

â MùîräXëxü)èuétäétæ?ðtìdñaòtó—ä?òtæXðHó‡éèhæ ñ
òHìdèuë .ŸèhéHäêrëxìdä
ñaò™èuétä”éHæXðtì_ñaòtó‡ô'õ|äXëxìdðHîrä”èuétä”üfñaìdèuëfòHêrä0ý˜ñ
èué™èuétä—üñaë 
ñaòtüñaêrëxèuæXî˜.ß !ñaó‡ôŸà dâ:ô
CAUTION: Do not spread over 0.50 mm (0.020 in). If
the housing is over-spread, it could be distorted or
damaged.

ß6_âTãVäXå6æhçä+èuétä+üñaëñaòtüñaêrëxèhæ?î®ô
ß7_
â "\òtì_èuë #üfñ
í
íkäXîQäXòtèuñaë Vñ
ò”étæ?ðtìdñaòtó¬ô
ß8_
â "\òtì_èuë #Žêrëfì_äZñaòTèhétä˜étæXðtì_ñaòtó‡ô 9 ëxù„èuétäZüñaíkí
äXîrä?òtèuñ
ë
êrëxìdäZý˜ñ
èuéëµîrë_ýZétñaüäæ?î0îrð øfø ä?î0å6ë #aäXè˜èuæäXòtì_ðtîräèuétä
ø äXëxîrñaòtó‡ì|ëxîräTík ð . ÿ÷ì_äXëxèuäXünñaòšèuétäüñaíkíkä?îräXòtèuñaë éHæXðtì_ñaòtó
ß!†ñaó‡
ô à@âQô
ß :_âTãVäXå6æhçä+èuétä+ìdùfîräXëxüä?î®ô


Fig. 19 Spread Differential Housing

Fig. 21 Differential Installation

Fig. 20 Differential Removal

Qß à_á_âTãVäXå6æhçä”èhétä”êrëxìdä”íkîræXåïéHæXðtì_ñaòtó‡ôõ|ëfîrö÷æ?îèhëxó
ø äXëxîrñaòtó2êrðtùìúèhæûñaòtüñaêrëxèuä¢ý˜étñaêréþìdñaüfä«èuétä\ÿ2ýZä?îrä
îrä?å6æ\çä?üTíkîræXå6ô

 


Qß à@â†æXì_ñ
èuñaæXòùfîräXëxüä?îà„ýZñaèhé|èhéHäèuæXæüæhýZä 
ùñaòtìJìdä?ëfèuäXü|ñ
òèhétä aæXêrëxèhñaòtówétæ aä?ìß!†ñaó‡ôàdâ:ô"hòtìdèuë#èuétä
étæ 
ü·üæ\ý˜ò $ê aëfåZùìnëxòtüvèuñaó‡étèuä?ò èhéHäšèuæX æ wèuðtîrò ø ðtêr%ö aä
íkñaòtó¬äX$î xèuñ
ó¬étèuô
ß _

â "\òtì_èuë #
ë &ŸðHñ
üf'
ä †ña)
ò (+*,--*.¡ëfè"èuét/
ä 
ä?íkè"ì_ñ
üfä6æ?í
èuétä¢üñaíkíkä?îräXòtèuñaë ¡étæXðHìdñaòtó‡1
ô 0mèuèuëfêré¤üñaë ¡ñaòtüñaêrëxèhæ?î¥èuæ
étæ?ðtìdñaòtó8ù#ñ aæXè¦ì_èhðHü3
ô 2æ?ëxü©èuétäªñaòtüñaêrëxèhæ?î«4ù aðtòHó‡äXî

ß -_â"\òtì_èuë#'èhéHä ø äXëxîrñaòtó”êrëxùì|ëxèZèuétäXñaî0æ?îrñaó‡ñaòtë;aæ?êrë*

èuñ
æ?òtì+ß!†ñ
ó¬ô<dâ:ô9ñaó‡éHèhä?òoèuétä ø ä?ëxîrñ
òHó‚êrëxù ø æ
èuì+èhæ)à_á
ß -xáíkèu
ô  ø ìdô âèhæ?$î @xðtäXô

=?> å
ß _

â "\òtì_èuë #ë Aaä+ì_étëxíkèhì_ô
DIFFERENTIAL SIDE BEARINGS
B<C D<EFG

ßQà@âTãVäXå6æhçä+üñaíkí
äXîrä?òtèuñ
ëêrëxì_ä+íkîræXå ëAaä+étæXðtì_ñaòtó‡ô
ß_âTãVäXå6æhçä+èuétä ø äXëxîrñaòtó‡ì˜íkîræXå èuétä+üñaíkí
äXîrä?òtèhñaëêrëxì_ä
ýZñaèuH
é †Ið #aäXKî JL†îräXì_M
ì (+*.,*0?NI0müëxùèuäXîrO
ì (+*,*Qà -N5ëfòHü
0müëxùèuäXP
î (+*,*.,ß !†ñaó‡
ô ,_âQô
ß ,_âTãVäXå6æhçäüñaíkíkä?îräXòtèuñaë ùfîr ä aæXëxünì_étñaå6ì„í
îræXåûüñaí
íkäXQî *

äXòHèhñaë êrëxìdäJétð ø ìdRô 9ëxóZèuétäì_étñaå6ì'èhæJñ
üfäXòtèuñaí ÿ˜ýZétñaêré„ì_ñaüä
æXíèuétä+üñaíkí
äXîräXòHèhñaë èuétä\ÿ)êrëxå6ä+íkîræ?å6ô

ÌMÍÂÎ4Ï

ÐXÑ#Ò%Ò4Ó4ÔXÓ]ÕXÖ_Ñ ×eØMׯÕ;ÐcÐXÔXÑ ÙeÓ4Ø%Ñ Õ;Ó

ÚÛ

ÜPÝmÞoß1àGáPâcáPãuäwå.ãuæmçXáPâ<â<á
ç'å.ßuã{èQéPê<ë<ìíë<î<ï<ð<ñ

Fig. 22 Differential Bearing Cap Reference Letters

Fig. 24 Install Differential Side Bearings

RING
GEAR
ÁGœ š $‘#“I”'•“I–u—4‘#“I‘#˜ “M”š•$›•$šP›š KF‘.¡$šP‘#“M•1¨'•¤°¡$œ š –
›¦š¤¥«m´Â˜¿“ ˜ ¤Ÿ$š — .•¡$š™¤°œ š¿$‘#“I”o”š •

·

‘.¤¥œI˜±I¤Ÿ$š —4 #•¡$‘#“I”

¤¥œIš1—4‘#“I‘#˜ “¿”š•«
Ã<Ä ÅŒ<ÆFŠG‹
¬’­®Ç

š ¨'˜°š1–4‘#ŽŽ.š $š“I¤¥‘.• <Ž.$˜ ¨È•¦ÀF #šuœ ˜ ±I›‘#“I”«

¬²®É  .•¡$š¿–4‘#ŽŽš$š “I¤¥‘#• U¡$•›š¸‘#“Ê•›±I‘#¤°•ž #š‘#›š
›¦˜Ž¤;¨'š¤°• Ë]• ·
¬¾®Ç

—$˜ ¤¥š ¡$¤¥˜ $›«

¬.½

‘#”«

·

‘#¤¥œ

²µ®

š ¨'˜°š™ž˜  #¤¥›bœI˜  #–4‘#“I”o$‘#“I”o”š•M¤¥˜™–4‘#ŽŽš$š “I¤¥‘#• 

¡$•›¦š«
¬ » ®³

›‘#“I”O•b›˜ Ž¤;œ •¨/¨'š L¢–4$‘ š1$‘#“I”O”§š •

Žš$š “I¤¥‘#• <¡$•›¦š

¬½ ‘#”«

²µ® «

Fig. 23 Differential Bearing Removal
†‡ˆ‰Š
‹ ‹ Š ‰
† Œ‡
Ž<’‘.“ ”•“I–b—‘.“ ‘.˜“™”š•$›

œI•FšŸžš š“™$š — #•¡$š–4¢4š$‘#Ž £

–4‘#ŽŽ.š $š“I¤¥‘.• ›¦‘#–4šPžš•$‘#“I”/—4$š  #˜•–u•“I–u”§š •m¨'š ›œMž•¡$©%ª
 #•›¦œI«
¬’­®

“I›¤¥• # ¯–4‘#ŽŽ.š $š“I¤°‘#• ¯—4$š .˜•–1›¦œI‘#¨'›m˜ “O–‘#ŽŽš$š “I¤¥‘#• 

¡$•›¦š1œI± ž›«
¬²®³

›‘#“I”H¤°˜˜  '´Gª ­µ¶¸·

–4‘#ŽŽ.š $š“I¤¥‘.• <›‘#–4š1žš •$‘#“I”›
¬¾®

‘#¤¥œcœ •“ –4 #šº¹+ª» ­¦¼¯­ ¢P‘#“I›¤¥• # 
¬½ ‘#”«

² » ® «

“I›¤¥• # <–‘.Ž.Žš ’š “I¤¥‘#• +‘.“¿•À #š1œI˜ ± ›¦‘#“I”«

Fig. 25 Ring Gear Removal

Ž.$˜ ¨È–4‘#Žª

¦s§

¨Z©ª
ª
«­¬Z«t®Z¯q© °-±°&®,¨3¨Z¬Z© ²³«
±
© ®,«

´‚µS¶
·

¸L¹º»%¼S½L¾3½L¿.ÀÂÁ¿.ÃÄZ½L¾-¾-½#ÄXÁ».¿jŀÆLÇ-È-ÉÊ^È-Ë-Ì-Í-Î
òóôõö
÷ ÷ ö õ
ò øó

CAUTION: Do not reuse the bolts that held the ring
gear to the differential case. The bolts can fracture
causing extensive damage.
ù’úûüýRþFÿI
 ÿ

. ÿ$ÿý ÿý #ý
 ÿ  !"#   %$
°þ& 4

 ÿ' ÿ((
 #ý)§
 ÿ  
. ÿ% 
 ý'
* ÿý!
ù

+ ûüýRþFÿ,I
 ÿ%

. ÿ$ÿý - ÿ.# ý/I
 ÿ?þ& ¦ ÿ!
ù

0 ûüý   ýIÿ1 #ý2
 ÿ34
 ý5 ° ÿ$ý¥ ÿ 6
 7¥ ÿ ý8:9 ;¯
< ú+ +'=?> * ù
@A <9AB !C  ! ûDEI
F ÿ ù
GH 7!
+I ûJ!
ù

K ûüý     ÿ’ÿ ý  L. ýMN&# ÿF# ýO
 ýP¸
 þFÿ 6
 ÿ*'ÿQ/

 ýPR ý J,$
¥ ÿ$ýP!

Fig. 27 Pinion Yoke Holder—Typical

Fig. 28 Pinion Yoke Removal

ù
IûDc+ÿ*X°þÿIÿ$
#ý  ýmÿdý$
$ÿT *X

Fig. 26 Ring Gear Bolt Installation

PINION
"S ÿT .GEAR
ýPUýV$
#ý ýW§ÿ2$ÿT¦ÿKþ& $ÿV2

*XIÿR¦ÿ!ZYSýP?$ÿ$   $ÿ.Iÿ.$
#ý  ý[ÿ\ F
$ÿ$
  # ý]I
 ÿ% #ý]
 ÿ ^!
_-`Paø-bFöG÷
ù’úûD+
c ÿ*þÿ   ÿ$ÿ ý  LQÿ*X 6d
*eNf.ÿPF(
#ý7!
ù

+ ûDgh ij$
# ý  ýk6&i ÿVýl$ $4ÿ .ÿm
2 
#ý     ý/ §
 ý'
* ÿ ý!
ù

0 ûDY\   ýIý ÿ:$
4
$ ÿ # ÿBQP :
*n$
# ý  ýd6&
i ÿ!
$ ÿ . ÿs
\rI
F ýP4
 ÿt6u!
o # ýhF  # ÿ $ÿpq# ÿr$ 4
ù

K û o # ýwvC 4
 ÿ[I9 ;x)O y6f%
i ÿp$ÿ*X þFÿzI
 ÿ
$
# ý  ý¸ýFP,
 ýPr I
 ÿPù
GH 7!{+@ ûJ!
ù

; û o # ý|+
c ÿ*X° þÿm}~(K ;+W
 ýPlvs 4
 ÿ5}~(
0+¯
x úp
$ÿ*X
 þÿ%I
 ÿ%$
# ý  ý.6&
i ÿ% *$
# ý  ý/Q ;
 ù
Gq u!{+¦x û€!


*|F .ýPºùGq 7!,+9ûJ!}~ wIÿ/$
#ý ý [6&FP

 ýD%$ $ÿþÿý, ,
*T    #ý]ýRÿ .ýP‚  *X§ÿ
!
ù

@ ûD+
c ÿ*X° þÿI
 ÿ
ý$
# ý  ýz
 ÿ  #ýƒFP$
p#ÿ #ýup
 q# ý§
 ÿ„pf 
ÿEF $

$ ÿ
p&
 ý.$
# ý
 ý‚¦ ÿ 
 ‚<
c ÿ*X þFÿ
Y\Q( úQK@
 ýDvC
 ýP
# ÿ%}~< ¯
K ú¯
@ ú/ù
GH u!{0A ûJ!
ù

x ûD+
c ÿ*X° þÿ]
 ÿ‚$ÿr$
# ý
 ý:
 ÿ #ýRFP$[
*…N&# ÿ
FQ# ý ù
GH 7!s¯
0 úûJ! o ¦ ÿ:+
c ÿ*X þÿƒYS’( úKxB
 ý)vC
 ý
# ÿ
}~<
K ú¯
@ ú!
ù

9 ûD+
c ÿ*X° þÿLI
 ÿL4
 ÿ$
 *X?
*†$ÿ,$
# ý  ý
 ÿ€(
#ý.JF$‚$ÿ# ýRN&# ÿFPQ# ý7!H+
c ÿ]
 ÿX %
i ýIÿL
I
 ÿ%4
 ÿ$ /QP *X!
NOTE: The pinion depth shims can be very thin.
Verify that all shims have been removed before proceeding.
ù’ú
A ûD+
c ÿ*X° þÿr
 ÿ%$ÿL$
#ý ý/ÿ #ýh
*Iÿr$
#ý(

 ý1 ˆ‡HF . ÿŠ‰„‡q$ÿQ‹}~<+90 (‡Œ
 ýŒ?  $ ° ÿ

}~(
+90(
Kb
x ù
GH u!{0+ ûJ!
Ž#^P‘ ’h“h”H•H–J’ —X˜™Šš‘›qœLœš–Jž’QŸy”qš žš–”H¡‚¢’
–€ž’R˜™’ —¤£„ ž¢/‘ P¢’
¥



  
!"# $  "
(*),+.-0/21*3#1*46587946:,;1*3<3<1=;>79-64@?BA*C<D<EGFHD<I<J<K<L

%'&

Fig. 31 Rear Bearing Cup Removal
Fig. 29 Remove Pinion Gear

Fig. 30 Front Bearing Cup Removal
Ï
Ð&ÑHÒ7Ó#ÔPÔÓPÒ{Ï ÕCÐ
NOTE: Pinion depth shims are placed between the
rear pinion bearing cup and axle housing to achieve
proper ring and pinion gear mesh. If the factory
installed ring and pinion gears are reused, the pinion depth shim should not require replacement.
Refer to Pinion Gear Depth to select the proper
thickness shim before installing pinion gear.

Fig. 32 Inner Bearing Removal
JÖ ×^ØDÙHÚÛÜÝ%Þ ßàÞ
Ýßáâã Üä­åÝæQæç
ÝÞ
áâ/æQâã èã å/ßÝÛßLÞ
ã åé
ã àå/êÝÛßã åë]ÜìÞDê àßÝ%ã å[áâÝ%Ûí&Ú Ý%âàìæã åë7î
Ö
ïØXð?Þ
Þ Ú ñ)òhàÞ
Ûß
àà߂ô~ÛæQÝõàß]Ýöìã ÷&ÛÚ ÝåPáõ\æQáã Üä
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ã åã àåMêÝÛßã åë
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Fig. 35 Pinion Seal Installation

Fig. 33 Rear Pinion Bearing Cup Installation

Fig. 34 Pinion Outer Bearing Cup Installation

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‚ŒPOq
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XSVjšXkSVeT~›SVpVW^fS
WYwVe6`aSVa^fSgieGX[]HqVœ<a9gmwVWYefSWzwVe6SVpbWtWz^6…!‰P„Rtž ’ŸM‰PŒ[™\WYq
ZcUlq O‡M‹Ša9gmq
‚ƒPOq

Fig. 36 Rear Pinion Bearing Installation
CAUTION: Never loosen pinion gear nut to
decrease pinion gear bearing rotating torque and
never exceed specified preload rotating torque.

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WY^6]^fWYX[WYe0WYwVe0`aSVa^fS{giefX]*UlwV^GpVZjRc[eG¥
]_agma9SbX[ZŠ—eGX[]_aSVgmUl§¨‰"Wz^‡‚tž ’©M‰P™Wz^‡…[™aSVq”ZcUlq Oq
• ¦tez~ª—eGX]_a9SbgiUl§Ž…
Wz^0rtž ’ªM‰PrWY^0‚[raSVq˜Zc[UPq Oq

M‰P…PORQT\«]_^fWYXWzaSVg¬WY^f]o[pbe­a9U®Xc^T¯”e­Wzwbe­jefUPa]_efj
X’>^fpVSbWzh]_eG’>^T¯”e°WYwVev`aSVa^fS±u”^f•e°XSVj#aSVx_]_efXUPe°WYwVe
`]_eGZ^fXj©UPwVa’¬`Xx_•£Wzwba9x•bSVeGUlUPq QTSVx_]_eGXUlaSVg#WzwVe‘Ulwba9’
`Xx_• Wzwba9x•bSVeGUlU"™q²™…r’>’©M™q ™™Š‰"aSVq O˜~ya9ZZŠjeGx_]_efXUPe*WYwVe
]_^fWYXWYa9Sbg
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tž ’ŸM9“a9Sbq
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.0/

132 46587:93;+93<=?>!<@ A93;-;-9BAC>!5<EDGF3H-I-JLKMI-N-O-P-Q

Fig. 37 Pinion Preload Shims–Typical

Fig. 38 Pinion Yoke Installation

Ù ÚPÛPÜ>Ý ÞßmàVázâGãäÞãVÞåGãælàbç[è9á=ãbéVá Þ9ã
ê[ë ì0ítî ï£Ù9ð6è9ázë}ñòælë Ü
ÞãVó_ô_âGï>âfãVáYæ|éVãVáYÞñ<áYàVâ0ï>çPõ}Þï>éVïªáYÞßiàVáYâfãVÞãVßöåGôy÷[âfæPÞ9ô_âG÷
ô_åGázçáYÞ9ãbß
áYåfôø[ébâ6Þæ|ô_âGç[ó_àbâf÷ë
ِÚPùPÜRúTèázàVâöï>çPõ}Þï>éVïûázÞßiàbázâGãVÞãVßRázåGô_ø[ébâ
Þæ0ô_âfçó_àVâG÷
äô_ÞåGôázå'çó_àVÞâTü”Þ9ãbß|áYàVâ‡÷[âfælÞô_âG÷0ô_åGázçáYÞãVß|áYåfô_øéVâGýVô_âfï>åzü}â
áYàVâ¨ä[ÞãVÞåfãdþ”åfÿâ¨çãV÷‘÷âfó_ô_âGçælâšázàbâ¨áYàVÞó_ÿbãbâfæPæ åGè6áYàVâ
äô_âGñåfç÷ælàVÞï«äçó_ÿbë  âGó_ô_âfçælÞãVߎáYàVâ
æPàVÞï äçó_ÿ.ázàVÞó_ÿ 
ãVâGæl
æ ë ð{ï>ï«Ù ë  ŠÚ6ÞãVë
Ü
|ÞññÞãVó_ô_âGç[æPâ
ázàVâ
ô_åGázçáYÞãVß
áYåfô_øéVâ0çääô_åzõ}Þï>çázâGñ
þ ë
í"î²ïªÙìÞãVë˜ñ9òæPë ܐë
ِÚPðPÜRúTãVæPázçññ<÷Þè9èâfô_âGãVáYÞ9çñ<çæPælâGï>ò[ñ þ ë

Fig. 39 Tightening Pinion Nut

FINAL
ِÚHÜ”ó_ASSEMBLY
ô_çäâ.ázàVâ.ô_âGælÞ÷ébç[ñyæPâfçñçãVá èô_åGï

áYàVâ.àVåfébælÞãVß
ç ãV÷ó_åTü}âGôï>çáYÞ9ãbß|æPéVô_èçó_âGælëñâfçã ázàbâ‡ï>çáYÞãVßyæléVô_è9ç[ó_âGæ

|ÞáYà
ï>ÞãVâfôç[ñŠæPäÞô_ÞázæPëtää[ñ þç0òâGç[÷0åfè åfä[ç[ô ”Þ9ñÞó_åGãVâ
t

èêé

ëì!ííîïîLðvñì ò(óò)ð*ë+ëïì ô-îóì ð*î

õ¥ö:÷ø÷

ù3ú û6ü8ý:þ3ÿ+þ þ3ÿ-ÿ-þ
 !ü

CAUTION: Overfilling the differential can result in
lubricant foaming and overheating.

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no\ _`bsRTVX¢!VXW¤`bc`ih V•¯—SU Woe^no\ _`°Yg±VXnoe^¢e^no\ `be^cX_kCklVLno`be!cL_6cL¢
`bhe^k¤mtWocXS ±›¢!cXW3`ihV8m¦VX\ W¨]^SU Woe^no\ _`*WoVLdSe^WoVL«CVX_`bkŸs
q uŸxžp_kŸ`b\]^]-`bhV8¢e^]^]-hcL]^V±]!S mts

DISASSEMBLY AND ASSEMBLY
STANDARD DIFFERENTIAL
²-³ ´—µ˜´—´:¶ ·¸˜¹bº
q wMxRTVX«CcifgV3±e^_e^cX_mtVX\ W*«C\ `bV¨kŸh\ ¢`(]!cLno»jklnoWoVi£ q!r e^mts
u  xys
q xRTVX«CcifgV8±e^_e^cL_¼m¦VX\ W¨«C\ `bV8klh\ ¢`bs
q¬ xRTcX`b\ `iV¼`bhV¼¡e^¢¢!VXWoVL_`ie^\ ]3kŸe!¡V6m¦VX\ Wok›\ _¡½WyVX«CcifgV
`bhV8±e^_e^cX_š«C\ `iV8mtVL\ Wok¤\_ ¡›`bhWoSkŸ`£¤\ kŸhVXWok q!r e^mtsvu ¬ xys

Fig. 40 Check Pinion Gear Rotating Torque

RTSU U VXWZY[VX\ ]^\ _`ba-cXWZVLd Se fg\ ]!VL_`ba-cX_ `ihVjhcLSkle^_mnocpf[VXW
qr e^mtsvu)wMxys

Fig. 42 Pinion Gear Mate Shaft Lock Screw

q uŸxRTVX«CcifgV`ih Vš¡e^¢!¢VXWoVL_`be!\ ]0kŸe!¡Všm¦VX\ Wok\ _¡`ih WoSkl`
£¤\ kŸhVXWokŸs

Fig. 41 Typical Housing Cover With Sealant

zo{|X}G~€}G‚ƒ„‚…†|X‡M{ˆŠ‰ …Œ‹vƒŽ‡}G‚‡{’‘„“‡{†}Gƒ|
~”b}yƒ•~–—–˜ ™‡{ˆš}G‚ƒ›|Lƒ~€~{}Gœ
q xžp_kŸ`b\]^]C`ih Vnocpf[VXWšcX_+`bhV¡e!¢!¢VXWyVX_`be^\] £¤e^`bh+`ih V
\ `i`b\ nohe^_mZU cX]^`bkls)ži_kl`b\ ]!]˜`ih V¤e^¡VL_`be!¢!e^no\`be^cX_¥`b\m¦s §-e!m¦h`bVX_
`bhV8nocpf[VXW¨U cL]!`bk¤`bc8u—w¤©*ª « q¬ ­ ¢!`is]!U kŸs x3`bcXWod SVLs

µ—´˜´B¶ ·•¸—¹iº
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£¤\ kŸhVXWokŸs
q xžp_kŸ`b\]^]v`ihVC±e^_e^cX_›«C\ `iVCm¦VX\ Wok3\ _¡`bhWoSkŸ`£¤\ kŸh®
VXWykls
q¬ xžp_kŸ`b\]^]-`bhV8±e^_e^cL_¼mtVL\ W¨«C\ `bVkŸh\ ¢`bs
q uŸxCÀ°]^e^mt_Á`bhV h cX]^V e^_Á`bhV6±e^_e^cX_Ám¦VX\ W›«C\ `iV6klh \¢!`
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q x¯—SU Woe!no\ `bVÃ\ ]^]Ä¡e!¢!¢VLWoVX_`be^\]ÅnocL«C±cX_ VX_`bkÆ£¨e!`bh
hŒÇ[±cXe^¡mtVX\ W3]^SU Woe!ny\_`bs

TRAC-LOK
È:ɠʽÈvËoÌ ÍoÎ DIFFERENTIAL
ϘÐXÑÓÒÔ!Õ!ÕÊXËyÊXÖ×bÔ^ÌؚÍoÐLÙCÚÐLÖÊXÖ×bÛÁÌËoÊÜÔ^Ø^Ø!Ý ÛlÞ
×bËoÌ×bÊLÒßÔ^Ö½àá—Ô!â¦ã ä äŸåyã æTÊLÕÊXËj×iЁ×bÉÔ^Û¥Ô^Ø^Ø!Ý Ûl×bËoÌ ×iÔ^ÐXÖ½ÒÝ ËoÔ!Ö â
ËoÊLÚÌ Ô!Ë3ÛlÊLˀçgÔ^ÍoÊLã

ƒK„b…=†=‡ ˆŠ‰‹=‹=Œ=ŠŒŽŠ‘‰ ’”“K’•Ž–ˆqˆŠŠ‰ —Œ$“=‰ Ž–Œ
š›Xœ œ œ ž Ÿy ¢¡¤£¥¦š¥œ œ ž Ÿ§ ¡¤£¨,©ª«¬­«®¯°±

Fig. 43 Pinion Mate Gear Removal

˜c™

Fig. 45 Differential Case Holding Tool

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A_<@4wD S 25093TxFH<@`_<TQTU2MAXseDFH0 se93^wZ)\H<yA_93FHGaGg<@25A/93TxZ]Dyz5<
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 93Z)\yZ)\H<€A_93FHGGv<2MA93FHTQZ)25030<;=V
*XhU-/k1<@4 D S <Z)\H<6=93FH93DF‚Gg<@25A 4 2MZ)<TU\H25^XZE03D@`_|yTQ`_A_< 
*Xf93GvVih5JU-,V

Fig. 44 Trac–Lok Differential Components

  "!$#&% ')(
*,+-/.103254 687:93;=<?>"<@25ACBED03;=93FHGCI DD@0KJML5J5N5OQP9FR2
9S 3TU<@V
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BcD@03;=93FHGI DD@0J5L5J5NMd Pe*Xf 93GgVih5jQ-V


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Fig. 46 Mate Shaft Lock Screw

X² ³U´/µ1¶@·w¸º¹:¶y»)¼H¶y½=¾3¿H¾3¸@¿ÁÀv¶ÂMÃÄ· Â5»]¶yÅQ¼rÂMÆ»]ǖȺÆw¿r¶@É_¶ÅQÊ
ÅUÂMÃtËuÌiÍHÅU¶€ÂÄÎ=Ã_¾3ÆX» ÂM¿HÎ/¼HÂ5· · ¶â²Ï ¾3ÀvÇiÐ5ÑU´,Ç
Fig. 48 Step Plate Tool Installation

Fig. 47 Mate Shaft Removal

X² ÒU´/Ⱥ¿HÅU»)ÂMÓ3ӑÂ5¿H΁Ó3ÍHÔ5Ã_¾3É_Â5»]¶¢Õ:»)¶@½&Ö Ó3Â5»]¶¢×1Ø5ÐMÐ5Ù5Ñ5ØÚc²Ï ¾3ÀvÇ
Ð5ÙU´,Ç
²XÑU´ ÛÜÅUÅQ¶@·wÔMÓ3¶–Ý
¼HÃ_¶ÂMÎM¶@ÎÜÛÜÎ=Â5½=»]¶ÃE×1ØMÐ5Ð5Ù5Ñ5ØMށ¾3¿H»]¸ »]¸½
ÅU¾ÎM¶ßÀv¶@Â5ÃoÇàÝ"¼HÃ_¶Â5Îáϸ@Ã_É,¾¿rÀmÕ¤É_Ã_¶]âã×1Ø5Ð5Ð5ÙMÑ5Ø5äå¾3¿H»)¸
Â5Î=Â5½=»)¶@ÃÍH¿H»)¾3Ó¾3»–ÔM¶É_¸@· ¶ÅwÉ_¶@¿H»)¶Ã_¶@Î/¾3¿yÂ5Î=Â5½=»)¶@ý=Ó3Â5»]¶Ç
²XÙU´/Ö¸@ÅU¾»)¾3¸@¿æÂçÅQ· Â5Ó3ÓèÅUÉ_Ã_¶ºâ Î=Ã_¾ ¹:¶Ã¾3¿æÅQÓ3¸@»l¸Æ
Ý
¼HÃ_¶@Â5Î=¶Î}ÛÜÎ=Â5½=»)¶@Ãe×1Ø5ÐMÐ5Ù5Ñ5Ø5Þé²XϾÀgÇêÐ5ëU´e»)¸ì½=Ã_¶]¹:¶¿H»
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Ã_¶· ¸º¹:¶~»)¼HÃ_ÍHÅU»Šâ¢Â5ÅQ¼H¶Ã_ÅwÆÃ_¸@·éÔ5¶¼H¾3¿HÎ/»)¼H¶~½=¾3¿H¾3¸@¿àÀv¶@Â5Ã_Å
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²,ÚÚo´/È]¿HÅQ¶Ã_»KÝiÍHÃ_¿H¾3¿HÀúò1Â5Ãp×1Ø5ÐMÐ5Ù5Ñ5ØMÐ8¾3¿íÉ,ÂMÅU¶e²Ï ¾3ÀvÇ
³5äU´,Ç
²,ÚUäU´/û ¸¸@ÅU¶@¿Á»)¼H¶yϸ@Ã_É_¾3¿HÀüÕ:É_Ã_¶]â×1ÊXÐ5Ð5Ù5ÑMÊäC¾3¿ÁÅU· ÂMÓ3Ó
¾3¿HÉ_Ã_¶· ¶@¿H»)ÅKÍr¿H»]¾3Ӗ»]¼r¶xÉ_Ó3ÍH»)É_¼ý½=Â5É_óC»)¶¿HÅQ¾3¸@¿C¾ŁÃ_¶@Ó3¾3¶º¹¤¶@Î

Â5¿H΀»]¼H¶EÎ=¾3ÆÆX¶@Ã_¶¿H»)¾Â5ÓÉ_Â5ÅU¶É_Â5¿Ô5¶»)ÍHÃ_¿H¶ÎÍrÅQ¾3¿HÀbÝiÍHÃ_¿r¾¿rÀ
ò1Â5â×1ÊXÐ5Ð5Ù5Ñ5ÊXÐ5Ç
²,ÚUÞU´/µ1¸@»)Â5»]¶€Î=¾3ÆXƶ@Ã_¶¿H»]¾3Â5ÓÉ_Â5ÅU¶ÍH¿r»]¾3Ó»)¼H¶€½=¾3¿H¾3¸@¿êÀv¶ÂMÃ,Å
É_Â5¿yÔ5¶€Ã_¶· ¸º¹:¶Î=Ç
²,ÚUÐU´/µ1¶@· ¸]¹:¶€½=¾3¿H¾3¸@¿êÀv¶ÂMÃ,Å ÆÃ_¸@·éÎ=¾3ÆXƶ@Ã_¶@¿r»]¾3Â5ÓÉ_Â5ÅQ¶Ç
²,ÚU³U´/µ1¶@· ¸]¹:¶§Ï¸@Ã_É_¾3¿HÀaÕ¤É_Ã_¶]âá×1ØMÐ5Ð5Ù5Ñ5ÊXä5ÌcÕ¤»)¶@½pÖÓÂ5»)¶
×1ÊXÐ5Ð5Ù5ÑMÊÚQ̑ÂM¿rÎ~Ý
¼HÃ_¶ÂMÎM¶@ÎEÛÜÎMÂM½M»]¶â×1ÊXÐ5Ð5Ù5Ñ5ÊXÞ5Ç
²,ÚUÒU´/µ1¶@· ¸]¹:¶p»)¸@½qÅQ¾3Î=¶pÀv¶Â5ÃoÌ~É_Ó3ÍH»)É_¼8½=Â5É_óþÃ_¶@»)Â5¾3¿H¶@ÃÌ
Â5¿HÎxÉ_Ó3ÍH»)É_¼§½MÂMÉ,órÇiÿb¶@¶½x½=Ó3Â5»]¶Å ¾¿yÉ_¸Ã_Ã_¶@É_»–¸@Ã_Î=¶âÎ=ÍHÃ_¾3¿HÀ
Ã_¶@·w¸º¹:Â5Ó²Ï ¾3ÀvǑ³MÞU´,Ç
Fig. 49 Threaded Adapter Installation

ÇÈdÉÊË ÌÍÎÎÏÐÏÒÑÓÍ ÔÕÔÑÌÌÐÍ ÖÏÕÍ ÑÏ
Ù"Ú$Û&Ü'Û&Û&Ý&Þ+ß-à/á0Ü'â2Ù0Ü'Û&Û&Ý&Þ3ß'à/á5ã7ä'åæç è<æéêëì

׿Ø

Fig. 50 Tighten Belleville Spring Compressor Tool

Fig. 53 Side Gear & Clutch Disc Removal

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NOTE: The clutch discs are replaceable as complete sets only. If one clutch disc pack is damaged,
both packs must be replaced.

Fig. 51 Remove Pinion Gear Thrust Washer

Fig. 52 Pinion Gear Removal

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Fig. 56 Upper Side Gear & Clutch Disc Pack
Installation

Fig. 54 Clutch Disc Pack

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Fig. 55 Clutch Discs & Lower Side Gear Installation

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Fig. 57 Pinion Gear ID Numbers

ADJUSTMENTS
PINION GEAR DEPTH

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Fig. 58 Shim Locations

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Fig. 60 Pinion Height Block—Typical

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tuzks¹zs¹j¸cˆ|h»}p mVlnz|sp…¼lnz|h»ƒh joqz|sp…¼€qoqjˆ|hkl6¡¢©z|…†Šv“%¥I¤CŠ
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tuz…‹}ptuh s6€qj~ƒ ˆ|tul{tw8®%¥{½v¾ r‰¡<–—¯º<tuŠZˆ|ƒlnŠ ¤CŠ

Fig. 59 Pinion Gear Depth Gauge Tools—Typical

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NOTE: Arbor Discs 6732 have different step diameters to fit other axle sizes. Pick correct size step for
axle being serviced.

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Fig. 61 Gauge Tools In Housing—Typical

  

 
 
  
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Fig. 62 Pinion Gear Depth Measurement—Typical

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Fig. 63 Axle Adjustment Shim Locations

ùUú

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NOTE: It is difficult to salvage the differential side
bearings during the removal procedure. Install
replacement bearings if necessary.

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Fig. 64 Install Differential Case W/Dummy Bearings

Fig. 65 Tighten Bolts Holding Bearing Caps

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Fig. 66 Seat Pinion Gear Side Differential Dummy
Bearing

Fig. 67 Seat Ring Gear Side Differential Dummy
Bearing

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Fig. 70 Hold Differential Case and Read Dial
Indicator

Fig. 68 Differential Side Play Measurement

Fig. 71 Hold Differential Case and Zero Dial
Indicator
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Fig. 69 Hold Differential Case and Zero Dial
Indicator
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Fig. 72 Hold Differential Case and Read Dial
Indicator



 



    
  

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GEAR
CONTACT PATTERN ANALYSIS
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Fig. 73 Ring Gear Backlash Measurement

Fig. 74 Backlash Shim Adjustment
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Fig. 75 Gear Tooth Contact Patterns

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SPECIFICATIONS
216 RBI AXLE
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”o•}–— … ˜3‹™ŒŽ£¢{ — ‹™…zwzy — {hŠŽ¦§‚¨|xŒŽž}yŒ©… ˜"ª™«¢¡š£o¬¢­ 
”o•}–— … ˜3‹™Œ®s‹~™‹™˜m…zŒ¯|°A¬¢ Ÿ¥ ”²± ­  †~ Œ©³¢ ´
usvxwzyOµs‹ŒŽ…zŠ³h¶™  ª·}¶ «™«·}­9¬¢ 
¸ …zˆ ˆ‰y — y}Œ©… ‹w¹sy‹ — … »º — y„wzŠ„‹“¼h ©¬Aƒ†ƒ ±     ­†…  ´
¸ …zˆ ˆ‰y — y}Œ©… ‹w‚…z“ yO½Ay„‹ — ®sw y‹ — ‹™˜myšh ™£ 9¬¢«†ƒ†ƒ
±  £™    ¾†…z} ´
µs…z}’½Ay„‹ —"¸ …z‹ƒ†y„Œ©y — h¿o¬¢¾†ƒ†ƒ ± Ÿ¯«»…  ´
µs…z}’½Ay„‹ — ¹s‹™˜mÀwz‹³ÁžÂh ™9¬¢¶£ ™ ¿ †ƒ†ƒ ±    ™ «£ ™   Ÿ
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¹ — ›º — ywzŠ„‹“ ·}ºo…z}…zŠ„ ± à yĦ"´Åh¿™ ¿¾£™­ «¿ ÃkÆ ƒ ± ¿ ™£­ 
… }w – ³¢ ´
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216 RBI TORQUE
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± ¿™«†ˆ ŒŽ}w – ³Á ´
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± ¬Á¾ †ˆ ŒŽ}w – ³¢ ´

Adapters—C-293-18

Adapters—C-293-48

SPECIAL TOOLS
216 RBI AXLE

Extension—C-293-3

Puller Set—C-293-M

Remover—C-452

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Trac-lok Tool Set—C-4487

Handle—C-4171

Installer—C-3972-A

Installer—D-156

Installer—D-144

Pilot—C-3288-B

Installer—D-145

Dial Indicator—C-3339


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Cup—8109
Remover—D-147

Splitter—1130
Remover—D-148

Installer—W-262
Spreader—W-129-B

Pinion Depth Set—6730
Installer—W-162–D

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Adapter—6790

Adapter Set—6987

Adapter Set—6956

Slide Hammer—7420

Holder—6958

Adapter—7420-8

Holder—6963-A

Installer—7913-A

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BRAKES
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BASE BRAKE SYSTEM
r n‰|uŠ
page
DESCRIPTION AND OPERATION
BRAKE HOSES AND LINES . . . . . . . . . . . . . . . . . 6
BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 2
COMBINATION VALVE . . . . . . . . . . . . . . . . . . . . . 4
FRONT DISC BRAKES . . . . . . . . . . . . . . . . . . . . . 4
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . 3
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . 5
POWER BRAKE BOOSTER . . . . . . . . . . . . . . . . . 2
REAR DRUM BRAKE . . . . . . . . . . . . . . . . . . . . . . 5
RED BRAKE WARNING LAMP . . . . . . . . . . . . . . . 2
SERVICE WARNINGS & CAUTIONS . . . . . . . . . . 2
STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING
BASE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . 6
BRAKE DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . 10
BRAKE FLUID CONTAMINATION . . . . . . . . . . . . 11
BRAKE LINE AND HOSES . . . . . . . . . . . . . . . . . 11
COMBINATION VALVE . . . . . . . . . . . . . . . . . . . . . 9
DISC BRAKE ROTOR . . . . . . . . . . . . . . . . . . . . . 10
MASTER CYLINDER/POWER BOOSTER . . . . . . . 8
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . 11
RED BRAKE WARNING LAMP . . . . . . . . . . . . . . . 8
STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . 8
SERVICE PROCEDURES
BASE BRAKE BLEEDING . . . . . . . . . . . . . . . . . . 12
BRAKE DRUM MACHINING . . . . . . . . . . . . . . . . 13
BRAKE FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . 11
BRAKE TUBE FLARING . . . . . . . . . . . . . . . . . . . 13
DISC ROTOR MACHINING . . . . . . . . . . . . . . . . . 13
MASTER CYLINDER BLEEDING . . . . . . . . . . . . . 11

page
REMOVAL AND INSTALLATION
BRAKE PEDAL . . . . . . . . . . . . . . . . . . .
COMBINATION VALVE . . . . . . . . . . . . .
DISC BRAKE CALIPER . . . . . . . . . . . .
DISC BRAKE ROTOR . . . . . . . . . . . . . .
DISC BRAKE SHOES . . . . . . . . . . . . . .
DRUM BRAKE SHOES . . . . . . . . . . . . .
MASTER CYLINDER . . . . . . . . . . . . . .
PARKING BRAKE HAND LEVER . . . . .
POWER BRAKE BOOSTER . . . . . . . . .
REAR PARKING BRAKE CABLE . . . . . .
STOP LAMP SWITCH . . . . . . . . . . . . . .
WHEEL CYLINDER . . . . . . . . . . . . . . .
DISASSEMBLY AND ASSEMBLY
DISC BRAKE CALIPER . . . . . . . . . . . .
MASTER CYLINDER RESERVOIR . . . .
WHEEL CYLINDER . . . . . . . . . . . . . . .
CLEANING AND INSPECTION
CALIPER . . . . . . . . . . . . . . . . . . . . . . .
REAR DRUM BRAKE . . . . . . . . . . . . . .
WHEEL CYLINDER . . . . . . . . . . . . . . .
ADJUSTMENTS
PARKING BRAKE CABLE TENSIONER
REAR DRUM BRAKE . . . . . . . . . . . . . .
STOP LAMP SWITCH . . . . . . . . . . . . . .
SPECIFICATIONS
BRAKE COMPONENTS . . . . . . . . . . . .
BRAKE FLUID . . . . . . . . . . . . . . . . . . .
TORQUE CHART . . . . . . . . . . . . . . . . .
SPECIAL TOOLS
BASE BRAKES . . . . . . . . . . . . . . . . . . .

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15
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. . . . . . . 23
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. . . . . . . 29






DESCRIPTION AND OPERATION
BRAKE
—{˜š™œ›eSYSTEM
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fresh brake fluid or Mopar brake cleaner to clean or
flush brake system components. These are the only
cleaning materials recommended. If system contamination is suspected, check the fluid for dirt, discoloration, or separation into distinct layers. Also
check the reservoir cap seal for distortion. Drain
and flush the system with new brake fluid if contamination 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 contaminants. Use fresh fluid from sealed containers
only to ensure proper antilock component operation.
CAUTION: Use Mopar multi-mileage or high temperature 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.

SERVICE WARNINGS & CAUTIONS
WARNING: DUST AND DIRT ACCUMULATING ON
BRAKE PARTS DURING NORMAL USE MAY CONTAIN ASBESTOS FIBERS FROM 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 SPECIFICALLY DESIGNED FOR THE REMOVAL OF
ASBESTOS FIBERS FROM BRAKE COMPONENTS.
IF A SUITABLE VACUUM CLEANER IS NOT AVAILABLE, CLEANING SHOULD BE DONE WITH A
WATER DAMPENED CLOTH. DO NOT SAND, OR
GRIND BRAKE LINING UNLESS EQUIPMENT USED
IS DESIGNED TO CONTAIN THE DUST RESIDUE.
DISPOSE OF ALL RESIDUE CONTAINING ASBESTOS FIBERS IN SEALED BAGS OR CONTAINERS
TO MINIMIZE EXPOSURE TO YOURSELF AND OTHERS. FOLLOW PRACTICES PRESCRIBED BY THE
OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION 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

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POWER
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FRONT DISC BRAKES

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Fig. 4 Brake Components

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Fig. 6 Stop Lamp Switch Terminal Identification

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Fig. 7 Typical Booster Vacuum Test Connections

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Fig. 8 Vacuum Check Valve And Seal

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Fig. 9 Checking Rotor Runout And Thickness
Variation


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Fig. 10 Measuring Rotor Thickness

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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.

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SERVICE PROCEDURES
BRAKE
FLUID
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µI°/¶²G·­LEVEL
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MASTER
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POWER BRAKE BOOSTER
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NOTE: If master cylinder is replaced, bleed cylinder
before installation.

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Fig. 22 Push Rod & Clip

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Fig. 27 Caliper Removal

Fig. 29 Caliper Installation

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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 proceeding. Bolts must not have a shank length greater
than 67.6 mm (2.66 in.) (Fig. 30).

Fig. 30 Mounting Bolt Dimensions

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CAUTION: Verify brake hose is not twisted or
kinked before tightening fitting bolt.

DISC BRAKE SHOES

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DISC BRAKE ROTOR

Fig. 31 Outboard Brake Shoe Removal
NOTE: If original brake shoes will be used, keep
them in sets left and right. They are not interchangeable.

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Fig. 33 Rotor & Hub

Fig. 32 Inboard Brake Shoe Removal

CAUTION: Do not use compressed air, this can
unseat dust boot and force dirt into piston bore.

NOTE: If drums are difficult to remove, back off
adjuster through support plate access hole with
brake tool and screwdriver.

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Fig. 37 Parking Brake Lamp Switch






















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Fig. 36 Parking Brake Cable Attachment





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Fig. 39 Parking Brake Cable Bracket
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KšNM=›œk{ko`\]h\]`dlPwk{TwlPWVXPa+T^žda]`efPwY[hTPw`^r_ j^YNk{`ll

Fig. 42 Loosening Reservoir

da]`erP YNhTSP T^qd`\]erj^€|vl
`k{PSs
KŸNM=›œ_{ !™Y[k„da]`efP Y[hTPSYUk{T _(a]™R¡yUjkohžda]`erP €`™€¢PSs
K‚NM ’W^YNk{`llda]`efP _(a]™Rn`^r_wyUhrPSPl
s
KLNM ’W^YNk{`ll\]`dlPW£¤da]`\]erPk„TS^ž™v(vPSa+Y[™YNv(P^Y[jTS^ž`a]R=s
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K©NM=›œ_{ !™Y[k„v`a‘erj^€|da]`erPY[s

KLNM OQPSR=ToVXP a]PY[PacVXTjapdNb/a]T\]erj^€xj
k-koTwTS^P YNj_(P `^_
v(™llj^€|ma]PP6Tm€a]TSRUR=PSk{YUK~¹j€¢s‚Ÿ[MAs
KtNM OQPSR=ToVXP6TSl_µ€a]TR=R=PSk{Y=ma]TR}\cbXlj^_(PaUdT_!bgK
~¹j€s
‚‚NM‘s

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ì{ò

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éîô[ì{ëööëì{éòSîžéî

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DISC BRAKE CALIPER



 



Û Ýß¹ÝÝ


 



¹à

QíSó=ò Xí çè]ë÷rí ôNõòSíôUøè]òó¯ê]ëöé íSè¤ý

â Nä

zè]ëéîžçè]ë÷fí øöæéù òSæì„òø<ê]ëöé (íè¤ý

â Nä

ë÷fíxë

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ì{õéê]÷rîríSôNô=òø<ôNõò ì{òWïUíöô[ý

Fig. 43 Reservoir Removal



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öëê]í ì{õéô






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Fig. 44 Grommet Removal
ÛÜXÝށß<àràSßrÞÛ áÜ

CAUTION: Do not use any type of tool to install the
grommets. Tools may cut, or tear the grommets creating a leak problem after installation. Install the
grommets using finger pressure only.


9
:
âþNä

â‘ãFä åæçè]é
ê‘ëì{í+îíWïñð¢è]òSó=ó=íìoôQïpé
ì{õ$ê]öíSëî$çè]ë÷fí+øöæéù

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ôNí øéîðíè

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;

,+!- .0/2143657/8+!1 +
=<

Fig. 46 Padding Caliper Interior



è]íSôNô[æè‘í=ê]òSó

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ôNì{òSîžòSæì„òø<çòè]í âü¹éð¢ýþ [äAý

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 PISTON AS IT LEAVES THE BORE. THIS MAY RESULT
IN PERSONAL INJURY.


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Fig. 45 Grommet Installation
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ÀÁ›ÂSà ÄKÅ0ÆHǬÈ!É
Í%ÎÏ?ÐXÏ?Ï?Ñ?Ò\ÓÔ_Õ`ÐXÖÍ`ÐXÏ?Ï?Ñ?ÒbÓXÔ_Õd× ØXÙKÚKÛ!ÜjÚKÝKÞKßKà

ÊÌË

Fig. 49 Piston Seal Removal

Fig. 47 Caliper Piston Removal

Fig. 50 Mounting Bolt Bushing And Boot

Fig. 48 Caliper Piston Dust Boot Removal

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CAUTION: Dirt, oil, and solvents can damage caliper seals. Insure assembly area is clean and dry.

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x–ˆz{q|0}=~€ ‚)ƒ„d€‚=…†)„"~—}=|0‡’0Š0˜8‡™‚=Š0šŠ0ƒ„!~€‰"~—‰"”
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}=|0‡ˆ’0Š0˜¢Šƒ‰}=‰"‰!ƒX‚=Š0\†S|0‡ˆ’*}=|0‡ˆ’0Š0˜¢Š0ƒ‰†)…‚=€„x£7˜¤•
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¥ ¦ˆz •
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¹»º ¦=´=¦=–¸‚=Š0 ·q‰"‰"…»¼A‚=Š0)…„ ¹»º ¦qyˆ³6y‘x£q˜¤• ¥=¥ z •
x½ˆz¾»„"†)…‚=€„;€‚=…†S„"~X}=…„!„"‡€~ „'¿”s~€„!±‰'©_„"S•
Fig. 51 Bushings And Boots Installation

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Fig. 52 Piston Seal Installation

Fig. 55 Piston Dust Boot Installation

Fig. 53 Dust Boot On Piston

Fig. 56 Wheel Cylinder Components–Typical

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Fig. 54 Caliper Piston Installation

WHEEL CYLINDER

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CLEANING AND INSPECTION
CALIPER
€ƒ‚„/…X†…‡
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ž ‰&Ÿ,‘& ¡•“+œ“#ŒH‹›#‰&‹!Œ¢•ƒ‰ £4¤¥T‘’‹›ŽC,‹ #Œ‰‘&’‹“+Œ, ¡’O‘&˜ ŽC•
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’O“#‹!˜ ˜‹ 
Œ‘&“8¤
CAUTION: Do not use gasoline, kerosene, thinner,
or similar solvents. These products may leave a
residue that could damage the piston and seal.

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± ƒ‹1’O‘&˜ ŽC•!²‘˜h–—Œ O‹ ž “•–³Œš’,‹ƒ•‰&‘&¡“#‹˜‘²´’O‰&Œ˜ ŽC‘
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˜Œƒ O‘&,»h•“ ’•‰&‘&˜ ,‘&,»¼¤
CAUTION: If the caliper piston is replaced, install
the same type of piston in the caliper. Never interchange phenolic resin and steel caliper pistons.
The pistons, seals, seal grooves, caliper bore and
piston tolerances are different.

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˜‹È‹!“#‹‰ £Î#•!“#“#• ‹ OϦ“#Ÿ,˜ŽK‹! OϦ˜ #•!“#‹ OϦ•“Б ž ’O•!‰&‘˜,‘&,»
™›•!Ÿ,‰& ¸‘&,#“#‹Œ˜‹·œ•!“#‹· O‘&Œ–—‹ŽC‹!“¢–—•!“#‹·ŽC,Œ”Ѥ ÑÒ̦–—–
´Ñ¤ ÑÑaӛ‘&,#4µ¤

Fig. 58 Shoe Contact Surfaces

WHEEL CYLINDER

Fig. 57 Polishing Piston Bore

REAR DRUM BRAKE
€ƒ‚„/…X†…‡
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ŽC,‹—˜ Ÿ,’’O•“#Ž’‰ŒŽC‹—Œƒ ›™›ƒ‹‹!‰V£‰&‘&, O‹!“[‹ÔWŽK‹!“#‘&•“8Ï™›‘&ŽK1Œ
™›ŒŽC‹“› Œ–—’‹,‹! ¨#‰&•ŽC*•!“™›‘&ŽKTœ“#ŒH‹¡#‰&‹!Œƒ‹“8¤ º •s,•!Ž

€ƒ‚„/…X†…‡
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ž ‰&Ÿ,‘& é•“*œ“#Œƒ‹²#‰&‹!Œ,‹!“*•,‰ £4¤ º •²,•!Ž1Ÿ,˜‹²Œ£L•ŽC,‹“
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º “£¦ŽKƒ‹£W‰‘&, ‹“ÛŒ, ·’O‘&˜ ŽC•ƒ˜°™ ‘ŽC¹•–—’O“#‹!˜ ˜‹ ·Œ‘&“8¤
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} ~Š2ÅX,š@„ ‘R…G„ †‚‡ˆ„ ‰

NOTE: Do not loosen/tighten equalizer adjusting
nut for any reason after completing adjustment.

ADJUSTMENTS
STOP
LAMP SWITCH
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PARKING BRAKE CABLE TENSIONER
NOTE: Parking brake adjustment is only necessary
when the tensioner, or a cable has been replaced or
disconnected for service. When adjustment is necessary, perform the following procedure for proper
parking brake operation.
tRuGvGwGx#yjzE{6|Gy
} ~g2€D‚ƒ'„b…G„ †‚‡ˆ„ ‰
}NŠ2‹D‡Œ ŽNŽj„ ƒ‚ „ ‘b’“•”ƒ'‚–&”a,5‡ ‘„ ,„7ƒ'ˆ‡Œ
‚P‡ —ˆ„ ƒ‰
}N˜2€D„ ™@…G„ ‘„ ‘Rš@†6„ „ ˆ ›`‚‘„ ƒƒ'„ ™1—ˆ‚„ ƒ@6’K‘„ ™1…„
—‘Œ6„ ’‘ ”™1ƒ'‰
}Nœ2D†„ ‡Œ]‘„ ‘T—‘Œ6„ƒ'† „P’“•”ƒ,™1„ bš@‚,†)ƒ'ž
’‘’;—‘Œi„K–%”–<„ ‰9ŸX j¡¢£ £ ¤ ¥C¢;£ ¦c§¢¨N© §6¨NªX«n¬c­®¡¯g¢°« ¨
°±c¡¢²a§«1³2§«n±4´o«n°µ#¢A¡§­¶X§6±c¢±c©p£@³2¤`¯¯b«n¢£ ¬c¯©&¤g±
· °¬c¯©N¸r¶X°6«nµX¤`±c¹´o«n°µ#¢E°6ª•º%¬c£ ©p­¢±c©Q°±cªW§¶X¢«<°6© ¤`§6±c»
}N¼1½D„ ‘‚Ž ¾A,†6"¿‘Œi‚–—‘Œi„F‡—ˆ„ ƒ@ ¿„ ‘,„ ŽN‘„ „ ˆ ¾
’‘„1 Q—‚6’‚–%ÀX ‘?ƒ„ ‚Á•„ ’‰X€D„ ¿ˆ‡„1ŽN”ˆÂ¾P‡—ˆ„ ƒÀ
—„ Ž ‘„ ¿‘ ‡„ „ ’‚–%‰
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—ˆ‚„ ƒ@ŽN,„ ‘5—‘Œi„ ƒ'† „ ’`“ ”ƒ,™1„ "‚ƒ@‡ ™1¿ˆ„ „ ‰
}NÄ2Å#š@„ ‘r…G„ †6‚‡ˆ„\„  ”6–%†ÆŽN ‘.‡‡„ ƒ'ƒ/\¿‘Œi‚–
—‘Œ6„ ˆ„…G„ ‘`‰6ÇR†„  · ¬c¯¯ ¸)¿¿ˆ ¾r¿‘ Œ6‚–:—‘ Œi„ ƒ‰jÅX„ …G„
—‘Œ6„ ƒ@¿¿ˆ‚„ ’2”‚ˆV’“ ”ƒ™1„ "‚ƒ@‡ ™1¿ˆ„ „ ‰

Fig. 59 Tensioner Rod Measurement

REAR
DRUM BRAKE
Ç9†6„1‘„ ‘M’‘ ”™Î—‘ Œi„ ƒ?‘„1„ Ì”‚¿¿„ ’5š5‚†KEƒ'„

ˆŽNžN’ž
“ 6
” ƒ'‚–&™1„ ‡†66‚ƒ™1‰GÏb’„ ‘" ‘™@ˆX‡‚‘‡”™1ƒ,‡„ ƒ'ÀG†„
 6ˆ ¾[‚™1„T’“•”ƒ'™1„ 6@‚ƒE‘„ Ì”‚‘„ ’r‚ƒ?š@†„ O†„2ƒ† „ ƒ
‘„r‘„ ¿ˆ‡„ ’ÀM‘„ ™1,…G„ ’)ŽN ‘K‡‡„ ƒ'ƒr ,†„ ‘K¿‘ƒ'ÀM ‘
š@†6„  „  ‘7— †P’‘”™1ƒ@‘„ ‘„ ¿ˆ‡„ ’‰
Ð ’“ ”6ƒ'™1„ 62‡Ñ—„=™1’„2š@‚,†Ñ^ƒ'’‘’4—‘Œi„
–%”–<„ҍ ‘;š@‚,†Ó’“ ”6ƒ'‚–+,  ˆ‰ Ð ’“ ”6ƒ'™1„ [‚ƒÑ¿„ ‘pž
ŽN ‘™1„ ’š@‚†.†„A‡ ™1¿ˆ„ „r—‘Œi„rƒƒ'„ ™1—ˆ ¾/‚ƒ,ˆˆ„ ’
 †„ —‡Œi‚–:¿ˆ,„ ‰
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}NŠ2€D‚ƒ'„A‘„ ‘K ŽU…„ †‚‡ˆ„A6’)‘„ ™1…„š5†„ „ ˆƒW’
—‘Œ6„ ’‘”6™1ƒ'‰
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ˆ„…„ ‘ƒ@’2‡—ˆ„ ƒ@‘„ ¿‘ ¿„ ‘ˆ ¾A‡ „ ‡,„ ’‰
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ÇR†„ ˆ ‡ŒW–<”–<„ ‚¿ ƒ'‚‚ }NÊX‚–<‰jÃÍ'p‰
}N¼2€D„…„ ‘ƒ„=–<”6–%„=’^‚ƒ'ˆˆ&‚ /—‘Œi„;ƒ'† „ ƒ‰
ß  ƒ'‚‚ 4–%”–%„Aˆ„ –%ƒWEƒ'† „r‡„ „ ‘ƒWƒƒ†,š@.}ÊX‚–%‰
Ão~g ‰DÛŽQ–%”–<„:’ „ ƒ  ?Ž‚M}N Eˆ  ƒ„›` :‚–%†Â ÀD’“•”ƒ'
ƒ'†6 „ ƒ'‰
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ƒ'‡ ‘„š-ƒ'‘9š5†„ „ ˆ‰

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Fig. 60 Adjusting Gauge On Drum

Fig. 62 Brake Adjustment

Fig. 61 Adjusting Gauge On Brake Shoes

 
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NOTE: Bring vehicle to complete standstill at each
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automatic adjusters.
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NOTE: Bring vehicle to complete standstill at each
stop. Incomplete, rolling stops will not activate
automatic adjusters.

SPECIFICATIONS
BRAKE
FLUID
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CAUTION: Never use reclaimed brake fluid or fluid
from an container which has been left open. An
open container will absorb moisture from the air
and contaminate the fluid.

SPECIAL TOOLS
BASE BRAKES

CAUTION: Never use any type of a petroleumbased 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.

BRAKE COMPONENTS

Installer Caliper Dust Boot C-4842

Disc Brake Caliper
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Handle C-4171

Adaptor Cap Pressure Bleeder 6921

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ANTILOCK BRAKES
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page

page
DESCRIPTION AND OPERATION
ABS SYSTEM RELAYS . . . . . . . . . . . . . . . . . .
ABS WARNING LAMP . . . . . . . . . . . . . . . . . .
ACCELERATION SWITCH . . . . . . . . . . . . . . .
ANTILOCK BRAKE SYSTEM . . . . . . . . . . . . .
COMBINATION VALVE . . . . . . . . . . . . . . . . . .
CONTROLLER ANTILOCK BRAKES . . . . . . . .
HYDRAULIC CONTROL UNIT . . . . . . . . . . . . .
WHEEL SPEED SENSORS AND TONE WHEEL
DIAGNOSIS AND TESTING
ANTILOCK BRAKES . . . . . . . . . . . . . . . . . . . .

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31

. . 33

DESCRIPTION AND OPERATION
ANTILOCK
SYSTEM
j;k,lnm2op[m2qiBRAKE
rslnqutv6k,ln
w:xvzy8{qu|}~r$€rsv6lu‚yrƒvzqnm2pl6„€luxv
… k,lili{@{qi|}†omˆ‡2op[y8x,‰Šm2lipyqu‡2rqit;k,y8‰‹k … kluli{Œrs{ym2Žpli
„€luxvzy8x,‰*{qi|}†om'k,li{m2rw:y8x,v6w:yx„€luky|{l:pw:},yx‰Xw|vzyqix
w:x‡‘r’vzlilupyx‰Q|qixvzpqi{
j;k,lnw:xvzy{8qu|}”“–•—˜w|[v6y „€w:vzlir‘v6k,lnr$€r’vzlu … kluxl™„–lip
rslixrsqipšr’y‰›x,w{rœyx‡2y|w:vzl”m2lipyqu‡2rœqitQky‰‹k … klilu{rs{8ym2
ž
y‰›k … klilu{Cr’{ymƒ|w:xŸlX‡2lur’|py:li‡‘w:r3v6klXm2quyxv … klupl
… k,lili{Epquvzwvzyqixlu‰›yxrwmm2pquw|k,y8x,‰3 :¡v6q
¢:¡m2lip|[lixvqit
w:|vzow:{„€luky|{lQr’m2luli‡Ÿ‡2o,py8x,‰‘pw:}†yx‰›Žlupyqi‡2rXqut7ky‰›k
… k,lili{r’{ymQqu||op … klux‘:pw:},lrsv6qum2r
yx£„€qu{ „€lky‰›kŠm2li‡w:{
m2plur’rsoplXw:x‡‘pwvzlXqitE„€luky|{lX‡2li|lu{lipw:vzy8qux
—w:v6vzlip¤„–qi{vzw‰‹lyrr’omm2{y8lu‡*v6qvzkl“–•—1y8‰‹xyv6yquxŠvzlup[
yxw:{ … k,lixQvzkl
y‰›xyvzyqixr … yvz|kQyrvzopxlu‡Xvzq
¥oxQmqir’y
vzyqixšjŒkl¦“–•—§m2luptSqupr¨w©r(€rsvzliªyxyvzyw:{8y«Gw:vzy8qux
m2pqu|li‡opl¬w:vŠvzkyršmqiyxvz­™xyvzyw{y«Gw:v6yqux®|qix,r’yr’vzr¯qitXw
rsv6w:vzy8|œw:x‡°‡’€xw:y|œr’lu{8tŠ|[kli|}±qitŠr$€rsv6lu²li{li|vzpy|w:{
|qum2qix,lixvzr’
j;k,lXr’vzw:vzy8||k,li|}ƒqi||o,pr3w:tSvzlipvzklXy‰›x,y8vzyqixŸr … yvz|kŸyr
vzopxlu‡³vzqœ¥ox®mqirsy8vzyqixŒj;klœ‡G–xw:y|n|klu|}´qi||[opr
… k,lix¬„€luky|{lœpqiw:‡µrsm2lilu‡µpliw:|klur¯w:m2m2pq6¶€yw:vzli{ °¢:¡
}†m2k”·¹¸’ºšm2ki»[7¼7opyx‰nv6k,lˆ‡G–xw:y|Q|kli|}†½7vzklˆ“–•—
:pylitS{ 1|S€|{lirvzkl*m2omˆw:x‡ˆrsqi{lix,qiy‡2rv6q„–lipyt šqim2lup[
w:v6yqux
­™tw:xŠ•—¾µ|qum2qix,lixvl™¶–kyyvzr‘w1tSw:o{v‡2opyx‰šyxy
vzyw{y«Gw:v6yqux½;v6k,lƒ“–•—°y{{oyxw:v6lurQv6kl‘w::lip … wpx,y8x,‰
{y‰›kv;wx‡'plu‰›yrsv6luprwQt8wo,{8v;|qi‡2l3y8xƒvzkly|pqum2pqi|lur’rsqip
luqip¤£

e€¿
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Â;ÃÄÀ€ÂŒÅdSe€Æ
¼7opyx‰xqupw:{!p[w}†yx‰›½Evzklw:r’vzlip |¤€{yx‡2lup(½Em2q … lip
:qiqur’vzlipŠwx‡ … kluli{:pw:}†l¯ox,y8vzrƒw{{t8ox|vzyqixµw:rƒv6k,l™
… quo{‡~yx³wŸ„–liky|{l … y8vzkquov•—¾€CjŒklšž
“Ǧ|qi3m2qi
xluxvzrw:plXxquv w:|v6y „€w:vzli‡

SERVICE PROCEDURES
BLEEDING ABS BRAKE SYSTEM .
REMOVAL AND INSTALLATION
ACCELERATION SWITCH . . . . . . .
COMBINATION VALVE . . . . . . . . . .
CONTROLLER ANTILOCK BRAKES
FRONT WHEEL SENSOR . . . . . . . .
HYDRAULIC CONTROL UNIT . . . . .
REAR WHEEL SPEED SENSOR . .
SPECIFICATIONS
T0RQUE CHART . . . . . . . . . . . . . .

. . . . . . . . . . 33
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36
35
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35

. . . . . . . . . . 37

Œe€È"dSÃi¿CɌÅ1ÄÀ€ÂŒÅd8e€Æ
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vzkl … kluli{C:pw:}†l*o,xyv6rs
—pw:},l*tS{oy‡ƒw:m2m2{ šm2plirsr’o,plyrqu‡2o{w:v6lu‡ˆw:||qup‡2yx‰
vzq … k,lilu{
rsm2luli‡2½7‡li‰›plulˆqutrs{y8m1wx,‡œpw:vzlˆqit
‡2lu|li{lipw:
vzy8qux"•¨rslix,r’qipˆw:v'luw:|k … klilu{|qux£„€lupvzr … kluli{3r’m2luli‡
yxvzqli{lu|v6py|w:{@r’y‰›x,w{rs–jŒklirslrsy‰›xw:{rw:plvzpw:xr’yvzvzli‡
vzqËvzkl̓–•—Ít8qip®m2pqi|lur’rsyx‰Îwx,‡Z‡livzlipyxw:vzy8quxÏqut
… k,lili{r’{ymƒw:x‡‘‡2lu|li{lip[wvzyqixŸpw:v6lu
j;k,l•—¾³r$€rsv6lu©k,wrƒvzkplulntS{oy‡Êm2plur’rsopln|qix,v6pqu{
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“–•—Ðw:xvzy{qi|}ˆm2pqu‰›pw:
j … q*rsqi{lix,qiy‡„–w{ „–lir3w:pl*o,r’li‡‘yxnluw|kŸw:xvzy8{qu|}ˆ|qix
vzpqi{|kw:xxli{Cj;kl'„–w:{ „–lirŸw:plšw:{{3{qi|w:vzli‡ … yvzkyx³v6k,l
ž
“Ç1„€w:{ „€l:qi‡GŠwx,‡ … qup}y8xQm2w:y8p[rvzqluy8vzklupyx|pliw:rsli½
kqu{8‡½3qup¯‡li|pluw:r’l¬w:m2m2{ ±mplirsr’opl¬w:ršx,lili‡li‡³yx®v6k,l
yx‡2y „€y‡ow{|qixvzpqu{C|kw:xxlu{8rs
j;k,l‘rsqi{lixquy‡'„€w:{ „€lurQw:pl‘x,qivr’vzw:v6y|*‡2o,py8x,‰Ÿw:xvzy8{qu|}
:pw:},yx‰‹7jŒkl™°wplœ|¤€|{li‡³|[qixvzyxoqio,r’{ ±vzq¬qi‡o{wvzl
m2plur’rsopli–¾€qu{8luxqiy‡*|¤€|{lv6yly8x'w:xv6y{qi|[}'qu‡2l|w:xŠ:l
liw:rsopli‡‘yxŸy8{{yr’lu|qix,‡2r’
CONTROLLER
Ñ;Ò,ÓXԖÕÖÐ×Ø3ÙÚuANTILOCK
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ACCELERATION SWITCH

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SYSTEM RELAYS
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REMOVAL AND INSTALLATION
CONTROLLER ANTILOCK BRAKES

 


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DIAGNOSIS AND TESTING
ANTILOCK
BRAKES
„…†“‡W‰ˆŠ¹‹
0Ž†œ‘˜@‘>’,†

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šY¡:£O¤’Ž¡:¢t• ¤:’,£O¤’›0šY0›0¤:šY’,‘¼’,•N«†80š"¨ ˜§’%…†“‘˜@‘>’,† Ÿ šY‘¼• £
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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 information refer to the Antilock Brake section in Group
8W. For test procedures refer to the Chassis Diagnostic Manual.

SERVICE PROCEDURES
BLEEDING
ABS BRAKE SYSTEM
ÅWƈÇ2ÈÉÈÊ%Ë8ÌÂÍÎYË Ë8ÏOÐYÑ:ÒÓ0Ë8ÔÕ:ÐYÓ0Ë È=Ö0×8ѦØË8Ñ:Ê,Ð"×8Ñ:ÙÎWÍÎYË

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Fig. 5 Controller Antilock Brakes




 

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Fig. 6 HCU Brake Lines

Fig. 8 Front Wheel Speed Sensor

Fig. 7 HCU Mount

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REAR WHEEL SPEED SENSOR

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Fig. 10 Setting Air Gap On Original Rear Sensor

Fig. 9 Wheel Speed Sensor

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Fig. 11 New Rear Sensor

COMBINATION VALVE

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Fig. 12 Combination Valve Brake Lines

Fig. 14 Acceleration Switch
ing arrow is pointing to the front of the vehicle (Fig.
15).

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CAUTION: The mercury switch (inside the acceleration switch), will not function properly if the switch
is installed incorrectly. Verify that the switch locat-

Fig. 15 Acceleration Switch Position Indicator

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CAUTION: Do not use an oxy/acetylene torch to
remove the old gear, or to heat and expand a new
gear. The high temperature of the torch flame can
cause localized heating that will damage the flywheel. In addition, using the torch to heat a replacement gear will cause uneven heating and
expansion. The torch flame can also anneal the
gear teeth resulting in rapid wear and damage after
installation.

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Fig. 4 Clutch Disc And Pressure Plate Inspection

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Š«ŒײŸsšd‹u”•”d’‹‘Ÿsš·£¤Nšš ¤•™@Ÿs¡

Fig. 5 Typical Method Of Aligning Clutch Disc

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Fig. 6 Release Bearing Attachment

PILOT BEARING
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Fig. 7 Pilot Bearing Installation

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NOTE: Be sure the transmission and housing mating surfaces are clean before installing an original,
or replacement clutch housing. Dirt/foreign material
trapped between the housing and transmission will
cause misalignment. If misalignment is severe
enough, the result will be clutch drag, incomplete
release and hard shifting.

CLUTCH
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Fig. 8 Clutch Housing Attachment

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Fig. 9 Slave Cylinder and Left Hand Drive Clutch
Master Cylinder

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DESCRIPTION AND OPERATION
TRANSMISSION
OIL COOLER
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COOLANT
RESERVE/OVERFLOW SYSTEM
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Fig. 2 Coolant Circulation—4.0L Engine

ACCESSORY
DRIVE BELTS
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HEATER
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WARNING: DO NOT OPERATE ENGINE UNLESS
BLOCK HEATER CORD HAS BEEN DISCONNECTED
FROM POWER SOURCE AND SECURED IN PLACE.

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BLOCK
HEATER
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WARNING: DO NOT OPERATE ENGINE UNLESS
BLOCK HEATER CORD HAS BEEN DISCONNECTED
FROM POWER SOURCE AND SECURED IN PLACE.

 

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Fig. 3 Coolant Recovery Bottle

THERMOSTAT
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CAUTION: Do not operate an engine without a thermostat, except for servicing or testing.

COOLANT
g _il_žryhwaPERFORMANCE
il_‚›_bdg´e”`a_uh_jcNx§` eslmj`NpruhbdwazNil_j_¼6_q“+pruh‚%€ prbd_i

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nom`a‚-_i„ƒ g _Gwauhslil_jprnˆ_‚˜bd_kM]-_jilprbqy il_Gslpru
il_noyh`ab–wau}_juhx§wauh_G‚_bdmuhprbdwmjuhƒ)Ùqu}pr‚-‚-wabdwamuh™?Šˆ‘r‘˜]_ilsl_juhb
_bdg´e”`_juh_cx§` eslmj`IzNil_j_¼6_jn pb+cÚrڍq’cNÛrqŽ-“•ƒ
Ü È6Ý Ü È ÍLÂRÏ»Ð)Ñ·¿-Ì¿-ÃNÒÑ Ð)ËrÓhÑÁhÌޘÀ¡ÁhÂR¿-¾›cNÙqnMbdgh_=il_s•mkMc
kM_u ‚-_‚~kMw ©bdyhil_™wab]-ilmq—wa‚-_jnC]ilmbd_slbdwamu˜px{pwauhnobzNil_j_¼6c
wauhxÖbdm‡cNØrߍq’àNcØ×rqŽ“•ƒg _1pruhbdwzil__j¼6_1slmjuhsl_u bqilprbdwmju
á ½âÂ
ÁhÑ ã˜Á´Ð
âª|r_¨ptkMwu wk yhkämz›×r×t]-_ils•_uhbd™?e_jpiRc
ilmy uh‚wauÅpr``†sl`wakMprbd_noƒLىz+]-_ils•_uhbdprx§_¬wan~`amq€ _i„™L_uhx{wauh_
]-prilbdnCkMpoe
|r_M_ilmj‚-_‚9|oe slpo—wabqprbdwamuhƒå›po©wakMyhkæ]-ilmbd_jslc
bdwmjuprx§prwauhnobGzil__j¼6wu xwan¡]ilm‰—”w‚_‚š€wabqgpÅçrÛÅ]-_jilsl_uhb
pruhbdwzil__j¼6_èslmuhsl_juhbdilprbqwamu ™€ g ws•gé]il_‰—_juhbdnêzNil_j_¼6wauhx
‚-mq€ u¶bqmëcçßrƒ ßrq’ΏNc‹‘rqŽ“•ƒ†\ìghwax§gh_ji¨]_ilsl_juhbqprx{_€ wa``
zNil_j_¼6_~prb%p=€ prilkM_iMbq_jkM]-_i•pbdyhil_jƒ»\–`anom™Ipšghwax{gh_iM]-_iRc
sl_u bqprx§_ mzpruhbdwazNil__j¼6_
slpruslpryhnˆ_ bqgh_ _uhx{wu _
bqm m‰—_ji•c
gh_jpb|_jslpryhnˆ_Mno]-_slwazwsgh_jpb†mjzpu bqwazNi•__¼6_MwanC`am‰€_ibqghpru
bdghprb+mz(€ prbd_iWƒ
CAUTION: Richer antifreeze mixtures cannot be
measured with normal field equipment and can
cause problems associated with 100 percent ethylene-glycol.

COOLANT
ADDITIVES
’mmj`pruhbÆnˆg SELECTION
myh`a‚›|r_kMprwauhAND
bdprwu _‚›
prbÆbqgh_Cnˆ]_slwazNwa_‚G`_q—_j`

€ aw bdgíp1kMw ©bdyhil_±mz9_bdg´e`a_u _x§` e”slm`acN|rprnˆ_j‚¢pruhbdwazNil__j¼6_
pruh‚˜`mq€EkMwu _ilpr`Islmjuhbd_uhb)€pbd_i„ƒ

CAUTION: Do not use coolant additives that are
claimed to improve engine cooling.

RADIATOR
î–ïaï~ðlñrò-óañrôqõjPRESSURE
ðlöµñrðl÷±÷ørùhóaú-CAP
ú÷ò¨û óaôdüvñ1ú-ðl÷jöˆöoùhðl÷±ýlñrú-þ

ÿ hü óaö}ý•ñúðl÷jï÷jñröˆ÷ö
úðl÷öoöˆùhðl÷ñrô9öoõM÷ú-õjóhôû óaôdühó1ñ
ðlñ §÷9õ 

ñ    ú-öoó •þ ÿ üh÷9ú-ðl÷jöˆöoùhðl÷¬ðl÷jïóa÷
ú-õjó  
ô Nó 
ú-õjù hòö CóaöM÷ §ðlñ ÷jò¡õ 
ôdõú¡õ Lôqü ÷Gýlñr
ú  ó {þ
•þ
ÿ ü ÷ ýlõõjïó  "ö !öoôq÷ ûóïaï²õú-÷jðlñrôq÷ ñrôEúðl÷öoöˆùhðl÷jö
öˆïaó §ü ôqï !¬ñ #r$õ ÷%ñr%ô Mõöoú-üh÷jðlóaý?úðl÷öoöˆùhðl÷jþ ÿ ühóaö+ðl÷jöˆùhïaôdö+ó ~ñ
ühó §ü ÷ðýlõõïañ h&
ô #rõjóïaó ¡ú-õjó hôCñrïaïõqû ó ¡ó hýlðl÷ñröo÷ò
ðlñrò-ó
ñrôqõjðtýlõjõïaó ¶ýlñrú-ñrýlóa'ô !{þ ÿ üh÷¢ýlñúEýlõ  ôqñró hö‡ñæöˆú-ðló (
ïaõñrò-÷jòúðl÷öoöˆùhð•÷¡ð•÷ïaóa÷ )ñrï ÷jþ ÿ ü ó&
ö ”ñrï ”÷˜õú-÷ höCû üh÷ 
ö !”öˆôd
÷ Õú-ðl÷jöˆöoùhðl÷›ðl÷ñrýlü ÷öôdüh÷›ðl÷ïa÷ñröo÷›ðlñ §÷›õ *


+
ñ    9ú-öˆó •þ
î ÷  -ô ”ñï ”÷Có 9ôdüh÷%ýl÷ hôd÷jð?õ ôqüh÷%ýlñrúGñrïaïaõ‰û ö+ñö ñïaï
,
ýlõjõïañ h.
ô ïõqûèôdühðlõjù §ü¨ôdüh÷˜ýlñú9û üh÷ ¨ýlõõjïa/ñ  ôMóa0
ö #÷jïaõ‰û
#rõóaïaó ôq÷ Mú-÷ðlñrôdùhðl÷jþ ÿ ü 0
÷ ”ñï ”÷}óaö¡ýlõ Mú-ïa÷ôd÷ï !týlïaõöˆ÷jò
û ü ÷ 1#rõóaïaó ú-õjó  ô¡óaöðl÷jñýlü ÷ò-þî–öýlõõjïa/ñ hô˜ýlõõjïaö 2 óaô
ýlõ hôqðlñrýlôdö¡ñ hò¨ýlðl÷ñrôd÷ö¡
ñ ”ñrýlùhù ìóôdüh÷
ýlõõjïaó 3ö !ö
ôd÷ Mþ ÿ ühóaöýlñrùhöo÷öCôdüh
÷ ”ñrýlùhù 4”ñï ”÷ôdõõjú-÷ ¡ñ hò¬ýlõjõï
ñ hô ó vðl÷jöˆ÷j5ð 7÷ 6W$õ ÷j8ð Nïaõ‰ûéôqñ ¢ôq9

õ #÷ªò-ðlño:
û vôdühðlõjù §ü

µ¢¶

·-¸B¸ ¹Eº »B¼4½J¾-½-¿MÀOÁ

Â=Ã*Ä

Å&ÆVÇVÈ&É=ÊËVÌ.Ê Í^Î`Ï&ÎaÅbÍ^ËVÆVÉ&ÏcÌ.Ê Í^ÎeÐÈ&ÑhÒhÓÔ"ÒlÕhÖh×hØ

Fig. 5 Reverse Rotating Water Pump—Typical

COOLING
SYSTEM HOSES
¦

Fig. 4 Radiator Pressure Cap
p8qrrsp8t%urvxwqys^urt%q{z8|/}/u|t%qz"~€$lt%ws ‚J|p8ƒƒ„…‚†|‡ ‚†s^uy
yt7ƒp8ˆ+ywƒt%‰Mz8|}/u|t%qzRwqysycŠ:u‡‡‹p8q‡‡|ŒEys:qrp8qq‡ }/q$Š:r3~
Ž z8ƒszRv|yˆ3st?ys|‡y&t7w3s.z8|}Eu|/t%qzRu‡‡szRrsp8ˆ3~/‘cwuy
uy}Eqr3s’t%q&„.|ur3t7|ur:‚†|/p8ƒ3ƒ„“}/ƒz8urv{p
qq‡|rtlp8qq‡ }Eq7Š:r
|r}”t%q•ŒEz8s$‚†srt’‡s|ˆ3|vs.Š’wsr–y"—Jyt%s„`uy0ƒr}/szaŒEz8sy
yƒz8s~

WATER PUMP

‘*w3s&Š’|t7sz.ŒEƒ3„.Œ˜u„.Œ/s‡‡sz.uy{ŒEz
syys},qrt7qxt%wsxz8s|z
qR|”yw|t{t%w|t.z8qt%|t7sy+ur9s|/z8urv(y+Œ/z8syys}™urt%q,t%ws
wqƒyurv(~E‘cws.w3qƒyurvaw|y&|xy„.|‡‡‹wq‡s.t%q.|‡‡q$ŠšyssŒ/
|vs+t%q•syp8|ŒEs~›‘cws:Š:|t7szaŒEƒ3„.Œ”ys|‡yx|/z8s+‡ƒz8up8|t7s}
—1t%wsœ|/r3t7u z8ssOsœur4t%ws™p8qq‡|rt=„.u žJt%ƒz8s~&Ÿ q™|}E}Eu
t%uqr|‡h‡ƒz8up8|t7uqruy:rsp
syy|z5—(~

CAUTION: All engines are equipped with a reverse
(counter-clockwise) rotating water pump and viscous fan drive assembly. REVERSE is stamped or
imprinted on the cover of the viscous fan drive and
inner side of the fan. The letter R is stamped into
the back of the water pump impeller (Fig. 5).
  rvursyš z
q„¡ŒEz8s7‚Juqƒy“„.q}Es‡,—Js|z8y‰™}/sŒEsr}Eurv
ƒŒ/qr0|ŒEŒ/‡up8|t%uqr‰„.|—=w|‚†s¢ssr0s£ƒuŒEŒEs}Š:ut%w0|. qz

Š:|z8}0¤p8‡qp8ˆŠ:uys7¥ z8qt7|t%ur3vŠ:|t%szŒEƒ„:ŒE~-$ryt%|‡‡|/t%uqr•q
t%wslŠ’z8qrv?Š’|t7sz?ŒEƒ„.ŒŠ’u‡‡-p8|ƒysRsrv(urs¢q7‚Jsz8w3s|t7urv(~

ƒsz:wqysy{z
qƒt%sxp8qq‡|rtt%qx|r} z8q„bt7wsaz8|}Eu|
t%qz‰€ur3t7|ˆs^„.|/r3uq‡}•|/r3}ws|t7sz’p8qz8s~
¦ |}Eu|/t%qza‡q7Š:szaw3qysy0|z8s+yŒEz
ur3v z8sur3 qz8p
s}”t%q•ŒEz
s
‚Jsrt:p8q‡‡|Œ/ys•z8q„§Š:|t%szaŒEƒ„.Œ”yƒp8t%uqr–|t:„.q}Esz
|/t%s
|r}•wuvw˜srv(ur3sayŒEss}Ey~
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. 6). SNAP-ON CLAMP TOOL (NUMBER
HPC-20) MAY BE USED FOR LARGER CLAMPS.
ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps (Fig. 7). If
replacement is necessary, use only an original
equipment clamp with matching number or letter.
$ryŒEsp8t9t%ws¨wqysy…|t©z
svƒ‡|zªurt%sz5‚†|/‡y~ ¦ sŒE‡|p8s
wqysyRt7w|tc|z8s’p8z8|p8ˆs}/‰- ss‡M/z
ut%t%‡s*Š’wsr+y£/ƒ3ssOs}E‰Jqz
yŠ’s‡‡hs7žJp8syyu ‚†s‡ —0Š:wsrt%ws^y—†yt%s„«uy:ŒEz8syyƒ3z8uOs}E~
¬ qz”|‡‡R‚Jsw3up
‡sy­.$r1|z8s|y+Š:wsz8s9yŒEsp
uup®z8qƒt%urv
p8‡|„.ŒEy¢|z8s.r3qt*ŒEz8q7‚Ju}Es}E‰›s:yƒz8s:t%w|t*wqysy¢|z8s:ŒEqyu
t%uqrs}¯Š:ut%w°yƒ  up8usr3t…p
‡s|z8|/r3p8s~™±)wsp8ˆ²p8‡s|z8|rp8s
 z8q„°s$žJw3|/ƒ3yt^„.|/r3uq‡}Ey|r}³Œ/uŒEs‰  |r´‡|}/sy‰ }Ez8u ‚†s
s‡t%yR|r}xy"Š:|—|z8y~J$„.ŒEz
qŒEsz8‡ —ŒEqyut7uqrs}xw3qysyRp8|r
sª}/|/„.|v(s}E‰0z8syƒ‡t%urv1ur§p8qq‡|rt”‡qyy´|r}¨srv(ur3s
q$‚†sz8ws|t7urv(~

O P1Q

R2STSKUV WTXY2Z[Y2\ ]^

_@`

acbHdHecf gDhHijgBk>lnmcloapk>hHbHfcmqijgBk>l,r"ecsutuvwxtzyu{u|u}

æ%áç9êçEååÛ9á9;:æ%èåF;Þ/Ýôæ%á®Þ–çEÚ8åÛEåæ%åÚ8â.ÜÝåÛ9â.ÞöJÜâ.ðâ
ìå$ó†åìhÞæ èÜãè3åÚ&åÝãÜÝå^êçEååÛEêù

Fig. 6 Hose Clamp Tool—Typical

Fig. 8 Water Pump Mounted Fan Drive

G“æ%èåÚ8â.áêæ7Þæ%Üëaò/Üâ.åæ7ÞììÜëaêçEÚ8ÜÝã,ë8áÜìVÜêxìáë8Þæ%å۔áÝ
æ%èå>; Ú8áÝæH; Þë8å^á9h
; æ7èå óJÜêë8áðêE; Þ/ݘÛ/Ú8Ü óJå^ðÝ3ÜæVí Þ=æ ߆çEÜë8Þì
óJÜêë8áðê”ðÝÜæ•Üêœêèá$à’Ý1ÜÝ1íB›
A Üã(ùEI ñù ? èÜê”êç/Ú8ÜÝ3ã´ë8áÜì
Ú8åÞë8æ%ê•æ%áæ%èå˜æ%åâ.ç/åÚ8Þæ%ðÚ8å˜á9&
; æ7è3å˜Ú8Þ/Û/ÜÞæ%áÚ=ÛEÜêë8è3Þ/Ú8ã(å
ÞÜÚùK7J æ^åÝã(Þãåê+æ7èåaó†Üêë8áðê4; ÞÝ©ÛEÚ8Ü ó†åL; áÚ=èÜãè3åÚ ; ÞÝ
êç/ååÛ®ÜMV
; æ%èå=ÞÜÚ{æ%åâ.çEåÚ8Þæ7ðÚ
å ; Ú8áâ÷æ%èå=Ú8ÞÛEÜÞ/æ%áÚ{Ú8Üêåê
Þòá$óJå:Þaë8åÚ
æ7ÞÜݕçEáÜÝæ%ù2
N Ýæ%Üì‹ÞÛEÛEÜæ%ÜáÝÞì€åÝã(ÜÝ3å:ë8ááìÜÝ3ã
Üê•Ý3åë8åêêÞ/Ú5ß6V
= æ%èåL; Þ/ݘà:Üìì¢Ú
åâ.ÞÜÝ©Þæ^ޜÚ8åÛEðë8åۖÚ8ç/â
Ú8åã(ÞÚ8ÛEìåêê:á9l
; åÝã(ÜÝå^êçEååÛEù

Fig. 7 Clamp Number/Letter Location
Ù Ú8Û/ÜÝ3Þ/Ú5ß²à’áÚ8âäãåÞÚbæ'ßJç/åéèáêåéë8ìÞ/â:çEêîí à’èåÝ
?
åïðÜç/çEåÛOñ³ë
Þ/ݯòåªÚ8åâ.á$ó†åÛôà:Üæ%è¯Þ¨êæ7Ú8ÞÜãèæ”êë8Ú8å7à:õ
ÛEÚ8Ü ó†åÚôáÚôÞ§è3å$ö÷êáë8øåæ%ù.úhûîü›ýÿþBþ 

þ
û
 û þ4ûý
=ü   þ  ûþ
=ü  û  -þ
"!#
 þ€þ$
û&%('*)
,+.-%/!#0120 34ûý652€þ017Rû&€û 
û6Bþ/ý8"!#
 þ  ûþ4
=ü90
: è3åݚçEåÚ<;áÚ8â.ÜÝã4ޅèáêåôÜÝ3êçEåë8æ%ÜáÝ =xÜÝêçEåë8æ®æ%èå
Ú8ÞÛEÜÞæ7áÚ&ìá$à’åÚ¢èáêå>;áÚ¢çEÚ8áç/åÚ&ç/áêÜæ%ÜáÝ,ÞÝەë
áÝÛEÜæ%ÜáÝ
á9;læ%èå^ÜÝæ%åÚ8ÝÞìhêçEÚ8ÜÝãù

VISCOUS
FAN DRIVE
? è3å:æ%èåÚ8â.ÞìóJÜêë8áðê@; ÞݕÛEÚ8Ü óJå’íBAMÜã(ùCñ ÜêRÞxêÜìÜë8áÝåõ

; ìðÜÛEõD; ÜììåÛ=ë8áðçEìÜÝãað3êåÛ=æ%á.ë8áÝÝåë8æ*æ%èåE; 
Þ ÝòìÞÛ/åê¢æ7á
åÜæ%èåÚ:æ%èåaåÝãÜÝå^áڒæ7è3åRà:Þæ%åڒçEðâ.çêèÞ; æ%ù ? èåaë8áðõ
çEìÜÝã:Þììá$à:êVæ7è3å*; ÞÝ0æ%á¢òå¢ÛEÚ8Ü óJåÝ0ÜÝ0Þ{ÝáÚ8â.Þì›â.ÞÝÝ3åÚù

? èÜê.Üê.ÛEáÝåaÞæ ìá$à«åÝãÜÝå^êçEååÛEê?à:èÜìåaìÜâ.Üæ7ÜÝã0æ7è3å

Fig. 9 Viscous Fan Drive—Typical
Ù Ýì ßà’èåݜêð ;B; Üë8ÜåÝæ&èåÞæ&ÜêaçEÚ8åêåÝæ.=-à’Üìì*æ7è3å’óJÜêõ
?
ë8áð3ê8; ÞݙÛEÚ8Ü óJå+åÝãÞãåù ? èÜêxÜê¢à:è3åݙæ%èå+ÞÜÚ>;ìá7à:ÜÝã
æ%èÚ8áð3ãè4æ%èåœÚ8ÞÛEÜÞæ7áژë8áÚ8å™ë8ÞðêåêÞ©Ú8åÞ/ë8æ%Üáݪæ7áœæ%èå

"$#

%'&(&)+* ,(-/.10'.'24365

7987

:<;>=>?<@9ACB>DEAGFIHKJ<H:LFIB>;>@<JDEAGFIHNMO?<PRQRSUTQVRWRXRY

~M€j9‚.ƒ„D„MM…@…<†9M„M‡ ˆ‰‚1‚‰Š9‹ŒM‹ …<<ƒŽ9ŽcDƒ‹ŒŽ‘9’ ‚.†j‘<†”“•M’
‚.Š >‹ 9…<Ž–Žƒ—˜ƒ’’M‚‰M†9‹ƒ„™9‹ š›D‹o…œ†9†9„MM‹ š›‡
 ‹ …<ž‚.Š ž9‹ š›M‹ žŠ ƒŽE…<††9„M’Ÿ‚.Š ž<ƒ’Mƒ‚.†9*’MŽ–…<Šƒ<š›
‚.9€j‘<ƒ‚‰ <¢¡EM„M„&’<†‘‡4£qŠ ¤~M€j9‚.ƒ„D„MM…¥…<†9M„&ƒš›ƒM‹
<ƒ…<‚.Ž8ƒ‹ ’˜‚.Š Bƒ‹¦Ž‘9’FDŽ8<’  …<’˜‚.†4‚.Š ‘<‰“[M†9  Ž
’MŽ9‹ š›ƒš›9’4Ž–‘99’‡

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 overheating.

ACCESSORY DRIVE BELT DIAGNOSIS
ØqÙ Ú·Û[Üq݌ÞuÙ Üß@à[áuÚ·Ù Ú
â/ã äå/æçMèé¾å êë–çMå éŒë–äì<íä9åî‰çMå ä èï<ï<äë–ëê9ìð¦æì<ç ñ[äòäóDî.ëô
ë–õEèóMóï<ì<èï<ö÷ëKî‰ã èîuì<ø åÃèï<ì<ê9ëëÇî.ã ä*ì<çMòòäæoëø ì<ùBèï<ä*ê9ù î‰ãä
òä9óMîÇùBì<êõúì<çMòŒî.êoì<çDò4ûDü çMé¾ýKþÿ œôTèì<ä8ïœê9å ëçDæä9ì<äæ½å êì<õjèóDý
qã ä9ëäoèì<ä>å ê9îKèì<ä9èë–êåÀî.êoì<äíóMèï<äoî.ã ä>òäóMî‰
ý @ê ¿ä”ñ[äì#ô
ï<ì<èï<ö÷ë>ì<øå å çMå é4èóMê9åé4èŒì<çMòŒûBå êî*èï<ì<êë–ë Eèì<
ä 
¿å êì 
õjèóM
ý Çå9ð¦òä9óM
î ¿çDî.ã˜ï<ì<èï<öë>ì<ø åå çMå éŒèóMê9åéŒè½ìœçDò½õEø ë–î
òä4ì<ä9íóMèï<äæ(ûDü çMé¾ýcþ–ÿ "ý
ÇóDëê4ì<ä9íóDèï<ä4î.ã ä4òä9óMîEçMùÇçDî¿ã èë
ä •ï<ä9ëë–ç ñ[
ä ¿ä9èì#ôµùDì<è–ð•ä9æ4ï<ê9ìœæëEê9ìcë–ä‰ñ[ä9ì<ä>é›óD
è çMå é›ý
™ä9ùDä9ì¿î.ê>î.ã 
ä Çï<ï<äë–ëê9ì
ð 1ì<ç ñ•
ä ™äóM
î 1çMèé¾å êë–çMëEï<ã èì<î.ë
ùBêì¿ùDø ì<î‰ãä9ìcòäóMîKæçMèé›å ê9ëçMë–ý

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.

DIAGNOSIS AND TESTING
ON-BOARD DIAGNOSTICS (OBD)
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Fig. 10 Belt Wear Patterns

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CONDITION
RIB CHUNKING (One or more ribs
has separated from belt body)

RIB OR BELT WEAR

BELT SLIPS

LONGITUDAL BELT CRACKING

9GROOVE JUMPING9
(Belt does not maintain correct
position on pulley)

BELT BROKEN
(Note: Identify and correct problem
before new belt is installed)

POSSIBLE CAUSES

CORRECTION

1. Foreign objects imbedded in
pulley grooves.

1. Remove foreign objects from
pulley grooves. Replace belt.

2. Installation damage

2. Replace belt

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

1. Belt slipping because of
insufficient tension

1. Adjust tension

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.

1. Belt has mistracked from pulley
groove

1. Replace belt

2. Pulley groove tip has worn away
rubber to tensile member

2. Replace belt

1. Belt tension either too low or too
high

1. Adjust belt tension

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

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



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DEIEJEKEL
CONDITION
NOISE
(Objectionable squeal, squeak, or
rumble is heard or felt while drive
belt is in operation)

TENSION SHEETING FABRIC
FAILURE
(Woven fabric on outside,
circumference of belt has cracked or
separated from body of belt)

CORD EDGE FAILURE
(Tensile member exposed at edges
of belt or separated from belt body)

POSSIBLE CAUSES

CORRECTION

1. Belt slippage

1. Adjust belt

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.

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

1. Excessive tension

1. Adjust belt tension

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

PRELIMINARY CHECKS
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NOTE: If investigation reveals none of the previous
items as a cause for an engine overheating complaint, refer to following Cooling System Diagnosis
charts.

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COOLING SYSTEM DIAGNOSIS
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CONDITION
TEMPERATURE GAUGE
READS LOW

TEMPERATURE GAUGE
READS HIGH OR ENGINE
COOLANT WARNING LAMP
ILLUMINATES. COOLANT
MAY OR MAY NOT BE LOST
OR LEAKING FROM
COOLING SYSTEM

POSSIBLE CAUSES

CORRECTION

1. Has a Diagnostic Trouble Code
(DTC) been set indicating a stuck open
engine thermostat.

1. Refer to group 25, Emission Control
Systems. Replace thermostat if
necessary. If a Diagnostic Trouble Code
(DTC) has not been set, the problem
may be with the temperature gauge.

2. Is the temperature gauge (if
equipped) connected to the
temperature gauge coolant sensor on
the engine?

2. Check the engine temperature
sensor connector in the engine
compartment. Refer to Group 8E.
Repair as necessary.

3. Is the temperature gauge (if
equipped) operating OK?

3. Check gauge operation. Refer to
Group 8E. Repair as necessary.

4. Coolant level low in cold ambient
temperatures accompanied with poor
heater performance.

4. Check coolant level in the coolant
reserve/overflow tank and the radiator.
Inspect system for leaks. Repair leaks
as necessary. Refer to the Coolant
section of the manual text for Warnings
and precautions before removing the
radiator cap.

5. Improper operation of internal heater
doors or heater controls.

5. Inspect heater and repair as
necessary. Refer to Group 24, Heating
and Air Conditioning for procedures.

1. Trailer is being towed, a steep hill is
being climbed, vehicle is operated in
slow moving traffic, or engine is being
idled with very high ambient (outside)
temperatures and the air conditioning
is on. Higher altitudes could aggravate
these conditions.

1. This may be a temporary condition
and repair is not necessary. Turn off the
air conditioning and attempt to drive the
vehicle without any of the previous
conditions. Observe the temperature
gauge. The gauge should return to the
normal range. If the gauge does not
return to normal range, determine the
cause for overheating and repair. Refer
to POSSIBLE CAUSES (numbers 2
through 18).

2. Is temperature gauge (if equipped)
reading correctly?

2. Check gauge. Refer to Group 8E.
Repair as necessary.

3. Is temperature warning lamp (if
equipped) illuminating unnecessarily?

3. Check warning lamp operation. Refer
to Group 8E. Repair as necessary.

4. Coolant low in coolant reserve/
overflow tank and radiator?

4. Check for coolant leaks and repair
as necessary. Refer to Testing Cooling
System for Leaks in this group.

5. Pressure cap not installed tightly. If
cap is loose, boiling point of coolant
will be lowered. Also refer to the
following step 6.

5. Tighten cap.

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CONDITION
TEMPERATURE GAUGE
READS HIGH OR ENGINE
COOLANT WARNING LAMP
ILLUMINATES. COOLANT
MAY OR MAY NOT BE LOST
OR LEAKING FROM
COOLING SYSTEM

POSSIBLE CAUSES

CORRECTION

6. Poor seals at radiator cap.

6. (a) Check condition of cap and cap
seals. Refer to Radiator Cap. Replace
cap if necessary.
(b) Check condition of radiator filler
neck. If neck is bent or damaged,
replace radiator.

7. Coolant level low in radiator but not
in coolant reserve/overflow tank. This
means the radiator is not drawing
coolant from the coolant reserve/
overflow tank as the engine cools.
As the engine cools, a vacuum is
formed in the cooling system of the
engine and radiator. If radiator cap
seals are defective, or cooling system
has leaks, a vacuum can not be
formed.

7. (a) Check condition of radiator cap
and cap seals. Refer to Radiator Cap in
this group. Replace cap if necessary.
(b) Check condition of radiator filler
neck. If neck is bent or damaged,
replace radiator.
(c) Check the condition of the hose
from the radiator to the coolant tank. It
should fit tight at both ends without any
kinks or tears. Replace hose if
necessary.
(d) Check coolant reserve/overflow tank
and tank hoses for blockage. Repair as
necessary

8. Freeze point of antifreeze not
correct. Mixture may be too rich.

8. Check antifreeze. Refer to Coolant
section of this group. Adjust antifreezeto-water ratio as required.

9. Coolant not flowing through system.

9. Check for coolant flow at radiator
filler neck with some coolant removed,
engine warm and thermostat open.
Coolant should be observed flowing
through radiator. If flow is not observed,
determine reason for lack of flow and
repair as necessary.

10. Radiator or A/C condenser fins are
dirty or clogged.

10. Clean insects or debris. Refer to
Radiator Cleaning in this group.

11. Radiator core is corroded or
plugged.

11. Have radiator re-cored or replaced.

12. Fuel or ignition system problems.

12. Refer to Fuel and Ignition System
groups for diagnosis. Also refer to the
appropriate Powertrain Diagnostic
Procedures service manual for
operation of the DRB scan tool.

13. Dragging brakes.

13. Check and correct as necessary.
Refer to Group 5, Brakes in the manual
text.

14. Bug screen is being used reducing
airflow.

14. Remove bug screen.

15. Thermostat partially or completely
shut. This is more prevalent of high
mileage vehicles.

15. Check thermostat operation and
replace as necessary. Refer to
Thermostats in this group.

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CONDITION

TEMPERATURE GAUGE
READING IS
INCONSISTENT
(FLUCTUATES, CYCLES OR
IS ERRATIC)

POSSIBLE CAUSES

CORRECTION

16. Thermal viscous fan drive not
operating properly.

16. Check fan drive operation and
replace if necessary. Refer to Viscous
Fan Drive in this group.

17. Cylinder head gasket leaking.

17. Check for cylinder head gasket
leaks. Refer to Testing Cooling System
for Leaks in this group. For repair, refer
to Group 9, Engines.

18. Heater core leaking.

18. Check heater core for leaks. Refer
to Group 24, Heating and Air
Conditioning. Repair as necessary.

1. During cold weather operation, with
the heater blower in the high position,
the gauge reading may drop slightly.

1. A normal condition. No correction is
necessary.

2. Temperature gauge or engine
mounted gauge sensor defective or
shorted. Also, corroded or loose wiring
in the circuit.

2. Check operation of gauge and repair
if necessary. Refer to Group 8E,
Instrument Panel and Gauges.

3. Gauge reading rises when vehicle is
brought to a stop after heavy use
(engine still running).

3. A normal condition. No correction is
necessary. Gauge reading should
return to normal range after vehicle is
driven.

4. Gauge reading high after restarting
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 Testing Cooling System for
Leaks in this group.

6. Cylinder head gasket leaking
allowing exhaust gas to enter cooling
system causing thermostat to open
late.

6. (a) Check for cylinder head gasket
leaks with a commercially available
Block Leak Tester. Repair as
necessary.
(b) Check for coolant in the engine oil.
Inspect for white steam emitting from
exhaust system. Repair as necessary.

7. Water pump impeller loose on shaft.

7. Check water pump and replace as
necessary. Refer to Water Pumps in
this group.

8. Loose accessory drive belt (water
pump slipping).

8. Refer to Engine Accessory Drive
Belts in this group. Check and correct
as necessary.

9. Air leak on the suction side of water
pump allows air to build up in cooling
system causing thermostat to open
late.

9. Locate leak and repair as necessary.

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CONDITION

POSSIBLE CAUSES

CORRECTION

PRESSURE CAP IS
BLOWING OFF STEAM
AND/OR COOLANT TO
COOLANT TANK.
TEMPERATURE GAUGE
READING MAY BE ABOVE
NORMAL BUT NOT HIGH.
COOLANT LEVEL MAY BE
HIGH IN COOLANT
RESERVE/OVERFLOW
TANK

1. Pressure relief valve in radiator cap
is defective.

1. Check condition of radiator cap and
cap seals. Refer to Radiator Caps in
this group. Replace cap as necessary.

COOLANT LOSS TO THE
GROUND WITHOUT
PRESSURE CAP BLOWOFF.
GAUGE IS READING HIGH
OR HOT

1. Coolant leaks in radiator, cooling
system hoses, water pump or engine.

1. Pressure test and repair as
necessary. Refer to Testing Cooling
System for Leaks in this group.

DETONATION OR PREIGNITION (NOT CAUSED
BY IGNITION SYSTEM).
GAUGE MAY OR MAY NOT
BE READING HIGH

1. Engine overheating.

1. Check reason for overheating and
repair as necessary.

2. Freeze point of antifreeze not
correct. Mixture is too rich or too lean.

2. Check antifreeze. Refer to the
Coolant section of this group. Adjust
antifreeze-to-water ratio as required.

HOSE OR HOSES
COLLAPSED WHEN
ENGINE IS COOLING

1. Vacuum created in cooling system
on engine cool-down is not being
relieved through coolant reserve/
overflow system.

1. (a) Radiator cap relief valve stuck.
Refer to Radiator Cap in this group.
Replace if necessary.
(b) Hose between coolant reserve/
overflow tank and radiator is kinked.
Repair as necessary.
(c) Vent at coolant reserve/overflow
tank is plugged. Clean vent and repair
as necessary.
(d) Reserve/overflow tank is interally
blocked or plugged. Check for blockage
and repair as necessary.

NOISY FAN

1. Fan blades loose.

1. Replace fan blade assembly. Refer
to Cooling System Fans in this group.

2. Fan blades striking a surrounding
object.

2. Locate point of fan blade contact and
repair as necessary.

3. Air obstructions at radiator or air
conditioning condenser.

3. Remove obstructions and/or clean
debris or insects from radiator or A/C
condenser.

4. Thermal viscous fan drive has
defective bearing.

4. Replace fan drive. Bearing is not
serviceable. Refer to Viscous Fan Drive
in this group.

5. A certain amount of fan noise
(roaring) may be evident from the
thermal viscous fan drive. Some of this
noise is normal.

5. Refer to Viscous Fan Drive in this
group for an explanation of normal fan
noise.

ø+ùOúû

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   !"$#&%')()*,+-().)/)0)1
CONDITION
INADEQUATE AIR
CONDITIONER
PERFORMANCE (COOLING
SYSTEM SUSPECTED)

INADEQUATE HEATER
PERFORMANCE.
THERMOSTAT FAILED IN
OPEN POSITION

POSSIBLE CAUSES

CORRECTION

1. Radiator and/or A/C condenser is
restricted, obstructed or dirty (insects,
leaves etc.)

1. Remove restriction and/or clean as
necessary. Refer to Radiator Cleaning
in this group.

2. Thermal viscous fan drive is
free-wheeling.

2. Refer to Viscous Fan Drive for
diagnosis. Repair as necessary.

3. Engine is overheating (heat may be
transferred from radiator to A/C
condenser. High underhood
temperatures due to engine
overheating may also transfer heat to
A/C components).

3. Correct overheating condition. Refer
to text in Group 7, Cooling.

4. Some models with certain engines
are equipped with air seals at the
radiator and/or A/C condenser. If these
seals are missing or damaged, not
enough air flow will be pulled through
the radiator and A/C condenser.

4. Check for missing or damaged air
seals and repair as necessary.

1. Has a diagnostic trouble code (DTC)
been set?

1. Refer to group 25, Emission Control
System and replace thermostat if
necessary.

2. Coolant level low.

2. Refer to Testing Cooling System for
Leaks in the manual text. Repair as
necessary.

3. Obstructions in heater hose fittings
at engine.

3. Remove heater hoses at both ends
and check for obstructions. Repair as
necessary.

4. Heater hose kinked.

4. Locate kinked area and repair as
necessary.

5. Water pump is not pumping water to
heater core. When the engine is fully
warmed up, both heater hoses should
be hot to the touch. If only one of the
hoses is hot, the water pump may not
be operating correctly. The accessory
drive belt may also be slipping causing
poor water pump operation.

5. Refer to Water Pumps in this group.
Repair as necessary. If a slipping belt is
detected, refer to Engine Accessory
Drive Belts in this group. Repair as
necessary.

243
HIJKLMNINJLHO P N OI!L"K$Q&RS)T)U,V-T)W)X)Y)Z
CONDITION
HEAT ODOR

POSSIBLE CAUSES

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BDCFE:G

CORRECTION

1. Various heat shields are used at
certain drive line components. One or
more of these shields may be missing.

1. Locate missing shields and replace
or repair as necessary.

2. Engine running hot

2. Preform thermostat, water pump and
fan test. Repair or replace as
necessary.

3. Cooling fan malfunctioning.

3. Refer to Cooling System Fan in this
group for diagnosis. Repair as
necessary

4. Undercoating or other contaminate
applied to cooling or exhaust system.

4. Clean as necessary.

5. Engine may be running rich causing
the catalytic converter to overheat.

5. Refer to the DRB scan tool and the
appropriate Powertrain Diagnostic
Procedures service manual. Repair as
necessary.

POOR DRIVEABILITY
(THERMOSTAT POSSIBLY
STUCK OPEN). GAUGE
MAY BE READING LOW

1. For proper driveability, good vehicle
emissions and for preventing build-up
of engine oil sludge, the thermostat
must be operating properly. Has a
diagnostic trouble code (DTC) been
set?

1. Refer to group 25, Emission Control
System. DTC’s may also be checked
using the DRB scan tool. Refer to the
proper Powertrain Diagnostics
Procedures service manual for
checking the thermostat using the DRB
scan tool. Replace thermostat if
necessary.

STEAM IS COMING FROM
FRONT OF VEHICLE NEAR
GRILL AREA WHEN
WEATHER IS WET, ENGINE
IS WARMED UP AND
RUNNING, AND VEHICLE IS
STATIONARY.
TEMPERATURE GAUGE IS
IN NORMAL RANGE

1. During wet weather, moisture (snow,
ice or rain condensation) on the
radiator will evaporate when the
thermostat opens. This opening allows
heated water into the radiator. When
the moisture contacts the hot radiator,
steam may be emitted. This usually
occurs in cold weather with no fan or
airflow to blow it away.

1. Occasional steam emitting from this
area is normal. No repair is necessary.

COOLANT COLOR

1. Coolant color is not necessarily an
indication of adequate corrosion or
temperature protection. Do not rely on
coolant color for determining condition
of coolant.

1. Refer to Coolant in this group for
antifreeze tests. Adjust antifreeze-towater ratio as necessary.

COOLANT LEVEL
CHANGES IN COOLANT
RESERVE/OVERFLOW
TANK. TEMPERATURE
GAUGE IS IN NORMAL
RANGE

1. Level changes are to be expected
as coolant volume fluctuates with
engine temperature. If the level in the
tank was between the FULL and ADD
marks at normal engine operating
temperature, the level should return to
within that range after operation at
elevated temperatures.

1. A normal condition. No repair is
necessary.

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ebxfnmebkmnmqiabw„sdebgihst\ikm`oq^h‚\Šnm`o`oabebgihx-{xˆst]ouf}

COOLING SYSTEM—TESTING FOR LEAKS

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WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING.

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Fig. 12 Pressurizing System—Typical

Fig. 11 Leak Detection Using Black Light—Typical

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NOTE: It is normal for fan noise to be louder (roaring) when:
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WARNING: BE SURE THAT THERE IS ADEQUATE
FAN BLADE CLEARANCE BEFORE DRILLING.

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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.
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RADIATOR CAP TO FILLER NECK SEAL—
PRESSURE
RELIEF CHECK
ü$#&%"')(+*,#&*%"-.(0/+*12#&34
%5*6&6&7.,2-.398#&6:6&7;(<37;/+=?>@(+7.AB-5CD7

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%"-O3#&116&7;PSY@17.(+*%"7O1WAB1ZW3%"#:6[*\(+7;*,#&3]V-.8@^_%5-<`a
=?b*dceaf^d%"-\a
gd#&3Pihj]+kl*117.*(+4m-;3!]n*W]o7.Pip58[%"'7q(+7.*,r
#&3]d4f%"*
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4f%"7;*,fso>%"'7T1(+7;4f4
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*%5-;(/+*1V#&8[(+7;*,#&3]O,-.7;4m3-.% '-.6&,P

WARNING: THE WARNING WORDS (DO NOT OPEN
HOT) ON THE RADIATOR PRESSURE CAP (Fig. 13)
ARE A SAFETY PRECAUTION. WHEN HOT, PRESSURE BUILDS UP IN COOLING SYSTEM. TO PREVENT SCALDING OR INJURY, THE RADIATOR CAP
SHOULD NOT BE REMOVED WHILE THE SYSTEM
IS HOT AND/OR UNDER PRESSURE.

y z{.|+{~}&L€~€{;{.‚„ƒ"~|+{.…B5†D{~ƒ"z{~|+‡‚}&‡ƒ5;|‰ˆ+‡Š
@
‹tŒŽ‹l‘ ;|ƒ"z{ ‘ ;’:’&5“m}&€”OŠ•|+Š.
{.f–

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 overheating.
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.

Fig. 13 Radiator Pressure Cap

—˜™ yqˆ+z{;ˆ+š\‡€‚V‡‚I›;•
ƒ ‡€ƒ5} ‘ |{.{.œt{ ‘ |+{.{;œt{0Š.}&€ƒ"
—ž
™ yq|+{ ‘ }&’:’vIŸFfƒ"{.… “m}&ƒ5zZ€{5“¡‡€ƒ"} ‘ |+{;{.œt{.
—¢
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
—¤
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ÔGÕ

ÖØ×MאÙ6Ú ÛMܘÝÞØÝØß
àÐá

âŠãPä6å

æÓçèêé“ë“ì“íLçí³èêë“æeîEïEíEîLç$ëéað§ñêò‹ó‹ô8õyó‹ö‹÷‹ø‹ù

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.

WARNING: IF VEHICLE HAS BEEN RUN RECENTLY,
WAIT AT LEAST 15 MINUTES BEFORE REMOVING
RADIATOR CAP. WITH A RAG, SQUEEZE RADIATOR
UPPER HOSE TO CHECK IF SYSTEM IS UNDER
PRESSURE. PLACE A RAG OVER THE CAP AND
WITHOUT
PUSHING
DOWN,
ROTATE
CAP
COUNTER-CLOCKWISE TO THE FIRST STOP.
ALLOW FLUID TO ESCAPE THROUGH OVERFLOW
HOSE INTO COOLANT RESERVE/OVERFLOW
TANK. SQUEEZE RADIATOR UPPER HOSE TO
DETERMINE WHEN PRESSURE HAS BEEN
RELEASED. WHEN COOLANT AND STEAM STOP
BEING PUSHED INTO TANK AND SYSTEM PRESSURE DROPS, REMOVE RADIATOR CAP COMPLETELY.



 

RÞ&â
äØæ&æ þãÞ&çâfÙÒ.Ö+ßBß"åÒ\ÙÛ+Ò.â
âfäÛÒqÕDØæ ÕDÒènØâ
ìÒ;ßBÔ.ç×ß"åÒ
+Ö ØÙàBÑvÒ.Ùæ&ØÖ+Ò×Ö+ØÙ³Þ&ÚOß5åÒ×ènØâfì?Ò.ßÞ&âwâIíÔ.æ&æ&Ò.ç  ß"Ô.Û+ç Ô.Û
ímÔ;Û+çà ÿ5çâfÙÒ.Ö+ß[ß"åÒØÛ+Ò.ØqØÛ+Ô.äçÝ<Û+ØÝÞ&Øß"Ô.Û ÚÞ&æ&æ:Ò;Û çÒ.Ö+ì©Ú:Ô.Û
ímåÞ:ß"ÒqÝÒ.ÙÔ.â
Þ:ß"âmß"åØß Þ&çÝÞ&Ö+Øß5ÒqØdæ&Ò;Øì?Þ&çèOÖ+ØÙà

COOLANT—LOW
ÿHÚ ß5åÒdÖ+Ô.Ô;æ:Øçßæ&Ò5ÕDÒ.LEVEL
æRÞ&ç9Û+ØÝAERATION
Þ&Øß"Ô.ÛqÝÛ+Ô.Ùâ<ëÒ;æ&ÔHí

RADIATOR
TESTING
ÑvÒ.ÓBÔ5ÕDÒ×Ö+ØCAP—PRESSURE
Ù Ú:Û+Ô.ÓÜÛØÝÞ:Øß"Ô.ÛIàBávÒã
â
äÛ+Ò×ß5åØß\â
Ò.Øæ&Þ&çè

ß"Ô.Ù$Ô.Ú
Û+ØÝÞ&Øß5Ô;ÛÖ+Ô;Û+Òqß5äëÒ;â  ØÞ&Û[ímÞ&æ&æSÒ.çß"Ò.Û¾Ö+Ô.Ô;æ&Þ:çè©âþDâ
ß5Ò;ÓBà
Ô5í‰Ö+Ô.Ô;æ:Øçß æ:Ò5ÕDÒ;æÖ+ØçdÖ+ØäâfÒß"åÒ.ÛÓBÔ.â
ß5Øß[ÙÒ;æ&æ:Ò;ß[ß"ÔëÒ
âfäâfÙÒ;çÝÒ;ÝUÞ&ç9ØÞ:Û0Þ&çâfß"Ò;ØÝ2Ô.ÚéÖ+Ô;Ô.æ&Øçß"àù@åÞ:â¾íÞ:æ&æ ÖØäâfÒ
ß"åÒ.Û+ÓBÔ;âfß"Øß ß"Ô¾Ô;ÙÒ;ç©æ&Øß"Ò.Û  ímåÞ&Ö+å©Þ&ç©ß"äÛ+ç©Ö+Øäâ
Ò.â åÞ&ènåÒ;Û
Ö+Ô;Ô.æ&Øçß©ß"Ò.ÓmÙÒ.Û+Øß"äÛ+Ò.à éÞ&Û\ß5ÛØÙÙÒ.ÝãÞ:çøÖ+Ô.Ô;æ:Þ&çè9âIþFâfß"Ò.Ó
Øæ&âfÔ©Û+Ò;ÝäÖ+Ò;â0ØÓBÔ.äçß¾Ô.ÚRÖ+Ô.Ô.æ&ØçßlÖ+Þ&Û+Ö+äæ&Øß"Þ&çèÞ&çUåÒ;Øß"Ò.Û
Ö+Ô;Û+Ò0Û+Ò;âfäæ:ß"Þ&çèOÞ&ç!æ&ÔHí~åÒ;Øß Ô.äß"Ùäß"à

â
äÛ+ÚØÖ+Ò.âéØÛ+ÒÖæ:Ò;Øçà ê<Ô.Þ&â
ß5Ò;çVÛäëëÒ;ÛéèoØâfì?Ò.ßíÞ&ß5åmímØß"Ò.Û
ØçÝUÞ&çâ
ß"Øæ&æ ß"åÒÖ+ØÙ2Ô.ç)ÙÛ+Ò.â
âfäÛ+ÒVß"Ò.âfß"Ò;Û<îß"Ô.Ô;æéïïðð$Ô.Û
Øç!Ò;ñäÞ ÕDØæ&Ò.çßóòlîôÞ&èoàÅõ
öfòeà

COOLING
SYSTEM DEAERATION
 !#"$%'& () *,+- /.0+-213+)"4*5*,+-(6(6879"4;:,&8& <4"4!
=1>? @A!B+-C% *,ED768*FC%G*,+-76"4+-& *F:,+-(6H2IG%KJ0"4@L
'8!B"4"4&8(68*,+)876.MC% *,@L+-<NKJ>(6+-/"$&8;&8OP:,&8& <4+-
"4<4<()D?;+-21R*,+)()(6 79+-"4*5(6+-?*,+-76"4+-& *5:,+-(S"4&'
Q

:,&8& <4+-*, / *UTCV=&KT8*,O<4& Q
+)%W%HMX8*,'"4 /:,+-(6 L&'
+-C@L&8?() *,Y"4&ZYC+-W[H\]8^Y !#"$%Z:,&8& <4
76& Q ;:,& &8<4+)%C.M"4 Q "4<4<N_-76*,+ Q ;O$*,& @`C*,8?8*UTKV
&KT> *,O$<$& Q
+-Wa"4C&bc*d+)7)"$+-& *e&b*, (6<4+-:,b+) 1
*,8@L&KT87f+-"4*=H

SERVICE PROCEDURES
COOLANT LEVEL—ROUTINE CHECK
NOTE: Do not remove radiator cap for routine
coolant level inspections. The coolant level can be
checked at coolant reserve/overflow tank.
gPh%ikj,l8l m4n-opZq,i r/i qUs>iKt=lKs>i q,u$m$lCvwryxr/pCi8z|{6q,lCs}4~6i8rn

Fig. 14 Pressure Testing Radiator Pressure
Cap—Typical

÷ ÙÒ;Û+Øß5Òwß5åÒ9ß"Ò;âfß"Ò.Û!ÙäÓBÙøØçÝøÔ;ëâfÒ.ÛÕDÒ9ß"åÒ9ènØäèoÒ
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üöTìýØTîõ
ü
ß"ÔOõ
úTÙâfÞ òRÛØçènÒlÚÔ.ÛRûðTâfÒ;Ö+Ô.çÝâéÔ;ÛÅÓBÔ;Û+Ò.àFÿ5Úß"åÒlÙÔ.Þ&çß"Ò.Û
ÝÛ+Ô;ÙâmñäÞ&Ö+ì?æ þ  Û+Ò;Ùæ&ØÖ+Ò0ß"åÒqÖ+ØÙà
CAUTION: Radiator pressure testing tools are very
sensitive to small air leaks, which will not cause

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j,l8l m4n-op9m4iKs>i m}$oŽq,i8r?i8qUsiCtlCsi8q,um4lKvpn-o‚[ˆghi‘j,l8l m4n-op
m4iKs>i m‹r/hl  m$~’-i“)i8p”v•i i8o5–—F—˜n-o~f™š››RzLn-q,‚[r?ˆ

COOLANT—ADDING
ADDITIONAL
œ9žŸ 2¡6¢Š2£¡„ 2¤¥¦=¤Ÿ§ “¨-¤©3Ÿ§9¤¥¥3¨-ªU¤žŸŸd
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WATER PUMP
CAUTION: If the water pump is replaced because of
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Fig. 16 Coolant Reserve/Overflow Bottle
could have been damaged due to excessive vibration.

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CAUTION: All engines have a reverse (counterclockwise) rotating water pump. The letter R is
stamped into the back of the water pump impeller
(Fig. 17) to identify. Engines from previous model
years, depending upon application, may be
equipped with a forward (clockwise) rotating water
pump. Installation of the wrong water pump will
cause engine over heating.

–S—P˜|¤r8›c˜@œ ®:¬P )®>™; )®:˜!žž;˜!œ ™;Ÿ®:œ6˜!Ÿ2ŸH˜@£>¡!š{›c—,˜eœ6˜!8œ ¡@ª
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®:¬, r®U™;ŸrŸ2˜!œ¦¥R™;¢6˜!£U¡!š,ž ´k8Ÿr>¢6¡! )®:ž;˜@›c˜8Ÿ2ŸH˜@ )§8ž ´€¨
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.

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Ò[× Ó„¿¹¡@¡@ŸH˜@š Ò §8¬,›>£:¡AšP¡@›>œ6˜@ )¡.¥R˜Š8›„›c—,™;Ÿ‰›.™; )˜.Ó5›c—,˜
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Ò ¸¹™;³j¨ ÄHÝHÓ¨

NOTE: The engine accessory drive belt must be
removed prior to removing the fan.

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¨€©
ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps (Fig. 21). If
replacement is necessary, use only an original
equipment clamp with matching number or letter.

Fig. 17 Reverse Rotating Water Pump—Typical

Fig. 18 Fan Mounting Nuts

 


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WARNING: CONSTANT TENSION HOSE CLAMPS
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WHEN REMOVING OR INSTALLING, USE ONLY
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER
6094) (Fig. 20) SNAP-ON CLAMP TOOL (NUMBER
HPC-20) MAY BE USED FOR LARGER CLAMPS.

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CAUTION: When installing the serpentine engine
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. Refer to
the Belt Removal and Installation in this group for
appropriate belt routing. You may also refer to the
Belt Routing Label in the vehicle engine compartment.

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Fig. 19 Power Steering Pump Attachment

Fig. 20 Hose Clamp Tool–Typical

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Fig. 21 Clamp Number/Letter Location

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­!®
replacement is necessary, use only an original
equipment clamp with matching number or letter.

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<?GOQFlt:P9;58L[<?B87:=H

Fig. 22 Water Pump Remove/Install—Typical

THERMOSTAT

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WARNING: DO NOT LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND PRESSURIZED. SERIOUS BURNS FROM THE COOLANT
CAN OCCUR.

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1,23- 465879;:=<?>?@A7CB8DDE@A<?F;GIHKJILMGON;7C:PDE@A9;GOQADEF
QA:RB8@A7E<?F;SUTV58<VQAFWGON;7XB8DED@<?F;G!QAF;GODX<YB8@A7E<?FWB8DEF;GO<?QAF;7E5ZL[DE5
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D:=GO<?GMN;DE9;:PQAF;l3H

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. 20). SNAP-ON CLAMP TOOL (NUMBER
HPC-20) MAY BE USED FOR LARGER CLAMPS.
ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps (Fig. 21). If

Fig. 23 Thermostat Removal/Installation

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D:=GO<?G
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CAUTION: Tightening the thermostat housing
unevenly or with the thermostat out of its recess
may result in a cracked housing.

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Fig. 24 Thermostat Recess

RADIATOR

è éê!ë ì$í&î

WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND PRESSURIZED. SERIOUS BURNS FROM THE COOLANT
CAN OCCUR.

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BLOCK HEATER

è éê!ë ì$í&î

WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND PRESSURIZED. SERIOUS BURNS FROM THE COOLANT
CAN OCCUR.

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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. Refer to Serpentine
Drive Belt Removal and Installation in this group for
correct belt routing.

Fig. 29 2.5L/4.0L Engines–With A/C

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Fig. 32 Power Steering Pump Bracket and Idler
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Fig. 30 2.5L/4.0L Engines—Without A/C

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not, the engine may overheat due to the water
pump rotating in the wrong direction. Refer to (Fig.
29) (Fig. 30) (Fig. 31) for correct belt routing.
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CLEANING AND INSPECTION
RADIATOR
CAP
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Fig. 31 2.5L/4.0L Engines—Without A/C or P/S
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RADIATOR

 
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COOLING SYSTEM
CAUTION: The cooling system normally operates at
97 to 124 kPa (14 to 18 psi) pressure. Exceeding
this pressure may damage the radiator or hoses.

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WARNING: DO NOT ATTEMPT TO BEND OR
STRAIGHTEN FAN BLADES IF NOT WITHIN SPECIFICATIONS.

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»B°"À­º¾
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.

COOLING
§ ­³(Á·®@¶´¶SYSTEM
½·â½°"³6·"³¯HOSES—INSPECTION
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ADJUSTMENTS
ACCESSORY
DRIVE BELT
!"#"#$%#&('"#) *+$-,.$/0&(&1$234)526)037"#$8:9)0"#$';&-$2349"#$

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FW@:9FG$3X?O"Y%#C$%#Z[)02F($)0&C$"E@\3I$"<$2&)02$]"E@E^_H5&`Q+<$
,:$/0&Jba!$?O$"c&d&C$T)023I&"#9%#&)02V3;349<<./5)0$'feg)0&C&C$
FW@:9FG$JDhi3I$j&1CV$k%#"#"#$%&MFG@:9FW$MegC$2l%#CV$%#Z[)02Fm,:$/5&n&$2H
3I)02JoB/5@:%#$mFW@:9FW$m)02b&C$m=>)5'.'/0$p?n&C$m3I$%#&1)02b?_,:$/0&
,:$)02F]&$34&1$'\q5,:$&Reg$$2&RegX<.9/0/5$1QD3sr>&1X%#C$%#Zt&$234)02J
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x )0&C\&1C$Y$2FW)02$Y?O?yqO2&A"#922)02Frz*D)03I9@:/0/ Q )52V3I<$%#&
@:%#%#$343I"Q{'"#) *D$|,:$/0&\?O"7FG/0@.}~)02FGzY%#"#@:%#Z[3 "L%#C92Z[3
=>)03I34)02FWJ€€/03Ic)023I<.$%#&<9/0/0$wQ+3|?O"=>)534@:/0)5FG2=>$2V&L"
'$?O$%&134JDa!$?O$"v&j@:%#%#$343I"Q‚'"#) *D$
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–>—Œ˜–k™1š‹“t›“!œMt“!žA”€™`•AžŠ’ŸA‘y–m

BELT

TENSION

**NEW SERPENTINE
BELT

800-900 N (180-200 lbs.)

USED SERPENTINE
BELT

623-712 N (140-160 lbs.)

**Belt is considered new if it has been used 15
minutes or less.
Specifications for use with a belt tension gauge. Refer
to operating instructions supplied with gauge.

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=>$2V&X)03b2$$'$'.zj"#$=>w*+$ ,:$/0&E&1$23I)02‰FW@:9FW$t!HO‡ƒ4ˆ.„
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…w?>,:$/0&E&1$234)52‰)03b9&E?>34<$%#)0?5)5%#@:&)02Š@.2V'-@:'U~93I&H
=>$2V&v)03j2$%#$3I34@:"QGz‹%#2&1)029V$ieg)0&CŒ&C$m?5/0/0weg)02F†<"#%$H
'9"$J
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qO‡4r>€'U~93I&t&1$234)52{@:'U934&)52VF;,./0& qOB)0FWJE:Ir79V2&)5/
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ß Í5ÚÒàWá€Óâ× ß ÐiÍ0ãnÒÑÝ#Ñ ßIß Û:ÕØGà

ACCESSORY DRIVE BELT TENSION
BELT

TENSION

**NEW SERPENTINE
BELT

800-900 N (180-200 lbs.)

USED SERPENTINE
BELT

623-712 N (140-160 lbs.)

**Belt is considered new if it has been used 15
minutes or less.
Specifications for use with a belt tension gauge. Refer
to operating instructions supplied with gauge.

TORQUE

Fig. 33 Power Steering Pump Bracket and Idler
Pulley

SPECIFICATIONS
COOLING SYSTEM CAPACITIES
ENGINE

CAPACITY

2.5L

8.5L (9.0 Qts.)

4.0L

9.9L (10.5 Qts.)

NOTE: Cooling system capacity does not vary with
or without A/C since the components are the same.

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SPECIAL TOOLS
COOLING

Cooling System Pressure Tester—7700–A

Hose Clamp Pliers—6094

Quick Disconnect Tool—6935

Belt Tension Gauge —C-4162

prq

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BATTERY
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page

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DESCRIPTION AND OPERATION
BATTERY
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ÝÛßÜèàJØèíÄÙ0ÜÖßØê/ÖÜTç ÜØ/èé¥äRîéàVäÙÛßèÚ9ÜÖÜRÝÛà4Ù0ß´ÝÛØ/Ö[ÜèÜRÙÛÚÛá
ßèøØÐÝÛôÜç ßÝÛØ/րîäRÙÛç õdöGôßéùç ÜØ/èéùäî¥ÜRèÜÙÛÚ0áúé2à4äRÙÛØ/ÚMÜ
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WARNING:
• IF THE BATTERY SHOWS SIGNS OF FREEZING, LEAKING, LOOSE POSTS, OR LOW ELECTROLYTE LEVEL, DO NOT TEST, ASSIST-BOOST, OR
CHARGE. THE BATTERY MAY ARC INTERNALLY
AND EXPLODE. PERSONAL INJURY AND/OR VEHICLE DAMAGE MAY RESULT.
• EXPLOSIVE HYDROGEN GAS FORMS IN AND
AROUND THE BATTERY. DO NOT SMOKE, USE
FLAME, OR CREATE SPARKS NEAR THE BATTERY.
PERSONAL INJURY AND/OR VEHICLE DAMAGE
MAY RESULT.
• THE BATTERY CONTAINS SULFURIC ACID,
WHICH IS POISONOUS AND CAUSTIC. AVOID 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.
• 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 SERVICE. PERSONAL INJURY AND/OR VEHICLE DAMAGE MAY
RESULT FROM LOOSE OR MISSING CELL CAPS.

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NOTE: Completely discharged batteries may take
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for more information.

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Battery Diagnosis
Condition

Possible Causes

Correction

The battery seems weak or
dead when attempting to start
the engine.

1. The battery has an
incorrect size or rating for
this vehicle.
2. The battery is physically
damaged.
3. The battery terminal
connections are loose or
corroded.
4. The battery is discharged.
5. The electrical system
ignition-off draw is excessive.
6. The battery is faulty.
7. The starting system is
faulty.
8. The charging system is
faulty.

1. Refer to Battery in the Specifications section of
this group. Replace an incorrect battery with the
correct battery.
2. Inspect the battery for loose terminal posts or a
cracked and leaking case. Replace the battery, if
damaged.
3. Refer to Voltage Drop Test in the Diagnosis
and Testing section of this group. Clean and
tighten the battery terminal connections, if
required.
4. Determine the battery state-of-charge. Refer to
Built-In Test Indicator, Hydrometer Test, or
Open-Circuit Voltage Test in the Diagnosis and
Testing section of this group. Charge the battery,
if required.
5. Refer to Ignition-Off Draw Test in the Diagnosis
and Testing section of this group. Repair the
electrical system, if required.
6. Determine the battery cranking capacity. Refer
to Load Test in the Diagnosis and Testing section
of this group. Replace the battery, if required.
7. Determine if the starting system is performing
to specifications. Refer to Starting System in the
Diagnosis and Testing section of Group 8B Starting Systems for more information. Repair the
starting system, if required.
8. Determine if the charging system is performing
to specifications. Refer to Charging System in the
Diagnosis and Testing section of Group 8C Charging System for more information. Repair the
charging system, if required.

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Battery Diagnosis
Condition

Possible Causes

Correction

The battery state-of-charge
cannot be maintained.

1. The battery has an
incorrect size or rating for
this vehicle.
2. The battery terminal
connections are loose or
corroded.
3. The generator drive belt is
slipping.
4. The electrical system
ignition-off draw is excessive.
5. The battery is faulty.
6. The starting system is
faulty.
7. The charging system is
faulty.
8. Electrical loads exceed the
output of the charging
system.
9. Slow driving or prolonged
idling with high-amperage
draw systems in use.

1. Refer to Battery in the Specifications section of
this group. Replace an incorrect battery with the
correct battery.
2. Refer to Voltage Drop Test in the Diagnosis
and Testing section of this group. Clean and
tighten the battery terminal connections, if
required.
3. Refer to Accessory Drive Belt Diagnosis in the
Diagnosis and Testing section of Group 7 Cooling System for more information. Replace or
adjust the generator drive belt, if required.
4. Refer to Ignition-Off Draw Test in the Diagnosis
and Testing section of this group. Repair the
electrical system, if required.
5. Determine the battery cranking capacity. Refer
to Load Test in the Diagnosis and Testing section
of this group. Replace the battery, if required.
6. Determine if the starting system is performing
to specifications. Refer to Starting System in the
Diagnosis and Testing section of Group 8B Starting Systems for more information. Repair the
starting system, if required.
7. Determine if the charging system is performing
to specifications. Refer to Charging System in the
Diagnosis and Testing section of Group 8C Charging System for more information. Repair the
charging system, if required.
8. Inspect the vehicle for aftermarket electrical
equipment which might cause excessive electrical
loads.
9. Advise the vehicle operator, as required.

The battery will not accept a
charge.

1. The battery is faulty.

1. Refer to Battery Charging in the Service
Procedures section of this group. Replace the
faulty battery, if required.

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Fig. 2 Built-In Test Indicator
WARNING:
• IF THE BATTERY SHOWS SIGNS OF FREEZING, LEAKING, LOOSE POSTS, OR LOW ELECTROLYTE LEVEL, DO NOT TEST, ASSIST-BOOST, OR
CHARGE. THE BATTERY MAY ARC INTERNALLY
AND EXPLODE. PERSONAL INJURY AND/OR VEHICLE DAMAGE MAY RESULT.
• EXPLOSIVE HYDROGEN GAS FORMS IN AND
AROUND THE BATTERY. DO NOT SMOKE, USE
FLAME, OR CREATE SPARKS NEAR THE BATTERY.
PERSONAL INJURY AND/OR VEHICLE DAMAGE
MAY RESULT.
• THE BATTERY CONTAINS SULFURIC ACID,
WHICH IS POISONOUS AND CAUSTIC. AVOID 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.
• 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 SERVICE. PERSONAL INJURY AND/OR VEHICLE DAMAGE MAY
RESULT FROM LOOSE OR MISSING CELL CAPS.

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WARNING:
• IF THE BATTERY SHOWS SIGNS OF FREEZING, LEAKING, LOOSE POSTS, OR LOW ELECTROLYTE LEVEL, DO NOT TEST, ASSIST-BOOST, OR
CHARGE. THE BATTERY MAY ARC INTERNALLY
AND EXPLODE. PERSONAL INJURY AND/OR VEHICLE DAMAGE MAY RESULT.
• EXPLOSIVE HYDROGEN GAS FORMS IN AND
AROUND THE BATTERY. DO NOT SMOKE, USE
FLAME, OR CREATE SPARKS NEAR THE BATTERY.
PERSONAL INJURY AND/OR VEHICLE DAMAGE
MAY RESULT.
• THE BATTERY CONTAINS SULFURIC ACID,
WHICH IS POISONOUS AND CAUSTIC. AVOID 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.
• 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 SERVICE. PERSONAL INJURY AND/OR VEHICLE DAMAGE MAY
RESULT FROM LOOSE OR MISSING CELL CAPS.

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CAUTION: Exercise care when inserting the tip of
the hydrometer into a cell to avoid damaging the
plate separators. Damaged plate separators can
cause early battery failure.

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WARNING:
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CHARGE. THE BATTERY MAY ARC INTERNALLY
AND EXPLODE. PERSONAL INJURY AND/OR VEHICLE DAMAGE MAY RESULT.
• EXPLOSIVE HYDROGEN GAS FORMS IN AND
AROUND THE BATTERY. DO NOT SMOKE, USE
FLAME, OR CREATE SPARKS NEAR THE BATTERY.
PERSONAL INJURY AND/OR VEHICLE DAMAGE
MAY RESULT.
• THE BATTERY CONTAINS SULFURIC ACID,
WHICH IS POISONOUS AND CAUSTIC. AVOID 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.
• 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 SERVICE. PERSONAL INJURY AND/OR VEHICLE DAMAGE MAY
RESULT FROM LOOSE OR MISSING CELL CAPS.

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Fig. 5 Testing Open-Circuit Voltage - Typical

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Open Circuit Voltage
Open Circuit Volts

Charge Percentage

11.7 volts or less

0%

12.0 volts

25%

12.2 volts

50%

12.4 volts

75%

12.6 volts or more

100%

+-?z*("12(
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!#"##$%'&)(*,+,-/.0+,1,2,3,4
WARNING:
• IF THE BATTERY SHOWS SIGNS OF FREEZING, LEAKING, LOOSE POSTS, OR LOW ELECTROLYTE LEVEL, DO NOT TEST, ASSIST-BOOST, OR
CHARGE. THE BATTERY MAY ARC INTERNALLY
AND EXPLODE. PERSONAL INJURY AND/OR VEHICLE DAMAGE MAY RESULT.
• EXPLOSIVE HYDROGEN GAS FORMS IN AND
AROUND THE BATTERY. DO NOT SMOKE, USE
FLAME, OR CREATE SPARKS NEAR THE BATTERY.
PERSONAL INJURY AND/OR VEHICLE DAMAGE
MAY RESULT.
• THE BATTERY CONTAINS SULFURIC ACID,
WHICH IS POISONOUS AND CAUSTIC. AVOID 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.
• 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 SERVICE. PERSONAL INJURY AND/OR VEHICLE DAMAGE MAY
RESULT FROM LOOSE OR MISSING CELL CAPS.

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Fig. 6 Volt-Ammeter-Load Tester - Typical

Fig. 7 Volt-Ammeter-Load Tester Connections Typical

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Fig. 8 Remove Surface Charge from Battery Typical

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Fig. 9 Load 50% CCA Rating - Note Voltage - Typical
Load Test Temperature
Minimum Voltage

Temperature
°F

°C

9.6 volts

70° and above

21° and above

9.5 volts

60°

16°

9.4 volts

50°

10°

9.3 volts

40°



9.1 volts

30°

-1°

8.9 volts

20°

-7°

8.7 volts

10°

-12°

8.5 volts



-18°

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PBLTG,fE/Ua=XtpEIPBPBA/tK=@O$E/PLTPBM:=@?BAWNLT=@=@AIJdcqfE/UaOV=ZO C_A%tpLNWTGVAI]
WARNING:
• IF THE BATTERY SHOWS SIGNS OF FREEZING, LEAKING, LOOSE POSTS, OR LOW ELECTROLYTE LEVEL, DO NOT TEST, ASSIST-BOOST, OR

CHARGE. THE BATTERY MAY ARC INTERNALLY
AND EXPLODE. PERSONAL INJURY AND/OR VEHICLE DAMAGE MAY RESULT.
• EXPLOSIVE HYDROGEN GAS FORMS IN AND
AROUND THE BATTERY. DO NOT SMOKE, USE
FLAME, OR CREATE SPARKS NEAR THE BATTERY.
PERSONAL INJURY AND/OR VEHICLE DAMAGE
MAY RESULT.
• THE BATTERY CONTAINS SULFURIC ACID,
WHICH IS POISONOUS AND CAUSTIC. AVOID 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.
• 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 SERVICE. PERSONAL INJURY AND/OR VEHICLE DAMAGE MAY
RESULT FROM LOOSE OR MISSING CELL CAPS.

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Fig. 10 Test Battery Negative Connection
Resistance - Typical

Fig. 12 Test Battery Positive Cable Resistance Typical

Fig. 13 Test Ground Circuit Resistance - Typical

Fig. 11 Test Battery Positive Connection Resistance
- Typical

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CAUTION: Do not open any doors, or turn on any
electrical accessories with the lowest milliampere
scale
damaged.
ӍРselected, or the multi-meter may be
›
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4}“ž@4lulr®Žnsk3š3Švu7k3€“n+r\ŽnsŠš3r2y

SERVICE PROCEDURES
BATTERY
CHARGING
Ä psn+rtrtu4vxw¯k3€“ŽŠš3š w)¦„n+v&mŸu4ˆW¥“„ulî


Ä š3šuš3š3€¬nsvu“mŸns€€ k3lm7Žvu4u4š w‹ˆ+Švk3lm7psnsr2rtu4vw‹„nsvmŸ¦

k3lmŸy

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psŠk3š3r2¦klrtu4€r®klˆ@k3nsr2v=y
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Œ)nsš3€ ƒ{k3lˆ@k3nsr2uÆlÆklvu4ns€ uÆk3l~rt„uÆr2u}Wž@uvn+rtŠvu¦v&¦
vur2uˆ«€ž@ukŽk3-mŸvnŒ;kr·wy
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WARNING:
• IF THE BATTERY SHOWS SIGNS OF FREEZING, LEAKING, LOOSE POSTS, OR LOW ELECTROLYTE LEVEL, DO NOT TEST, ASSIST-BOOST, OR
CHARGE. THE BATTERY MAY ARC INTERNALLY
AND EXPLODE. PERSONAL INJURY AND/OR VEHICLE DAMAGE MAY RESULT.
• EXPLOSIVE HYDROGEN GAS FORMS IN AND
AROUND THE BATTERY. DO NOT SMOKE, USE
FLAME, OR CREATE SPARKS NEAR THE BATTERY.
PERSONAL INJURY AND/OR VEHICLE DAMAGE
MAY RESULT.
• THE BATTERY CONTAINS SULFURIC ACID,
WHICH IS POISONOUS AND CAUSTIC. AVOID 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.
• 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 SERVICE. PERSONAL INJURY AND/OR VEHICLE DAMAGE MAY
RESULT FROM LOOSE OR MISSING CELL CAPS.

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ÝÞßàÞáâãä
CAUTION:
• Always disconnect and isolate the battery negative cable before charging a battery. Do not exceed
sixteen volts while charging a battery. Damage to
the vehicle electrical system components may
result.
• Battery electrolyte will bubble inside the battery case during normal battery charging. Electrolyte boiling or being discharged from the battery
vents indicates a battery overcharging condition.
Immediately reduce the charging rate or turn off the
charger to evaluate the battery condition. Damage
to the battery may result from overcharging.
• The battery should not be hot to the touch. If
the battery feels hot to the touch, turn off the
charger and let the battery cool before continuing
the charging operation. Damage to the battery may
result.

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Charge Rate
Voltage

Hours

16.0 volts maximum

up to 4 hours

14.0 to 15.9 volts

up to 8 hours

13.9 volts or less

up to 16 hours

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Fig. 15 Remove Battery Cable Terminal Clamp Typical

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å%êDî"å{êDî"øYð7î"ûî.ü0æðNöç
ð7æ÷öç,ûæðNå$æç,ûó>íDî"ôë,ô>î.ûï.ø]ù

WARNING: NEVER EXCEED TWENTY AMPERES
WHEN CHARGING A COLD (-1° C or 30° F) BATTERY. THE BATTERY MAY ARC INTERNALLY AND
EXPLODE. PERSONAL INJURY AND/OR VEHICLE
DAMAGE MAY RESULT.
Battery Charging Timetable
Charging
Amperage
Open
Circuit
Voltage

5
Amperes

10
Amperes

20
Amperes

Hours Charging at 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

*Refer to Charging A Completely Discharged Battery

REMOVAL AND INSTALLATION
BATTERY

#%$&('%)+* ,
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4ý 3B6
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íDæë,æøBø]î"ç(èHéXìDøBæ±î²ï7ìDô>ô>æç å%ö¿çFæûö\õæ±å$ê-æ±å$æç,ûó>íDî"ô
ë,ô>î"ûï7øY÷ç,öûå%êDæñ"î.å%å%æç(èRï7öø]å%øY4ý 9Jó6ü0:ù -<;BþFù
4ý =B6
þ 7\íDøBï7æë,åLå%êDæRñ"î"å%å$æç(èTë,î"ñ.ô>æ<å$æç,ûó>íDî"ô;ë,ô>î"ûï7øe÷öç
ë,öç,ç,öøBó6öíeî"íDð_ð7î"ûî.ü0æ ù >zæûö\õAæYî"íHè…ë,öç,ç,öø]ó>öíNìDø]ó>íDüî
òYó>ç,æ:ñ.çFìDø]êEöç
îqï7öøBå{î"íDðiå$æç,ûó>íDî"ôzë,ô6æî"íDó>íDü_å%ööô6éuî"íDð
îqø]öð7ó>ìDûjñ"ó6ëFî.ç,ñ"öíDî"å$æ:ýñ"@î ?vó>íDü_øBöð.î]þ[î.í-ðòYî"ç,û¥òYî"å%æç

Fig. 16 Clean Battery Cable Terminal Clamp Typical
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 BATTERY IS CRACKED OR LEAKING, THE ELECTROLYTE CAN BURN THE SKIN AND EYES.

4ý CB6
þ >zæûö$õAæaå%êDæ[ñ.î"å%å$æç(èiêDöô>ðð7ö\ò;íDø{î"íDðç,æûö\õæaå$ê-æ
ñ"î"å$å%æç(èR÷ç,öûå%êDæñ"î"å$å%æç(èRå%ç,îBè*ý9gó>üWù-<D]þ ù
4ý ;B6
þ 7\íDøBï7æë,å…å%êDæXñ"î"å%å$æç(èŒå%ç,îBèŒî"íDð‹êDöô>ð‹ð7ö\ò;íDø³÷6öç
ë,öçFç,öøBó6öíMöçLð7î"ûî"üWæù >zæûYö\õAæeî"íHèkë,öç,ç,öø]ó>öíMìDøBó>íDü<î
òYó>ç,æeñ"ç,ìDøBêMî.í-ðVî*øBöð7ó>ìDû°ñ"ó>ë,î.çFñ.öíDî"å$æeý6ñ"@î ?vó>íDü<øBöð7îBþ
î"íDðpòYî"ç,ûkò;î.å%æç‡ë,ô>æî.í-ó6í-üYø]öô>ìDå$ó>öíD ù Egî"ó>íDåzî.íèiGæ Fï7öøBæð
ñ"î"ç,æ ûYæå%î.ôzî.í-ðeç,æï7ô>î"ë,æî.íHèRð7î"ûî"üWæðNï7î"ç,å$øBù
4ý BB6
þ Hô6ó>ð7æNå%êDæNå%êDæç,ûöüWìDî"ç,ð*ö÷÷pö÷[å%êDæNñ"î.å%å%æç(èXë,î"ø]æù
7\íDøBï7æë,å;å%êDæiñ"î"å%å$æç(èMë,î"ø]æq÷öçëFç,î.Ië ?vø öçöå%êDæçð7î"ûî"üWæ

ú ûWü ý þ

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wI{~vƒ ‚ƒ ›¿€y{zt…‚yƒá| y~߃ yt­~ƒ t~}¯tu ~  vtt…~}†âwI~{{
tu }Iyz›Šuãt…u ~¿¡+~ƒ täu y{~€ˆ ¾ ”åt…u ~  vtt…~}†°‚  ~‚ƒ›
}I~“@{v@wI~| Œ§}I~”~}1ty ÂÎ ÆÈÆ Ê ÐÈÔ ¹ Î ÆÈÄ É × Ë Î ÉÌ ÕŐΠËË ÄæÄÍÎ Ç
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”4‚}I’tu vt(tu ~ }I~“ {vwI~’/~ƒ t  vtt…~}†­‚štu ~ wIy}I}I~wIt‹€‚çè~
vƒ |6u v1t…u ~ewIy}I}I~wItx}v@t‚ƒ ›Š1”y}htu ~‹¡8~u ‚wI{~ˆ

Fig. 17 Battery Hold Downs

tu vtxwIyz{|6}I~€z {tx‚ƒ„~{~wIt…}y{ †8t~e{~v‡<ˆŠ‰‹{€yŒwIu ~wI‡Žtu ~
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Fig. 19 Clean Battery - Typical

Fig. 18 Removing Cell Caps - Typical

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~C

€‚ƒƒ|„…†

‡‰ˆŠ‹

Œ Ž‘ ’‘ “”•“–—‘ ’ ’ ‘!—"•“$˜&™ š › œ+,› ž Ÿ   ¡
CAUTION: Be certain that the battery cables are
connected to the correct battery terminals. Reverse
polarity may damage electrical components.

132547698;:<:>=;?A@CBD:>EF@HGJILK<@H=+:M@NK>=PODBQ@N@N=;RTSVU8;W5GJ@HG XY=Z?ABDOD[J=
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WsGJWILRA=+BQW5=C@N8C@NK>= ={zfUQ8;W5=;EW5x>RAw3BD?A=+Wo8+w|@HK<=CODBD@H@N=;RTSZ?ABDOQ[J=
@N=;RA\"GJ:>BD[ ?A[JBD\"UW}BD:>E7ODBQ@N@N=;RTS@N=;RA\"GJ:>BD[ U8+Ws@NWs_

Fig. 20 Clean Battery Terminal Post - Typical

Fig. 21 Battery Cables

¢£‰¤¥¢

¦‚£§§¨©ª

« ¬

SPECIFICATIONS
BATTERY
Battery Classifications and Ratings
Part Number

BCI Group Size
Classification

Cold Cranking
Amperage

Reserve
Capacity

Ampere-Hours

Load Test
Amperage

56027960

34

500

110 Minutes

60

250

56041003

34

600

120 Minutes

66

300

ª;«

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STARTING SYSTEMS
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Starting System Diagnosis
CONDITION

POSSIBLE CAUSE

CORRECTION

STARTER FAILS TO
OPERATE.

1. Battery discharged or
faulty.
2. Starting circuit wiring
faulty.
3. Starter relay faulty.
4. Ignition switch faulty.
5. Clutch pedal position
switch faulty.
6. Park/Neutral position
switch faulty or
misadjusted.
7. Starter solenoid faulty.
8. Starter motor faulty.

1. Refer to Battery in the Diagnosis and Testing section of
Group 8A - Battery. Charge or replace the battery, if
required.
2. Refer to Starting System in Group 8W - Wiring
Diagrams. Test and repair the starter feed and/or control
circuits, if required.
3. Refer to Starter Relay in the Diagnosis and Testing
section of this group. Replace the starter relay, if
required.
4. Refer to Ignition Switch and Key Lock Cylinder in the
Diagnosis and Testing section of Group 8D - Ignition
System. Replace the ignition switch, if required.
5. Refer to Clutch Pedal Position Switch in the Diagnosis
and Testing section of Group 6 - Clutch.
6. Refer to Park/Neutral Position Switch in the Diagnosis
and Testing section of Group 21 - Transmission. Replace
the park/neutral position switch, if required.
7. Refer to Starter Motor in the Diagnosis and Testing
section of this group. Replace the starter motor assembly,
if required.
8. If all other starting system components and circuits test
OK, replace the starter motor assembly.

STARTER ENGAGES,
FAILS TO TURN
ENGINE.

1. Battery discharged or
faulty.
2. Starting circuit wiring
faulty.
3. Starter motor faulty.
4. Engine seized.

1. Refer to Battery in the Diagnosis and Testing section of
Group 8A - Battery. Charge or replace the battery, if
required.
2. Refer to Starting System in Group 8W - Wiring
Diagrams. Test and repair the starter feed and/or control
circuits, if required.
3. If all other starting system components and circuits test
OK, replace the starter motor assembly.
4. Refer to Engine Diagnosis in the Diagnosis and Testing
section of Group 9 - Engine.

STARTER ENGAGES,
SPINS OUT BEFORE
ENGINE STARTS.

1. Starter ring gear faulty.
2. Starter motor faulty.

1. Refer to Starter Motor in the Removal and Installation
section of this group. Remove the starter motor to inspect
the starter ring gear. Replace the starter ring gear, if
required.
2. If all other starting system components and circuits test
OK, replace the starter motor assembly.

STARTER DOES NOT
DISENGAGE.

1. Starter motor
improperly installed.
2. Starter relay faulty.
3. Ignition switch faulty.
4. Starter motor faulty.

1. Refer to Starter Motor in the Removal and Installation
section of this group. Tighten the starter mounting
hardware to the correct tightness specifications.
2. Refer to Starter Relay in the Diagnosis and Testing
section of this group. Replace the starter relay, if
required.
3. Refer to Ignition Switch and Key Lock Cylinder in the
Diagnosis and Testing section of Group 8D - Ignition
System. Replace the ignition switch, if required.
4. If all other starting system components and circuits test
OK, replace the starter motor assembly.



 

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WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, 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 PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
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Fig. 3 Test Battery Positive Connection Resistance Typical
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Fig. 4 Test Battery Positive Cable Resistance Typical

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ëAìíîHï$ðDî8ì#ñ0ò5óZôõ ëö+÷&ô
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ù÷ ôö ëAîò#ú&ûø
ò#îžù÷ ì<û@îò#þìü"ú îìö 

NOTE: The shim thickness is 0.381 mm (0.015 in.).
These shims may be stacked if additional thickness
is required.

NOTE: This is a condition that will generally cause
broken starter (flywheel/torque converter drive
plate) ring gear teeth or broken starter motor housings.

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(e÷ ôö\ùìö+ùQþíõ©ò#õ&ý ð^ïìpû"ìîøMò#î8ñ0ì#ü & ôù÷¦ù÷ ìpö$ùíîùì#î
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ø
ôþí@ùôò#õ ö 
CAUTION: The 2.5L engine uses a permanent magnet starter. Permanent magnet starters are highly
sensitive to hammering, shocks, external pressure
and reverse polarity. This starter motor must never
be clamped in a vise by the starter field frame. The
starter should only be clamped by the mounting
flange. Do not reverse the battery cable connections to this starter motor when testing. The permanent magnets may be damaged and the starter
rendered unserviceable if it is subjected to any of
these conditions.

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ö ëîò#ú ûøMòîKù÷ ì<û"îòþì#ü"ú&îì#ö 
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ö ëîò#ú ûøMòîKù÷ ì<û"îòþì#ü"ú&îì#ö 
þýíñ0ûòõ|ù÷ ì<ö$ùíîùì#îžñ0ò#ùò#îžï$ðPù÷ ì<øMôìý
üøMîíñ0ì/
Fig. 8 Starter Motor Shim




 

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NOTE: Shim thickness available is 0.381 mm (0.015
in.). Refer to Starter Motor Noise - 2.5L Engine in
the Diagnosis and Testing section of this group for
more information.

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Starter Motor and Solenoid
Manufacturer

Mitsubishi

Engine Application

2.5L, 4.0L

Power Rating
Voltage

2.5L - 1.2 Kilowatt (1.6 Horsepower)
4.0L - 1.4 Kilowatt (1.9 Horsepower)
12 Volts

Number of Fields

4

Number of Poles

4

Number of Brushes

4

Drive Type
Free Running Test Voltage
Free Running Test Maximum Amperage Draw
Free Running Test Minimum Speed
Solenoid Closing Maximum Voltage Required
*Cranking Amperage Draw Test

Planetary Gear Reduction
11.2 Volts
90 Amperes
2.5L - 2600 rpm
4.0L - 2500 rpm
7.8 Volts
2.5L - 130 Amperes
4.0L - 160 Amperes

*Test at operating temperature. Cold engine, tight (new) engine, or heavy oil will increase starter amperage draw.

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CAUTION: Never force a belt over a pulley rim
using a screwdriver. The synthetic fiber of the belt
can be damaged.
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 Group
7, Cooling System.

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Fig. 2 Generator Remove/Install

Fig. 4 Battery Temperature Sensor Remove/Install

Fig. 3 Generator Connectors (Typical)

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TYPE

PART NUMBER

RATED SAE AMPS

ENGINES

MINIMUM TEST AMPS

DENSO

56005684AB

81

2.5L/4.0L

57

DENSO

56005685AB

117

2.5L/4.0L

88

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Fig. 1 Powertrain Control Module (PCM) Location

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Fig. 3 Crankshaft Position Sensor—4.0L 6-Cyl.
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Fig. 4 Crankshaft Position Sensor—2.5L 4-Cyl.
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Fig. 7 Sensor Operation—4.0L 6-Cyl. Engine—
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Fig. 8 Sensor Operation—4.0L 6-Cyl. Engine—
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Fig. 10 Ignition Coil—4.0L Engine

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COIL MANUFACTURER

PRIMARY RESISTANCE
21-27°C (70-80°F)

SECONDARY RESISTANCE
21-27°C (70-80°F)

Diamond

0.97 - 1.18 Ohms

11,300 - 15,300 Ohms

Toyodenso

0.95 - 1.20 Ohms

11,300 - 13,300 Ohms

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NOTE: Base (initial) ignition timing is NOT adjustable on any 2.5L 4-cylinder or 4.0L 6-cylinder
engine. Do not attempt to adjust ignition timing by
rotating the distributor.
NOTE: Do not attempt to modify the distributor
housing to get distributor rotation. Distributor position will have no effect on ignition timing.

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“š‡?¯\±?•)ˆl¡
Fig. 17 Electrode Gap Bridging

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Fig. 16 Oil or Ash Encrusted

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Fig. 18 Scavenger Deposits

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Fig. 20 Preignition Damage

Fig. 19 Chipped Electrode Insulator

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Fig. 21 Spark Plug Overheating

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CAUTION: When disconnecting a high voltage
cable from a spark plug or from the distributor cap,
twist the rubber boot slightly (1/2 turn) to break it
loose (Fig. 22). Grasp the boot (not the cable) and
pull it off with a steady, even force.

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Fig. 22 Cable Removal

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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.

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Fig. 24 Ignition Coil—2.5L Engine

Fig. 26 Crankshaft Position Sensor—4.0L 6-Cyl.
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Fig. 25 Ignition Coil—4.0L Engine

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Fig. 27 Crankshaft Position Sensor—2.5L 4-Cyl.
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Fig. 30 Plastic Alignment Pin

NOTE: Do not attempt to modify this fork to attain
ignition timing.

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Fig. 36 Distributor Pre-position—All Engines
Fig. 35 Pin Alignment Holes

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Fig. 37 Distributor Engaged Position—2.5L
4-Cylinder Engine

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Fig. 38 Distributor Engaged Position—4.0L
6-Cylinder Engine

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Fig. 39 Key Cylinder Release Tang

CAUTION: If the distributor cap is incorrectly positioned on distributor housing, cap or rotor may be
damaged when engine is started.

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Fig. 40 Key Cylinder and Cover Removal

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Fig. 41 Ignition Switch Lock Tab

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ENGINE

PLUG TYPE

ELECTRODE GAP

MINIMUM

MAXIMUM

2.5L/4.0L

RC12ECC

0.89 mm (0.035 in.)

250 Ohms Per Inch

1000 Ohms Per Inch

3000 Ohms Per Foot

12,000 Ohms Per Foot

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COIL MANUFACTURER

PRIMARY RESISTANCE
21-27°C (70-80°F)

SECONDARY RESISTANCE
21-27°C (70-80°F)

Diamond

0.97 - 1.18 Ohms

11,300 - 15,300 Ohms

Toyodenso

0.95 - 1.20 Ohms

11,300 - 13,300 Ohms

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WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO GROUP 8M - PASSIVE

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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
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RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
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RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
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INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.

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Audio System Diagnosis
CONDITION
NO AUDIO.

POSSIBLE CAUSE
1. Fuse faulty.
2. Radio connector faulty.
3. Wiring faulty.
4. Ground faulty.
5. Radio faulty.
6. Speakers faulty.

NO DISPLAY.

1. Fuse faulty.
2. Radio connector faulty.
3. Wiring faulty.
4. Ground faulty.
5. Radio faulty.

CLOCK WILL
NOT KEEP SET
TIME.

1. Fuse faulty.
2. Radio connector faulty.
3. Wiring faulty.
4. Ground faulty.
5. Radio faulty.

POOR RADIO
RECEPTION.

1. Antenna faulty.
2. Ground faulty.
3. Radio faulty.

NO/POOR TAPE
OPERATION.

NO COMPACT
DISC
OPERATION

1. Faulty tape.
2. Foreign objects behind
tape door.
3. Dirty cassette tape
head.
4. Faulty tape deck.
1. Faulty CD.
2. Foreign material on
CD.
3. Condensation on CD
or optics.
4. Faulty CD player.

CORRECTION
1. Check radio fuses in Power Distribution Center. Replace fuses,
if required.
2. Check for loose or corroded radio connector. Repair, if
required.
3. Check for battery voltage at radio connector. Repair wiring, if
required.
4. Check for continuity between radio chassis and a known good
ground. There should be continuity. Repair ground, if required.
5. Exchange or replace radio, if required.
6. See speaker diagnosis, in this group.
1. Check radio fuses in Power Distribution Center. Replace fuses,
if required.
2. Check for loose or corroded radio connector. Repair, if
required.
3. Check for battery voltage at radio connector. Repair wiring, if
required.
4. Check for continuity between radio chassis and a known good
ground. There should be continuity. Repair ground, if required.
5. Exchange or replace radio, if required.
1. Check ignition-off draw fuse. Replace fuse, if required.
2. Check for loose or corroded radio connector. Repair, if
required.
3. Check for battery voltage at radio connector. Repair wiring, if
required.
4. Check for continuity between radio chassis and a known good
ground. There should be continuity. Repair ground, if required.
5. Exchange or replace radio, if required.
1. See antenna diagnosis, in this group. Repair or replace
antenna, if required.
2. Check for continuity between radio chassis and a known good
ground. There should be continuity. Repair ground, if required.
3. Exchange or replace radio, if required.
1. Insert known good tape and test operation.
2. Remove foreign objects and test operation.
3. Clean head with Mopar Cassette Head Cleaner.
4. Exchange or replace radio, if required.
1. Insert known good CD and test operation.
2. Clean CD and test operation.
3. Allow temperature of vehicle interior to stabilize and test
operation.
4. Exchange or replace radio, if required.

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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.

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SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
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INJURY.

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NOTE: This model has a two-piece antenna coaxial
cable. Tests 2 and 4 must be conducted in two
steps to isolate a coaxial cable problem; from the
coaxial cable connection under the right end of the
instrument panel near the right cowl side inner
panel to the antenna base, and then from the coaxial cable connection to the radio chassis connection.

Fig. 1 Antenna Tests

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SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
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INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.

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Install

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Fig. 12 Engine-To-Frame Ground Strap Remove/
Install - 4.0L Engine

Fig. 11 Engine-To-Frame Ground Strap Remove/
Install - 2.5L Engine

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Fig. 2 Combination Flasher - Typical

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WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, 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 PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.

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WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, 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 PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.

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Fig. 3 Multi-Function Switch Continuity

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WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
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INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.

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NOTE: The combination flasher and flasher bracket
are serviced only as a unit.

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WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, 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 PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.

Fig. 4 Combination Flasher Remove/Install

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Fig. 5 Steering Column Shrouds Remove/Install

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Fig. 5 Rear Wiper Switch and Washer Switch
Continuity

Fig. 4 Windshield Wiper Switch and Washer Switch
Continuity

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CAUTION: The use of a screwdriver or other prying
tool to remove a wiper arm may distort it. This distortion could allow the arm to come off of the pivot
shaft, regardless of how carefully it is installed.

NOTE: The notched retainer end of the wiper element should always be oriented towards the end of
the wiper blade that is nearest to the wiper pivot.

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Fig. 6 Wiper Blade Remove/Install - Typical

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Fig. 7 Wiper Arm Remove/Install

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the wiper blade that is nearest to the wiper pivot.
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Install

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å‡æ-ç(è Module
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Fig. 12 Rear Wiper and Washer System

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.0/214365879.0/2:<;4=?>@BA?.C>74=B365879.0/2:6;=
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WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, 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 PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
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LAMPS

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LAMP DIAGNOSIS

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page

page

GENERAL INFORMATION
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING
DAYTIME RUNNING LAMP . . . . . . . . . . . . . . . . . . 4

DIAGNOSTIC PROCEDURES . . . . . . . . . . . . . . . . 1
FOG LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
HEADLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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WARNING: EYE PROTECTION SHOULD BE USED
WHEN SERVICING GLASS COMPONENTS. PERSONAL INJURY CAN RESULT.
CAUTION: Do not touch the glass of halogen bulbs
with fingers or other possibly oily surface, reduced
bulb life will result.
Do not use bulbs with higher candle power than
indicated in the Bulb Application table at the end of

this group. Damage to lamp and/or Daytime Running Lamp Module can result.
Do not use fuses, circuit breakers or relays having greater amperage value than indicated on the
fuse panel or in the Owners Manual.

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Ö!Û)äÏä ÙVÐ9äåÖ!ÒÑÉËÊÍÏß

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!#"%$!&#"%')(
*,+.-0/1-0234/56-798,:,;%5<;
CONDITION

POSSIBLE CAUSES

E,F

CORRECTION

HEADLAMPS ARE DIM
WITH ENGINE IDLING

1. Loose or corroded battery cables.

1. Clean and secure battery cable clamps
and posts.

OR IGNITION TURNED
OFF

2. Loose or worn generator drive
belt.

2. Adjust or replace generator drive belt.

3. Charging system output too low.

3. Test and repair charging system, refer to
Group 8A,

4. Battery has insufficient charge.

4. Test battery state-of -charge
, refer to Group 8A.

5. Battery is sulfated or shorted.

5. Load test battery, refer to Group 8A.

6. Poor lighting circuit Z1-ground.

6. Test for voltage drop across Z1-ground
locations, refer to Group 8W.

7. Both headlamp bulbs defective.

7. Replace both headlamp bulbs.

HEADLAMP BULBS BURN
OUT

1. Charging system output too high.

1. Test and repair charging system, refer to
Group 8A.

FREQUENTLY

2. Loose or corroded terminals or
splices in circuit.

2. Inspect and repair all connectors and
splices, refer to Group 8W.

HEADLAMPS ARE DIM
WITH ENGINE RUNNING

1. Charging system output too low.

1. Test and repair charging system, refer to
Group 8A.

ABOVE IDLE*

2. Poor lighting circuit Z1-ground.

2. Test for voltage drop across Z1-ground
locations, refer to Group 8W.

3. High resistance in headlamp
circuit.

3. Test amperage draw of headlamp circuit.

4. Both headlamp bulbs defective.

4. Replace both headlamp bulbs.

1. Poor lighting circuit Z1-ground.

1. Test for voltage drop across Z1-ground
locations, refer to Group 8W.

2. High resistance in headlamp
circuit.

2. Test amperage draw of headlamp circuit.
Should not exceed 30 amps.

3. Faulty headlamps switch circuit
breaker.

3. Replace headlamp switch.

4. Loose or corroded terminals or
splices in circuit.

4. Inspect and repair all connectors and
splices, refer to Group 8W.

1. No voltage to headlamps.

1. Repair open headlamp circuit, refer to
Group 8W.

2. No Z1-ground at headlamps.

2. Repair circuit ground, refer to Group 8W.

3. Faulty headlamp switch.

3. Replace headlamp switch.

4. Faulty headlamp dimmer
(multi-function) switch.

4. Replace multi-function switch.

5. Broken connector terminal or wire
splice in headlamp circuit.

5. Repair connector terminal or wire splice.

6. Both headlamp bulbs defective.

6. Replace both headlamp bulbs.

HEADLAMPS FLASH
RANDOMLY

HEADLAMPS DO NOT
ILLUMINATE

*Canada vehicles must have lamps ON.

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gh!ikj#l%m)n
opXqsrut0vIwyxz6tq9{p,|%z6|

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CONDITION

POSSIBLE CAUSES

FOG LAMPS ARE DIM
WITH ENGINE IDLING OR
IGNITION TURNED OFF.

1. Loose or corroded battery cables.

1. Clean and secure battery cable clamps
and posts.

2. Loose or worn generator drive
belt.

2. Adjust or replace generator drive belt.

3. Charging system output too low.

3. Test and repair charging system. Refer to
Group 8A,

4. Battery has insufficient charge.

4. Test battery state-of -charge. Refer to
Group 8A.

5. Battery is sulfated or shorted.

5. Load test battery. Refer to Group 8A.

6. Poor lighting circuit Z1-ground.

6. Test for voltage drop across Z1-ground
locations. Refer to Group 8W.

1. Charging system output too high.

1. Test and repair charging system. Refer to
Group 8A.

2. Loose or corroded terminals or
splices in circuit.

2. Inspect and repair all connectors and
splices. Refer to Group 8W.

1. Charging system output too low.

1. Test and repair charging system. Refer to
Group 8A.

2. Poor lighting circuit Z1-ground.

2. Test for voltage drop across Z1-ground
locations. Refer to Group 8W.

3. High resistance in fog lamp circuit.

3. Test amperage draw of fog lamp circuit.

1. Poor lighting circuit Z1-ground.

1. Test for voltage drop across Z1-ground
locations. Refer to Group 8W.

2. High resistance in fog lamp circuit.

2. Test amperage draw of fog lamp circuit.

3. Faulty fog lamp switch.

3. Replace fog lamp switch.

4. Loose or corroded terminals or
splices in circuit.

4. Inspect and repair all connectors and
splices. Refer to Group 8W.

1. Blown fuse for fog lamp.

1. Replace fuse. Refer to Group 8W.

2. No Z1-ground at fog lamps.

2. Repair circuit ground. Refer to Group
8W.

3. Faulty fog lamp switch.

3. Replace fog lamp switch.

4. Broken connector terminal or wire
splice in fog lamp circuit.

4. Repair connector terminal or wire splice.

5. Defective or burned out bulb.

5. Replace bulb.

FOG LAMP BULBS BURN
OUT FREQUENTLY

FOG LAMPS ARE DIM
WITH ENGINE RUNNING
ABOVE IDLE

FOG LAMPS FLASH
RANDOMLY

FOG LAMPS DO NOT
ILLUMINATE

CORRECTION

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ÂIÃKÄMÅOÆOÇOÈRÃKÈSÄMÆOÂUÉ!Ê!È!ÉRÃWÆXÅZË\ÌMÍ9Î9ÏaÐbÎ9Ñ9Ò9Ó9Ô
šœ›%žŸb )¡¢¤£!¥!¥!Ÿb¥!¦k§#›% )¨
©0ª¤«¬.­<®¯4°±9²,²X­<²X³s´uª0®Iµy©­6ª³9²¶,·%­6·
CONDITION
DAYTIME RUNNING LAMPS DO
NOT WORK

POSSIBLE CAUSES
1. Poor connection at DRL module.
2. Parking brake engaged.
3. Parking brake circuit shorted to
ground.
4. Headlamp circuit shorted to
ground.
5. Defective DRL module.

À,Á

CORRECTION
1. Secure connector on DRL
module.
2. Disengage parking brake.
3. Check voltage on pin 3 of
module, refer to Group 8W.
4. Check L3 circuit, refer to Group
8W.
5. Replace DRL module.

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HEADLAMP ALIGNMENT

ÕWÖ9×9ØÙ
page

page

GENERAL INFORMATION
HEADLAMP ALIGNMENT . . . . . . . . . . . . . . . . . . . 5
SERVICE PROCEDURES
FOG LAMP ADJUSTMENT . . . . . . . . . . . . . . . . . . 7
HEADLAMP ADJUSTMENT . . . . . . . . . . . . . . . . . 6

LAMP ALIGNMENT SCREEN PREPARATION . . . . 5
VEHICLE PREPARATION FOR HEADLAMP
ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SPECIAL TOOLS
HEADLAMP ALIGNMENT . . . . . . . . . . . . . . . . . . . 7

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Fig. 4 Fog Lamp Adjustment

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LAMP BULB SERVICE

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page
REMOVAL AND INSTALLATION
BACK-UP LAMP BULB . . . . . . . . . . . . . . . . . . . . . 9
CENTER HIGH MOUNTED STOP LAMP
(CHMSL) BULB . . . . . . . . . . . . . . . . . . . . . . . . . 9
DOME LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
FOG LAMP BULB . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Fig. 1 Fog Lamp Bulb

CAUTION: Do not touch the bulb glass with fingers
or other oily surfaces. Reduced bulb life will result.

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page
FRONT PARK/TURN SIGNAL LAMP BULB .
HEADLAMP BULB . . . . . . . . . . . . . . . . . . .
SIDE MARKER LAMP BULB . . . . . . . . . . . .
TAIL/TURN SIGNAL/BACK-UP LAMP BULB
UNDERHOOD LAMP BULB . . . . . . . . . . . .

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LAMP SERVICE

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page
REMOVAL AND INSTALLATION
CENTER HIGH MOUNTED STOP LAMP
(CHMSL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DOME LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
FOG LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

page
FRONT PARK/TURN SIGNAL LAMP . . . . . . . . . .
HEADLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SIDE MARKER LAMP . . . . . . . . . . . . . . . . . . . . .
TAIL/STOP/TURN SIGNAL/BACK-UP LAMP . . . .
UNDERHOOD LAMP . . . . . . . . . . . . . . . . . . . . .

12
11
12
12
13

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Fig. 2 Headlamp Retaining Ring

Fig. 1 Headlamp Bezel

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GENERAL INFORMATION
DAYTIME RUNNING LIGHTS (CANADA ONLY) . . 15

REMOVAL AND INSTALLATION
DAYTIME RUNNING LAMP (DRL) MODULE . . . . 15

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BULB APPLICATION

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SPECIFICATIONS
EXTERIOR LAMPS . . . . . . . . . . . . . . . . . . . . . . . 16

INTERIOR LAMPS . . . . . . . . . . . . . . . . . . . . . . . 16

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CAUTION: Do not use bulbs that have a higher candle power than the bulb listed in the Bulb Application Table. Damage to lamp can result. Do not touch
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Bulb life will be reduced.

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LAMP DIAGNOSIS

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GENERAL INFORMATION
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1
HEADLAMP LEVELING MOTOR . . . . . . . . . . . . . . 1

DIAGNOSIS AND TESTING
DIAGNOSTIC PROCEDURES . . . . . . . . . . . . . . . . 2

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WARNING: EYE PROTECTION SHOULD BE USED
WHEN SERVICING GLASS COMPONENTS. PERSONAL INJURY CAN RESULT.
CAUTION: Do not touch the glass of halogen bulbs
with fingers or other possibly oily surfaces,
reduced bulb life can result.

Do not use bulbs with higher candle power than
indicated in the Bulb Application Table at the end of
this group. Damage to lamp can result.
Do not use fuses, circuit breakers or relays having greater amperage value than indicated on the
fuse panel or in the Owners Manual.

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CONDITION
HEADLAMPS ARE
DIM WITH ENGINE
IDLING OR
IGNITION TURNED
OFF

HEADLAMP BULBS
BURN OUT
FREQUENTLY

HEADLAMPS ARE
DIM WITH ENGINE
RUNNING ABOVE
IDLE

HEADLAMPS
FLASH RANDOMLY

HEADLAMPS DO
NOT ILLUMINATE

POSSIBLE CAUSES

CORRECTION

1. Loose or corroded battery cables.

1. Clean and secure battery cable clamps
and posts.

2. Loose or worn alternator drive belt.

2. Adjust or replace alternator drive belt.

3. Charging system output too low.

3. Test and repair charging system. Refer to
Group 8A.

4. Battery has insufficient charge.

4. Test battery state-of -charge. Refer to
Group 8A.

5. Battery is sulfated or shorted.

5. Load test battery. Refer to Group 8A.

6. Poor lighting circuit Z1-ground.

6. Test for voltage drop across Z1-ground
locations. Refer to Group 8W.

1. Charging system output too high.

1. Test and repair charging system. Refer to
Group 8A.

2. Loose or corroded terminals or splices in
circuit.

2. Inspect and repair all connectors and
splices. Refer to Group 8W.

1. Charging system output too low.

1. Test and repair charging system. Refer to
Group 8A.

2. Poor lighting circuit Z1-ground.

2. Test for voltage drop across Z1-ground
locations. Refer to Group 8W.

3. High resistance in headlamp circuit.

3. Test amperage draw of headlamp circuit.

1. Poor lighting circuit Z1-ground.

1. Test for voltage drop across Z1-ground
locations, refer to Group 8W.

2. High resistance in headlamp circuit.

2. Test amperage draw of headlamp circuit.

3. Loose or corroded terminals or splices in
circuit.

3. Inspect and repair all connectors and
splices. Refer to Group 8W.

1. No voltage to headlamps.

1. Repair open headlamp circuit. Refer to
Group 8W.

2. No Z1-ground at headlamps.

2. Repair circuit ground. Refer to Group
8W.

3. Faulty headlamp switch.

3. Replace headlamp switch.

4. Faulty headlamp dimmer (multi-function)
switch.

4. Replace multi-function switch.

5. Broken connector terminal or wire splice
in headlamp circuit.

5. Repair connector terminal or wire splice.

6. Defective or burned out bulb.

6. Replace bulb.

7. Body controller malfunction.

7. Refer to appropriate body controller
diagnostics.

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CONDITION

POSSIBLE CAUSES

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 alternator drive
belt.

2. Adjust or replace alternator drive belt.

3. Charging system output too low.

3. Test and repair charging system. Refer to
Group 8A.

4. Battery has insufficient charge.

4. Test battery state-of -charge. Refer to
Group 8A.

5. Battery is sulfated or shorted.

5. Load test battery. Refer to Group 8A.

6. Poor lighting circuit Z1-ground.

6. Test for voltage drop across Z1-ground
locations. Refer to Group 8W.

1. Charging system output too high.

1. Test and repair charging system. Refer to
Group 8A.

2. Loose or corroded terminals or
splices in circuit.

2. Inspect and repair all connectors and
splices. Refer to Group 8W.

1. Charging system output too low.

1. Test and repair charging system. Refer to
Group 8A.

2. Poor lighting circuit Z1-ground.

2. Test for voltage drop across Z1-ground
locations. Refer to Group 8W.

3. High resistance in fog lamp circuit.

3. Test amperage draw of fog lamp circuit.

1. Poor lighting circuit Z1-ground.

1. Test for voltage drop across Z1-ground
locations. Refer to Group 8W.

2. High resistance in fog lamp circuit.

2. Test amperage draw of fog lamp circuit.

3. Faulty fog lamp switch.

3. Replace fog lamp switch.

4. Loose or corroded terminals or
splices in circuit.

4. Inspect and repair all connectors and
splices. Refer to Group 8W.

1. Blown fuse for fog lamp.

1. Replace fuse. Refer to Group 8W.

2. No Z1-ground at fog lamps.

2. Repair circuit ground. Refer to Group
8W.

3. Faulty fog lamp switch.

3. Replace fog lamp switch.

4. Broken connector terminal or wire
splice in fog lamp circuit.

4. Repair connector terminal or wire splice.

5. Defective or burned out bulb.

5. Replace bulb.

FOG LAMP BULBS BURN
OUT FREQUENTLY

FOG LAMPS ARE DIM
WITH ENGINE RUNNING
ABOVE IDLE

FOG LAMPS FLASH
RANDOMLY

FOG LAMPS DO NOT
ILLUMINATE

CORRECTION

$%'&(
%*),+.-0/
346587:9:;:<=46<>589:3@?BAB<B?=4C97EDGF8HIJLKMINOPQ
 
 


  ! "#!#
CONDITION
ONE MOTOR DOES NOT
OPERATE

BOTH MOTORS DO NOT
OPERATE

POSSIBLE CAUSES

12

CORRECTION

1. Poor connection at motor.

1. Secure connector on motor.

2. No voltage at motor.

2. Repair circuit. Refer to Group 8W,
Wiring.

3. Defective motor.

3. Replace motor.

1. No voltage at headlamp leveling
switch.

1. Repair circuit or replace fuse. Refer to
Group 8W, Wiring.

2. No voltage at both motors.

2. Repair circuit or replace fuse. Refer to
Group 8W, Wiring.

3. Poor connection at motors.

3. Secure connectors on motors.

4. Both motors defective.

4. Replace motors.

ÁÃÂ

Ä*Å,Æ.Ç0È

ÉÄ ÊË

LAMP BULB SERVICE
RCSTUWV
page
REMOVAL AND INSTALLATION
CENTER HIGH MOUNTED STOP LAMP
(CHMSL) BULB . . . . . . . . . . . . . . . . . . . . . . . . . 7
CITYLIGHT LAMP BULB . . . . . . . . . . . . . . . . . . . . 6

page
HEADLAMP BULB . . . . . . . . .
LICENSE PLATE LAMP BULB
REAR FOG LAMP BULB . . . .
TAIL LAMP BULB . . . . . . . . . .

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Fig. 2 Headlamp Retaining Ring

Fig. 3 Headlamp Rubber Seal Boot

Fig. 1 Headlamp Bezel

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Fig. 4 Headlamp Bulb Retaining Ring

Fig. 6 Citylight Lamp Bulb Housing

Fig. 5 Headlamp Bulb

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Fig. 7 Citylight Lamp Bulb

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bCc
debgf7hCigj
deFig.
kmlo9nqTail
pCj7n Lamp Bulbs
rst>uvxw3y
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Fig. 10 REAR FOG LAMP LENSE

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LAMP SERVICE

èéêë€ì
page

page

REMOVAL AND INSTALLATION
CENTER HIGH MOUNTED STOP LAMP
(CHMSL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
HEADLAMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . 8

HEADLAMP LEVELING MOTOR . . . . . . . . . . . . . . 8
REAR FOG LAMP . . . . . . . . . . . . . . . . . . . . . . . 10
TAIL LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

í·î¸ïgðµñeòóôòöõµ÷ùø€õµú¸û¤òó¡ó3òû¸ø€ðµõ
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Fig. 2 Headlamp Retaining Ring

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NOTE: The headlamp leveling motor arm is
snapped into the headlamp housing very securely.
Use a firm, steady pull to disengage motor arm
from the headlamp housing.

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Fig. 1 Headlamp Bezel

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Fig. 4 Headlamp Housing
Fig. 6 Tail Lamp Lense

Fig. 5 Headlamp Leveling Motor

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Fig. 7 Tail Lamp Housing

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NOTE: It may be necessary to remove the spare
tire.

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Fig. 8 CHMSL Assembly

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*,+-/.021436570…8;:<0 Q 0 RQ [` 32M Lc R 1od R 8O8 RT :<ILK<MoH TSQ 06W *er†ILMtX
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Fig. 9 Rear Fog Lamp

?;@

ACBED
F=G

HA%IKJLJ

BULB APPLICATION
¯e°±²2³
page

page

GENERAL INFORMATION
GENERAL INFORMATION . . . . . . . . . . . . . . . . . 11
SPECIFICATIONS
EXTERIOR LAMPS . . . . . . . . . . . . . . . . . . . . . . . 11

INTERIOR LAMPS . . . . . . . . . . . . . . . . . . . . . . . 11

´¶µC·¶µC¸™¹»º½¼2·¶¾4¿¶¸ÀÁ¹/ÂC¼2¿¶·
à ÄÅ ÄÆvÇȶÉÅ ÊË ÆÍ̙ÇÏÎÉË Å
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Û<Þ<æ4Ý_ÕGêm×GÛëã;Ô<ՙêSÚLÜtÔ<ã;ì
CAUTION: Do not use bulbs that have a higher candle power the bulb listed in the Bulb Application
Table. Damage to lamp can result. Do not touch
halogen bulbs with fingers or other oily surfaces.
Bulb life will be reduced.

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WARNING:
• THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENTS YOU MUST FIRST DISCONNECT
AND ISOLATE THE BATTERY NEGATIVE (GROUND)
CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
• THE DRIVER SIDE AIRBAG MODULE INFLATOR
ASSEMBLY CONTAINS SODIUM AZIDE AND POTASSIUM NITRATE. THESE MATERIALS ARE POISONOUS AND EXTREMELY FLAMMABLE. CONTACT
WITH ACID, WATER, OR HEAVY METALS MAY PRODUCE HARMFUL AND IRRITATING GASES (SODIUM
HYDROXIDE IS FORMED IN THE PRESENCE OF
MOISTURE) OR COMBUSTIBLE COMPOUNDS. THE
PASSENGER AIRBAG MODULE CONTAINS ARGON

GAS PRESSURIZED TO OVER 2500 PSI. DO NOT
ATTEMPT TO DISMANTLE AN AIRBAG MODULE 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).
• REPLACE AIRBAG SYSTEM COMPONENTS
ONLY WITH PARTS SPECIFIED IN THE CHRYSLER
MOPAR PARTS CATALOG. SUBSTITUTE PARTS
MAY APPEAR INTERCHANGEABLE, BUT INTERNAL
DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION.
• THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE
SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY
SUBSTITUTES. ANY TIME A NEW FASTENER IS
NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR
SPECIFIED IN THE CHRYSLER MOPAR PARTS CATALOG.
• WHEN A STEERING COLUMN HAS AN AIRBAG
MODULE ATTACHED, NEVER PLACE THE COLUMN
ON THE FLOOR OR ANY OTHER SURFACE WITH
THE STEERING WHEEL OR AIRBAG MODULE FACE
DOWN.

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WARNING: THE KEY MUST ALWAYS BE REMOVED
FROM THE PASSENGER SIDE AIRBAG ON/OFF
SWITCH KEY ACTUATOR AFTER THE SWITCH HAS
BEEN USED. NEVER LEAVE A KEY IN THE SWITCH
KEY ACTUATOR. FAILURE TO OBSERVE THIS
WARNING COULD RESULT IN ACCIDENTAL,
INCOMPLETE OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE OCCUPANT INJURIES.



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Fig. 3 Vacuum Heater and A/C Outlets - Typical

Fig. 2 Wear Safety Glasses and Rubber Gloves Typical
WARNING: IF YOU EXPERIENCE SKIN IRRITATION
DURING CLEANUP, RUN COOL WATER OVER THE
AFFECTED AREA. ALSO, IF YOU EXPERIENCE
IRRITATION OF THE NOSE OR THROAT, EXIT THE
VEHICLE FOR FRESH AIR UNTIL THE IRRITATION
CEASES. IF IRRITATION CONTINUES, SEE A PHYSICIAN.

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WARNING:
• THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENTS YOU MUST FIRST DISCONNECT
AND ISOLATE THE BATTERY NEGATIVE (GROUND)
CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
• WHEN REMOVING A DEPLOYED AIRBAG MODULE, RUBBER GLOVES, EYE PROTECTION, AND A
LONG-SLEEVED SHIRT SHOULD BE WORN. THERE
MAY BE DEPOSITS ON THE AIRBAG MODULE AND
OTHER INTERIOR SURFACES. IN LARGE DOSES,
THESE DEPOSITS MAY CAUSE IRRITATION TO THE
SKIN AND EYES.

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WARNING:
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SIDE
AIRBAG
MODULE,
OR
BECOMING
ENTRAPPED BETWEEN THE AIRBAG CUSHION
AND THE DRIVER SIDE AIRBAG TRIM COVER.
FAILURE TO OBSERVE THIS WARNING COULD
RESULT IN OCCUPANT INJURIES UPON AIRBAG
DEPLOYMENT.
• THE DRIVER SIDE AIRBAG MODULE TRIM
COVER MUST NEVER BE PAINTED. REPLACEMENT
TRIM COVERS 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.

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WARNING:
• THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENTS YOU MUST FIRST DISCONNECT
AND ISOLATE THE BATTERY NEGATIVE (GROUND)
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WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
• THE HORN SWITCH IS INTEGRAL TO THE AIRBAG MODULE TRIM COVER. SERVICE OF THIS
COMPONENT SHOULD BE PERFORMED ONLY BY
CHRYSLER-TRAINED AND AUTHORIZED DEALER
SERVICE TECHNICIANS. FAILURE TO TAKE THE
PROPER PRECAUTIONS OR TO FOLLOW THE
PROPER PROCEDURES COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIRBAG
DEPLOYMENT AND POSSIBLE OCCUPANT INJURIES.

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r úGù`ÿdìIíï.ò&ëHr úGù`ÿIs íÿ

Fig. 5 Horn Switch Feed Wire Remove/Install - w/o
Speed Control

Fig. 6 Horn Switch Feed Wire Remove/Install w/Speed Control

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Fig. 7 Driver Side Airbag Trim Cover Retainers
Remove/Install - w/o Speed Control

Fig. 9 Driver Side Airbag Trim Cover Remove/Install
- w/o Speed Control

Fig. 8 Driver Side Airbag Trim Cover Retainers
Remove/Install - w/Speed Control

Fig. 10 Driver Side Airbag Trim Cover Remove/
Install - w/Speed Control

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WARNING:
• USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE DRIVER
SIDE
AIRBAG
MODULE,
OR
BECOMING
ENTRAPPED BETWEEN THE AIRBAG CUSHION
AND THE DRIVER SIDE AIRBAG TRIM COVER.
FAILURE TO OBSERVE THIS WARNING COULD
RESULT IN OCCUPANT INJURIES UPON AIRBAG
DEPLOYMENT.
• THE DRIVER SIDE AIRBAG MODULE TRIM
COVER MUST NEVER BE PAINTED. REPLACEMENT
TRIM COVERS 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.

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WARNING:
• THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENTS YOU MUST FIRST DISCONNECT
AND ISOLATE THE BATTERY NEGATIVE (GROUND)
CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
• WHEN REMOVING A DEPLOYED AIRBAG MODULE, RUBBER GLOVES, EYE PROTECTION, AND A
LONG-SLEEVED SHIRT SHOULD BE WORN. THERE
MAY BE DEPOSITS ON THE AIRBAG MODULE AND
OTHER INTERIOR SURFACES. IN LARGE DOSES,
THESE DEPOSITS MAY CAUSE IRRITATION TO THE
SKIN AND EYES.

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Fig. 11 Driver Side Airbag Trim Cover Locking
Blocks Engaged

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Install
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WARNING:
• THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENTS YOU MUST FIRST DISCONNECT
AND ISOLATE THE BATTERY NEGATIVE (GROUND)
CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
• WHEN REMOVING A DEPLOYED AIRBAG MODULE, RUBBER GLOVES, EYE PROTECTION, AND A
LONG-SLEEVED SHIRT SHOULD BE WORN. THERE
MAY BE DEPOSITS ON THE AIRBAG MODULE AND
OTHER INTERIOR SURFACES. IN LARGE DOSES,
THESE DEPOSITS MAY CAUSE IRRITATION TO THE
SKIN AND EYES.
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WARNING: USE EXTREME CARE TO PREVENT
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PASSENGER SIDE AIRBAG MODULE, OR BECOMING ENTRAPPED BETWEEN THE AIRBAG CUSHION
AND THE PASSENGER SIDE AIRBAG DOOR. FAILURE TO OBSERVE THIS WARNING COULD RESULT
IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT.

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Fig. 13 Passenger Side Airbag Door Upper Screws
Remove/Install

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Fig. 14 Passenger Side Airbag Door Remove/Install

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WARNING:
• USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE PASSENGER SIDE AIRBAG MODULE, OR BECOMING
ENTRAPPED BETWEEN THE AIRBAG CUSHION
AND THE PASSENGER SIDE AIRBAG DOOR. FAILURE TO OBSERVE THIS WARNING COULD RESULT
IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT.
• THE PASSENGER SIDE AIRBAG DOOR MUST
NEVER BE PAINTED. REPLACEMENT AIRBAG
DOORS ARE SERVICED IN THE ORIGINAL COLORS. 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.
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WARNING: THE AIRBAG SYSTEM IS A SENSITIVE,
COMPLEX ELECTROMECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENTS YOU MUST FIRST DISCONNECT
AND ISOLATE THE BATTERY NEGATIVE (GROUND)
CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.

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Fig. 16 Passenger Side Airbag On/Off Switch
Remove/Install

Fig. 15 Passenger Side Airbag On/Off Switch Wire
Harness Connectors

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WARNING:
• THE AIRBAG CONTROL MODULE CONTAINS
THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG
SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND
ISOLATE THE BATTERY NEGATIVE (GROUND)
CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
• NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT
SENSOR OR AFFECT ITS CALIBRATION. 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 AIRBAG DEPLOYMENT AND POSSIBLE
OCCUPANT INJURIES.

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Fig. 17 Acceleration Switch Remove/Install
NOTE: Always remove and replace the airbag control module and its mounting bracket as a unit.
Replacement modules include a replacement
mounting bracket. Do not transfer the module to
another mounting bracket.

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TVÎZ˜i'Z$^‰qsW$tsZYi'i'W$ts^‰^a`'W˜prgj^a^aWYqŽÏi'W$o…gr^’n \ W˜tsgjprwxW˜gr^
^a`'nxz+^anxXEWY~#UW$vW$q[^aZ.º1ÂľÑп'Ò£ÆӇÔYÁ ¼ÕÖnxi5^a`'W>Înxgro…i'Z$z{nxz
gri'k7¥&W$z{^anxi'o}z
WYts^anxZYi5Z$v9^’`nAzEo…qsZ$m'y_vZ$q[^a`'W˜yqsZ$yW$q[yqsZY

Fig. 18 Airbag Control Module Remove/Install

tsWYkjm'qsWYz
~
×ØÙ3×ÚÛÜÝ3ÞMß3à
¥9`W±tswxZYtsu“z
yqsnxi'oátsgri'iZY^5prW±qsWYyjgrnAqsW$k~˜¢]^5XEm'z
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qsW$ywxgjtsW$kšnxv1vgrm'wx^⎭ZYq·kgrXEgjoÀWYk³3ZYq}nxv1^’`'W|kqsn \ WYq}z
nxkW
grnxqspjgroŒ`'grz[prWYWYi|kW$ywxZ]Ž WYk~

WARNING: THE AIRBAG SYSTEM IS A SENSITIVE,
COMPLEX ELECTROMECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENTS YOU MUST FIRST DISCONNECT
AND ISOLATE THE BATTERY NEGATIVE (GROUND)
CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
ãä剈栄9†

NOTE: Before starting this procedure, be certain to
turn the steering wheel until the front wheels are in
the straight-ahead position.
R‹ŠMTVçƒwAgrtsWè^’`W®vAqsZYi'^7[`WYW$wAzœnxié^a`'Wèz{^aqsgrnxo…`'^agr`'WYgrk

Fig. 19 Airbag Control Module Connector Removal
RS
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"‰$#&%('*),+.-/'C0324'C032469''C:<nG69'.K,:0I24?@0~:<'n9D469'C0324'CE=+.K1'*6
Fig. 21 Clockspring Remove/Install
G¥$!$
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NOTE: If the clockspring plastic latches are broken,
be certain to remove the broken pieces from the
steering column upper housing.

Fig. 20 Steering Column Shrouds Remove/Install

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D4E=E zxE=+.K1'*69'5Yp7+*:<8=038=+*J4N

Fig. 22 Upper Clockspring Latch Access Window

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NOTE: Before starting this procedure, be certain
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position.

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WARNING: THE AIRBAG SYSTEM IS A SENSITIVE,
COMPLEX ELECTROMECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENTS YOU MUST FIRST DISCONNECT
AND ISOLATE THE BATTERY NEGATIVE (GROUND)
CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG 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.

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WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO GROUP 8M - PASSIVE
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Fig. 2 Defogger Switch Continuity

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RESTRAINT SYSTEMS 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.

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WARNING: MATERIALS
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IN
THE
REPAIR KIT MAY CAUSE SKIN OR EYE IRRITATION.
THE KIT CONTAINS EPOXY RESIN AND AMINE
TYPE HARDENER, WHICH ARE HARMFUL IF SWALLOWED. AVOID CONTACT WITH THE SKIN AND

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EYES. FOR SKIN CONTACT, WASH THE AFFECTED
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IMMEDIATELY. USE WITH ADEQUATE VENTILATION. DO NOT USE NEAR FIRE OR FLAME. CONTAINS FLAMMABLE SOLVENTS. KEEP OUT OF THE
REACH OF CHILDREN.

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Fig. 5 PDC Mounting Bracket Remove/Install

Fig. 3 Power Distribution Center Connections

Fig. 4 Power Distribution Center Remove/Install

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NOTE: If the PDC is being replaced with a new unit,
be certain to transfer each of the fuses and relays
from the old PDC to the proper cavities of the new
PDC. Refer to Power Distribution in the Contents of
Group 8W - Wiring Diagrams for the proper PDC
cavity assignments.
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WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
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NOTE: The following tests may not prove conclusive in the diagnosis of this system. The most reliable, efficient, and accurate means to diagnose the
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z”|P} } …†zA‡|Py–£”wT} ‚™|PŸ=‡•¥ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ@ˆ‡ˆ‡ˆ‡ˆ‡ˆMŠ‡‹‚™Š‡¢€‚„‘
zA|} } …†zA‡|Py=¦<Py=|PŸ } ~–›†| zAv‡€w |P}=•§ˆ@ˆ‡ˆ‡ˆ‡ˆMŠ‡‹Œ‚Ž¨‡¢‚’‘
©‡y=|P}=0›‡w Pƒ=wT}=ªˆ‡ˆ‡ˆ‡ˆ‡ˆ@ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ@ˆ‡ˆ‡ˆ‡ˆ‡ˆMŠ‡‹‚™ž‡¢€‚„‘
©‡Ÿ …‡›†¦dw P} w €w |P}«•”—A•”€…‡˜P•¬ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ@ˆ‡ˆ‡ˆ‡ˆMŠ‡‹‚™š‡¢€‚„‘
©‡Ÿ=•x…†¦­©‡Ÿ=•x…8“A›†| zxœˆ‡ˆ‡ˆ‡ˆ@ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ@ˆ‡ˆ‡ˆ‡ˆMŠ‡‹‚„‘‡‘‡‚„‘
P…‡} …‡y=vx›8wT} ©†|Py ˜Pv‡€w |P}®ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ@ˆ‡ˆ‡ˆ‡ˆMŠ‡‹‚™¢€‘‡‚„‘
Py=|PŸ } ~–~ w •”€y wT“”Ÿ=€w |P}‰ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ@ˆ‡ˆ‡ˆ‡ˆMŠ‡‹‚„‘†ž€‚„‘

page

ƒ=|Py }=¦Tzxw  vxy¯›‡w Pƒ=€…‡y=¦­£*| ‹0…‡y{|PŸ=€›‡…†\ˆMŠ‡‹‚™€‘‡‚„‘
wT}=•”€y Ÿ ˜…‡}=8zx›‡Ÿ=•A€…@y°ˆ‡ˆ@ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ@ˆ‡ˆ‡ˆMŠ‡‹‚™‡¢€‚„‘
wT}=€…‡y w |Py¯›@w Pƒ=€wT}=\ˆ‡ˆ‡ˆ‡ˆ‡ˆ@ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ@ˆ‡ˆ‡ˆMŠ‡‹‚™‡€‚„‘
£.| ‹0…‡y–~ w •”€y wT“”Ÿ=€w |P}±ˆ‡ˆ@ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ@ˆ‡ˆ‡ˆMŠ‡‹‚„‘†¢€‚„‘
y …†v2y–›‡w Pƒ=€wT}=¥ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ@ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ@ˆ‡ˆ‡ˆMŠ‡‹‚™ž€‘‡‚„‘
y …†v2y{‹0wT} ~=| ‹¡~ …‡©†|  P…@yˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ@ˆ‡ˆ‡ˆMŠ‡‹‚™‡Š€‚„‘
•2£”›‡w zx…8wT} ©†|Py ˜²v‡w |P}³ˆ‡ˆ‡ˆ@ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ@ˆ‡ˆ‡ˆMŠ‡‹‚™ ‡¢€‚„‘
•2£”›‡w zx…8›†| zAv‡€w |P}=•¬ˆ‡ˆ‡ˆ‡ˆ‡ˆ@ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ@ˆ‡ˆ‡ˆMŠ‡‹‚™¨‡ž€‚„‘
•A´v2yG€w<}=¯•”—A•”€…‡˜ ˆ‡ˆ‡ˆ‡ˆ‡ˆ@ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ@ˆ‡ˆ‡ˆMŠ‡‹‚™€‘‡‚„‘
€y=v2}=•x˜w •A•xw |P}{zA|P}=€y=|P›M•”—A•”€…‡˜±ˆ‡ˆ@ˆ‡ˆMŠ‡‹‚™š€‘‡‚„‘
€Ÿ y }{•2w }=v2›†•ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ@ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ@ˆ‡ˆMŠ‡‹‚™ž‡€‚„‘
‹0wT£A…@y=•Jˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ@ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ@ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ‡ˆ@ˆ‡ˆMŠ‡‹‚™ž‡š€‚„‘

UWV

X&Y[Z]\&^_*`a*`&bc9dNe a*fg*b#h;c&ije gka

X&YlZ)\&^0ZT^

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Ü<Ý Þ ß†à
page
DESCRIPTION AND OPERATION
CIRCUIT FUNCTIONS . . . . . . . . . . . . . . . . .
CIRCUIT INFORMATION . . . . . . . . . . . . . . .
CONNECTOR INFORMATION . . . . . . . . . . .
ELECTROSTATIC DISCHARGE (ESD)
SENSITIVE DEVICES . . . . . . . . . . . . . . . .
INTRODUCTION . . . . . . . . . . . . . . . . . . . . .
NOTES, CAUTIONS, and WARNINGS . . . . .
SECTION IDENTIFICATION . . . . . . . . . . . . .
SPLICE LOCATIONS . . . . . . . . . . . . . . . . . .
SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . .
TAKE OUTS . . . . . . . . . . . . . . . . . . . . . . . . .
TERMINOLOGY . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS AND TESTING
INTERMITTENT AND POOR CONNECTIONS

.... 4
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.... 7
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8
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8
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TROUBLESHOOTING TESTS . . . . . . . . . . . . . . . . 9
TROUBLESHOOTING TOOLS . . . . . . . . . . . . . . . 8
TROUBLESHOOTING WIRING PROBLEMS . . . . 10
SERVICE PROCEDURES
CONNECTOR AND TERMINAL REPLACEMENT . 12
CONNECTOR REPLACEMENT . . . . . . . . . . . . . . 11
DIODE REPLACEMENT . . . . . . . . . . . . . . . . . . . 14
TERMINAL REPLACEMENT . . . . . . . . . . . . . . . . 13
TERMINAL/CONNECTOR REPAIR-MOLEX
CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . 10
TERMINAL/CONNECTOR REPAIR—THOMAS
AND BETTS CONNECTORS . . . . . . . . . . . . . . 11
WIRING REPAIR . . . . . . . . . . . . . . . . . . . . . . . . 10
SPECIAL TOOLS
WIRING/TERMINAL . . . . . . . . . . . . . . . . . . . . . . 15

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The System shown here is an EXAMPLE ONLY. It does not represent the actual circuit shown in the WIRING
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The System shown here is an EXAMPLE ONLY. It does not represent the actual circuit shown in the WIRING
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Fig. 1 Wire Code Identification

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COLOR CODE

COLOR

./

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

STANDARD
TRACER
COLOR

L

EXTERIOR LIGHTING

M

INTERIOR LIGHTING

BL

BLUE

WT

N

NOT USED

BK

BLACK

WT

O

NOT USED

BR

BROWN

WT

P

POWER OPTION (BATTERY FEED)

DB

DARK BLUE

WT

Q

POWER OPTIONS (IGNITION FEED)

DG

DARK GREEN

WT

R

PASSIVE RESTRAINT

GY

GRAY

BK

S

SUSPENSION/STEERING

LB

LIGHT BLUE

BK

T

LG

LIGHT GREEN

BK

TRANSMISSION/TRANSAXLE/
TRANSFER CASE

OR

ORANGE

BK

U

OPEN

PK

PINK

BK or WT

V

SPEED CONTROL, WIPER/WASHER

RD

RED

WT

W

OPEN

TN

TAN

WT

X

AUDIO SYSTEMS

VT

VIOLET

WT

Y

OPEN

WT

WHITE

BK

Z

GROUNDS

YL

YELLOW

BK

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WITH TRACER

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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-90

Connector Locations
(including grounds)

8W-95

Splice Locations

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CAUTION: Not all connectors are serviced. Some
connectors are serviced only with a harness. A typical example might be the Supplemental Restraint
System connectors. Always check parts availability
before attempting a repair.

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Terminal Removing Tool 6934

Terminal Pick 6680

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8W - 10 - 2

8W-10 POWER DISTRIBUTION

TJ

POWER DISTRIBUTION CENTER

ENGINE
STARTER
MOTOR
RELAY

13

D
14

6
10

12

8

ABS
SYSTEM
RELAY

4

13

C
14

9
10

12

6

8

11
A/C
COMPRESSOR
CLUTCH
RELAY

2

5

11

REAR
WINDOW
DEFOGGER
RELAY

3
2

5
7

ABS
PUMP
MOTOR
RELAY

4

1
FUEL
PUMP
RELAY

B

AUTOMATIC
SHUT
DOWN
RELAY

HORN
RELAY

A

1

2

7

8

13

14

19

20

3

4

9

10

15

16

21

22

5

6

11

12

17

18

23

24

FUSES
7

6

8
7

14

21

15
40A

28

13

20

14
40A

27

13
30A

26

5

6
30A

12

19

4

5
40A

11

18

3

4
40A

10

17

11
40A

24

2

3
30A

9

16

10
30A

23

1

2
40A

8

15

9
20A

22

12

25

+
J998W-5

M1
TJI01002

TJ

8W-10 POWER DISTRIBUTION

8W - 10 - 3

FUSES
FUSE NO.
2

AMPS
40A

FUSED CIRCUIT
A2 12PK/BK

FEED CIRCUIT
A0 6RD

A2 12PK/BK
3

30A

A1 14RD

A0 6RD

4

40A

A6 12RD/BK

A0 6RD

5

40A

F30 12RD/PK

A0 6RD

6

30A

A14 14RD/WT

A0 6RD

A14 14RD/WT
7

-

-

A0 6RD

8

-

-

A0 6RD

9

20A

L9 16BK/WT

A0 6RD

10

30A

A3 14RD/WT

A0 6RD

11

40A

A111 12RD/LB

A0 6RD

12

-

13

30A

A20 14RD/DB

A0 6RD

14

40A

A10 12RD/DG

A0 6RD

15

40A

A4 12BK/PK

A0 6RD

16

10A

A17 20RD/GY

A0 6RD

17

20A

-

F31 18VT

A0 6RD

A0 6RD

F31 18VT

TJI01003

18

20A

F42 18DG/LG

A142 14DG/PK

19

20A

A61 18DG/BK

A0 6RD

20

10A

M1 20PK/WT

A0 6RD

21

10A

B47 14RD/LB

B48 20RD/YL

22

-

-

23

-

-

24

-

-

25

20A

26

-

27

10A

F61 18WT/OR

A0 6RD
-

F142 20OR/DG

A142 14DG/PK

J998W-5

8W - 10 - 4

8W-10 POWER DISTRIBUTION

CAVITY

ABS
PUMP
MOTOR
RELAY

-

C2

A10 12RD/DG

FUSED B (+)

C3

Z1 14BK

GROUND

B47 14RD/LB

ABS SYSTEM RELAY OUTPUT

B47 14RD/LB

ABS SYSTEM RELAY OUTPUT

B116 20GY
-

C8

B120 12BR/WT

C9

-

ABS PUMP MOTOR RELAY CONTROL
ABS PUMP MOTOR RELAY OUTPUT
-

CIRCUIT

FUNCTION

C10

B47 14RD/LB

ABS SYSTEM RELAY OUTPUT

C11

F20 20VT/WT

FUSED IGNITION SWITCH OUTPUT (RUN)

C12

Z1 14BK

GROUND

C13

B58 20GY/LB

ABS SYSTEM RELAY CONTROL

C14

A20 14RD/DB

FUSED B(+)

CAVITY

CIRCUIT

FUNCTION

B6

A17 20RD/GY

FUSED B (+)

B7

C3 20DB/BK

A/C COMPRESSOR CLUTCH RELAY OUTPUT

B8

F20 20VT/WT

FUSED IGNITION SWITCH OUTPUT (RUN)

B9

-

B10

C13 18DB/OR

CAVITY

A/C COMPRESSOR CLUTCH RELAY CONTROL

CIRCUIT

FUNCTION

B1

A14 14RD/WT

FUSED B (+)

B2

A142 14DG/PK

AUTOMATIC SHUT DOWN RELAY OUTPUT SENSE

B3

F15 20DB

FUSED IGNITION SWITCH OUTPUT (ST-RUN)

B4
B5
J998W-5

-

C7

CAVITY

AUTOMATIC
SHUT DOWN
RELAY

-

C4

C6

A/C
COMPRESSOR
CLUTCH
RELAY

FUNCTION

C1

C5

ABS
SYSTEM
RELAY

CIRCUIT

TJ

K51 18DB/YL

AUTOMATIC SHUT DOWN RELAY CONTROL
TJI01004

TJ

8W-10 POWER DISTRIBUTION

CAVITY
ENGINE
STARTER
MOTOR
RELAY

A2 12PK/BK

FUSED B (+)

D11

T141 14YL/RD

FUSED IGNITION SWITCH OUTPUT (ST)

D12

T41 20BR/LB

PARK/NEUTRAL POSITION SWITCH SENSE

D14

T40 12BR

ENGINE STARTER MOTOR RELAY OUTPUT

FUNCTION

A61 18DG/BK

FUSED B (+)

B17

A141 18DG/WT

FUEL PUMP RELAY OUTPUT

B18

F15 20DB

FUSED IGNITION SWITCH OUTPUT (ST-RUN)

CAVITY

K31 18BR

FUEL PUMP RELAY CONTROL

CIRCUIT

FUNCTION

B11

F31 18VT

FUSED B (+)

B12

X2 18WT/RD

HORN RELAY OUTPUT

B13

F31 18VT

FUSED B (+)

B14
B15

CAVITY

TJI01005

CIRCUIT

B16

B20

REAR
WINDOW
DEFOGGER
RELAY

-

D13

B19

HORN
RELAY

FUNCTION

D10

CAVITY
FUEL
PUMP
RELAY

CIRCUIT

8W - 10 - 5

X3 20RD/YL

HORN RELAY CONTROL

CIRCUIT

FUNCTION

D2

A4 12BK/PK

FUSED B (+)

D4

F20 20VT/WT

FUSED IGNITION SWITCH OUTPUT (RUN)

D5

-

D6

C81 20LB/WT

REAR WINDOW DEFOGGER RELAY CONTROL

D8

C15 12BK/WT

REAR WINDOW DEFOGGER RELAY OUTPUT

-

J998W-5

8W - 10 - 6

8W-10 POWER DISTRIBUTION

TJ
S136

A0
6
RD

A0
6
RD

A11
6
BK/GY

FUSIBLE
LINK
A11
10
DG

BATTERY
(8W-20-2)

GENERATOR
(8W-20-2)

ENGINE
STARTER
MOTOR
(8W-21-2)

8

9
FUSE
2
40A
(8W-10-8)

1

F5

C106

A2
12
PK/BK
TO

IGNITION
SWITCH

FUSE
3
30A
(8W-10-9)

2

A2
12
PK/BK
F6

10

TO

ENGINE
STARTER
MOTOR
RELAY
(IN PDC)

FUSE
4
40A
(8W-10-10)

3

F7

FUSE
5
40A
(8W-10-10)

4

F1

(8W-10-2)

C106

F30
12
RD/PK

A1
14
RD

A6
12
RD/BK

TO

TO

IGNITION
SWITCH

FUSE
BLOCK

TO

S332

16

12
FUSE
6
30A
(8W-10-11)

5

A14
14
RD/WT
TO

AUTOMATIC
SHUT
DOWN
RELAY
(IN PDC)

FUSE
10
30A
(8W-10-13)

22
FUSE
9
20A
(8W-10-13)

15

J998W-5

11

POWER
DISTRIBUTION
CENTER

C103

3

A14
14
RD/WT
TO

POWERTRAIN
CONTROL
MODULE

C108

D11

L9
16
BK/WT
TO

TURN
SIGNAL/
HAZARD
SWITCH

23

17
FUSE
11
40A
(8W-10-13)

24

C170

4

A3
14
RD/WT

A
TO
FUSE
13 (PDC)
(8W-10-7)

A111
12
RD/LB
TO

C106

TO

HEADLAMP
SWITCH
TJI01006

TJ

8W-10 POWER DISTRIBUTION

8W - 10 - 7
POWER
DISTRIBUTION
CENTER

FROM
FUSE
11 (PDC)
(8W-10-6)

(8W-10-2)

A

20

19
FUSE
13
30A
(8W-10-17)

26

21
FUSE
14
40A
(8W-10-17)

27

A20
14
RD/DB

TO

ABS
SYSTEM
RELAY
(IN PDC)

A23
FUSE
15
40A
(8W-10-14)

28

A10
12
RD/DG

A4
12
BK/PK

TO

TO

ABS
PUMP
MOTOR
RELAY
(IN PDC)

REAR
WINDOW
DEFOGGER
RELAY
(IN PDC)

A21
FUSE
16
10A
(8W-10-16)

A24

A22

A17
20
RD/GY

FROM

F31
18
VT

A16
FUSE
19
20A
(8W-10-14)

TO

TO

TO

HORN
RELAY
(IN PDC)

HORN
RELAY
(IN PDC)

FROM

S146

S101

B48
20
RD/YL

A142
14
DG/PK

A17

A61
18
DG/BK

A15

M1
20
PK/WT

FUEL
PUMP
RELAY
(IN PDC)

TJI01007

FUSE
25
20A
(8W-10-16)

A5

F61
18
WT/OR

C108

D6
TO

TO

A1
FUSE
21
10A
(8W-10-17)

A6
FUSE
20
10A
(8W-10-15)

C108

F61
18
WT/OR
TO

FOG
LAMP
RELAY
NO. 1

F31
18
VT

A/C
COMPRESSOR
CLUTCH
RELAY
(IN PDC)

A14
A18

FUSE
17
20A
(8W-10-16)

A13

A2

B47
14
RD/LB

F142
20
OR/DG
LEAK
DETECTION

TO

ABS
PUMP
MOTOR
RELAY
(IN PDC)

FUSE
27
10A
(8W-10-11)

B47
14
RD/LB
TO

S114

F142
20
OR/DG

OTHER
F142
20
OR/DG

TO

TO

S107

C103
J998W-5

8W - 10 - 8

8W-10 POWER DISTRIBUTION

BATT A0

(8W-10-6)

FUSE
2
40A

FUSE
3
30A
(8W-10-9)

2

1

A2
12
PK/BK

A2
12
PK/BK

D10

D14

F5

A2
12
PK/BK

(8W-21-2)

T40
12
BR

(8W-10-2)

A1
14
RD

F6

ENGINE
STARTER
MOTOR
RELAY
(IN PDC)

C106
A1
14
RD

3

3

IGNITION
SWITCH

LHD

1 START
2 RUN
0 OFF
3 LOCK
4 ACC
(8W-10-9)

RHD

C104

POWER
DISTRIBUTION
CENTER

9

8

12

TJ

6

C104

1

4
2

T40
12
BR

0

1

3

4

ENGINE
STARTER
MOTOR

4
2

3

0

10

8
A41
14
YL

A22
12
BK/OR

S331

(8W-21-2)
5

20

FUSE
BLOCK
(8W-11-2)
FUSE
6
20A
(8W-11-6)

FUSE
5
10A
(8W-11-6)
25

26

FUSE
8
10A
(8W-11-7)

FUSE
7
10A
(8W-11-7)
27

28

A41
14
YL

FUSE
20
20A
(A/T)
(8W-11-9)
40
A/T
2
NOT
USED

J998W-5

M/T

CLUTCH
PEDAL
POSITION
SWITCH
CONNECTOR

2

CLUTCH
PEDAL
POSITION
SWITCH
(8W-21-2)

TJI01008

TJ

8W-10 POWER DISTRIBUTION
BATT A0

8W - 10 - 9
PARK
BRAKE
SWITCH

(8W-10-6)

POWER
DISTRIBUTION
CENTER

9

(8W-40-6)

(8W-10-2)
FUSE
3
30A

BRAKE
WARNING
INDICATOR
SWITCH

G9
20
GY/BK

2

LHD

G9

RHD

C322

9

C322

A1
14
RD

G9
20
GY/BK

BATT A2

A2
12
PK/BK

G9
20
GY/BK

C106

F5

(8W-10-8)

C106

F11

A1
14
RD

3

(8W-40-6)

1

G9
20
GY/BK
2

7

IGNITION
SWITCH
1

4
2

0

1

3

4
2

4

0

9

A22
12
BK/OR

1

3

2

10

0

1

3

4
2

8
A41
14
YL

A21
14
DB

4

0

3

1 START
2 RUN
0 OFF
3 LOCK
4 ACC

1

A31
14
BK/DG

Z1
16
BK

S307

(8W-10-8)

S304

A31
14
BK/DG

A31
14
BK/DG

RUN A22

(8W-15-9)
(8W-15-10)
Z1
16
BK

2

CIGAR
LIGHTER/
ACCESSORY
RELAY

ST A41
(8W-10-8)

9

(8W-15-9)
(8W-15-10)

(8W-41-2)

5

13

G300

FUSE
BLOCK
(8W-11-2)
FUSE
12
10A
(8W-11-8)

FUSE
10
10A
(8W-11-8)
FUSE
9
10A
(8W-11-8)
29
TJI01009

FUSE
11
10A
(8W-11-8)
30

31

FUSE
14
20A
(8W-11-9)

FUSE
13
10A
(8W-11-9)
32

33

34

FUSE
15
10A
(8W-11-9)
35
J998W-5

8W - 10 - 10

8W-10 POWER DISTRIBUTION

BATT A0

TJ

(8W-10-6)

10

POWER
DISTRIBUTION
CENTER

11

(8W-10-2)

FUSE
4
40A

FUSE
5
40A

3

4

A6
12
RD/BK

F30
12
RD/PK

F1

C106

F30
12
RD/PK

S332
F7

C106

F30
12
RD/PK
1

CIGAR
LIGHTER/
ACCESSORY
RELAY
(8W-41-2)

4

A6
12
RD/BK

F30
12
RD/PK

F22
12
WT/PK

1

19

18

FUSE
BLOCK
(8W-11-2)
FUSE
2
20A
(8W-11-4)

FUSE
1
20A
(8W-11-4)
21

J998W-5

22

FUSE
19
20A
(8W-11-10)
39

FUSE
18
15A
(8W-11-10)
38

TJI01010

TJ

8W-10 POWER DISTRIBUTION

BATT A0

8W - 10 - 11

(8W-10-6)

12

POWER
DISTRIBUTION
CENTER

B1
FUSE
6
30A

AUTOMATIC
SHUT
DOWN
RELAY
(8W-30-2)

5
B2

A14
14
RD/WT

A14
14
RD/WT

(8W-10-2)
A2

A20

A19

A142
14
DG/PK

A142
14
DG/PK

FUSE
27
10A

FUSE
18
20A
A1

A142
14
DG/PK

F142
20
OR/DG

F42
18
DG/LG

S101
3

11

A142
14
DG/PK

A14
14
RD/WT
A22

LHD

C103

C1

C12

RHD

C104

4

C104

F42
18
DG/LG

C3
POWERTRAIN
CONTROL
MODULE

B

(8W-30-2)

TO

S126
(8W-10-12)
LEAK
DETECTION

OTHER

S107
F142
20
OR/DG

3

F142
20
OR/DG
1

C180

F142
18
OR/DG

F142
20
OR/DG

S124

2

LEAK
DETECTION
PUMP
(EXCEPT BUILTUP-EXPORT)
(8W-30-11)

TJI01011

C103

F142
18
OR/DG

F142
18
OR/DG

1

1

OXYGEN
SENSOR
1/2
DOWNSTREAM

OXYGEN
SENSOR
1/1
UPSTREAM

(8W-30-9)

(8W-30-9)
J998W-5

8W - 10 - 12

8W-10 POWER DISTRIBUTION

TJ

FROM

C104
(8W-10-11)
B

F42
18
DG/LG

S126

F42
18
DG/LG

F42
18
DG/LG
1

FUEL
INJECTOR
NO. 6
(4.0L)

F42
18
DG/LG

(8W-30-6)

F42
18
DG/LG

1

1

FUEL
INJECTOR
NO. 5
(4.0L)

F42
18
DG/LG

IGNITION
COIL
(2.5L)
(8W-30-4)

(8W-30-6)
1

FUEL
INJECTOR
NO. 4

F42
18
DG/LG

(8W-30-5)
(8W-30-6)

S128
1

FUEL
INJECTOR
NO. 3

F42
18
DG/LG

(8W-30-5)
(8W-30-6)

1

FUEL
INJECTOR
NO. 2

F42
18
DG/LG

(8W-30-5)
(8W-30-6)

1

J998W-5

F42
18
DG/LG
1

FUEL
INJECTOR
NO. 1

IGNITION
COIL
(4.0L)

(8W-30-5)
(8W-30-6)

(8W-30-4)
TJI01012

TJ

8W-10 POWER DISTRIBUTION
BATT A0

8W - 10 - 13

(8W-10-6)

16

22

17
FUSE
10
30A

FUSE
9
20A
23

15

L9
16
BK/WT

FUSE
11
40A

POWER
DISTRIBUTION
CENTER
(8W-10-2)

24

A111
12
RD/LB

A3
14
RD/WT

F12

C106

A111
12
RD/LB

D11

C108

4

C170

A12

C202

A111
12
RD/LB

8

HVAC
UNIT

A3
14
RD/WT

L9
16
BK/WT

6

(8W-42-2)
(8W-42-3)

8

TURN
SIGNAL/
HAZARD
SWITCH

HEADLAMP
SWITCH
(8W-50-2)
(8W-50-5)

(8W-52-2)

TJI01013

J998W-5

8W - 10 - 14

8W-10 POWER DISTRIBUTION

BATT A0

TJ

(8W-10-6)

POWER
DISTRIBUTION
CENTER

A18

21

FUSE
19
20A

FUSE
15
40A

(8W-10-2)

A17

28
A4
12
BK/PK

A61
18
DG/BK
B16

FUEL
PUMP
RELAY
(IN PDC)

D2

REAR
WINDOW
DEFOGGER
RELAY
(IN PDC)

D8

(8W-48-2)

C15
12
BK/WT

7
F8

(8W-30-3)

B17
A141
18
DG/WT

C103

C106
A141
18
DG/WT

C15
12
BK/WT

S320

1

FUEL
PUMP
MODULE

C15
12
BK/WT
LHD
H1

(8W-30-3)

RHD

C323

1

1

C323

C326

C15
12
BK/WT
1

C15
14
BK/WT

C331

C15
12
BK/WT

17

FUSE
BLOCK
FUSE
17
10A
(8W-11-9)
37

(8W-11-2)

C15
12
GY

REAR
WINDOW
DEFOGGER
(HARD TOP)
(8W-48-2)

J998W-5

TJI01014

TJ

8W-10 POWER DISTRIBUTION
BATT A0

(8W-10-6)

FUSE
20
10A

(8W-40-2)

(8W-10-2)

C2

9

LEFT
COURTESY
LAMP

A15

(8W-44-4)

M1
20
PK/WT

DATA LINK
CONNECTOR

M1
20
PK

C108

D12

INSTRUMENT
CLUSTER

POWER
DISTRIBUTION
CENTER

A16

M1
20
PK/WT

8W - 10 - 15

(8W-30-13)
16

1

C203

B7

M1
20
PK/WT

2

UNDERHOOD
LAMP

M1
20
PK/WT

M1
20
PK/WT

M1
20
PK/WT

S204

(8W-44-3)

M1
20
PK/WT

M1
20
PK/WT

HARD TOP

M1
20
PK/WT

SOFT TOP
7

M1
20
PK/WT
2 SPEAKER
SYSTEM
LHD
H2

RHD

C323

2

M1
20
PK/WT
LHD

RHD
LHD

H2
C323
NOT
USED

M1
20
PK/WT
2 SPEAKER
SYSTEM

2
C323
NOT
USED

H2

8

M1
20
PK/WT

2

C323

M1
20
PK/WT

S313

C326
C331

(8W-44-4)
RHD

C323

4 SPEAKER
SYSTEM

8

RIGHT
COURTESY
LAMP

M1
20
PK/WT

C323

(8W-47-2)

M1
20
PK

4 SPEAKER
SYSTEM

C1
RADIO

1

M1
20
PK/WT

3
3

C325
C330

M1
20
PK/WT
1

DOME
LAMP
(8W-44-2)
TJI01015

SOUND
BAR
DOME
LAMP
(8W-44-2)

J998W-5

8W - 10 - 16
BATT A0

8W-10 POWER DISTRIBUTION
(8W-10-6)

A21

A23

A5

A17
20
RD/GY

F61
18
WT/OR

B6

F31
18
VT

A/C
COMPRESSOR
CLUTCH
RELAY
(IN PDC)

B7

(8W-10-2)

FUSE
25
20A

A22

A24

POWER
DISTRIBUTION
CENTER

A6
FUSE
17
20A

FUSE
16
10A

F31
18
VT

D6

C108

F61
18
WT/OR

(8W-42-4)

C3
20
DB/BK
14

TJ

B13

B11

3

FOG
LAMP
RELAY
NO. 1

HORN
RELAY
(IN PDC)

C103

(8W-41-3)

C3
20
DB/BK

B15

B12

L39
18
LB

X2
18
WT/RD

1

A/C
COMPRESSOR
CLUTCH

(8W-50-7)

5

C107

E10
6

C110
L39
18
LB

(8W-42-4)
X2
18
WT/RD
EXCEPT
BUILT-UP-EXPORT

BUILTUP-EXPORT

C110

13
L39
18
LB

S115

S116
X2
18
WT/RD

X2
18
WT/RD

1

J998W-5

L39
18
LB

1

L39
18
LB

2

2

LOW
NOTE
HORN

HIGH
NOTE
HORN

LEFT
FOG
LAMP

RIGHT
FOG
LAMP

(8W-41-3)

(8W-41-3)

(8W-50-7)

(8W-50-7)

TJI01016

TJ

8W-10 POWER DISTRIBUTION

8W - 10 - 17

ABS
DIODE
(8W-35-3)
A

S146
B48
20
RD/YL

BATT A0

(8W-10-6)

POWER
DISTRIBUTION
CENTER

A14
FUSE
21
10A

(8W-10-2)

A13
19

20
FUSE
13
30A

FUSE
14
40A

26

27

A20
14
RD/DB

B47
14
RD/LB

A10
12
RD/DG

C10

ABS
SYSTEM
RELAY
(PDC)
C14

C12

C4

C2

(8W-35-2)
C6
B47
14
RD/LB

C8

C3

B47
14
RD/LB

B48
20
RD/YL

S110
B120
12
BR/WT

B120
12
BR/WT

S112

1

ABS
PUMP
MOTOR
(8W-35-2)

10

TJI01017

1

(8W-35-2)

B120
12
BR/WT

B47
14
RD/LB

S114
B47
14
RD/LB

ABS
PUMP
MOTOR
RELAY
(PDC)

B120
16
BR/WT
3

C2

5

C2

HYDRAULIC
CONTROL
UNIT

CONTROLLER
ANTI-LOCK
BRAKE

(8W-35-4)

(8W-35-2)
(8W-35-3)

J998W-5

[‘

’“•”I––‹—t˜z™(š›a—˜z™(šxœ(tžzŸ; 

’“•”I––A”–

íSîUï*ðSðUñSòAóeôõ'ñSòAóeôÕöb÷$ø[ùûú
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v 7q v >Py+
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v 7O v >Py+
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v 74 v >Py+
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v 7. v >Py+
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v 7l v >Py+
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v b2< v >Pm+
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üýmþ•ÿ-ý

8W - 11 - 2

8W-11 FUSE/FUSE BLOCK

TJ

FRONT OF
FUSE BLOCK

J998W-5

40

39

38

37

FUSE
20

FUSE
19

FUSE
18

FUSE
17

20

19

18

17

36

35

34

33

FUSE
16

FUSE
15

FUSE
14

FUSE
13

16

15

14

13

32

31

30

29

FUSE
12

FUSE
11

FUSE
10

FUSE
9

12

11

10

9

28

27

26

25

FUSE
8

FUSE
7

FUSE
6

FUSE
5

8

7

6

5

24

23

22

21

FUSE
4

FUSE
3

FUSE
2

FUSE
1

4

3

2

1

TJI01102

TJ

8W-11 FUSE/FUSE BLOCK

8W - 11 - 3

FUSES

FUSE NO.

AMPS

FUSED CIRCUIT

1

20A

F34 18TN/BK

2

20A

F32 18PK/DB

3

10A

E2 20OR

FEED CIRCUIT
A6 12RD/BK

E1 18TN

E2 20OR
Z1 20BK

M23 20YL/BK

Z1 20BK

M23 20YL/BK

4

10A

5

10A

F23 18DB/YL

6

20A

V23 18BR/PK

7

10A

F20 20VT/WT

8

10A

F24 20RD/DG

9

10A

A22 12BK/OR

F14 18LG/YL
F14 18LG/YL

10

10A

G5 20DB/WT
G5 20DB/WT

11

10A

12

10A

A21 14DB

F12 20RD/LG
F15 20DB
F15 20DB

13

10A

L5 20BK/GY

14

20A

V6 18PK/BK

15

10A

X12 20PK

16

10A

L22 20LG/DG

L2 16LG

17

10A

F81 20DB/RD

C15 14BK/WT

18

15A

A18 16RD/BK

F30 12RD/PK

19

20A

A31 14BK/DG

F38 16LB
F22 12WT/PK
F38 16LB
20

20A

T141 14YL/RD

A41 14YL

FRONT FOG LAMPS
REAR FOG LAMPS
A/T

TJI01103

J998W-5

8W - 11 - 4

8W-11 FUSE/FUSE BLOCK

TJ
HEADLAMP
SWITCH
(8W-50-2)

1
E1
18
TN

C202

A3
E1
18
TN

BATT A6

(8W-10-10)

3

FUSE
BLOCK
(8W-11-2)
FUSE
2
20A

FUSE
1
20A

21

22

F34
18
TN/BK
A11

FUSE
3
10A

23
E2
20
OR

F32
18
PK/DB
5

C202
F34
20
TN/BK

F34
18
TN/BK
4

1

BRAKE
LAMP
SWITCH

PRNDL
LAMP

E2
20
OR

(8W-51-6)

(8W-44-5)

FRONT
FOG
LAMP
SWITCH
(EXCEPT
BUILT-UP
-EXPORT)

1

SENTRY
KEY
IMMOBILIZER
MODULE

HEADLAMP
SWITCH
(8W-50-2)
(8W-50-4)

C202

A4

1

(8W-30-14)

E2
20
OR

E2
20
OR

(8W-50-7)

S206
E2
20
OR

E2
20
OR

E2
20
OR

4

5

C1
RADIO
(8W-47-2)

(8W-48-2)

4

REAR
FOG
LAMP
SWITCH
(BUILT-UPEXPORT)

REAR
WIPER/
WASHER
SWITCH
(HARD TOP)
4

C2

(8W-53-4)

A/CHEATER
CONTROL
(8W-42-2)
(8W-42-3)

J998W-5

E2
20
OR

3

REAR
WINDOW
DEFOGGER
SWITCH
(HARD TOP)

E2
20
OR

E2
20
OR

3

C2
INSTRUMENT
CLUSTER

(8W-51-7)
(8W-51-8)

(8W-40-8)
TJI01104

TJ

8W-11 FUSE/FUSE BLOCK
DRIVER
DOOR
AJAR
SWITCH
1

(8W-44-4)

M23
20
YL/BK

8W - 11 - 5

PASSENGER
DOOR
AJAR
SWITCH
(8W-44-4)

1

M23
20
YL/BK

4

FUSE
BLOCK
(8W-11-2)
FUSE
4
10A

1

FOG
LAMP
RELAY
NO. 1
(EXCEPT BUILTUP-EXPORT)

2

24

Z1
20
BK

Z1
20
BK

(8W-50-7)
3

Z1
20
BK

1

2

REAR
FOG
LAMP
RELAY
(BUILT-UP
-EXPORT)

Z1
20
BK

FOG
LAMP
RELAY
NO. 2
(EXCEPT BUILTUP-EXPORT)

(8W-51-7)
(8W-51-8)

(8W-50-6)

LHD

RHD

S304
(8W-15-9)
Z1
16
BK

Z1
20
BK

G300
(8W-15-9)
(8W-15-10)
TJI01105

J998W-5

8W - 11 - 6

8W-11 FUSE/FUSE BLOCK

RUN A22

TJ

(8W-10-8)

FUSE
BLOCK
(8W-11-2)
FUSE
6
20A

FUSE
5
10A

25

26

F23
18
DB/YL

V23
18
BR/PK
LHD
SOFT TOP
V23
18
BR/PK
H4
C323
NOT
USED

RHD
SOFT TOP

HARD TOP

V23
18
BR/PK

V23
18
BR/PK

4
C323
NOT
USED

LHD
H4

RHD

C323

4

C323

V23
18
BR/PK
20

AIRBAG
CONTROL
MODULE

5

C326

5

C331
S401

(8W-43-2)

4

C331

4

C326

V23
18
BR/PK
1

REAR
WIPER
MOTOR

V23
18
BR/PK

(8W-53-4)
LHD
G10

RHD

C322

10

V23
18
BR/PK

C322

V23
18
BR/PK

C6

C204

V23
18
BR/PK
5

REAR
WIPER/
WASHER
SWITCH
J998W-5

(8W-53-4)

TJI01106

TJ

8W-11 FUSE/FUSE BLOCK
RUN A22

8W - 11 - 7

(8W-10-8)

FUSE
BLOCK
(8W-11-2)
FUSE
8
10A

FUSE
7
10A

27

28

F20
20
VT/WT

F3

F24
20
RD/DG

C106

A1

F20
20
VT/WT

C202

F24
20
RD/DG

F24
20
RD/DG

3
1

5

C2

F24 20RD/DG

9

HVAC
UNIT

A/CHEATER
CONTROL

(8W-42-2)
(8W-42-3)

(8W-42-2)
(8W-42-3)

S108
F20
20
VT/WT

10

F20
20
VT/WT

F20
20
VT/WT

F20
20
VT/WT

F20
20
VT/WT

C104
C11

F20
20
VT/WT
A/T

CONTROLLER
ANTI-LOCK
BRAKE

F20
20
VT/WT

C154

4

F20
18
VT/WT

1

B

(8W-51-2)
(8W-51-3)

(8W-35-2)

C13

(8W-35-3)
D4

C154

F20
18
VT/WT

PARK/
NEUTRAL
POSITION
SWITCH
TJI01107

C1

M/T

F20
20
VT/WT
4

5

ABS
SYSTEM
RELAY
(IN PDC)

B8

BACK-UP
LAMP
SWITCH
(8W-51-2)
(8W-51-3)

B10

D6

A/C
COMPRESSOR
CLUTCH
RELAY
(IN PDC)

REAR
WINDOW
DEFOGGER
RELAY
(IN PDC)
(8W-48-2)
LHD
RHD

(8W-42-4)
J998W-5

8W - 11 - 8

8W-11 FUSE/FUSE BLOCK

ST-RUN A21

TJ

(8W-10-9)

FUSE
BLOCK
(8W-11-2)
FUSE
10
10A

FUSE
9
10A

29

FUSE
11
10A

30

31

G5
20
DB/WT

F14
18
LG/YL

A10

FUSE
12
10A

32

F12
20
RD/LG

G5
20
DB/WT

F15
20
DB

F15
20
DB

C202

3

SENTRY
KEY
IMMOBILIZER
MODULE

2
F14
18
LG/YL

BRAKE
SHIFT
INTERLOCK
SOLENOID

G5
20
DB/WT

F10

C106

C106

F4

F15
20
DB

(8W-30-14)

(8W-31-2)
8

S131

C2
INSTRUMENT
CLUSTER

F15
20
DB

F12
20
RD/LG

(8W-40-2)

F15
20
DB

F15
20
DB

S102

1

F12
20
RD/LG

F12
20
RD/LG

C1
PASSENGER
AIRBAG
ON/OFF
SWITCH

9

C103

13

RHD

C104

7

C104

5

B18

FUEL
PUMP
RELAY
(IN PDC)

DAYTIME
RUNNING
LAMP
MODULE

F12
20
RD/LG

(8W-43-2)

LHD

F12
20
RD/LG

(8W-50-8)

B20

(8W-30-3)

B3
A

TORQUE
CONVERTER
CLUTCH
SOLENOID
11

B5

F15
18
DB

(8W-31-2)

C110

AUTOMATIC
SHUT
DOWN
RELAY
(IN PDC)
(8W-30-2)

F12
20
RD/LG

17

AIRBAG
CONTROL
MODULE
(8W-43-2)

2

DUTY
CYCLE
EVAP/
PURGE
SOLENOID

A2

C1
POWERTRAIN
CONTROL
MODULE
(8W-30-2)

(8W-30-11)
J998W-5

TJI01108

TJ

8W-11 FUSE/FUSE BLOCK
BATT A4

8W - 11 - 9

(8W-10-14)

REAR
WINDOW
DEFOGGER
RELAY
(IN PDC)

D8

F8

(8W-48-2)

C106

C15
12
BK/WT

C15
12
BK/WT

S320
(8W-10-14)
C15
14
BK/WT

RUN-ACC A31

(8W-10-9)

ST A41

17

(8W-10-8)

FUSE
BLOCK
FUSE
14
20A

FUSE
13
10A

33

FUSE
15
10A

34

35

V6
18
PK/BK

37
A5

X12
20
PK

L5
20
BK/GY

C204

C10
V6
18
PK/BK

V6
18
PK/BK

C202

T141
14
YL/RD
F9

3

X12
20
PK
6

40

F81
20
DB/RD

S306

C1
RADIO
(8W-47-2)

(8W-11-2)

FUSE
20
20A
(A/T)

FUSE
17
10A

C106

T141
14
YL/RD

REAR
WINDOW
DEFOGGER
SWITCH
(HARD
TOP)

M/T

(8W-48-2)

A/T

1
NOT
USED

1

WINDSHIELD
WIPER
MOTOR

CLUTCH
PEDAL
POSITION
SWITCH

5

WINDSHIELD
WIPER
SWITCH

T141
14
YL/RD

(8W-53-2)
(8W-53-3)
5

TURN
SIGNAL/
HAZARD
SWITCH

(8W-21-2)

D11

(8W-52-2)
D13
TJI01109

(8W-21-2)

1

(8W-53-2)
(8W-53-3)

CLUTCH
PEDAL
POSITION
SWITCH
CONNECTOR

ENGINE
STARTER
MOTOR
RELAY
(IN PDC)
(8W-21-2)

J998W-5

8W - 11 - 10

8W-11 FUSE/FUSE BLOCK
BATT F30

TJ

BATT A3

(8W-10-10)

(8W-10-13)

CIGAR
LIGHTER/
ACCESSORY
RELAY

HEADLAMP
SWITCH

CIRCUIT
BREAKER
24A

0 OFF
1 PARK
2 HEAD
(8W-50-2)

(8W-41-2)

4
F22
12
WT/PK

0

1

2

2
L2
16
LG

C202

A8

L2 14LG

2

HEADLAMP
DIMMER
SWITCH

L2
16
LG

BATT F30

(8W-10-10)

19

(8W-50-2)

16

FUSE
BLOCK
FUSE
18
15A

FUSE
16
10A
(BUILT-UP
-EXPORT)

FUSE
19
20A

38

39

36
F38
16
LB

A18
16
RD/BK

F38
16
LB

UNSWITCHED
AUXILIARY
POWER
(TAPED TO
HARNESS IN
FB T/O)

(8W-11-2)

L22
20
LG/DG

C202

A9

S330

F38
16
LB

L22
20
LG/DG

1

SWITCHED
AUXILIARY
POWER
(TAPED TO
HARNESS IN
FB T/O)

CIGAR
LIGHTER/
POWER
OUTLET
(8W-41-2)

L22
20
LG/DG
D13

C204

L22
20
LG/DG

5

1

C108

L22
20
LG/DG
9

C9

L22
20
LG/DG

C110

L22
20
LG/DG

REAR
FOG
LAMP
RELAY
(8W-51-7)
(8W-51-8)

L22
20
LG/DG

S151
1

J998W-5

1

2

LEFT
HEADLAMP
LEVELING
MOTOR

RIGHT
HEADLAMP
LEVELING
MOTOR

(8W-50-5)

(8W-50-5)

HEADLAMP
LEVELING
SWITCH
(8W-50-5)
TJI01110



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8W - 15 - 2

8W-15 GROUND DISTRIBUTION
VEHICLE
SPEED
CONTROL
SERVO

UNDERHOOD
LAMP

DAYTIME
RUNNING
LAMP
MODULE

(8W-30-16)

4

TJ

ABS
PUMP
MOTOR

(8W-44-3)

(8W-50-8)

8

1

(8W-35-2)
2

ABS
PUMP
MOTOR
RELAY
(IN PDC)

C3

Z1
12
BK
Z1
18
BK

Z1
18
BK

(8W-35-2)

Z1
18
BK

ABS
SYSTEM
RELAY
(IN PDC)

Z1
14
BK

(8W-35-2)

C12
Z1
14
BK

OTHER

BASE

S106
Z1
12
BK

Z1
18
BK

CONTROLLER
ANTI-LOCK
BRAKE
(8W-35-3)
13

C2

Z22
16
BK/PK

14

C2

G100

Z22
16
BK/PK

S109

Z22
14
BK/PK

G101
J998W-5

TJI01502

TJ

8W-15 GROUND DISTRIBUTION
LEFT
REPEATER
LAMP
(BUILTUP-EXPORT)

2

(8W-52-3)

LEFT
FRONT
PARK/
TURN
SIGNAL
LAMP

LEFT
FOG
LAMP
(8W-50-7)
1

3

8W - 15 - 3
LEFT
FRONT
TURN
SIGNAL
LAMP

3

(8W-52-3)

LEFT
FRONT
PARK/
TURN
SIGNAL
LAMP
(EXCEPT
BUILT-UP-EXPORT
EXCEPT
FRONT FOG LAMPS)

(8W-50-4)
(8W-52-3)
Z1
18
BK

Z1
18
BK

FRONT FOG
LAMPS

BUILT-UPEXPORT
Z1
18
BK

3

S122

(8W-50-4)
(8W-52-3)

LOW
NOTE
HORN
(EXCEPT
BUILTUP-EXPORT)

2

LEFT
HEADLAMP
(8W-50-2)

(8W-41-3)

3

HIGH
NOTE
HORN

LEFT
HEADLAMP
LEVELING
MOTOR
(BUILTUP-EXPORT)

3

(8W-41-3)
2

(8W-50-5)

LEFT
CITY
LAMP
(BUILTUP-EXPORT)

2

Z1
18
BK

Z1
18
BK

WINDSHIELD
WASHER
PUMP

Z1
18
BK

(8W-53-2)
(8W-53-3)

B

(8W-50-4)

Z1
18
BK

Z1
18
BK

Z1
20
BK

Z1
20
BK

Z1
18
BK

S117

Z1
16
BK

G102
TJI01503

J998W-5

8W - 15 - 4

8W-15 GROUND DISTRIBUTION
EXCEPT BUILT-UP-EXPORT

RIGHT
FOG
LAMP
3

Z1
18
BK

GENERATOR

RIGHT
FRONT
PARK/
TURN
SIGNAL
LAMP
(FRONT FOG
LAMPS)

(8W-50-7)
1

TJ

Z1
18
BK

(8W-50-4)
(8W-52-3)

(8W-20-2)

Z0
6
BK

S125
G104

RIGHT
HEADLAMP

RIGHT
FRONT
PARK/
TURN
SIGNAL
LAMP
(EXCEPT FRONT
FOG LAMPS)

3

(8W-50-2)
3

(8W-50-4)
(8W-52-3)
Z1
18
BK

Z1
18
BK

Z1
18
BK

G103

J998W-5

TJI01504

TJ

8W-15 GROUND DISTRIBUTION
BUILT-UP-EXPORT

RIGHT
REPEATER
LAMP

GENERATOR

RIGHT
FRONT
TURN
SIGNAL
LAMP

(8W-52-3)
2

8W - 15 - 5

3

(8W-20-2)

(8W-52-3)

Z1
18
BK

Z1
18
BK

Z0
6
BK

S125
G104

RIGHT
HEADLAMP

RIGHT
CITY
LAMP

(8W-50-2)

(8W-50-4)
2

3

RIGHT
HEADLAMP
LEVELING
MOTOR
(8W-50-5)

3

Z1
20
BK

Z1
18
BK

Z1
18
BK

Z1
18
BK

S150
Z1
18
BK

G103
TJI01505

J998W-5

8W - 15 - 6

8W-15 GROUND DISTRIBUTION

TJ
D11

SENTRY
KEY
IMMOBILIZER
MODULE

NOT
USED
1
C154
Z1
20
BK

Z12
20
BK/LB

C154

3
Z1
20
BK

POWERTRAIN
CONTROL
MODULE

C104

T41
20
BR/LB

5

Z12
20
BK/LB

Z12
20
BK/TN

C202

C4

S134

C204

POWERTRAIN
CONTROL
MODULE

Z12
20
BK/TN

Z12
20
BK/LB

(8W-30-12)

T41
18
BR/LB

4

A6

C1

A6

(8W-30-13)

Z1
20
BK

A/T

(8W-21-2)

5

DATA LINK
CONNECTOR

MANUAL
TRANSMISSION
JUMPER
C154

1

D13

(8W-30-14)

4

T41
20
BR/LB

ENGINE
STARTER
MOTOR
RELAY
(IN PDC)

(8W-30-2)
A31

E6

E9

C107

11

10

C103

C1

A32

C1

M/T

Z12
20
BK/TN

Z12
20
BK/LB

TRANSFER
CASE
SWITCH

Z12
14
BK/TN

(8W-31-2)
B

S130
OXYGEN
SENSOR
1/2
DOWNSTREAM
(8W-30-9)

2

1

OXYGEN
SENSOR
1/1
UPSTREAM
Z1
20
BK

Z1
18
BK

LHD

POWER
STEERING
PRESSURE
SWITCH
(2.5L)
(8W-30-12)
RHD

Z1
20
BK

(8W-30-9)

2
Z1
20
BK

Z12
14
BK/TN

FUEL
PUMP
MODULE

Z1
18
BK

(8W-30-3)
6

Z1
18
BK

Z1
18
BK

S132
Z1
20
BK
2

A/C
COMPRESSOR
CLUTCH
(8W-42-4)
J998W-5

Z1
14
BK

Z12
10
BK/TN

G105
TJI01506

TJ

8W-15 GROUND DISTRIBUTION
LHD
REAR
WIPER/
WASHER
SWITCH
(HARD TOP)

A/CHEATER
CONTROL
C3

C

C2

5

(8W-42-2)
(8W-42-3)

1

HEADLAMP
LEVELING
SWITCH
(BUILT-UP
-EXPORT)

4

(8W-53-4)

8W - 15 - 7
REAR
WINDOW
DEFOGGER
SWITCH
(HARD
TOP)

1

(8W-50-5)

(8W-48-2)

1
Z1
12
BK

Z1
20
BK

Z1
20
BK

REAR
FOG
LAMP
SWITCH
(BUILT-UP
-EXPORT)
(8W-51-7)
(8W-51-8)

CIGAR
LIGHTER/
POWER
OUTLET
(8W-41-2)

3
Z1
18
BK/WT

FRONT
FOG
LAMP
SWITCH
(EXCEPT
BUILT-UPEXPORT)

4

Z1
16
BK

Z1
20
BK

Z1
20
BK

(8W-50-7)

Z1
20
BK

G202

S207
BATTERY
(8W-20-2)

HEADLAMP
SWITCH

HVAC
UNIT

(8W-50-3)

(8W-42-2)
(8W-42-3)
10

Z1
20
BK

Z1
16
BK

Z0
6
BK

Z0
6
BK

Z1
16
BK

G200
G106

G107

INSTRUMENT
CLUSTER
(8W-40-2)
9

C1

6

HVAC
UNIT

C2

(8W-42-2)
(8W-42-3)
Z2
18
BK/LG

A/CHEATER
CONTROL

Z2
18
BK/LG
1

G201

TJI01507

C2

Z11
20
BK/WT

1

(8W-42-2)
(8W-42-3)

Z11
20
BK/WT

G203

J998W-5

8W - 15 - 8

8W-15 GROUND DISTRIBUTION
RHD
REAR
WIPER/
WASHER
SWITCH
(HARD TOP)

A/CHEATER
CONTROL
C3

C

C2

5

(8W-42-2)
(8W-42-3)

1

Z1
12
BK

REAR
WINDOW
DEFOGGER
SWITCH
(HARD
TOP)

(8W-50-3)
1

(8W-48-2)

CIGAR
LIGHTER/
POWER
OUTLET

(8W-51-7)
(8W-51-8)
Z1
20
BK

Z1
20
BK

HEADLAMP
SWITCH

(8W-53-4)

REAR
FOG
LAMP
SWITCH
1

TJ

(8W-41-2)

3

Z1
18
BK/WT

Z1
16
BK

Z1
16
BK

Z1
20
BK

G202

S207
BATTERY
(8W-20-2)

HVAC
UNIT

HEADLAMP
LEVELING
SWITCH
(BUILT-UP
-EXPORT)

(8W-42-2)
(8W-42-3)
10

(8W-50-5)
Z1
20
BK

Z1
20
BK

Z0
4
BK

Z0
6
BK

4

Z1
16
BK

G200
G106

G107

INSTRUMENT
CLUSTER
(8W-40-2)
9

C1

Z2
18
BK/LG

6

HVAC
UNIT
(8W-42-2)
(8W-42-3)

C2

Z2
18
BK/LG

A/CHEATER
CONTROL
3

C2

Z11
20
BK/WT

G201

1

(8W-42-2)
(8W-42-3)

Z11
20
BK/WT

G203
J998W-5

TJI01508

TJ

8W-15 GROUND DISTRIBUTION
LHD
DRIVER
DOOR
AJAR
SWITCH

FOG
LAMP
RELAY
NO. 1
(EXCEPT BUILTUP-EXPORT)

2

(8W-50-7)

2

(8W-44-4)

1

M23
20
YL/BK

FOG
LAMP
RELAY
NO. 2
(EXCEPT BUILT
-UP-EXPORT)

Z1
20
BK

PASSENGER
DOOR
AJAR
SWITCH

(8W-44-4)

1

8W - 15 - 9

M23
20
YL/BK

4

3

FUSE
BLOCK

(8W-50-6)
FUSE
4
10A
(8W-11-5)

Z1
20
BK

REAR
FOG
LAMP
RELAY
(BUILT-UP
-EXPORT)
(8W-51-7)

(8W-11-2)
Z1
20
BK

24

WINDSHIELD
WIPER
SWITCH

IGNITION
SWITCH

COMBINATION
FLASHER

(8W-10-9)

(8W-52-2)

(8W-53-3)
1

1

WINDSHIELD
WIPER
MOTOR

4

(8W-44-5)

(8W-53-2)
(8W-53-3)

4
Z1
20
BK

PRNDL
LAMP

2

Z1
18
BK

Z1
20
BK

Z1
16
BK

Z1
20
BK

Z1
20
BK

S304
BRAKE
LAMP
SWITCH
(8W-51-6)
2

CIGAR
LIGHTER/
ACCESSORY
RELAY

Z1
20
BK

(8W-41-2)

5

Z1
20
BK

Z1
16
BK

G300

TJI01509

J998W-5

8W - 15 - 10

8W-15 GROUND DISTRIBUTION
RHD

WINDSHIELD
WIPER
SWITCH

PASSENGER
DOOR
AJAR
SWITCH

(8W-53-3)
1

1

WINDSHIELD
WIPER
MOTOR

REAR
FOG
LAMP
RELAY

(8W-53-2)
(8W-53-3)

4

TJ

(8W-44-4)

M23
20
YL/BK

DRIVER
DOOR
AJAR
SWITCH
(8W-44-4)

1
M23
20
YL/BK

(8W-51-8)

3

4

IGNITION
SWITCH

FUSE
BLOCK

Z1
20
BK

(8W-10-9)

FUSE
4
10A
(8W-11-5)

1

(8W-11-2)

24

PRNDL
LAMP

COMBINATION
FLASHER

(8W-44-5)

(8W-52-2)

2

Z1
20
BK

Z1
18
BK

Z1
16
BK

4

Z1
20
BK

Z1
20
BK

Z1
20
BK

S304
Z1
20
BK

Z1
20
BK

2

SENTRY
KEY
IMMOBILIZER
MODULE

5

CIGAR
LIGHTER/
ACCESSORY
RELAY

Z1
20
BK

(8W-30-14)

(8W-41-2)

Z1
16
BK

G300
2

BRAKE
LAMP
SWITCH
(8W-51-6)
J998W-5

TJI01510

TJ

8W-15 GROUND DISTRIBUTION

8W - 15 - 11

REAR
WIPER
MOTOR

REAR
WINDOW
DEFOGGER

(8W-53-4)

(8W-48-2)

2
Z1
12
BK
Z1
16
BK

Z1
12
BK

S400
(HARD TOP)

2

REAR
FOG
LAMP

LEFT
LICENSE
LAMP

RIGHT
LICENSE
LAMP

(8W-51-7)
(8W-51-8)

(8W-51-7)
(8W-51-8)

(8W-51-7)
(8W-51-8)

2

Z1
20
BK

Z1
20
BK

CENTER
HIGH
MOUNTED
STOP
LAMP

REAR
WASHER
PUMP
(HARD TOP)
(8W-53-4)

B

2

(8W-51-4)

Z1
12
BK

Z1
20
BK

SEAT
BELT
SWITCH
(EXCEPT LHD
BUILT-UP
-EXPORT)

2

Z1
20
BK

Z1
12
BK

C329

3

C331

6

S316
(BUILT-UP
-EXPORT)

C326

6

(8W-40-4)
Z1
18
BK

Z1
20
BK

Z1
18
BK

Z1
20
BK

Z1
12
BK

S309
PASSENGER
AIRBAG
ON/OFF
SWITCH
(8W-43-2)
2

AIRBAG
CONTROL
MODULE

SENTRY
KEY
IMMOBILIZER
MODULE
(LHD)

(8W-43-2)
10

2

LHD
Z1
12
BK
G5

Z6
18
BK/PK

G301
TJI01511

Z1
12
BK

(8W-30-14)

C1

Z6
20
BK/PK

RHD

C322

5

C322

Z1
20
BK

G302
J998W-5

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8W - 20 - 2

8W-20 CHARGING SYSTEM

ST-RUN A21

(8W-10-9)

FUSIBLE
LINK

FUSE
BLOCK

5

FUSE
6
30A
(8W-10-11)

(8W-10-2)
A0
6
RD

32
F15
20
DB

F15
20
DB

TO

C106

A14
14
RD/WT

SENTRY
KEY
IMMOBILIZER
MODULE

F15
20
DB

A0
6
RD

BATTERY
S136

A11
6
BK/GY

(8W-30-14)
B (+)

S131
(8W-11-8)
F15
20
DB

ENGINE
STARTER
MOTOR
(8W-21-2)

B3

Z0
6
BK

B1

AUTOMATIC
SHUT
DOWN
RELAY
(IN PDC)

F15
20
DB
B5

B2

(8W-30-2)
LHD

A11
10
DG

POWER
DISTRIBUTION
CENTER

12

(8W-11-2)

FUSE
12
10A
(8W-11-8)

F4

TJ

RHD

LHD

RHD

Z0
6
BK

Z0
4
BK

G106

G107

(8W-15-7)
(8W-15-8)

(8W-15-7)
(8W-15-8)

1

GENERATOR
13

C104

7

A142
14
DG/PK

C104

K72
18
DG/OR

2

C103

S101
(8W-10-11)
2
F15
18
DB

A2

K51
18
DB/YL

C1

FUSED
IGNITION
SWITCH
OUTPUT
(ST-RUN)

J998W-5

C3

C3

AUTOMATIC
SHUT
DOWN
RELAY
CONTROL

A142
14
DG/PK

C12

C3

AUTOMATIC
SHUT
DOWN
RELAY
OUTPUT
SENSE

K20
18
DG

K72
18
DG/OR

C25

C3

VOLTAGE
REGULATOR
SIGNAL

B10

Z0
6
BK

C2

GENERATOR
FIELD
DRIVER
(+)

POWERTRAIN
CONTROL
MODULE
(8W-30-2)
(8W-30-12)

G104
(8W-15-4)
(8W-15-5)
TJI02002




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8W - 21 - 2

8W-21 STARTING SYSTEM

BATT A1

(8W-10-8)

IGNITION
SWITCH
1
3

0

10

POWER
DISTRIBUTION
CENTER

8

1 START
2 RUN
0 OFF
3 LOCK
4 ACC
(8W-10-9)

4
2

TJ

FUSE
2
40A
(8W-10-8)

1

(8W-10-2)

A2
12
PK/BK

S331
A41
14
YL

A/T

20

FUSE
BLOCK

2
NOT
USED
1

(8W-11-2)

FUSE
20
20A
(A/T)
(8W-11-9)

CLUTCH
PEDAL
POSITION
SWITCH
CONNECTOR

2

C106

F6

A2
12
PK/BK

M/T

A0
6
RD

A2
12
PK/BK

CLUTCH
PEDAL
POSITION
SWITCH

TO

IGNITION
SWITCH

1

(8W-10-9)

40

BATTERY

T141 14YL/RD
F9

(8W-20-2)

C106
T141
14
YL/RD
D11

D10

D13

D14

T41
20
BR/LB
5

3

T40
12
BR

C104
S134
(8W-15-6)
(8W-70-4)

A/T

ENGINE
STARTER
MOTOR
RELAY
(IN PDC)

C154

LHD
M/T
3

T41
20
BR/LB

12

RHD

C104

C154
Z1 MANUAL
20 TRANSMISSION
BK JUMPER

6

C104

A0
6
RD

T40
12
BR

C154

1
Z1
20
BK

2
P/N

PARK/
NEUTRAL
POSITION
SWITCH

S132

2

ENGINE
STARTER
MOTOR

1

1 PULL-IN
2 HOLD-IN

(8W-15-6)
Z1
14
BK

M

G105
J998W-5

(8W-15-6)

TJI02102

Ç È

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8W - 30 - 2

8W-30 FUEL/IGNITION SYSTEM

ST-RUN A21

BATT A0

(8W-10-9)

FUSE
BLOCK
FUSE
12
10A
(8W-11-8)

TJ

(8W-10-6)

POWER
DISTRIBUTION
CENTER

12

(8W-11-2)

5

FUSE
6
30A
(8W-10-11)

(8W-10-2)

32
F15
20
DB

F15
20
DB

C106

F4

3
FUSED
IGNITION
SWITCH
OUTPUT
(ST-RUN)

F15
20
DB

A14
14
RD/WT

SENTRY
KEY
IMMOBILIZER
MODULE

A14
14
RD/WT

(8W-30-14)

S131
(8W-11-8)
F15
20
DB

F15
20
DB

3

B3
LHD

13

AUTOMATIC
SHUT
DOWN
RELAY
(IN PDC)

RHD

C104

7

C103

B1

C104
B5

B2

A14
14
RD/WT

S101
(8W-10-11)
F15
18
DB
A2

K51
18
DB/YL

C1

FUSED
IGNITION
SWITCH
OUTPUT
(ST-RUN)

C3

A142
14
DG/PK

C3

C12

AUTOMATIC
SHUT
DOWN
RELAY
CONTROL
GROUND
A31

C1

Z12
14
BK/TN

C3

AUTOMATIC
SHUT
DOWN
RELAY
OUTPUT
SENSE

A22

C1

FUSED
B(+)

POWERTRAIN
CONTROL
MODULE

GROUND
A32

C1

Z12
14
BK/TN

S130
(8W-15-6)
Z12
10
BK/TN

G105
J998W-5

(8W-15-6)

TJI03002

TJ

8W-30 FUEL/IGNITION SYSTEM
ST-RUN A21

8W - 30 - 3
BATT A0

(8W-10-9)

FUSE
BLOCK

A18

(8W-11-2)

FUSE
12
10A
(8W-11-8)

(8W-10-6)

FUSE
19
20A
(8W-10-14)

A17

POWER
DISTRIBUTION
CENTER
(8W-10-2)

32
F15
20
DB

F15
20
DB

C106

F4

3

S131

SENTRY
KEY
IMMOBILIZER
MODULE

FUSED
IGNITION
SWITCH
OUTPUT
(ST-RUN)

(8W-11-8)
F15
20
DB

A61
18
DG/BK

(8W-30-14)

B18

B16

FUEL
PUMP
RELAY
(IN PDC)
B20

B17
A141
18
DG/WT

B8

A/C
COMPRESSOR
CLUTCH
RELAY
(IN PDC)

B10

6

7

K226
20
DB/LG

A141
18
DG/WT

3

1

C103

M
6

4

(8W-42-4)

FUEL
PUMP
MODULE

K167
20
BR/YL

S133
C13
18
DB/OR

K31
18
BR

K226
18
DB/LG

(8W-70-3)
K167
18
BR/YL

Z1
18
BK

S132
C1

C3

A/C
COMPRESSOR
CLUTCH
RELAY
CONTROL

C19

C3

FUEL
PUMP
RELAY
CONTROL

C26

C3

FUEL
LEVEL
SENSOR
SIGNAL

A4

C1

SENSOR
GROUND

(8W-15-6)

POWERTRAIN
CONTROL
MODULE

Z1
14
BK

G105
(8W-15-6)

TJI03003

J998W-5

8W - 30 - 4

8W-30 FUEL/IGNITION SYSTEM
BATT A14

POWER
DISTRIBUTION
CENTER

AUTOMATIC
SHUT
DOWN
RELAY
(8W-30-2)

FUSE
18
20A
(8W-10-11)

A19

F42
18
DG/LG

(8W-10-11)

B1

A20

(8W-10-2)

B2

A142
14
DG/PK

A142
14
DG/PK

S129
(8W-70-4)

S101
LHD
11

RHD

C104

K7
20
OR

(8W-10-11)

C104

4

3

CRANKSHAFT
POSITION
SENSOR

5V
SUPPLY

S126
CRANKSHAFT
POSITION
SENSOR SENSOR
GROUND
SIGNAL
1
2
K167
20
BR/YL

(8W-10-12)
F42
18
DG/LG

2.5L

4.0L

F42
18
DG/LG

F42
18
DG/LG

TJ

K7
20
OR

S127
(8W-70-3)

3
5V
SUPPLY

S128
(8W-10-12)

F42
18
DG/LG

SENSOR
GROUND

1

IGNITION
COIL

2
K167
20
BR/YL

S133
(8W-70-3)

K19
18
GY

K24
18
GY/BK

K7
18
OR

C1

IGNITION
COIL
NO. 1
DRIVER

J998W-5

CAMSHAFT
POSITION
SENSOR
SIGNAL
1

K167
20
BR/YL

2

A7

CAMSHAFT
POSITION
SENSOR

A17

C1

5V
SUPPLY

A8

C1

CRANKSHAFT
POSITION
SENSOR
SIGNAL

K167
18
BR/YL
A4

C1

SENSOR
GROUND

K44
18
TN/YL
A18

C1

CAMSHAFT
POSITION
SENSOR
SIGNAL

POWERTRAIN
CONTROL
MODULE

TJI03004

TJ

8W-30 FUEL/IGNITION SYSTEM
2.5L
BATT A14

8W - 30 - 5

(8W-10-11)

B1

POWER
DISTRIBUTION
CENTER

A20

AUTOMATIC
SHUT
DOWN
RELAY
(8W-30-2)

A19

B2

(8W-10-2)

FUSE
18
20A
(8W-10-11)

A142
14
DG/PK

A142
14
DG/PK

S101

F42
18
DG/LG
LHD

RHD

(8W-10-11)
11

C104

4

C104

F42
18
DG/LG

S126
(8W-10-12)
F42
18
DG/LG

S128
(8W-10-12)
F42
18
DG/LG

F42
18
DG/LG

1

1

2

K11
18
WT/DB

C2

FUEL
INJECTOR
NO. 1
DRIVER

TJI03005

1

FUEL
INJECTOR
NO. 2

2

K12
18
TN

B15

F42
18
DG/LG

1

FUEL
INJECTOR
NO. 1

B4

F42
18
DG/LG

C2

FUEL
INJECTOR
NO. 2
DRIVER

FUEL
INJECTOR
NO. 3

FUEL
INJECTOR
NO. 4

2

2

K13
18
YL/WT

K14
18
LB/BR

B5

C2

FUEL
INJECTOR
NO. 3
DRIVER

B16

C2

FUEL
INJECTOR
NO. 4
DRIVER

POWERTRAIN
CONTROL
MODULE

J998W-5

8W - 30 - 6

8W-30 FUEL/IGNITION SYSTEM
4.0L

BATT A14

TJ

(8W-10-11)

B1

POWER
DISTRIBUTION
CENTER

A19

AUTOMATIC
SHUT
DOWN
RELAY
(8W-30-2)

FUSE
18
20A
(8W-10-11)

A20

B2

A142
14
DG/PK

(8W-10-2)

F42
18
DG/LG

A142
14
DG/PK
LHD

RHD

S101
(8W-10-11)

11

C104

4

C104

F42
18
DG/LG

S126
(8W-10-12)

F42
18
DG/LG

F42
18
DG/LG

F42
18
DG/LG

F42
18
DG/LG

F42
18
DG/LG

S128
(8W-10-12)
F42
18
DG/LG

F42
18
DG/LG

1

1

1

FUEL
INJECTOR
NO. 2
2

1

FUEL
INJECTOR
NO. 4
2

1

FUEL
INJECTOR
NO. 1

B4

C2

FUEL
INJECTOR
NO. 1
DRIVER

J998W-5

FUEL
INJECTOR
NO. 5
2

2

K11
18
WT/DB

K12
18
TN
B15

2

1

FUEL
INJECTOR
NO. 3

2

K13
18
YL/WT

C2

FUEL
INJECTOR
NO. 2
DRIVER

B5

FUEL
INJECTOR
NO. 6

C2

FUEL
INJECTOR
NO. 3
DRIVER

K14
18
LB/BR
B16

C2

FUEL
INJECTOR
NO. 4
DRIVER

K15
18
PK/BK
B6

C2

FUEL
INJECTOR
NO. 5
DRIVER

K16
18
LG/BK
B12

C2

FUEL
INJECTOR
NO. 6
DRIVER

POWERTRAIN
CONTROL
MODULE

TJI03006

TJ

8W-30 FUEL/IGNITION SYSTEM
2.5L

8W - 30 - 7

S129
(8W-70-4)
K7
20
OR
3

MANIFOLD
ABSOLUTE
PRESSURE
SENSOR
2

1
K167
20
BR/YL

S127
(8W-70-3)
K167
20
BR/YL

K167
20
BR/YL

K167
20
BR/YL

2

ENGINE
COOLANT
TEMPERATURE
SENSOR

3

ENGINE
OIL
PRESSURE
SENSOR
2

K167
20
BR/YL

1

1

2

INTAKE
AIR
TEMPERATURE
SENSOR

K6
20
VT/OR
1

K7
18
OR
A17

C1

5V
SUPPLY

TJI03007

G60
18
GY/YL

K1
18
DG/RD
A27

C1

MANIFOLD
ABSOLUTE
PRESSURE
SENSOR
SIGNAL

B23

C2

ENGINE
OIL
PRESSURE
SENSOR
SIGNAL

S123

S133

(8W-70-4)

(8W-70-3)

K6
18
VT/OR

B31

C2

5V
SUPPLY

K167
18
BR/YL

A4

C1

SENSOR
GROUND

K2
18
TN/BK
A16

C1

ENGINE
COOLANT
TEMPERATURE
SENSOR
SIGNAL

K21
18
BK/RD
A15

C1

INTAKE
AIR
TEMPERATURE
SENSOR
SIGNAL

POWERTRAIN
CONTROL
MODULE

J998W-5

8W - 30 - 8

8W-30 FUEL/IGNITION SYSTEM
4.0L

TJ

S129
(8W-70-4)
K7
20
OR
3

MANIFOLD
ABSOLUTE
PRESSURE
SENSOR
2

1
K167
20
BR/YL

S127
(8W-70-3)
K167
20
BR/YL

K167
20
BR/YL

K167
20
BR/YL

S133
(8W-70-3)

K167
20
BR/YL

2

ENGINE
COOLANT
TEMPERATURE
SENSOR
1
2

3

INTAKE
AIR
TEMPERATURE
SENSOR

ENGINE
OIL
PRESSURE
SENSOR
2

1

1
K6
20
VT/OR

S123
K7
18
OR
A17

C1

5V
SUPPLY

J998W-5

G60
18
GY/YL

K1
18
DG/RD
A27

C1

MANIFOLD
ABSOLUTE
PRESSURE
SENSOR
SIGNAL

B23

C2

ENGINE
OIL
PRESSURE
SENSOR
SIGNAL

(8W-70-4)
K6
18
VT/OR
B31

C2

5V
SUPPLY

K167
18
BR/YL
A4

C1

SENSOR
GROUND

K2
18
TN/BK
A16

C1

ENGINE
COOLANT
TEMPERATURE
SENSOR
SIGNAL

K21
18
BK/RD
A15

C1

INTAKE
AIR
TEMPERATURE
SENSOR
SIGNAL

POWERTRAIN
CONTROL
MODULE

TJI03008

TJ

8W-30 FUEL/IGNITION SYSTEM

8W - 30 - 9

BATT A14

(8W-10-11)

POWER
DISTRIBUTION
CENTER

B1
AUTOMATIC
SHUT
DOWN
RELAY
(8W-30-2)

A1
FUSE
27
10A
(8W-10-11)

A2

B2

F142
20
OR/DG

A142
14
DG/PK

A142
14
DG/PK

LEAK
DETECTION

OTHER

(8W-10-2)

S101
(8W-10-11)

S107
(8W-10-11)
F142
20
OR/DG

F142
20
OR/DG

3

C103

1

C180

2

S124
F142
18
OR/DG

F142
18
OR/DG
4

F142
18
OR/DG

1

1

(8W-30-11)
4

OXYGEN
SENSOR
1/2
DOWNSTREAM

OXYGEN
SENSOR
1/1
UPSTREAM
3
K167
20
BR/YL

2

2
Z1
18
BK

3
K167
20
BR/YL

Z1
18
BK

S127

S132

(8W-70-3)

(8W-15-6)

K167
20
BR/YL

LEAK
DETECTION
PUMP
(EXCEPT BUILTUP-EXPORT)

FUSED
AUTOMATIC
SHUT DOWN
RELAY
OUTPUT

(8W-10-11)

Z1
14
BK

G105
(8W-15-6)

S133
K41
18
BK/DG
A24

C1

OXYGEN
SENSOR
1/1
SIGNAL

TJI03009

(8W-70-3)
K167
18
BR/YL
A4

C1

SENSOR
GROUND

K141
18
TN/WT
A25

C1

OXYGEN
SENSOR
1/2
SIGNAL

POWERTRAIN
CONTROL
MODULE

J998W-5

8W - 30 - 10

8W-30 FUEL/IGNITION SYSTEM

K7
20
OR

S129
(8W-70-4)

2

THROTTLE
POSITION
SENSOR
2

5V
SUPPLY

SENSOR
GROUND

3

TJ

VEHICLE
SPEED
SENSOR

VEHICLE
SPEED
SENSOR
SIGNAL

1

3

K6
20
VT/OR

G7
20
WT/OR

K167
20
BR/YL

1
K167
20
BR/YL

S127
(8W-70-3)
K167
20
BR/YL

S133
(8W-70-3)
8

C103

S123

S135

(8W-70-4)

K167
20
BR/YL

S147

K6
20
VT/OR

(8W-70-3)
LHD

RHD

K167
20
BR/YL

K167
18
BR/YL

G7
20
WT/OR

12

C103

G7
20
WT/OR

2

BATTERY
TEMPERATURE
SENSOR

1
5V
SUPPLY

1

7

ENGINE
OIL
PRESSURE
SENSOR

VEHICLE
SPEED
SENSOR
SIGNAL

(8W-30-7)
(8W-30-8)
K22
18
OR/DB

K7
18
OR

A17

C1

5V
SUPPLY

J998W-5

A23

C1

THROTTLE
POSITION
SENSOR
SIGNAL

K118
18
PK/YL

C15

C3

BATTERY
TEMPERATURE
SENSOR
SIGNAL

K167
18
BR/YL

A4

C1

SENSOR
GROUND

DAYTIME
RUNNING
LAMP
MODULE
(8W-50-8)

K6
18
VT/OR

B31

C2

5V
SUPPLY

G7
18
WT/OR

B27

C2

VEHICLE
SPEED
SENSOR
SIGNAL

POWERTRAIN
CONTROL
MODULE

TJI03010

TJ

8W-30 FUEL/IGNITION SYSTEM

ST-RUN A21

8W - 30 - 11
FROM

(8W-10-9)

S101

FUSE
BLOCK

(8W-10-11)

(8W-11-2)

FUSE
11
10A
(8W-11-8)

A1

31
A2

FUSE
27
10A
(8W-10-11)

F12
20
RD/LG
F10

S102

S107
(8W-10-11)

F12
20
RD/LG

F12
20
RD/LG

9

F142
20
OR/DG

C103

2

TORQUE
CONVERTER
CLUTCH
SOLENOID

LEAK
DETECTION
PUMP
SOLENOID
CONTROL

B
2

DUTY
CYCLE
EVAP/
PURGE
SOLENOID

10

C20

C3

DUTY
CYCLE/
EVAP
PURGE
SOLENOID
CONTROL

TJI03011

4

K106

IDLE
AIR
CONTROL
NO. 1
DRIVER

C110

K52
18
PK/BK

LEAK
DETECTION
PUMP
SWITCH
SENSE

3

K52
20
PK/BK

B11

C2

TRANSMISSION
LOW/
OVERDRIVE
SOLENOID

IDLE
AIR
CONTROL
NO. 2
DRIVER

IDLE
AIR
CONTROL
NO. 3
DRIVER

IDLE
AIR
CONTROL
NO. 4
DRIVER

4

3

2

1

K39
18
GY/RD

K60
18
YL/BK

K40
18
BR/WT

K59
18
VT/BK

T23
18
OR/LG

A19

C1

IDLE
AIR
CONTROL
NO. 1
DRIVER

LEAK
DETECTION
PUMP
(EXCEPT
BUILT-UP
-EXPORT)

FUSED
AUTOMATIC
SHUT DOWN
RELAY
OUTPUT

A

F12
20
RD/LG

C180

3

F12
20
RD/LG

C110

1

(8W-10-2)

F142
20
OR/DG

C106
(8W-11-8)

11

POWER
DISTRIBUTION
CENTER

A10

C1

IDLE
AIR
CONTROL
NO. 2
DRIVER

A11

C1

IDLE
AIR
CONTROL
NO. 3
DRIVER

A20

C1

IDLE
AIR
CONTROL
NO. 4
DRIVER

K105
20
WT/OR

20
IDLE
WT/DG
AIR
CONTROL
MOTOR

C10

C180

2

1

K106
18
WT/DG

K105
18
WT/OR

C3

LEAK
DETECTION
PUMP
SOLENOID
CONTROL

C14

C3

LEAK
DETECTION
PUMP
SWITCH
SENSE

POWERTRAIN
CONTROL
MODULE

J998W-5

8W - 30 - 12

8W-30 FUEL/IGNITION SYSTEM
A/CHEATER
CONTROL

C21 20 DB/OR
2

2

A/C
LOW
PRESSURE
SWITCH

A/C
HIGH
PRESSURE
SWITCH

1
C22
20
DB/WT

1
C90
20
LG

2

1

A/C
SELECT
INPUT

VOLTAGE
REGULATOR
SIGNAL
1

(8W-42-3)

K72
18
DG/OR

C90
20
LG

C104

2

C3

C23

C25

A/C
SELECT
INPUT

A/C
SWITCH
SENSE

PARK/
NEUTRAL
POSITION
SWITCH
SENSE

BRAKE
SWITCH
SENSE
C24

C3

A6

K29
18
WT/PK
D14

C108

VOLTAGE
REGULATOR
SIGNAL

B10

C2

POWERTRAIN
GENERATOR
FIELD
CONTROL
DRIVER
MODULE
(+)
POWER STEERING
PRESSURE
SWITCH SENSE

C1

GROUND

2

5
Z1 20BK

LHD

CIGAR
LIGHTER/
ACCESSORY
RELAY

K10
18
DB/BR

Z1
20
BK

1

BRAKE
SHIFT
INTERLOCK
SOLENOID

A/T

C154

LHD

RHD

Z1
20
BK

Z1
18
BK

C154
Z1
20
BK

S304

S132

2
P/N

G300

C154
Z1 MANUAL
20 TRANSMISSION
BK JUMPER

1

(8W-15-10)

(8W-15-9)
(8W-15-10)

POWER
STEERING
PRESSURE
SWITCH
(2.5L)

M/T

T41
20
BR/LB

Z1
16
BK

1

3
3

RHD

2

T41
20
BR/LB

(8W-41-2)

Z1
20
BK

K29
20
WT/PK

C1

A12

(8W-15-6)
(8W-70-4)

(8W-51-6)

J998W-5

C3

S134

BRAKE
LAMP
SWITCH

(8W-31-2)

K20
18
DG

T41
18
BR/LB

K29
20
WT/PK
1

BRAKE
SWITCH
SENSE

C103

K72
18
DG/OR

(8W-42-4)

C90
18
LG

C3

(8W-20-2)

C170

6

S103

C22

GENERATOR
FIELD
DRIVER
(+)
2

C90
20
LG

C90
20
LG

C22
18
DB/WT

GENERATOR

C3

A

TJ

PARK/
NEUTRAL
POSITION
SWITCH
(8W-21-2)

(8W-15-6)

Z1
14
BK

G105
(8W-15-6)

TJI03012

TJ

8W-30 FUEL/IGNITION SYSTEM
BATT A0

(8W-10-6)

A16
FUSE
20
10A
(8W-10-15)

A15

POWER
DISTRIBUTION
CENTER
(8W-10-2)

M1
20
PK/WT
D12

C108

B7

C203

M1
20
PK/WT
2
FUSED
B(+)

UNDERHOOD
LAMP

M1
20
PK/WT
HARD
TOP

S204

(8W-44-3)

8W - 30 - 13

(8W-10-15)
M1
20
PK/WT
16

SOFT
TOP

TO

TO

DOME
LAMP
AND
SOUND
BAR
DOME
LAMP

SOUND
BAR
DOME
LAMP
(8W-44-2)

DATA
LINK
CONNECTOR

(8W-44-2)
6

7
D20
20
LG

SENTRY
KEY
IMMOBILIZER
MODULE

D21
20
PK
B10

B8
D20
20
LG

C203
D21
20
PK

E13

GROUND
(8W-30-14)
4

5

Z12
20
BK/LB

Z12
20
BK/TN

A6

C202

Z12
20
BK/LB
E6
Z12
20
BK/LB
11

D20
18
LG
C29

D21
18
PK

C3

SCI
RECEIVE

C27

C4

C204

Z12 20BK/LB

C107

E14

4

C3

SCI
TRANSMIT/
ISO
9141K

Z12
20
BK/LB

D21
20
PK

POWERTRAIN
CONTROL
MODULE

Z12
20
BK/TN

E9

C107

Z12
20
BK/TN
10

C103

Z12
20
BK/TN

S130
3

(8W-15-6)

C1

SCI
TRANSMIT/
ISO
9141K

CONTROLLER
ANTI-LOCK
BRAKE

Z12
10
BK/TN

(8W-35-5)

G105
TJI03013

(8W-15-6)

J998W-5

8W - 30 - 14

8W-30 FUEL/IGNITION SYSTEM
BATT A6

INSTRUMENT
CLUSTER
CCD
BUS
(-)
1

2

C1

ST-RUN A21

(8W-10-10)

FUSE
1
20A
(8W-11-4)

C1

D1
20
VT/BR

A11

TWISTED
PAIR

(8W-11-2)

FUSE
12
10A
(8W-11-8)

21
F34
18
TN/BK
D2
20
WT/BK

(8W-10-9)

FUSE
BLOCK

(8W-40-3)
(8W-40-4)
(8W-40-5)
(8W-40-7)

CCD
BUS
(+)

TJ

32

C202
DATA
LINK
CONNECTOR

F15
20
DB

F34
18
TN/BK

(8W-30-13)
4

4

11

(8W-50-2)
(8W-50-4)

B11

C203

D1
20
VT/BR

TWISTED
PAIR

Z12
20
BK/LB

3

FUSED
B(+)

D1
20
VT/BR

B12

D2
20
WT/BK

HEADLAMP
SWITCH

1

3

D2
20
WT/BK

FUSED
B(+)

F34
20
TN/BK

DATA
LINK
CONNECTOR

FUSED
IGNITION
SWITCH
OUTPUT
(ST-RUN)
CCD
BUS
(+)

CCD
BUS
(-)
5

6

D2
20
WT/BK

D1
20
VT/BR

TWISTED
PAIR

GROUND

SENTRY
KEY
IMMOBILIZER
MODULE

GROUND
4

2

Z12
20
BK/LB
Z1
20
BK

S302

D1
20
VT/BR

D5

D4

LHD

C108

TWISTED
PAIR

TWISTED
PAIR
D2
18
WT/BK

C3

C28

CCD
BUS
(-)

D2
18
WT/BK

D1
18
VT/BR
C30

S304
(8W-15-10)

G302

18

POWERTRAIN
CONTROL
MODULE

CCD
BUS
(-)

CCD
BUS
(+)

AIRBAG
CONTROL
MODULE

E6

C107

11

C103

Z12
20
BK/LB

S130
(8W-15-6)
Z12
10
BK/TN

19

(8W-43-3)
J998W-5

Z1
16
BK

(8W-15-11)

C3
CCD
BUS
(+)

RHD

Z1
20
BK
D1
18
VT/BR

C202

Z12
20
BK/LB

S303
D2
20
WT/BK

A6

G300
(8W-15-10)

G105
(8W-15-6)
TJI03014

TJ

8W-30 FUEL/IGNITION SYSTEM
POWERTRAIN
CONTROL
MODULE

SPEED
CONTROL
SWITCH
SIGNAL
C32
C3

SENSOR
GROUND
A4

BATTERY
TEMPERATURE
SENSOR

RHD

K167
20
BR/YL

K167
18
BR/YL

8

POWER
DISTRIBUTION
CENTER
(8W-10-2)

B15

C103
X3
20
RD/YL

S147

D3

SPEED
CONTROL

C108

C107

E7

(NOT
USED)

D3

C108
X3
20
RD/YL

OTHER
K167
20
BR/YL

V37
20
RD/LG
2

HORN
RELAY
(8W-41-3)

(8W-70-3)
K167
20
BR/YL

(8W-70-3)
K167
20
BR/YL

D10

B13

S133

2
LHD

C1

K167
18
BR/YL

SENSOR
RETURN (8W-30-10)

V37
18
RD/LG

8W - 30 - 15

C2

3

C2

C2

1

CLOCKSPRING

HORN
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1

TJI03015

2

LEFT
SPEED
CONTROL
SWITCH
POD
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2 SET

1

2

3

RIGHT
SPEED
CONTROL
SWITCH
POD
1 RESUME/ACCEL
2 CANCEL
3 COAST

J998W-5

8W - 30 - 16

SPEED
CONTROL
VACUUM
SOLENOID
CONTROL
C4
C3

V36
18
TN/RD

8W-30 FUEL/IGNITION SYSTEM

SPEED
CONTROL
VENT
SOLENOID
CONTROL
C5
C3

TJ

SPEED
CONTROL
ON/OFF
SWITCH
SENSE
C11
C3

BRAKE
SWITCH
SENSE
C24
C3

V32
18
YL/RD

K29
18
WT/PK

POWERTRAIN
CONTROL
MODULE

BRAKE
SWITCH
SENSE
1

V35
18
LG/RD
D1

D14

V32
20
YL/RD

2

K29
20
WT/PK

C108

1

5

BRAKE
LAMP
SWITCH

3

VACUUM
SOLENOID

VENT
SOLENOID

VEHICLE
SPEED
CONTROL
SERVO

(8W-51-6)
4

2

V30
20
DB/RD

DUMP
SOLENOID

6

Z1
20
BK

GROUND
V30
20
DB/RD

4

(8W-31-2)

K29
20
WT/PK

3
1

BRAKE
SHIFT
INTERLOCK
SOLENOID

E11

C107

CIGAR
LIGHTER/
ACCESSORY
RELAY
(8W-41-2)

5
Z1
20
BK

Z1
18
BK

LHD

RHD
Z1
20
BK

S106
(8W-15-2)

Z1
20
BK

S304
(8W-15-10)
Z1
16
BK

Z1
12
BK

G300
G100
J998W-5

(8W-15-2)

(8W-15-9)
(8W-15-10)
TJI03016

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8W - 31 - 2

8W-31 TRANSMISSION CONTROL SYSTEM

ST-RUN A21

TJ

(8W-10-9)

FUSE
BLOCK
FUSE
11
10A
(8W-11-8)
31

(8W-11-2)

FUSE
10
10A
(8W-11-8)
30

G5 20DB/WT
F12
20
RD/LG
F10

C106

F12
20
RD/LG

G5
20
DB/WT

2

INSTRUMENT
CLUSTER
4WD
INDICATOR

K29
20
WT/PK

F12
20
RD/LG

D14

5
C1
G107
20
BK/RD

C108

K29
20
WT/PK
1

F12
20
RD/LG

BRAKE
LAMP
SWITCH
TORQUE
CONVERTER
CLUTCH
SOLENOID

Z1
20
BK
K29
18
WT/PK

J998W-5

C103

GROUND
(8W-41-2)
5
Z1
20
BK
LHD

C2

13

CIGAR
LIGHTER/
ACCESSORY
RELAY

T23
18
OR/LG

B11

C170

A

2

B

5

G107
20
BK/RD

(8W-51-6)

A

TRANSMISSION
LOW/
OVERDRIVE
SOLENOID

(8W-40-5)

1

(8W-11-8)

C103

C2

8

BRAKE
SHIFT
INTERLOCK
SOLENOID

S102

9

C202

A10
G5
20
DB/WT

C24

C3

BRAKE
SWITCH
SENSE

POWERTRAIN
CONTROL
MODULE

TRANSFER
CASE
SWITCH
B

Z1
20
BK

RHD

S304

Z1
20
BK

Z1
16
BK

(8W-30-11)
(8W-30-12)

S132

(8W-15-10)

(8W-15-6)
Z1
14
BK

G300

G105

(8W-15-9)
(8W-15-10)

(8W-15-6)

TJI03102

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8W - 35 - 2

8W-35 ANTI-LOCK BRAKES

RUN A22

TJ

FROM

(8W-10-8)

S146
FUSE
BLOCK

(8W-35-3)
A

(8W-11-2)
FUSE
7
10A
(8W-11-7)

BATT A0

B48
20
RD/YL
(8W-10-6)

27
F20
20
VT/WT
F3

POWER
DISTRIBUTION
CENTER

A14

(8W-10-2)

FUSE
21
10A
(8W-10-17)

C106
A13

F20
20
VT/WT
19

S108
(8W-11-7)
F20
20
VT/WT

26

C11

20
FUSE
13
30A
(8W-10-17)
B47
14
RD/LB

ABS
SYSTEM
RELAY
(IN PDC)
C13

C14

27

A20
14
RD/DB

C10

FUSE
14
40A
(8W-10-17)

A10
12
RD/DG

C4

C2

C12

B58
20
GY/LB

Z1
14
BK

B47
14
RD/LB

B47
14
RD/LB

C6
B116
20
GY

C3

C8
B120
12
BR/WT

Z1
14
BK

S110

S114

1

ABS
PUMP
MOTOR

M
B47
14
RD/LB

B47
14
RD/LB

B

C

TO

TO

HYDRAULIC
CONTROL
UNIT

HYDRAULIC
CONTROL
UNIT

(8W-35-4)

11

B120
12
BR/WT

2
Z1
12
BK

S112
S106
(8W-15-2)

B120
16
BR/WT

(8W-35-4)

C2

ABS
MAIN
RELAY
CONTROL
J998W-5

ABS
PUMP
MOTOR
RELAY
(IN PDC)

7

C2

ABS
PUMP
MOTOR
RELAY
CONTROL

3

C2

ABS
PUMP
MOTOR
RELAY
OUTPUT

CONTROLLER
ANTI-LOCK
BRAKE

Z1
12
BK

G100
(8W-15-2)
TJI03502

TJ

8W-35 ANTI-LOCK BRAKES
RUN A22

(8W-10-8)

ST-RUN A21

8W - 35 - 3

(8W-10-9)

FUSE
BLOCK
(8W-11-2)
FUSE
7
10A
(8W-11-7)
27

FUSE
10
10A
(8W-11-8)
30

F20
20
VT/WT

G5
20
DB/WT
A10
8

F3

G5
20
DB/WT

C202
C2

C106

INSTRUMENT
CLUSTER
(8W-40-6)

ABS
WARNING
INDICATOR

F20
20
VT/WT
4
B14
D2

C2
C203
C108

2

S108

B

(8W-11-7)

BRAKE
SHIFT
INTERLOCK
SOLENOID

FUSED
IGNITION
SWITCH
OUTPUT
(ST-RUN)

ABS
DIODE

(8W-31-2)

A

S146
B48
20
RD/YL
A
F20
20
VT/WT

5

C1

FUSED
IGNITION
SWITCH
OUTPUT
(RUN)

G19
20
LG/OR
1

B48
20
RD/YL

TO

POWER
DISTRIBUTION
CENTER
(8W-35-2)

C1

5

ABS
WARNING
INDICATOR
DRIVER

C2

ABS
MAIN
RELAY
OUTPUT
GROUND
13

C2

Z22
16
BK/PK

CONTROLLER
ANTI-LOCK
BRAKE

GROUND
14

C2

Z22
16
BK/PK

S109
(8W-15-2)

Z22
14
BK/PK

G101
TJI03503

(8W-15-2)

J998W-5

8W - 35 - 4

8W-35 ANTI-LOCK BRAKES

TJ

FROM

FROM

S114

S114

(8W-35-2)

(8W-35-2)

B

C

B47
14
RD/LB

B47
14
RD/LB

10

1

HYDRAULIC
CONTROL
UNIT

2

7

9

4

8

3

B251
20
WT/BK

B254
20
DG/OR

B243
20
DG/BK

B245
20
WT/LG

B248
20
DG/WT

B249
20
WT/DG

4

C2

REAR
INLET
VALVE
CONTROL

J998W-5

12

C2

REAR
OUTLET
VALVE
CONTROL

8

C2

LEFT
FRONT
OUTLET
VALVE
CONTROL

18

C2

LEFT
FRONT
INLET
VALVE
CONTROL

6

C2

RIGHT
FRONT
OUTLET
VALVE
CONTROL

15

C2

RIGHT
FRONT
INLET
VALVE
CONTROL

CONTROLLER
ANTI-LOCK
BRAKE

TJI03504

TJ

8W-35 ANTI-LOCK BRAKES
BATT A6

8W - 35 - 5

(8W-10-10)

FUSE
BLOCK
(8W-11-2)
FUSE
2
20A
(8W-11-4)
22
F32
18
PK/DB
5

BRAKE
LAMP
SWITCH

DATA
LINK
CONNECTOR

(8W-51-6)
6

(8W-30-13)
7

L50
18
WT/TN

D21
20
PK

D9

C203

B10

C108

POWERTRAIN
CONTROL
MODULE

SCI
TRANSMIT (8W-30-13)
C27
C3

G SWITCH
D21
20
PK

L50
18
WT/TN

8

C1

BRAKE
LAMP
SWITCH
OUTPUT

TJI03505

2

1

B43
20
PK/OR

B41
20
YL/VT

B42
20
TN/WT

2

C1

G-SWITCH
TEST
SIGNAL

6

C1

G-SWITCH
NO. 1
SENSE

7

C107

E14

3

C1

G-SWITCH
NO. 2
SENSE

D21
18
PK

D21
20
PK

3

C1

SCI
TRANSMIT

CONTROLLER
ANTI-LOCK
BRAKE

J998W-5

8W - 35 - 6

8W-35 ANTI-LOCK BRAKES

RIGHT
FRONT
WHEEL
SPEED
SENSOR

LEFT
REAR
WHEEL
SPEED
SENSOR
LEFT
FRONT
WHEEL
SPEED
SENSOR

1

2

B3
18
LG/DB

2

B8
18
RD/DB

1

B4
18
LG

LEFT
FRONT
WHEEL
SPEED
SENSOR
(-)

J998W-5

RIGHT
REAR
WHEEL
SPEED
SENSOR

1

B7
18
WT

B6
18
WT/DB

9

1

2

B1
18
YL/DB

C2

LEFT
FRONT
WHEEL
SPEED
SENSOR
(+)

9

C104

3

B3
18
LG/DB

C2

2

B9
18
RD

4

10

TJ

C1

LEFT
REAR
WHEEL
SPEED
SENSOR
(-)

B4
18
LG

10

4

5

B7
18
WT

C1

LEFT
REAR
WHEEL
SPEED
SENSOR
(+)

1

C103

B6
18
WT/DB

C2

RIGHT
FRONT
WHEEL
SPEED
SENSOR
(+)

2

C2

RIGHT
FRONT
WHEEL
SPEED
SENSOR
(-)

7

B2
18
YL

B1
18
YL/DB

11

C104

6

C1

RIGHT
REAR
WHEEL
SPEED
SENSOR
(-)

B2
18
YL

12

C1

RIGHT
REAR
WHEEL
SPEED
SENSOR
(+)

CONTROLLER
ANTI-LOCK
BRAKE

TJI03506

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8W - 40 - 2

8W-40 INSTRUMENT CLUSTER
BATT A0

FUSE
20
10A
(8W-10-15)

A15

ST-RUN A21

(8W-10-6)

A16

TJ

POWER
DISTRIBUTION
CENTER

(8W-10-9)

FUSE
BLOCK
(8W-11-2)

FUSE
10
10A
(8W-11-8)

(8W-10-2)

30
M1
20
PK/WT
D12

M1
20
PK/WT

C108

2
FUSED
B (+)

UNDERHOOD
LAMP
(8W-44-3)

G5
20
DB/WT

M1
20
PK/WT

HARD
TOP

SOFT
TOP

M1
20
PK/WT

M1
20
PK/WT

A10

C202
G5
20
DB/WT

TO
B7

C203

M1
20
PK/WT

DOME
LAMP
AND
SOUND
BAR
DOME
LAMP

2

TO

S204

SOUND
BAR
DOME
LAMP

(8W-10-15)

(8W-44-2)

(8W-44-2)

M1
20
PK/WT
9

FUSED
IGNITION
SWITCH
OUTPUT
(ST-RUN)

BRAKE
SHIFT
INTERLOCK
SOLENOID
(8W-31-2)

G5
20
DB/WT

C2

8

C2
INSTRUMENT
CLUSTER

FUSED
B(+)

FUSED
IGNITION
SWITCH
OUTPUT
(ST-RUN)
GROUND

6

C2

Z2
18
BK/LG

9

C1

Z2
18
BK/LG

G201
(8W-15-7)
(8W-15-8)
J998W-5

TJI04002

TJ

8W-40 INSTRUMENT CLUSTER

BATT M1

ST-RUN G5

(8W-10-15)

8W - 40 - 3

(8W-11-8)

INSTRUMENT
CLUSTER
VOLT
METER

FUSED
B(+)

VOLT
METER
CONTROL

CCD
BUS
(+)

CCD
BUS
(-)

SPEEDOMETER
CONTROL

FUSED
IGNITION
SWITCH
OUTPUT
(ST-RUN)

C1

1

D1
20
VT/BR

C1

TACHOMETER
CONTROL
ENGINE
COOLANT
TEMPERATURE
GAUGE

TACHOMETER

(8W-30-14)
3

11

D1
20
VT/BR

B12

D2
20
WT/BK

D1
20
VT/BR

D2
20
WT/BK

TWISTED
PAIR

S302

S303

(8W-30-14)

(8W-30-14)

D1
20
VT/BR
D4

ENGINE
OIL
PRESSURE
SENSOR
SIGNAL

TWISTED
PAIR

D5

C3
CCD
BUS
(+)

TJI04003

C3
CCD
BUS
(-)

C1

Z2
18
BK/LG

(8W-15-7)
(8W-15-8)

FUEL
FUEL
PUMP
LEVEL
MODULE
SENSOR
SIGNAL (8W-30-3)
3
K226
20
DB/LG

6

S135

ENGINE
COOLANT
TEMPERATURE
SENSOR
SIGNAL

C103

1

ENGINE
COOLANT
TEMPERATURE
SENSOR
(8W-30-7)
(8W-30-8)

(8W-30-10)
G7
18
WT/OR

D2
18
WT/BK
C28

9

G201

(8W-30-7)
(8W-30-8)

G7
20
WT/OR

C108

Z2
18
BK/LG

ENGINE
OIL
PRESSURE
SENSOR

VEHICLE
VEHICLE SPEED
SPEED
SENSOR
SENSOR
SIGNAL (8W-30-10)
3

D2
20
WT/BK

TWISTED
PAIR

D1
18
VT/BR
C30

C203

C2

6

2
B11

GROUND

DATA
LINK
CONNECTOR

D2
20
WT/BK

TWISTED
PAIR

OIL
PRESSURE
GAUGE
CONTROL

ENGINE
COOLANT
TEMPERATURE
CONTROL

FUEL
GAUGE
CONTROL

FUEL
GAUGE

2

OIL
PRESSURE
GAUGE

SPEEDOMETER

B27

C2

VEHICLE
SPEED
SENSOR
SIGNAL

G60
18
GY/YL
B23

C2

ENGINE
OIL
PRESSURE
SENSOR
SIGNAL

K226
18
DB/LG
C26

C3

FUEL
LEVEL
SENSOR
SIGNAL

K2
18
TN/BK
A16

C1

ENGINE
COOLANT
TEMPERATURE
SENSOR
SIGNAL

POWERTRAIN
CONTROL
MODULE
(8W-30-3)
(8W-30-7)
(8W-30-8)
(8W-30-10)
(8W-30-14)
J998W-5

8W - 40 - 4

8W-40 INSTRUMENT CLUSTER

BATT M1

ST-RUN G5

(8W-10-15)

TJ

(8W-11-8)

INSTRUMENT
CLUSTER
AIRBAG
WARNING
INDICATOR

FUSED
B(+)
CCD
BUS
(+)

AIRBAG
WARNING
INDICATOR
DRIVER

CHECK
ENGINE
INDICATOR
DRIVER

CHECK
GAUGES
INDICATOR
DRIVER

ODOMETER CONTROL

TRIP RESET

GROUND

C1

1

D1
20
VT/BR

C1

C2

6

DATA
LINK
CONNECTOR

D2
20
WT/BK

Z2
18
BK/LG

(8W-30-14)
3

TWISTED
PAIR

SEAT
BELT
SWITCH
SENSE

TRIP
ODOMETER
RESET
SWITCH

ODOMETER/
TRIP
ODOMETER
2

CHECK
GAUGES
INDICATOR

LOW
FUEL
INDICATOR
DRIVER

FUSED
IGNITION
SWITCH
OUTPUT
(ST-RUN)

CCD
BUS
(-)

CHECK
ENGINE
INDICATOR

LOW
FUEL
INDICATOR

C1

9

Z2
18
BK/LG

D1
20
VT/BR

G10
20
LG/RD

G201

11

B12

D1
20
VT/BR

D2
20
WT/BK

RHD

C322

C203

SEAT
BELT
SWITCH
(EXCEPT LHD
BUILT-UP
-EXPORT)

(8W-30-14)

S302
D1
20
VT/BR

(8W-30-14)

D2
20
WT/BK

D1
18
VT/BR

TWISTED
PAIR
TWISTED
PAIR

D5

D1
18
VT/BR
C30

C3
CCD
BUS
(+)

C322

1

S303

D4

6

G10
20
LG/RD

D2
20
WT/BK

TWISTED
PAIR

C204

C3

(8W-15-7)
(8W-15-8)
LHD
G6

B11

C1

10

C108

TWISTED
PAIR

19

D2
18
WT/BK

Z1
20
BK

S309

18
CCD
BUS
(+)

CCD
BUS
(-)

AIRBAG
CONTROL
MODULE

(8W-15-11)
Z1
12
BK

(8W-43-3)

D2
18
WT/BK
C28

2

LHD
G5

RHD

C322

5

C322

C3
CCD
BUS
(-)

POWERTRAIN
CONTROL
MODULE

G302
(8W-15-11)

(8W-30-14)
J998W-5

TJI04004

TJ

8W-40 INSTRUMENT CLUSTER
BATT M1

ST-RUN G5

(8W-10-15)

8W - 40 - 5

(8W-11-8)

INSTRUMENT
CLUSTER
SENTRY
KEY
IMMOBILIZER
MODULE
INDICATOR
FUSED
B(+)

CCD
BUS
(+)

2

SENTRY
KEY
IMMOBILIZER
MODULE
INDICATOR
DRIVER

SEAT
BELT
WARNING
INDICATOR
FUSED
IGNITION
SWITCH
OUTPUT
(ST-RUN)

SEAT
BELT
WARNING
INDICATOR
DRIVER

CCD
BUS
(-)

C1

1

D1
20
VT/BR

C1

6

DATA
LINK
CONNECTOR
(8W-30-14)

TWISTED
PAIR

3
D1
20
VT/BR

B12

D1
20
VT/BR

C203

D2
20
WT/BK

TWISTED
PAIR

UPSHIFT
INDICATOR
DRIVER
(M/T)

GROUND

D2
20
WT/BK

B11

4WD
INDICATOR

UPSHIFT
INDICATOR
(M/T)

C2

Z2
18
BK/LG

9

C1

Z2
18
BK/LG

C1

5

G107
20
BK/RD

C170

5

G201
11
D2
20
WT/BK

(8W-15-7)
(8W-15-8)
G107
20
BK/RD

C103

13

G107
20
BK/RD
A

S302

S303

(8W-30-14)

(8W-30-14)

D1
20
VT/BR

D2
20
WT/BK

TWISTED
PAIR

D4

TWISTED
PAIR

TRANSFER
CASE
SWITCH
(8W-31-2)
B

D5

C108

Z1
20
BK

S132

C30

C3
CCD
BUS
(+)

(8W-15-6)

D2
18
WT/BK

D1
18
VT/BR
C28

C3
CCD
BUS
(-)

POWERTRAIN
CONTROL
MODULE
(8W-30-14)

TJI04005

Z1
14
BK

G105
(8W-15-6)
J998W-5

8W - 40 - 6

8W-40 INSTRUMENT CLUSTER

ST-RUN G5

TJ
BATT M1

(8W-11-8)

(8W-10-15)

INSTRUMENT
CLUSTER
BRAKE
WARNING
INDICATOR

FUSED
B(+)

FUSED
IGNITION
SWITCH
OUTPUT
(ST-RUN)

ABS
WARNING
INDICATOR

GROUND

2

C2

C2

4

G99
20
GY/WT

G19
20
LG/OR

C170

C2

9

C1

Z2
18
BK/LG

Z2
18
BK/LG

C203

B14
3

6

OTHERS

ABS

G201

2

BRAKE
WARNING
INDICATOR
SWITCH

G19
20
LG/OR

(8W-15-7)
(8W-15-8)

C108

D2

G99
20
GY/WT

G19
20
LG/OR

G19
20
LG/OR

B
D2

1

NOT
USED

G9
20
GY/BK
F11

C108

1

ABS
WARNING
INDICATOR
DRIVER

ABS
DIODE
(8W-35-3)

C1

ABS
WARNING
INDICATOR
DRIVER

CONTROLLER
ANTI-LOCK
BRAKE
(8W-35-3)

C106
G9 20 GY/BK
2

G9
20
GY/BK
LHD

IGNITION
SWITCH
1

RHD

4
2

G9

C322

9

C322

0

1
Z1
16
BK

G9
20
GY/BK

1 START
2 RUN
0 OFF
3 LOCK
4 ACC
(8W-10-9)

S304

PARK
BRAKE
SWITCH

J998W-5

3

(8W-15-9)
Z1 (8W-15-10)
16
BK

G300
(8W-15-9)
(8W-15-10)
TJI04006

TJ

8W-40 INSTRUMENT CLUSTER
BATT M1

8W - 40 - 7

ST-RUN G5

(8W-10-15)

(8W-11-8)

INSTRUMENT
CLUSTER
FUSED
B(+)
CCD
BUS
(+)

2

CCD
BUS
(-)

C1

1

D1
20
VT/BR

KEY-IN
IGNITION
SWITCH
SENSE

GROUND

C1

C2

6

Z2
18
BK/LG

D2
20
WT/BK

FUSED
IGNITION
SWITCH
OUTPUT
(ST-RUN)

C1

9

C1

8

G26 20LB

Z2
18
BK/LG

G26 20 LB
5

G201

HEADLAMP
SWITCH

(8W-15-7)
(8W-15-8)

DATA
LINK
CONNECTOR

TWISTED
PAIR

(8W-30-14)
3

11

D1
20
VT/BR

D2
20
WT/BK

0

2

KEY-IN
SWITCH

0 OFF
1 PARK
2 HEAD
(8W-50-3)

2

1

C203

B3

6

1

G16
20
BK/LB

G16
20
BK/LB

B4

C203
G16 20BK/LB

B12

B11
D1
20
VT/BR

D2
20
WT/BK

TWISTED
PAIR

S302

S303

(8W-30-14)

(8W-30-14)

D1
20
VT/BR

DOOR
AJAR
SWITCH
OUTPUT
1
M23
20
YL/BK

DRIVER
DOOR
AJAR
SWITCH

PASSENGER
DOOR
AJAR
SWITCH
(8W-44-4)

D5

M23
20
YL/BK
4
FUSE
4
10A
(8W-11-5)

C108

TWISTED
PAIR
LHD
D2
18
WT/BK

D1
18
VT/BR

C3

C30

CCD
BUS
(+)

C28

(8W-11-2)

RHD

Z1
20
BK

S304
POWERTRAIN
CONTROL
MODULE
(8W-30-14)

TJI04007

24

FUSE
BLOCK

Z1 20BK

C3
CCD
BUS
(-)

(8W-44-4)

1

D2
20
WT/BK

TWISTED
PAIR

D4

3

C203

(8W-15-9)
Z1 16BK

G300
(8W-15-9)
(8W-15-10)

J998W-5

8W - 40 - 8

8W-40 INSTRUMENT CLUSTER
BATT F34

TJ

(8W-11-4)

HEADLAMP
SWITCH
0

1

2

3 4

5
1

RUN F20

E1
18
TN

(8W-11-7)

REAR
WINDOW
DEFOGGER
RELAY
(IN PDC)

D6

0 HEAD
1 PARK
2 HEAD
3 DOME
4 MAX
5 MIN
(8W-50-2)

C202

A3
3

FUSE
BLOCK
FUSE
3
10A
(8W-11-4)

(8W-48-2)

C81
20
LB/WT

(8W-11-2)

23
E2
20
OR

2

E2
20
OR

C170
C202

A4

1
FUSED
PANEL
LAMPS
DIMMER
SWITCH
SIGNAL

S206
(8W-11-4)

C81
20
LB/WT

BATT M1

(8W-10-15)

3

C1

E2
20
OR

ST-RUN G5

(8W-11-8)

3

PRNDL
LAMP
(8W-44-5)

C2
INSTRUMENT
CLUSTER

FUSED
B(+)
REAR
WINDOW
DEFOGGER
SWITCH
SENSE

4

REAR
WINDOW
DEFOGGER
RELAY
CONTROL

FUSED
IGNITION
SWITCH
OUTPUT
(ST-RUN)

CLUSTER
ILLUMINATION
LAMPS

GROUND

C1

6

C80
20
DB/LG

C2

Z2
18
BK/LG

9

C1

Z2
18
BK/LG

2
REAR
WINDOW
DEFOGGER
SWITCH
SENSE

REAR
WINDOW
DEFOGGER
SWITCH
(HARD TOP)

G201
(8W-15-7)
(8W-15-8)

(8W-48-2)
J998W-5

TJI04008

TJ

8W-40 INSTRUMENT CLUSTER

8W - 40 - 9

HEADLAMP
DIMMER
SWITCH

DIMMER
SWITCH
HIGH
BEAM
OUTPUT

TURN
SIGNAL/
HAZARD
SWITCH

(8W-50-2)

3
L3
14
RD/OR

C107

E4

(8W-52-3)

RIGHT
TURN
SIGNAL

LEFT
TURN
SIGNAL
10

1

L3
16
RD/OR

S105
OTHER

DRL

L3
16
RD/OR

L3
16
RD/OR
G34
18
RD/GY
4
HIGH
BEAM
INDICATOR
DRIVER

D7

C203

B1

1
DIMMER
SWITCH
HIGH
BEAM
OUTPUT

DAYTIME
RUNNING
LAMP
MODULE
(8W-50-8)

G34
16
RD/GY
1

C203

G34
16
RD/GY
5

C203

B2

C108

G34
16
RD/GY

B5

L60
18
TN

L61
18
GY

(8W-50-2)

HIGH
BEAM
INDICATOR
DRIVER

FOG LAMP
RELAY
NO. 2
(EXCEPT
BUILT-UP
-EXPORT)
(8W-50-6)

C2

10
HIGH
BEAM
INDICATOR

L60
18
TN

L61
18
GY

C2

6

C1

LEFT
TURN
SIGNAL
INDICATOR

RIGHT
TURN
SIGNAL
INDICATOR

6

C2

Z2
18
BK/LG

9

INSTRUMENT
CLUSTER

C1

Z2
18
BK/LG

G201
TJI04009

(8W-15-7)
(8W-15-8)

J998W-5

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8W - 41 - 2

8W-41 HORN/CIGAR LIGHTER/POWER OUTLET
BATT A0

BRAKE
LAMP
SWITCH
GROUND
2

TJ
(8W-10-6)

POWER
DISTRIBUTION
CENTER

11

(8W-51-6)

BATT A1

1

4
2

0

FUSE
5
40A
(8W-10-10)

(8W-10-9)

3

IGNITION
SWITCH

4

1 START
2 RUN
0 OFF
3 LOCK
4 ACC
(8W-10-9)

F30
12
RD/PK
F1

8

(8W-10-2)

C106
S332

S307

(8W-10-10)

(8W-10-9)
A31
14
BK/DG

F30
12
RD/PK

2

1

CIGAR
LIGHTER/
ACCESSORY
RELAY

Z1
20
BK
5

4
F22
12
WT/PK

Z1
20
BK

LHD

19
FUSE
19
20A
(8W-11-10)

RHD

S304
(8W-15-10)
Z1
20
BK

FUSE
BLOCK
(8W-11-2)

39

Z1
16
BK

C202

A9
F38
16
LB
1

G300
(8W-15-9)
(8W-15-10)

F38
16
LB
SWITCH
AUXILIARY
POWER
(TAPED TO
HARNESS
IN FB T/O)

CIGAR
LIGHTER/
POWER
OUTLET
3
Z1
16
BK

S207
(8W-15-7)
(8W-15-8)

G200
J998W-5

(8W-15-7)
(8W-15-8)

TJI04102

TJ

8W-41 HORN/CIGAR LIGHTER/POWER OUTLET
BATT A0

(8W-10-6)

POWER
DISTRIBUTION
CENTER

A21
FUSE
17
20A
(8W-10-16)

A22

8W - 41 - 3

(8W-10-2)

F31
18
VT

F31
18
VT

B13

B11

HORN
RELAY
(IN PDC)
B15

B12
X2
18
WT/RD

X3
20
RD/YL

C110

6

X2
18
WT/RD

E7

BUILTUP-EXPORT

C107

EXCEPT BUILTUP-EXPORT

S115
X3
20
RD/YL

X2
18
WT/RD
1

1

C2
CLOCKSPRING
(8W-30-15)

X2
18
WT/RD

HIGH
NOTE
HORN

2

1

LOW
NOTE
HORN

2
Z1
18
BK

Z1
18
BK

S117
HORN
SWITCH

(8W-15-3)
Z1
16
BK

G102
TJI04103

(8W-15-3)

J998W-5

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8W - 42 - 2

8W-42 AIR CONDITIONING-HEATER
HEATER ONLY
RUN A22

TJ
BATT A0

(8W-10-8)

FUSE
BLOCK

POWER
DISTRIBUTION
CENTER

17

(8W-11-2)

FUSE
8
10A
(8W-11-7)

(8W-10-6)

FUSE
11
40A
(8W-10-13)

24

28

(8W-10-2)

A111
12
RD/LB

F24
20
RD/DG

C106
C202

F12
A1

A12

F24 20RD/DG
F24
20
RD/DG

F24
20
RD/DG

A111
12
RD/LB

5

9

8

HVAC
UNIT

BLOWER
MOTOR
RELAY

BLOWER
M MOTOR
FROM

S206
(8W-11-4)

BLEND
DOOR
ACTUATOR

M

E2
20
OR

2

C2

4

1
3

3
C4
16
TN

C2

D

C5
16
LG/LB

C1

7

4
C6
14
LB

C1

C

7
8

C7
12
BR/TN

C1

B

6

A

C1

C1
12
DG

J998W-5

3

2

0

C3

G200
(8W-15-7)
(8W-15-8)

LHD
RHD

Z1
20
BK

0 OFF
1 VENT
2 HEAT
3 MIX
4 DEFROST
5 HIGH
6 M2
7 M1
8 LOW

1

Z1
12
BK

Z1
16
BK
(8W-15-7)
(8W-15-8)

C2

5

C

S207

2

6

C2
Z1
20
BK

C36
20
DB/RD

C3

B

10

A/CHEATER
CONTROL

4

5

C1

E

1

1
3

C2

Z11
20
BK/WT

Z11
20
BK/WT

G202

G203

(8W-15-7)
(8W-15-8)

(8W-15-7)
(8W-15-8)

G200
(8W-15-7)
(8W-15-8)

TJI04202

TJ

8W-42 AIR CONDITIONING-HEATER
RUN A22

8W - 42 - 3
BATT A0

(8W-10-8)

FUSE
BLOCK

POWER
DISTRIBUTION
CENTER

17

(8W-11-2)

FUSE
8
10A
(8W-11-7)

(8W-10-6)

FUSE
11
40A
(8W-10-13)

24

(8W-10-2)

28
F24
20
RD/DG

A111
12
RD/LB
F12

A1

A12

F24 20RD/DG

F24
20
RD/DG

F24
20
RD/DG

C106
C202

A111
12
RD/LB

5

9

8

HVAC
UNIT

BLOWER
MOTOR
RELAY

BLOWER
M MOTOR

FROM

S206
(8W-11-4)

E2
20
OR

2

C2

4

1
3

3
C4
16
TN

C2

C1

D

4

C5
16
LG/LB

3

6

(8W-15-7)
(8W-15-8)

C1

E

C3

B

1

2

C2

7

2

4

3

1

6

0

G200
(8W-15-7)
(8W-15-8)

1

6

C3

6

0

C3

C
Z1
12
BK

C90
20
LG

S103
(8W-42-4)

2

5

FROM

Z1
16
BK

3

4

2

5
0

10

C36
20
DB/RD

A/CHEATER
CONTROL

A

S207

TJI04203

C1

A

C2
Z1
20
BK

C1
12
DG

8

1

5

C7
12
BR/TN

C1

B

10

4

6

7
C6
14
LB

C1

C
9

5

BLEND
DOOR
ACTUATOR

M

C170

1
C2
3 Z11

Z11
20
BK/WT

20
BK/WT

G202
(8W-15-7)
(8W-15-8)

Z1
20
BK

0 OFF
1 MAX
2 NORM
3 VENT
4 HEAT
5 MIX
6 DEFROST
7 HIGH
8 M2
9 M1
10 LOW

G200
(8W-15-7)
(8W-15-8)

G203
LHD

(8W-15-7)
(8W-15-8)

RHD
J998W-5

8W - 42 - 4

8W-42 AIR CONDITIONING-HEATER

A/C
SWITCH
SENSE
C22
C3
C22
18
DB/WT

A/C
SELECT
INPUT
C23
C3
C90
18
LG

A/C
COMPRESSOR
CLUTCH
RELAY
CONTROL
C1
C3
C13
18
DB/OR

POWERTRAIN
CONTROL
MODULE
(8W-30-3)
(8W-30-12)

RUN A22

FUSE
7
10A
(8W-11-7)

C22
20
DB/WT
1

(8W-11-2)

27

A/C
LOW
PRESSURE
SWITCH

F20
20
VT/WT
F3

2
C21
20
DB/OR

BATT A0

C106

S108

A/C
HIGH
PRESSURE
SWITCH

(8W-10-6)

A23

F20
20
VT/WT

2

A24

FUSE
16
10A
(8W-10-16)

POWER
DISTRIBUTION
CENTER
(8W-10-2)

(8W-11-7)
F20
20
VT/WT

A17
20
RD/GY
B6

B8

1
C90
20
LG
1

(8W-10-9)

FUSE
BLOCK

C104

2

TJ

A/C
COMPRESSOR
CLUTCH
RELAY
(IN PDC)

C104
B10

C90
20
LG

B7
C3
20
DB/BK

S103

C103

14

C3
20
DB/BK

C90
20
LG

1

3

4

6

C170

A

C3
A/C
HEATER
CONTROL

2
1

5
6

0

C3

C

A/C
COMPRESSOR
CLUTCH

0 OFF
1 MAX
2 NORM
3 VENT
4 HEAT
5 MIX
6 DEFROST

2
Z1
20
BK

S132
(8W-15-6)

Z1
12
BK

Z1
14
BK

G202
(8W-15-7)
(8W-15-8)
J998W-5

G105
(8W-15-6)

TJI04204




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8W - 43 - 2

8W-43 AIRBAG SYSTEM

ST-RUN A21

RUN A22

(8W-10-9)

TJ

(8W-10-8)

FUSE
BLOCK
(8W-11-2)
FUSE
9
10A
(8W-11-8)

FUSE
5
10A
(8W-11-6)

29

25

F14
18
LG/YL

F14
18
LG/YL

F23
18
DB/YL

17

20

FUSED
IGNITION
SWITCH
OUTPUT
(ST-RUN)

FUSED
IGNITION
SWITCH
OUTPUT
(RUN)

PASSENGER
AIRBAG SQUIB
LINE 2
6
R144
18
VT/YL

C1

1

PASSENGER
AIRBAG SQUIB
LINE 1
5
R142
18
BR/YL

C2

2

AIRBAG
CONTROL
MODULE

1

GROUND
10

C2
PASSENGER
AIRBAG
ON/OFF
SWITCH

Z6
18
BK/PK

DRIVER
AIRBAG
LINE 1
2

DRIVER
AIRBAG
LINE 2
1

R43
18
BK/LB

R45
18
DG/LB

TWISTED
PAIR

2

C1

1

C1
CLOCKSPRING

FUSED
RESISTOR

2

C1

Z6
20
BK/PK

G301
(8W-15-11)
J998W-5

4

C2

3

R42
18
BK/YL

A

B

PASSENGER
AIRBAG
LINE 2

PASSENGER
AIRBAG
LINE 1

R45
18
DG/LB

DRIVER
AIRBAG
LINE 1

DRIVER
AIRBAG
LINE 2

G301

C2

R44
18
DG/YL

R43
18
BK/LB
(8W-15-11)

PASSENGER
AIRBAG

DRIVER
AIRBAG
SQUIB
TJI04302

TJ

8W-43 AIRBAG SYSTEM

8W - 43 - 3

ST-RUN A21

FUSE
BLOCK

AIRBAG
CONTROL
MODULE

18

30

19

D2
18
WT/BK

G5
20
DB/WT

D1
18
VT/BR

A10

TWISTED
PAIR

G5
20
DB/WT

C202
2
FUSED
IGNITION
SWITCH
OUTPUT
(ST-RUN)

G5
20
DB/WT

S303

S302

(8W-30-14)
D2
20
WT/BK

TWISTED
PAIR

(8W-11-2)

FUSE
10
10A
(8W-11-8)

CCD
BUS
(+)

CCD
BUS
(-)

(8W-10-9)

(8W-30-14)

8

BRAKE
SHIFT
INTERLOCK
SOLENOID
(8W-31-2)

C2
INSTRUMENT
CLUSTER

D1
20
VT/BR

DATA
LINK
CONNECTOR

AIRBAG
WARNING
INDICATOR

(8W-40-2)

(8W-30-14)
3
D1
20
VT/BR
B12

B11

C203

11
D2
20
WT/BK

CCD
BUS
(+)
2

AIRBAG
WARNING
INDICATOR
DRIVER

C1

CCD
BUS
(-)
1

C1

TWISTED
PAIR
D1
20
VT/BR

TJI04303

D2
20
WT/BK

J998W-5

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8W - 44 - 2

8W-44 INTERIOR LIGHTING
BATT A0

(8W-10-6)

POWER
DISTRIBUTION
CENTER

A16
FUSE
20
10A
(8W-10-15)

A15

(8W-10-2)

M1
20
PK/WT
M1
20
PK/WT

LHD

TO

UNDERHOOD
LAMP
(8W-44-3)

2

4 SPEAKER
SYSTEM

C323

2 SPEAKER
SYSTEM

8
8

LHD

C326
C331

S204
(8W-10-15)

3

C330
C325

4

C326

4

LHD
H3

C323

3

C323

4 SPEAKER
SYSTEM
M2
20
YL

C323

NOT
USED
H3
C323
M2
20
YL

M2
20
YL

RHD

HARD
TOP

RHD
3

4 SPEAKER
SYSTEM

M2
20
YL

C323

C323

M2
20
YL

S314

H3

2
C323
NOT
USED

2

M2
18
YL

LHD

H2
C323
NOT
USED

SOUND
BAR
DOME
LAMP

M2 20YL

2 SPEAKER
SYSTEM

M1
20
PK/WT

M1
20
PK/WT
1

C331

9

2

RHD 2
SPEAKER SYSTEM

C325
C330

3

DOME
LAMP

9

RHD

C323

H2

M1
20
PK/WT

TO

M1
20
PK/WT

4 SPEAKER
SYSTEM

S313

M1
20
PK/WT

LHD 2
SPEAKER SYSTEM

M1
20
PK/WT

M1
20
PK/WT

C203

B7

SOFT
TOP

RHD

C323

H2

M1
20
PK/WT
B

M1
20
PK/WT

HARD
TOP

C108

D12

TJ

LHD 2
SPEAKERSYSTEM

NOT
USED
3
C323
M2
20
YL
RHD 2 SPEAKER
SYSTEM

SOFT
TOP

A
TO

S301
(8W-44-4)
J998W-5

TJI04402

TJ

8W-44 INTERIOR LIGHTING

8W - 44 - 3

FROM

C108
(8W-44-2)
B

M1
20
PK/WT
2

UNDERHOOD
LAMP

MERCURY
SWITCH

1

BASE

OTHER

Z1
18
BK

Z1
18
BK

S106
(8W-15-2)

Z1
12
BK

TJI04403

G100

G100

(8W-15-2)

(8W-15-2)
J998W-5

8W - 44 - 4

8W-44 INTERIOR LIGHTING

BATT A0

(8W-10-6)

A16
FUSE
20
10A
(8W-10-15)

A15

UNDERHOOD
LAMP

POWER
DISTRIBUTION
CENTER

FUSED
B (+)
2

(8W-10-2)

(8W-44-3)

B7

(8W-40-7)

C1

8

G26 20LB

C108
C203

12

INSTRUMENT
CLUSTER

KEY-IN
IGNITION
SWITCH
SENSE

M1
20
PK/WT

M1
20
PK/WT

TJ

G26 20LB

5

S204

(8W-10-15) FROM
M1
DOME
20
LAMP
PK/WT

M1
20
PK/WT

AND
SOUND
BAR
DOME
LAMP

1

LEFT
COURTESY
LAMP

1

(8W-44-2)
A

RIGHT
COURTESY
LAMP

M2
20
YL

2

HARD
TOP

SOFT
TOP

M1
20
PK/WT

M1
20
PK/WT

TO

TO

DOME
LAMP
AND
SOUND
BAR
DOME
LAMP

SOUND
BAR
DOME
LAMP

HEADLAMP
SWITCH
0

G26
20
LB

0 OFF
1 PARK
2 HEAD
(8W-50-3)

2

1

C203

B3

2

KEY-IN
SWITCH

6
G16
20
BK/LB
B4

C203

1
G16 20BK/LB

G16
20
BK/LB

(8W-44-2)

(8W-44-2)

S301
M2
20
YL

2

S202
M2
20
YL

2

3

PASSENGER
DOOR
AJAR
SWITCH

M2
20
YL

M2
20
YL

M2
20
YL

2

C204

C5
M2
20
YL

M2
20
YL

DRIVER
DOOR
AJAR
SWITCH

1
M23
20
YL/BK

1
M23
20
YL/BK
4

3

HEADLAMP
SWITCH
0

1

RHD

LHD

Z1
16
BK

Z1
16
BK

J998W-5

(8W-11-2)

24
Z1
20
BK
RHD

S207
Z1
16
BK

FUSE
4
10A
(8W-11-5)

0 OFF
1 DOME
(8W-50-3)

FUSE
BLOCK

LHD

S304

Z1
20
BK

(8W-15-8)

Z1
16
BK

(8W-15-9)

G200

G200

G300

G300

(8W-15-8)

(8W-15-7)

(8W-15-10)

(8W-15-9)
TJI04404

TJ

8W-44 INTERIOR LIGHTING

BATT F34

8W - 44 - 5

(8W-11-4)

HEADLAMP
SWITCH
0

1

2 3 4

5
1
E1
18
TN

0 OFF
1 PARK
2 HEAD
3 DOME
4 MAX
5 MIN
(8W-50-2)

S206
(8W-11-4)

E2
20
OR

A4

A3

E2
20
OR

E2
20
OR

E2
20
OR

E2
20
OR

E2
20
OR

C202

3

FUSE
BLOCK
FUSE
3
10A
(8W-11-4)

1

FRONT
FOG
LAMP
SWITCH
(EXCEPT
BUILT-UP
-EXPORT)

(8W-11-2)
E2
20
OR

23

4

(8W-50-7)

4

E2
20
OR

4

C2
A/CHEATER
CONTROL

REAR
WINDOW
DEFOGGER
SWITCH
(HARD TOP)
1

(8W-48-2)

4

1

REAR
WIPER/
WASHER
SWITCH
(HARD TOP)

REAR
FOG
LAMP
SWITCH
(BUILT-UP
-EXPORT)

1

C2

5

3

PRNDL
LAMP

2

(8W-42-2)
(8W-42-3)

1

(8W-53-4)

(8W-51-7)
(8W-51-8)
Z1
20
BK

Z1
20
BK

Z1
18
BK/WT

Z1
20
BK

Z1
20
BK

S304

S207

(8W-15-9)
(8W-15-10)

(8W-15-7)
(8W-15-8)

Z1
16
BK

TJI04405

Z1
20
BK

Z1
16
BK

G300

G200

(8W-15-9)
(8W-15-10)

(8W-15-7)
(8W-15-8)

J998W-5

8W - 44 - 6

8W-44 INTERIOR LIGHTING
BATT F34

TJ

(8W-11-4)

HEADLAMP
SWITCH
0

1

2 3 4

5
1
E1
18
TN

0 OFF
1 PARK
2 HEAD
3 DOME
4 MAX
5 MIN
(8W-50-2)

C202

A3
E1
18
TN
3

FUSE
BLOCK
FUSE
3
10A
(8W-11-4)

(8W-11-2)

23
E2
20
OR

C202

A4
E2
20
OR

E2
20
OR

TO

PRNDL
LAMP
(8W-44-5)

S206
(8W-11-4)
E2
20
OR
3

C2
INSTRUMENT
CLUSTER

E2
20
OR

(8W-40-8)

5

C1
RADIO
(8W-47-2)

6

C2

Z2
18
BK/LG

G201
J998W-5

(8W-15-7)
(8W-15-8)

TJI04406



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8W - 47 - 2

8W-47 AUDIO SYSTEM

RUN-ACC A31

TJ
BATT A0

(8W-10-9)

FUSE
BLOCK

3

35
X12
20
PK

E2
20
OR

M1
20
PK/WT

D12

C202
E1
18
TN

M1
20
PK/WT

C108

M1
20
PK/WT

M1
20
PK/WT
HARD
TOP

BATT F34

(8W-11-4)

1

0

4

9

SOFT
TOP

TO

HEADLAMP
SWITCH
2

(8W-10-2)

23

A3

1

FUSE
20
10A
(8W-10-15)

A15

E1
18
TN

C204

C10

POWER
DISTRIBUTION
CENTER

A16

(8W-11-2)

FUSE
3
10A
(8W-11-4)

FUSE
15
10A
(8W-11-9)

(8W-10-6)

UNDERHOOD
LAMP

0 OFF
1 HEAD
2 PARK
5 4 MAX
5 MIN
(8W-50-2)

(8W-44-3)

C202

A4

TO

TO

DOME
LAMP
AND
SOUND
BAR
DOME
LAMP

SOUND
BAR
DOME
LAMP
(8W-44-2)

(8W-44-2)
L7
18
BK/YL

E2
20
OR

B7

C203

RADIO
ANTENNA

M1
20
PK/WT
B6

S206

C203

S204

(8W-11-4)

(8W-10-15)
X12
20
PK

6

L7
18
BK/YL

C1

FUSED
IGNITION
SWITCH
OUTPUT
(RUN-ACC)

J998W-5

4

C1

HEADLAMP
SWITCH
OUTPUT

E2
20
OR

5

M1
20
PK/WT

C1

FUSED
PANEL
LAMPS
DIMMER
SWITCH
SIGNAL

7

C1

FUSED
B (+)

ANTENNA

RADIO

TJI04702

TJ

8W-47 AUDIO SYSTEM

8W - 47 - 3

2

2

2

LEFT
REAR
SPEAKER
(SOUND
BAR)

2

LEFT
FRONT
SPEAKER

RIGHT
FRONT
SPEAKER

1

1

1

X51
20
BR/YL

X58
20
DB/PK

X52
20
DB/WT

1

2

5

6

X57
18
BR/LB

X51
18
BR/YL

X58
18
DB/PK

X52
18
DB/WT

1

2

5

6

X58
18
DB/PK

X52
18
DB/WT

H7

C323

C12

2

C1

LEFT
FRONT
SPEAKER
(-)

TJI04703

4

X56
18
DB

C2

LEFT
FRONT
SPEAKER
(+)

3

X54
18
VT

C1

RIGHT
FRONT
SPEAKER
(-)

5

C2

H10

6

7

8

X51
18
BR/YL

C11

X57
18
BR/LB

RIGHT
FRONT
SPEAKER
(+)

C325

RHD

H9

C323

10

9

C323

RHD

X57
18
BR/LB

X53
18
DG

C330

LHD

X51
18
BR/YL

LHD

X55
18
BR/RD

1

X57
20
BR/LB

X57
18
BR/LB

H8

RIGHT
REAR
SPEAKER
(SOUND
BAR)

C2

LEFT
REAR
SPEAKER
(-)

X58
18
DB/PK

C14

X51
18
BR/YL

2

C323

C2

LEFT
REAR
SPEAKER
(+)

C13

X58
18
DB/PK

7

X52
18
DB/WT

C2

RIGHT
REAR
SPEAKER
(-)

C204

X52
18
DB/WT

3

C2

RIGHT
REAR
SPEAKER
(+)

RADIO

J998W-5

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8W - 48 - 2

8W-48 REAR WINDOW DEFOGGER
BATT A0

(8W-10-8)

POWER
DISTRIBUTION
CENTER

21
FUSE
15
40A
(8W-10-14)

28

RUN A22

(8W-10-6)

TJ

FUSE
BLOCK
(8W-11-2)

FUSE
7
10A
(8W-11-7)

(8W-10-2)

27

A4
12
BK/PK

F20 20VT/WT
F3

D2

D4

C106
S108
(8W-11-7)

REAR
WINDOW
DEFOGGER
RELAY
(PDC)

D6

D8
C15
12
BK/WT
F8

C106
S320
LHD

C15
14
BK/WT
17

H1

FUSE
17
10A
(8W-11-9)

FROM

S206
(8W-11-4)

RHD

C323

1

FUSE
BLOCK

1

C326

(8W-11-2)

1

C331

C81
20
LB/WT

C323

C15 12BK/WT
2

E2
20
OR

37
A5

C15
12
GY

C202

REAR
WINDOW
DEFOGGER
(HARD
TOP)

F81
20
DB/RD
4

3
ILLUMINATION
LAMP
(HARD
TOP)

INDICATOR
LAMP

REAR
WINDOW
DEFOGGER
SWITCH
(HARD
TOP)

Z1
12
BK

(8W-15-11)

2

1

6

Z1
20
BK

6

S207
(8W-15-7)
Z1 (8W-15-8)
16
BK

G200
J998W-5

(8W-15-7)
(8W-15-8)

C331
C326
S309
(8W-15-11)

C80
20
DB/LG

LHD
G5

RHD

C322

C81
20
LB/WT
3

S400

5

C322

C170

C1

REAR
WINDOW
DEFOGGER
RELAY
CONTROL

INSTRUMENT
CLUSTER
(8W-40-8)

REAR
WINDOW
DEFOGGER
SWITCH
SENSE
4
C1

G302
(8W-15-11)
TJI04802



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8W - 50 - 2

8W-50 FRONT LIGHTING

BATT F34

BATT A3

(8W-11-4)

(8W-10-13)

3

0 OFF
1 PARK
2 HEAD
3 DOME
4 MAX
5 MIN

3

5

0

2

1

2

2

4
1

1

9

A2
L2
14
LG

E1
18
TN

TO

FUSE
3 (FB)

D8

L20
16
LG/WT

C202

HEADLAMP
DIMMER
SWITCH
1

TO

FUSE
16 (FB)
(REAR FOG
LAMPS)

2

1 LOW
2 HIGH
3 FLASH

3

1

3

L4
14
VT/WT

L3
14
RD/OR

(8W-11-10)
E5

(8W-11-4)

DRL

C107

E4

L3
16
RD/OR

L4
16
VT/WT
OTHER

S104

S105

(8W-50-8)

OTHER

5

C110

4

L3
16
RD/OR

S119
L4
16
VT/WT

L3 16RD/OR

L4
16
VT/WT
2

1

LEFT
HEADLAMP

L3
16
RD/OR
1

RIGHT
HEADLAMP

Z1
20
BK

3

S117
(8W-15-3)

Z1
18
EXCEPT BUILT- BK BUILTUP-EXPORT
UP-EXPORT

Z1
16
BK

S150
(8W-15-5)

G102
(8W-15-3)

DRL
1
DIMMER SWITCH
HIGH BEAM OUTPUT
HIGH BEAM
INDICATOR DRIVER
4
G34
18
RD/GY

2

3

J998W-5

C108

L20
14
LG/WT
4

2

L2
16
LG

C202

A3

L20
16
LG/WT

L20
16
LG/WT

A8
E1
18
TN

(8W-50-8)

6

7
L2
16
LG

DAYTIME
RUNNING
LAMP
MODULE

FUSED
B(+)
OPTICAL
HORN
FEED

HEADLAMP
SWITCH

CIRCUIT
BREAKER
24A

0

TJ

G103
(8W-15-4)
(8W-15-5)

D7

C108

G34
16
RD/GY
B5
5

DAYTIME
RUNNING
LAMP
MODULE
(8W-50-8)
HIGH
BEAM
INDICATOR
DRIVER
1
G34
16
RD/GY

FOG
LAMP
RELAY
NO. 2
(EXCEPT
BUILT-UP
-EXPORT)
(8W-50-6)

C203
C2

HIGH
BEAM
INDICATOR
DRIVER

INSTRUMENT
CLUSTER
(8W-40-9)
TJI05002

TJ

8W-50 FRONT LIGHTING

8W - 50 - 3
INSTRUMENT

KEY-IN
CLUSTER
IGNITION (8W-40-7)
SWITCH
SENSE
8
C1
G26
20
LB
FROM

S202
(8W-44-4)

C203

B3

G26
20
LB

M2
20
YL
3

5

HEADLAMP
SWITCH
0
0

0 OFF
1 PARK
2 HEAD
3 DOME

2

1

3

6
G16
20
BK/LB

Z1
16
BK
RHD

LHD

B4

C203

S207
(8W-15-8)
Z1
16
BK

Z1
16
BK

G16
20
BK/LB

3
DRIVER
DOOR
AJAR
SWITCH
SENSE

Z1
16
BK

DRIVER
DOOR
AJAR
SWITCH
(8W-44-4)

G16
20
BK/LB

G200
(8W-15-7)
(8W-15-8)

TJI05003

1
DRIVER
DOOR
AJAR
SWITCH
SENSE

KEY-IN
SWITCH
(8W-40-7)
(8W-44-4)

J998W-5

8W - 50 - 4

8W-50 FRONT LIGHTING

INSTRUMENT
CLUSTER
(8W-40-9)
LEFT
TURN
SIGNAL
10
LEFT
C2
TURN
L61
SIGNAL
18
10
GY

BATT F34

0

1

RIGHT
TURN
SIGNAL
1

1 PARK
2 HEAD
3 OFF

2

L61
18
GY

L7
18
BK/YL

(8W-52-3)

INSTRUMENT
CLUSTER

9

FOG
LAMP
RELAY
NO. 2
(EXCEPT
BUILT-UP
EXPORT)

TURN
SIGNAL/
HAZARD
SWITCH

L60
18
TN

(8W-52-3)

3

C203

(8W-11-4)

HEADLAMP
SWITCH

TURN
SIGNAL/
HAZARD
SWITCH

HEADLAMP
SWITCH
OUTPUT

B2

TJ

RIGHT (8W-40-9)
TURN
SIGNAL
6
C1

L7
18
BK/YL

L60
18
TN

(8W-50-6)
B6

B1

C203
L7 18BK/YL

E3

E1

E2

C107

3

1

2

C110

LHD
G1

RHD

C322

C322

1

S118
(8W-70-2)

S141
2
L7
18
BK/YL

1

L61
18
GY
2

3
Z1
18
BK
FRONT
FOG LAMPS

LEFT
FRONT
PARK/
TURN
SIGNAL
LAMP
(EXCEPT BUILTUP-EXPORT)
EXCEPT FRONT
FOG LAMPS

L60
18
TN

LEFT
CITY
LAMP
(BUILT-UP
-EXPORT)

2

2

1

RIGHT
FRONT
PARK/
TURN
SIGNAL
LAMP
(EXCEPT BUILTUP-EXPORT)

2

3
Z1
18
BK
FRONT
FOG LAMPS

S150
(8W-15-5)
(8W-15-3)

G102

(8W-70-2)
RIGHT
SIDE
MARKER
LAMP
(EXCEPT BUILTUP-EXPORT)

S144
RIGHT
CITY
LAMP
(BUILT-UP
-EXPORT)

Z1
18
BK

S117

J998W-5

L7
18
BK/YL

Z1
20
BK

(8W-15-3)

1

L7
18
BK/YL

1

S122

Z1
16
BK

L7
18
BK/YL

1

(8W-15-3)
Z1
18
BK

TO

S310

2

L7
18
BK/YL

S143

1

S142

LEFT
SIDE
MARKER
LAMP
(EXCEPT BUILTUP-EXPORT)

Z1
18
BK

EXCEPT FRONT
FOG LAMPS

S125
(8W-15-4)
Z1
18
BK

G103
(8W-15-4)
(8W-15-5)

TJI05004

TJ

8W-50 FRONT LIGHTING
BUILT-UP-EXPORT
BATT A3

FUSE
BLOCK
FUSE
16
10A
(8W-11-10)

(8W-10-13)

CIRCUIT
BREAKER
24A

16

(8W-11-2)

0

36

HEADLAMP
SWITCH
0 OFF
1 PARK
2 HEAD

2

2

L2
16
LG

L22
20
LG/DG

1

8W - 50 - 5

L2
16
LG

C202

A8

S330
(8W-11-10)

L2
14
LG

L22
20
LG/DG

2

L22 20LG/DG
C9

C108

D13

C204

HEADLAMP
DIMMER
SWITCH

HEADLAMP
SWITCH
OUTPUT

L22
20
LG/DG

(8W-50-2)

C110

9

L22
20
LG/DG

S151
S138
L13
20
BR/YL
14
L22
20
LG/DG
2

L13
20
BR/YL

L13
20
BR/YL

C110

L13
20
BR/YL
1

C170

L22
20
LG/DG

5

HEADLAMP
LEVELING
SWITCH

2

2

Z1
20
BK
LHD

1

LEFT
HEADLAMP
LEVELING
MOTOR

3

4

M

RIGHT
HEADLAMP
LEVELING
MOTOR

3
Z1
20
BK

Z1
18
BK

RHD

S117

S207
Z1
16
BK

L22
20
LG/DG

1

M

TJI05005

(8W-11-10)

Z1
16
BK

(8W-15-7)

G200

G200

(8W-15-7)

(8W-15-8)

(8W-15-3)

S150
Z1
18
BK

(8W-15-5)

G102

G103

(8W-15-3)

(8W-15-5)
J998W-5

8W - 50 - 6

8W-50 FRONT LIGHTING
FOG LAMPS

DIMMER HEADLAMP
SWITCH DIMMER
HIGH
SWITCH
BEAM (8W-50-2)
OUTPUT

BATT F34

TJ

(8W-11-4)

HEADLAMP
SWITCH

3
L3
14
RD/OR
E4

0

2

1

C107

3

L3
16
RD/OR

9

4

5

0 OFF
1 PARK
2 HEAD
3 DOME
4 MAX
5 MIN
(8W-50-2)

1

S105
(8W-50-2)

L7
18
BK/YL

L3
16
RD/OR
D7

E1
18
TN

C108
B6

G34
16
RD/GY

C203

C202

A3

G34
16
RD/GY

C203

B5

HIGH
BEAM
INDICATOR
DRIVER

G34
16
RD/GY

L7
18
BK/YL

C2

5

INSTRUMENT
CLUSTER

E1
18
TN

(8W-40-9)

1

3

3

FUSE
BLOCK

FOG
LAMP
RELAY
NO. 2
2

4

FUSE
BLOCK
FUSE
4
10A
(8W-11-5)

Z1
20
BK

24
Z1
20
BK

(8W-11-2)

23
L95
18
DG/YL

C204

C1

E2
20
OR

E2
20
OR

C202

A4

1

Z1
20
BK

L95
18
DG/YL

E2
20
OR

B

C

A

S304

TO

FOG
LAMP
RELAY
NO. 1

(8W-15-9)
Z1
16
BK

(8W-50-7)

G300
J998W-5

(8W-11-2)

FUSE
3
10A
(8W-11-4)

(8W-15-9)

TO

TO

FRONT
FOG
LAMP
SWITCH

S206

FUSED
PANEL
LAMPS
DIMMER
SWITCH
SIGNAL

PRNDL
LAMP
(8W-44-5)

(8W-50-7)

(8W-50-7)
TJI05006

TJ

8W-50 FRONT LIGHTING
FOG LAMPS
FROM

C204

(8W-50-6)

(8W-50-6)

C

B

E2
20
OR

FOG
LAMP
RELAY
NO. 2

S206

(8W-50-6)
A

FROM

C202

FROM

8W - 50 - 7

BATT A6

POWER
DISTRIBUTION
CENTER

A6

L95
18
DG/YL

FUSE
25
20A
(8W-10-16)

(8W-11-4)
1

A5

3

FRONT
FOG
LAMP
SWITCH

4

B13

(8W-10-2)

F61
18
WT/OR

2
Z1
20
BK

(8W-10-10)

D6

C203

C108

F61
18
WT/OR

L35
18
BR/WT

S207
Z1
20
BK

(8W-15-7)

1

3

FOG
LAMP
RELAY
NO. 1

Z1
16
BK

G200
(8W-15-7)

2

5

C107

E10
L39
18
LB

C110

13

S116
2

2

LEFT
FOG
LAMP

1

S122
(8W-15-3)
Z1
18
BK

RIGHT
FOG
LAMP

1
Z1
18
BK

S125
(8W-15-4)

S117
(8W-15-3)
Z1
16
BK

G103
G102

TJI05007

Z1
18
BK

(8W-15-3)

(8W-15-4)
J998W-5

8W - 50 - 8

8W-50 FRONT LIGHTING
DRL

ST-RUN A21

VEHICLE

(8W-10-9)

VEHICLE SPEED
SPEED
SENSOR SENSOR
SIGNAL (8W-30-10)

FUSE
BLOCK
(8W-11-2)
FUSE
11
10A
(8W-11-8)

S135

L20
16
LG/WT

C106

F10

A2

G7
18
WT/OR

G7
20
WT/OR

C202

B27

L20 14LG/WT

F12
20
RD/LG

S102

D8

5

12

4

L20
16
LG/WT

(8W-11-8)

HEADLAMP
DIMMER
SWITCH

FUSED
B(+)
OPTICAL
HORN
FEED

C108

DIMMER
SWITCH
LOW
BEAM
OUTPUT

DIMMER
SWITCH
HIGH
BEAM
OUTPUT

10
DIMMER
SWITCH
HIGH
BEAM
OUTPUT

L3
16
RD/OR

1

L3
14
RD/OR

L4
14
VT/WT

E4

E5

L3
16
RD/OR

HIGH
BEAM
INDICATOR
DRIVER

D7

C108

C107

S106
(8W-15-2)
G34 16RD/GY

B5

L4
16
VT/WT

C203
1

S105

S104
5

L3 16RD/OR
2

FOG
LAMP
RELAY
NO. 2

Z1
12
BK

(8W-50-6)

C110
S119

1

HIGH
BEAM
INDICATOR
DRIVER

G34
16
RD/GY
5

2

Z1
18
BK

G34
16
RD/GY

(8W-50-2)

L3
16
RD/OR

GROUND
8

G34
18
RD/GY

L4
16
VT/WT

C110

POWERTRAIN

VEHICLE CONTROL
SPEED
SENSOR MODULE
SIGNAL (8W-30-10)

DAYTIME
RUNNING
LAMP
MODULE

4

DIMMER HEADLAMP
SWITCH DIMMER
LOW
SWITCH
BEAM (8W-50-2)
OUTPUT

3

C2

7
VEHICLE
SPEED
SENSOR
SIGNAL

FUSED
B(+)
OPTICAL
HORN
FEED

1

C103

G7
20
WT/OR

(8W-50-2)

6

FUSED
IGNITION
SWITCH
OUTPUT
(ST-RUN)

J998W-5

G7
20
WT/OR

(8W-50-2)

7

F12
20
RD/LG

1

3

HEADLAMP
SWITCH

FUSED
B(+)
OPTICAL
HORN
FEED

31

4

TJ

C2

HIGH
BEAM
INDICATOR
DRIVER

LEFT
HEADLAMP

RIGHT
HEADLAMP

(8W-50-2)

(8W-50-2)

INSTRUMENT
CLUSTER
(8W-40-9)

G100
(8W-15-2)

TJI05008

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Œ t HY
zKb|t Hxuw{z•” –a[A[A{f—f3ˆz•˜*™Z{‡ Y3˜~gMgMgMggMgMgMgMgMg'h3jk]_lnm3]_€
Œ t zA[A’t uZXZzA{Y
\{zKgMgMgMgMggMgMgMgMgMgMgMgMggMgMgMgMgMg'h3jk]_lnm3]_š
ph
Œ ˆ„Mu†zAˆ‡ ‡v{z–a„uwtv]vb'ˆ[A\‰XZzAY
\M{ŽgMgMgMgMggMgMgMgMgMg'h3jk]_lnm3]_
p€
›|ˆb'Y
de`cƒ…‡ ‡v’Mdet „YRuwt ˆ„œgMgMgMgMgMgMgMggMgMgMgMgMg'h3jk]_lnm3]_š
ph
›|ˆb'Y
de`cƒ…„Št [AY
uwˆzggMgMgMgMgMgMgMgMggMgMgMgMgMg'h3jk]_lnm3]_š
ph
›|’f—{Žoež_›|XŸKgMgMgMgMgMgMgMggMgMgMgMgMgMgMgMggMgMgMgMgMg'h3jk]_lnm3]_
p€
›|’f—{Žqež_›|XŸKgMgMgMgMgMgMgMggMgMgMgMgMgMgMgMggMgMgMgMgMg'h3jk]_lnm3]_š
ph
›|’f—{Žež_›|XŸKgMgMgMgMgMgMgMggMgMgMgMgMgMgMgMggMgMgMgMgMg'h3jk]_lnm3]_š
ph
›|’f—{Žšež_›|XŸKgMgMgMgMgMgMgMggMgMgMgMgMgMgMgMggMgMgMgMgMg'h3jk]_lnm3]_o
pq
›|’f—{‰m3€ež_›|XŸŽgMgMgMgMgMgMggMgMgMgMgMgMgMgMggMgMgMgMgMg'h3jk]_lnm3]_š
ph
›|’f—{ŽXZ‡ ˆ[A\ ggMgMgMgMgMgMgMgMggMgMgMgMgMg'h3jk]_lnm3]_o
pq
p
p€
pš
ph
¡ o
¢
¢œgMgMgMggMgMgMgMgMgMgMgMggMgMgMgMgMgMgMgMggMgMgMgMgMg'h3jk]_lnm3]_š
ph
¡ q
¢
¢£gMggMgMgMgMgMgMgMgMggMgMgMgMgMgMgMgMggMgMgMgMgMg'h3jk]_lnm3]_€
pš
ph

IKJML¤N|JOQPROQS
TVUMWP
¡ q
¢
o£gMggMgMgMgMgMgMgMgMggMgMgMgMgMgMgMgMggMgMgMgMgMg'h—j5]_lnm3]_
pš
ph
Ž{Y
Š‡ Y
de`;¥,t dede{z,rHs)t uw[Ax¦gMgMgMgMggMgMgMgMgMg'h—j5]_lnm3]_š
ph
Ž{Y
Š‡ Y
de`;r}s)t uw[Ax§gMgMgMgMgMgMgMggMgMgMgMgMg'h—j5]_lnm3]_o
pq
pš
ph
b|{‚_uZb|t [A{„f3{Žb'Y
de`¨gMggMgMgMgMgMgMgMgMggMgMgMgMgMg'h—j5]_lnm3]_š
ph
b|{‚_uZ™Z{YRz,b'Y
de`V–af3f—{de©
‡ ˜igMgMgMgMgMg'h—j5]_lnm3]_o
pq
p
pl
p€
ª|YRzA\”¬«a{’uwzAYR‡nª|ˆf3t u†t ˆ„‘r}s)t uw[Ax­gMgMggMgMgMgMgMg'h—j5]_lnm3]_o
pq
ª|ˆ…s){zAu†z®YRt „ Œ ˆ„uwzAˆ‡“‘ˆŠR’‡ {¯gMgMgMgMgMgMggMgMgMgMgMg'h—j5]_lnm3]_€
ª|™Z«a¥Kbœb|Y
de`°gMgMgMgMgMggMgMgMgMgMgMgMgMggMgMgMgMgMg'h—j5]_lnm3]_š
ph
™Z{Y
z,›'ˆ)b|Y
de`¤gMgMgMgMggMgMgMgMgMgMgMgMggMgMgMgMgMg'h—j5]_lnm3]_š
ph
™Z{Y
z,›'ˆ)b|Y
de`;™Z{‡vY3˜±gMgMgMgMgMgMgMgMggMgMgMgMgMg'h—j5]_lnm3]_š
ph
™Z{Y
z,›'ˆ)b|Y
de`;r}s)t uw[AxFgMgMgMgMgMgMgMggMgMgMgMgMg'h—j5]_lnm3]_š
ph
™Zt HxuZb|t [A{„f3{Žb'Y
de`ggMgMgMgMgMgMgMgMggMgMgMgMgMg'h—j5]_lnm3]_š
ph
™Zt HxuZ™Z{YRz,b'Y
de`V–af3f—{de©
‡ ˜‰gMgMgMgMg'h—j5]_lnm3]_o
pq
p
pl
p€
²³YRt ‡ ”¬ru†ˆ`´” ²³’z®„‘rtv}„Y
‡nb'Y
de`RfCgMgMggMgMgMgMgMg'h—j5]_lnm3]_o
pl
²³YRt ‡ ” ²³’MzA„‘rt H„Y
‡nb|YRde`Rf<gMgMgMgMgMgMgMgMggMgMgMgMgMg'h—j5]_lnm3]_q
²³’MzA„‘rt H„Y
‡ ”¬Y
µ´Y
zAŠcrHstvuw[Ax¤ggMgMgMgMgMg'h—j5]_lnm3]_o
pq
pl
p€
¶Z{xt [A‡ {Žr“`R{{Š Œ ˆ„Mu†zAˆ‡nr{z•·“ˆ‘gMgMgMgMgMggMgMgMgMgMg'h—j5]_lnm3]_€

8W - 51 - 2

8W-51 REAR LIGHTING
EXCEPT BUILT-UP-EXPORT
RUN A22

TJ

BATT F34

(8W-10-8)

(8W-11-4)

FUSE
BLOCK

HEADLAMP
SWITCH

(8W-11-2)
FUSE
7
10A
(8W-11-7)

0

F20
20
VT/WT

L7
18
BK/YL

C106

F3

S108
C104

10

A/T

M/T

C154

F20
18
VT/WT
B

3

A

L1
18
VT/BK

L1
18
VT/BK

C154

2

G1

C110

C322

L63
18
DG/RD

L62
18
BR/RD

TO
(8W-70-2)

S310
G2

(8W-70-2)

L1
20
VT/BK

G3

(8W-52-2)

S118

C104

C106

3

L7
18
BK/YL

C322

L7
18
BK/YL

C154

L1
20
VT/BK

L1
20
VT/BK

L7
18
BK/YL
1

BACK-UP
LAMP
SWITCH

PARK/
NEUTRAL
POSITION
SWITCH

F2

9

C107

E1
L7
18
BK/YL

C154

4

9

RIGHT
TURN
SIGNAL

L7
18
BK/YL

F20
20
VT/WT

F20
18
VT/WT
1

LEFT
TURN
SIGNAL

TURN
SIGNAL/
HAZARD
SWITCH

C203

B6

(8W-11-7)

2

1

9

27

4

0 OFF
1 PARK
2 HEAD
(8W-50-4)

2

G4

C322

C322
S335
S311

L1
20
VT/BK

L7
18
BK/YL

L63
18
DG/RD

1

3

2

BACK-UP
LAMP

J998W-5

TAIL/
STOP/
TURN
SIGNAL
LAMP

LEFT
REAR
LAMP
ASSEMBLY

L63
18
DG/RD

L1
20
VT/BK

L7
18
BK/YL

L62
18
BR/RD

4

1

3

2

NOT
USED
BACK-UP
LAMP

TAIL/
STOP/
TURN
SIGNAL
LAMP

RIGHT
REAR
LAMP
ASSEMBLY

TJI05102

TJ

8W-51 REAR LIGHTING
BUILT-UP-EXPORT
RUN A22

8W - 51 - 3

BATT F34

(8W-10-8)

(8W-11-4)

FUSE
BLOCK
(8W-11-2)

FUSE
7
10A
(8W-11-7)
27
F3

HEADLAMP
SWITCH
0

L7
18
BK/YL

C104

10

A/T

C154

4

F20
18
VT/WT

B

L1
18
VT/BK

L1
18
VT/BK

C154

L63
18
DG/RD

L62
18
BR/RD

C110

1

TO

LHD

RHD

C322

G1

1

C322

C154

2

LHD

L1
20
VT/BK

L7
18
BK/YL

G2

L7
18
BK/YL

C106

LHD
G4

C322

4

C322

L7
18
BK/YL

L63
18
DG/RD

L62
18
BR/RD

S311

TJI05103

C322

C322

C322

BACK-UP
LAMP

2

RHD

RHD

3

C322

(8W-70-2)

L1
20
VT/BK

2

RHD

S310

C104

3

(8W-52-2)

(8W-70-2)

A

LHD

3

S118

L1
20
VT/BK

G3

L7
18
BK/YL

BACK-UP
LAMP
SWITCH

3

F2

9

L7
18
BK/YL

PARK/
NEUTRAL
POSITION
SWITCH

9

RIGHT
TURN
SIGNAL

C107

E1

F20
18
VT/WT

1

LEFT
TURN
SIGNAL

TURN
SIGNAL/
HAZARD
SWITCH

L7
18
BK/YL

M/T

C154

C203

B6

F20
20
VT/WT

2

1

9

C106
S108
(8W-11-7)

4

0 OFF
1 PARK
2 HEAD
(8W-50-4)

2

4

1

TAIL/
STOP
LAMP

2

TURN
SIGNAL
LAMP

LEFT
REAR
LAMP
ASSEMBLY

3

BACK-UP
LAMP

4

1

TAIL/
STOP
LAMP

TURN
SIGNAL
LAMP

RIGHT
REAR
LAMP
ASSEMBLY

J998W-5

8W - 51 - 4

8W-51 REAR LIGHTING

TJ

BATT A6

(8W-10-10)

FUSE
BLOCK
(8W-11-2)
FUSE
2
20A
(8W-11-4)
22

CONTROLLER

F32
18
PK/DB
5

BRAKE
LAMP
SWITCH
(8W-51-6)

BRAKE ANTI-LOCK
LAMP
BRAKE
SWITCH
OUTPUT (8W-35-5)
8
C1
L50
18
WT/TN

6
L50
18
WT/TN

L50 18WT/TN
LHD
BUILT-UPEXPORT

RHD

7

G7

C322

BUILT-UPEXPORT

EXCEPT
BUILT-UPEXPORT

C322

G7

C108

D9

C322

L50
18
WT/TN

EXCEPT
BUILT-UPEXPORT

L50
18
WT/TN

S315
L50
18
WT/TN

L50
18
WT/TN

CENTER
HIGH
MOUNTED
STOP
LAMP

3

RIGHT
REAR
LAMP
ASSEMBLY

TAIL/STOP/TURN
SIGNAL LAMP

A
TO

TURN
SIGNAL/
HAZARD
SWITCH
(8W-51-5)

TAIL/STOP LAMP
Z1
18
BK

S309

3

TAIL/STOP/TURN
SIGNAL LAMP
TAIL/STOP LAMP

LEFT
REAR
LAMP
ASSEMBLY

Z1
12
BK

(8W-15-11)

LHD
G5

RHD

C322

5

C322

EXCEPT BUILT-UP-EXPORT
BUILT-UP-EXPORT

G302
J998W-5

(8W-15-11)

TJI05104

TJ

8W-51 REAR LIGHTING

8W - 51 - 5
FROM

C322
(8W-51-4)
A

L50
18
WT/TN
4

2

3
3

1

4

3

1 LEFT
2 RIGHT
3 NORMAL
4 HAZARD

1

1

2

10

3
L62
18
BR/RD

L63
18
DG/RD

EXCEPT
BUILT-UPEXPORT
G4

LHD
BUILT-UPEXPORT

EXCEPT
BUILT-UPEXPORT

RHD

LHD
BUILT-UPEXPORT

C322

G2
G4

L63
18
DG/RD

C322

4

4

2

9

TURN
SIGNAL/
HAZARD
SWITCH

4

C322

G2

RHD

C322

2

C322

C322
L62
18
BR/RD

S335
(8W-51-2)

1

L63
18
DG/RD

L63
18
DG/RD

2
TAIL/
STOP/
TURN
SIGNAL
LAMP

L63
18
DG/RD

LEFT
REAR
LAMP
ASSEMBLY

L62
18
BR/RD

4
NOT
USED

(8W-51-2)

1

TURN
SIGNAL
LAMP

LEFT
REAR
LAMP
ASSEMBLY

TURN
SIGNAL
LAMP

RIGHT
REAR
LAMP
ASSEMBLY
(8W-51-3)

2
TAIL/
STOP/
TURN
SIGNAL
LAMP

RIGHT
REAR
LAMP
ASSEMBLY
(8W-51-2)

(8W-51-3)
TJI05105

J998W-5

8W - 51 - 6

8W-51 REAR LIGHTING

SPEED
CONTROL
ON/OFF
SWITCH
SENSE
C11
C3

POWERTRAIN
CONTROL
MODULE

BRAKE
SWITCH (8W-30-16)
SENSE
C24
C3

BRAKE
SWITCH
SENSE
1

K29
18
WT/PK

V32
18
YL/RD
D1

D14

V32
20
YL/RD

BATT A6

1

22

(8W-31-2)

F32
18
PK/DB

5

BRAKE
LAMP
SWITCH
4

2

Z1
20
BK

V30
20
DB/RD

GROUND

C107

5
LHD

CIGAR
LIGHTER/
ACCESSORY
RELAY

Z1
20
BK

RHD

VEHICLE
SPEED
CONTROL
SERVO
(8W-30-16)

G7
7

EXCEPT
BUILT-UP
-EXPORT

BUILT-UP
-EXPORT

C322

C322

D9

EXCEPT
BUILT-UP
-EXPORT

S315
G7

C322

C108
L50
18
WT/TN

L50
18
WT/TN

L50
18
WT/TN

BRAKE
LAMP
SWITCH
OUTPUT

L50
18
WT/TN

RHD

3

S304

BRAKE
LAMP
SWITCH
OUTPUT

L50
18
WT/TN

(8W-15-10)
Z1
16
BK

G300
3

LHD
BUILT-UP
-EXPORT

(8W-41-2)

Z1
20
BK

V30
20
DB/RD

J998W-5

L50 18WT/TN

6
L50
18
WT/TN

SPEED
CONTROL
BRAKE
SWITCH
OUTPUT

(8W-11-2)

FUSE
2
20A
(8W-11-4)

BRAKE
SHIFT
INTERLOCK
SOLENOID

K29
20
WT/PK

3

E11

(8W-10-10)

FUSE
BLOCK

K29
20
WT/PK

C108

TJ

CENTER
HIGH
MOUNTED
STOP
LAMP
(8W-51-4)

RIGHT
REAR
LAMP
ASSEMBLY
(8W-51-4)

8

3

C1

BRAKE CONTROLLER
LAMP
ANTI-LOCK
SWITCH BRAKE
OUTPUT (8W-35-5)

(8W-15-9)
(8W-15-10)

BRAKE
LAMP
SWITCH
OUTPUT

LEFT
REAR
LAMP
ASSEMBLY
(8W-51-4)

2
BRAKE
LAMP
SWITCH
OUTPUT

TURN
SIGNAL/
HAZARD
SWITCH
(8W-51-5)

TJI05106

TJ

8W-51 REAR LIGHTING
LHD BUILT-UP-EXPORT
BATT A3

BATT F34

(8W-10-13)

HEADLAMP
SWITCH
0 OFF
1 PARK
2 HEAD
3 MAX
4 MIN
(8W-50-2)
(8W-50-4)

(8W-50-2)
0

2

1

0

2

4
L2
16
LG

L2
14
LG

1

9
E1
18
TN

L7
18
BK/YL

C202

A3
3

16

L22
20
LG/DG

5

1

HEADLAMP
SWITCH
FUSED
OUTPUT
REAR
FOG
LAMP
RELAY
CONTROL

REAR
FOG
LAMP
RELAY

HEADLAMP
SWITCH
FUSED
OUTPUT
REAR
FOG
LAMP
FEED
4
L38
20
BR/WT

2
L95
18
DG/YL

FUSE
16
10A
(8W-11-10)

(8W-11-10)
L22
20
LG/DG
36

FUSE
3
10A
(8W-11-4)

TO

PRNDL
LAMP

G8

C8
3

C204

FOG
LAMP
INDICATOR
FOG
LAMP
ILLUMINATION

1

REAR
FOG
LAMP
SWITCH

4
Z1
20
BK

E2
20
OR

1

C110

L7
18
BK/YL
G1

S310

S118

(8W-70-2)

(8W-70-2)

C322

L38
20
BR/WT
1

Z1
20
BK

2

1

L7
18
BK/YL

2

REAR
FOG
LAMP

C329
S317

C329

L38
18
BR/WT

C322

L7
18
BK/YL

TO

(8W-11-4)

FUSE
BLOCK
FUSE
4
10A
(8W-11-5)

C107

L7
18
BK/YL

S206

Z1 20BK

24

E1

C202

A4

L38 20BR/WT
C1
2

(8W-11-2)

E2
20
OR

(8W-44-5)

3

L7
18
BK/YL

23
E2
20
OR

GROUND

C203

B6

FUSE
BLOCK

S330
L22
20
LG/DG

2

1

3

C202

A8

L2 16LG

1

L7
18
BK/YL

LEFT
LICENSE
LAMP

2

1

2

RIGHT
LICENSE
LAMP
S316

C329

3

(8W-11-2)

Z1
20
BK

S304
(8W-15-9)

S309
Z1
16
BK

S207
(8W-15-7)

Z1
12
BK

Z1 16BK

G5

G200
TJI05107

(8W-11-4)

CIRCUIT
BREAKER
24A

HEADLAMP
DIMMER
SWITCH

HEADLAMP
SWITCH
OUTPUT
2

8W - 51 - 7

(8W-15-7)

G300
(8W-15-9)

(8W-15-11)

C322
G302
(8W-15-11)

J998W-5

8W - 51 - 8

8W-51 REAR LIGHTING
RHD BUILT-UP-EXPORT
BATT A3

BATT F34

(8W-10-13)

HEADLAMP
SWITCH
0 OFF
1 PARK
2 HEAD
3 MAX
4 MIN
(8W-50-2)
(8W-50-4)

(8W-50-2)
0

2

1

0

2

4
1

9
E1
18
TN

C202

A8

L2 16LG

L7
18
BK/YL

C202

A3
3

16

S330
L22
20
LG/DG
5

FUSE
16
10A
(8W-11-10)

L22
20
LG/DG

1

HEADLAMP
SWITCH
FUSED
OUTPUT

REAR
FOG
LAMP
RELAY

HEADLAMP
SWITCH
FUSED
OUTPUT

REAR
FOG
LAMP
RELAY
CONTROL

REAR
FOG
LAMP
FEED
4
L38
20
BR/WT

2
L95
18
DG/YL

36

TO

PRNDL
LAMP

C8
3

8

C204

FOG
LAMP
INDICATOR
FOG
LAMP
ILLUMINATION

1

REAR
FOG
LAMP
SWITCH

C322

C107

1

C110

L7
18
BK/YL

C202

A4

S206

L7
18
BK/YL
1

S310

S118

L38
20
BR/WT

(8W-70-2)
2

1

L7
18
BK/YL

2

REAR
FOG
LAMP

FUSE
BLOCK
FUSE
4
10A
(8W-11-5)

E2
20
OR

C329
S317

C329

L38
18
BR/WT

C322

L7
18
BK/YL

TO

(8W-11-4)

1

Z1
20
BK

Z1 20BK

24

4
Z1
20
BK

E1

(8W-70-2)

L38 20BR/WT
C1
2

(8W-11-2)

E2
20
OR

(8W-44-5)

3

L7
18
BK/YL

23
E2
20
OR

GROUND

FUSE
3
10A
(8W-11-4)

C203

B6

FUSE
BLOCK

(8W-11-10)

L22
20
LG/DG

2

1

3

L2
16
LG

L2
14
LG

1

L7
18
BK/YL

LEFT
LICENSE
LAMP

2

1

2

RIGHT
LICENSE
LAMP
S316

C329

3

(8W-11-2)

Z1
20
BK

S309
Z1
12
BK

S207
(8W-15-8)
Z1 16BK

5

G200
J998W-5

(8W-11-4)

CIRCUIT
BREAKER
24A

HEADLAMP
DIMMER
SWITCH

HEADLAMP
SWITCH
OUTPUT
2

TJ

(8W-15-8)

G300
(8W-15-10)

(8W-15-11)

C322
G302
(8W-15-11)

TJI05108

*,+

-/.1032/465/798;:=<?> @A:ABDC!<

-/.E0F2/4G0IH

È/É7ʗË/Ì7ÍFÎÐÏ9ÑÓÒFÔAÕCÑE֋×Ò
ØKÙMÚ*Û'ÙÜQÝRÜQÞ
ßVàMáÝ
âZãä)åRæ çè
éwæ ãç‘ê|ë è
ì—íîï¦ððMðMðMðMðMðMðMðMðMððMðMðMðMðMð'ñ3òkó_ô
õ
ó_õ
ê|öì—îŽ÷eø_ù|úKâûÐðMðMðMðMðMðMðMððMðMðMðMðMðMðMðMððMðMðMðMðMð'ñ3òkó_ô
õ
ó_õ
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8W - 52 - 2

8W-52 TURN SIGNALS

RUN-ACC A31

BATT A0

(8W-10-9)

FUSE
BLOCK
FUSE
13
10A
(8W-11-9)

(8W-10-6)

POWER
DISTRIBUTION
CENTER

22

(8W-11-2)

FUSE
9
20A
(8W-10-13)

15

TJ

(8W-10-2)

COMBINATION
FLASHER

33

COMBINATION
FLASHER
INPUT

L9
16
BK/WT

COMBINATION
FLASHER
OUTPUT GROUND

6

2

4
Z1
20
BK

L5
20
BK/GY

L55
16
RD/WT

C108

D11

L32
16
PK

S304
(8W-15-9)
Z1 (8W-15-10)
16
BK

L9
16
BK/WT

G300
5

6

3

11

4

3

4
3

1

4

G4

3

LHD
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2 RIGHT
3 NORMAL
4 HAZARD

1

2

10

3

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LHD
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C322

G2
G4

L63
18
DG/RD

L63
18
DG/RD

C322

TAIL/
STOP/
TURN
SIGNAL
LAMP

LEFT
REAR
LAMP
ASSEMBLY
(8W-51-2)

G2

1

LEFT
REAR
LAMP
ASSEMBLY
(8W-51-3)

RHD

C322

2

(8W-51-2)

1
L62
18
BR/RD

NOT
USED

C322

C322

S335

4
TURN
SIGNAL
LAMP

L62
18
BR/RD

L62
18
BR/RD

L63
18
DG/RD

L63
18
DG/RD

2

J998W-5

C322

4

4

1

L63
18
DG/RD

TURN
SIGNAL/
HAZARD
SWITCH

4

2

9
EXCEPT
BUILT-UPEXPORT

(8W-15-9)
(8W-15-10)

2

TURN
SIGNAL
LAMP

RIGHT
REAR
LAMP
ASSEMBLY
(8W-51-3)

2
TAIL/
STOP/
TURN
SIGNAL
LAMP

RIGHT
REAR
LAMP
ASSEMBLY
(8W-51-2)
TJI05202

TJ

8W-52 TURN SIGNALS
5

6

3

11

4

2

4

3
3

1

4

3

4

1 LEFT
2 RIGHT
3 NORMAL
4 HAZARD
1

L60
18
TN

3
L61
18
GY

B2

C203

10

C2

B1
6

2

10

1

L60
18
TN

TURN
SIGNAL/
HAZARD
SWITCH

4

2

9

8W - 52 - 3

C1

RIGHT
TURN
SIGNAL

LEFT
TURN
SIGNAL

L61
18
GY

INSTRUMENT
CLUSTER
(8W-40-9)

E2

3
L60
18
TN

BUILTUP-EXPORT

C107
C110

E3

2
EXCEPT
BUILTUP-EXPORT

L61
18
GY

BUILTUP-EXPORT

EXCEPT
BUILTUP-EXPORT

S142
2

S142
1

RIGHT
REPEATER
LAMP
1

2
Z1
18
BK

1

RIGHT
FRONT
TURN
SIGNAL
LAMP

3

S144

L60
18
TN

1

(8W-50-4)
L7
18
BK/YL
2

S125
(8W-15-5)
Z1
18
BK

RIGHT
SIDE
MARKER
LAMP

3
FRONT
FOG LAMPS

S141
1

LEFT
REPEATER
LAMP
1

2
Z1
18
BK

RIGHT
FRONT
PARK/
TURN
SIGNAL
LAMP

1

LEFT
FRONT
TURN
SIGNAL
LAMP
S122

3

OTHER

Z1
16
BK
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(8W-15-5)

2

LEFT
FRONT
PARK/
TURN
SIGNAL
LAMP
FRONT
FOG LAMPS

(8W-15-3)

(8W-15-3)

G103

(8W-50-4)
L7
18
BK/YL

S122

S117
Z1
18
BK

1

3

(8W-15-4)

(8W-15-5)

L61
18
GY

Z1
18
BK

OTHER

S141
LEFT
SIDE
MARKER
LAMP
S143

(8W-15-3)

S125

S150

TJI05203

2

Z1
18
BK

G102
(8W-15-3)

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8W - 53 - 2

8W-53 WIPERS
STANDARD

RUN-ACC A31

TJ

(8W-10-9)

FUSE
BLOCK
(8W-11-2)

FUSE
14
20A
(8W-11-9)
34
V6
18
PK/BK

S306
V6
18
PK/BK
5

WINDSHIELD
WIPER
SWITCH
0

2

V6
18
PK/BK

2

2

1

4

V5
18
DG/YL

1

1

0

2

6

V3
18
BR/WT

5

3

V10
18
BR

WINDSHIELD
WIPER
MOTOR
M

2

C107

E8
V10
18
BR

6
4

1 PARK
2 RUN
3 LOW
4 HIGH

C110

8
V10
18
BR
A

M
4
Z1
18
BK

Z1
16
BK

WINDSHIELD
WASHER
PUMP

B

S304

Z1
18
BK

(8W-15-9)
(8W-15-10)

S117
(8W-15-3)

G300
(8W-15-9)
(8W-15-10)
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0 OFF
1 LOW
2 HIGH
3 WASH

3

V4
18
RD/YL

3
1

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Z1
16
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G102
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TJI05302

TJ

8W-53 WIPERS
INTERMITTENT

RUN-ACC A31

8W - 53 - 3

(8W-10-9)

FUSE
BLOCK
(8W-11-2)

FUSE
14
20A
(8W-11-9)
34
V6
18
PK/BK

S306
5

WINDSHIELD
WIPER
SWITCH

5
3

0
1

6

0 OFF
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2 LOW
3 HIGH
4 WASH
5 MIN
6 MAX

3

0

2

1

2

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V6
18
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2

4

6

V5
18
DG/YL

V3
18
BR/WT

V4
18
RD/YL

4

3
V10
18
BR

C107
C110

E8
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1

2

5

6
4
3

1

M

WINDSHIELD
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MOTOR
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2

V10
18
BR
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M

WINDSHIELD
WASHER
PUMP

B
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Z1
20
BK

Z1
18
BK

Z1
18
BK

S117

S304
(8W-15-9)
Z1 (8W-15-10)
16
BK

G300
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(8W-15-9)
(8W-15-10)

(8W-15-3)
Z1
16
BK

G102
(8W-15-3)
J998W-5

8W - 53 - 4

8W-53 WIPERS
HARD TOP
BATT F34

TJ
RUN A22

(8W-11-4)

HEADLAMP
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5

4

2

3

1

0 OFF
1 PARK
2 HEAD
3 DOME
4 MAX
5 MIN
(8W-50-2)

0

1
E1
18
TN

1

V13
18
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FUSE
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10A
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3

(8W-11-2)

V23
18
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3

C202

A4

Z1
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LHD

RHD

C323

H4

C331

H5

5

C326

C323

5

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E2
20
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(8W-44-5)

S206

V13
18
BR/LG
C2

E2
20
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C204

6

4

6

C322

S309
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C322

10

V23
18
BR/PK

Z1
12
BK

Z1
18
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2

1

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C204

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12
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C323

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18
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C322

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18
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Z1
16
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C331
C326

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12
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V23
18
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4

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V13
18
BR/LG

3

Z1
12
BK

V23
18
BR/PK

G10

(8W-11-4)

S400

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C323

C323

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C326
C331
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5

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20
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18
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20
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26

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3

C202

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WIPER
MOTOR
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(8W-10-8)

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C323

G200
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(8W-15-7)
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TJI05304

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8W - 70 - 2

1

8W-70 SPLICE INFORMATION
RADIO

LEFT
LICENSE
LAMP
(BUILT-UP
-EXPORT)

HEADLAMP
SWITCH

(8W-47-2)

(8W-50-4)

C1

4

(8W-51-7)
(8W-51-8)

L7
18
BK/YL

B6

(8W-51-7)
(8W-51-8)

LEFT
REAR
LAMP
ASSEMBLY

L7
18
BK/YL

C203

RIGHT
REAR
LAMP
ASSEMBLY

(8W-51-2)
(8W-51-3)

S317

9

L7
18
BK/YL

RIGHT
LICENSE
LAMP
(BUILT-UP
-EXPORT)

1

L7
18
BK/YL

TJ

(8W-51-2)
(8W-51-3)

3
4

3
4

C329

2

L7
18
BK/YL

L7
18
BK/YL

L7
18
BK/YL

L7
18
BK/YL

S310

2

LEFT
FRONT
PARK/
TURN
SIGNAL
LAMP
(EXCEPT
BUILT-UPEXPORT)

2

(8W-50-4)

1
L7
18
BK/YL

L7
18
BK/YL

3

FOG
LAMP
RELAY
NO. 2
(EXCEPT
BUILT-UP
-EXPORT)

L7
18
BK/YL
LHD
G1

RHD

C322

1

C322

(8W-50-4)

LEFT
SIDE
MARKER
LAMP
(EXCEPT
BUILT-UPEXPORT)
(8W-50-4)

1
L7
18
BK/YL

S143
L7
18
BK/YL

RIGHT
FRONT
PARK/
TURN
SIGNAL
LAMP
(EXCEPT
BUILT-UPEXPORT)

L7
18
BK/YL

RIGHT
SIDE
MARKER
LAMP
(EXCEPT
BUILT-UPEXPORT)
(8W-50-4)

S144
L7
18
BK/YL

(8W-50-6)

L7
18
BK/YL

RIGHT
CITY
LAMP
(BUILT-UP
-EXPORT)

L7
18
BK/YL
E1

C107

L7
18
BK/YL
1

C110

L7
18
BK/YL

1

L7
18
BK/YL

LEFT
CITY
LAMP
(BUILT-UP
-EXPORT)

1

(8W-50-4)

(8W-50-4)
L7
18
BK/YL

S118
EXCEPT BUILT-UP-EXPORT
BUILT-UP-EXPORT
J998W-5

TJI07002

TJ

8W-70 SPLICE INFORMATION

3

INTAKE
AIR
TEMPERATURE
SENSOR

MANIFOLD
ABSOLUTE
PRESSURE
SENSOR

OXYGEN
SENSOR
1/1
UPSTREAM
(8W-30-9)

(8W-30-7)
(8W-30-8)

1

K167
20
BR/YL

2

K167
20
BR/YL

8W - 70 - 3

(8W-30-7)
(8W-30-8)

K167
20
BR/YL

ENGINE
COOLANT
TEMPERATURE
SENSOR
(8W-30-7)
(8W-30-8)

2

BATTERY
TEMPERATURE
SENSOR

K167
20
BR/YL

(8W-30-10)

S127
K167
20
BR/YL

K167
20
BR/YL

2

1

CRANKSHAFT
POSITION
SENSOR

THROTTLE
POSITION
SENSOR

(8W-30-4)

(8W-30-10)

(8W-30-3)

K167
20
BR/YL

RHD

K167
20
BR/YL

K167
18
BR/YL

3

ENGINE
OIL
PRESSURE
SENSOR
(2.5L)

CLOCKSPRING
(8W-30-15)

(8W-30-7)
3
C2
K167
20
BR/YL

(8W-30-9)

3

4

K167
20
BR/YL

OXYGEN
SENSOR
1/2
DOWNSTREAM

FUEL
PUMP
MODULE

2
LHD

VEHICLE
SPEED
SENSOR

SPEED
CONTROL

OTHER

(8W-30-10)
K167
20
BR/YL

K167
20
BR/YL

D3
C108
K167
20
BR/YL

2
K167
20
BR/YL

D3
C108
NOT
USED

S147
S133

K167
18
BR/YL

K167
20
BR/YL

K167
20
BR/YL

K167
20
BR/YL

2

8

K167
20
BR/YL

C103

CAMSHAFT
POSITION
SENSOR
(8W-30-4)

3

A4

ENGINE
OIL
PRESSURE
SENSOR
(4.0)
TJI07003

(8W-30-8)

C1
POWERTRAIN
CONTROL
MODULE
(8W-30-3)
J998W-5

8W - 70 - 4

8W-70 SPLICE INFORMATION

POWERTRAIN
CONTROL
MODULE

VEHICLE
SPEED
SENSOR

(8W-30-7)

(8W-30-10)

C2

B31

K6
18
VT/OR

TJ

ENGINE
OIL
PRESSURE
SENSOR
(8W-30-7)
(8W-30-8)

1

1

K6
20
VT/OR

K6
20
VT/OR

S123
MANIFOLD
ABSOLUTE
PRESSURE
SENSOR
(8W-30-7)
(8W-30-8)

3

POWERTRAIN
CONTROL
MODULE

CAMSHAFT
POSITION
SENSOR

CRANKSHAFT
POSITION
SENSOR

(8W-30-4)

(8W-30-4)

(8W-30-4)

C1

A17

3

THROTTLE
POSITION
SENSOR
(8W-30-10)

3
3

K7
18
OR

K7
20
OR

K7
20
OR

K7
20
OR

K7
20
OR

S129
PARK/
NEUTRAL
POSITION
SWITCH

POWERTRAIN
CONTROL
MODULE
A6

C1

D11

ENGINE
STARTER
MOTOR
RELAY
(IN PDC)

D13

T41
18
BR/LB

(8W-21-2)

2

(8W-30-12)

C104

T41
20
BR/LB

MANUAL
TRANSMISSION
JUMPER

Z1
20
BK

C154

3

C154

1

(8W-21-2)

T41
20
BR/LB

5

T41
20
BR/LB

3

Z1
20
BK

C154

S132
(8W-15-6)

T41
20
BR/LB

T41
20
BR/LB

A/T

Z1
14
BK

M/T
T41
20
BR/LB

G105
S134
J998W-5

(8W-15-6)
TJI07004

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8W - 80 - 4

8W-80 CONNECTOR PIN-OUTS

TJ

BLACK
1

2

A/C COMPRESSOR
CLUTCH

CAV
1
2

CIRCUIT
C3 20DB/BK
Z1 20BK

FUNCTION
A/C COMPRESSOR CLUTCH RELAY OUTPUT
GROUND

CAV
A
B
C
D
E

CIRCUIT
C7 12BR/TN
C6 14LB
C5 16LG/LB
C4 16TN
C1 12DG

FUNCTION
HIGH SPEED BLOWER MOTOR
M2 SPEED BLOWER MOTOR
M1 SPEED BLOWER MOTOR
LOW SPEED BLOWER MOTOR
BLOWER MOTOR FEED

CAV
1
1
2
3
3
4
5

CIRCUIT
Z11 20BK/WT
F24 20RD/DG

FUNCTION
GROUND
FUSED IGNITION SWITCH OUTPUT (RUN)

C36 20DB/RD
F24 20RD/DG
Z11 20BK/WT
E2 20OR
Z1 20BK

BLEND DOOR FEEDBACK SIGNAL
FUSED IGNITION SWITCH OUTPUT (RUN)
GROUND
FUSED PANEL LAMPS DIMMER SWITCH SIGNAL
GROUND

CAV
A
B
C

CIRCUIT
C90 20LG
C1 12DG
Z1 12BK

A/C SELECT INPUT
BLOWER MOTOR FEED
GROUND

CAV
1
2

CIRCUIT
C90 20LG
C21 20DB/OR

A/C SELECT INPUT
A/C SWITCH SENSE

BLACK
A

E

B

D

C

A/C-HEATER
CONTROL - C1

BLACK

5

1

A/C-HEATER
CONTROL - C2

BLACK

A

C

FUNCTION

A/C-HEATER
CONTROL - C3

BLACK
1

2

A/C HIGH
PRESSURE SWITCH

FUNCTION

LHD
RHD
J998W-5

TJI08004

TJ

8W-80 CONNECTOR PIN-OUTS

8W - 80 - 5

GRAY
1

2

A/C LOW
PRESSURE SWITCH

CAV
1
2

CIRCUIT
C22 20DB/WT
C21 20DB/OR

A/C SWITCH SENSE
A/C SWITCH SENSE

FUNCTION

CAV
A
B

CIRCUIT
B48 20RD/YL
G19 20LG/OR

FUNCTION
ABS MAIN RELAY OUTPUT
ABS WARNING INDICATOR DRIVER

CAV
1
2

CIRCUIT
B120 12BR/WT
Z1 12BK

FUNCTION
ABS PUMP MOTOR RELAY OUTPUT
GROUND

CAV
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22

CIRCUIT
R45 18DG/LB
R43 18BK/LB
R142 18BR/YL
R144 18VT/YL
Z6 18BK/PK
F14 18LG/YL
D2 18WT/BK
D1 18VT/BR
F23 18DB/YL
-

CAV
A
B

CIRCUIT
L1 18VT/BK
F20 18VT/WT

BLACK
A

B

ABS DIODE
BLACK

2

1

ABS PUMP
MOTOR

YELLOW

11
22

1
12

AIRBAG
CONTROL
MODULE

BLACK

A

B

FUNCTION
DRIVER AIRBAG LINE 2
DRIVER AIRBAG LINE 1
PASSENGER AIRBAG SQUIB LINE 1
PASSENGER AIRBAG SQUIB LINE 2
GROUND
FUSED IGNITION SWITCH OUTPUT (ST-RUN)
CCD BUS(-)
CCD BUS(+)
FUSED IGNITION SWITCH OUTPUT (RUN)
-

FUNCTION
BACK-UP LAMP FEED
FUSED IGNITION SWITCH OUTPUT (RUN)

BACK-UP
LAMP SWITCH
(M/T)
TJI08005

J998W-5

8W - 80 - 6

8W-80 CONNECTOR PIN-OUTS

TJ

BLACK

1

2

BATTERY
TEMPERATURE
SENSOR

GRAY

1

6

BRAKE LAMP
SWITCH

CAV
1
2

CIRCUIT
K118 18PK/YL
K167 20BR/YL

FUNCTION
BATTERY TEMPERATURE SENSOR SIGNAL
SENSOR GROUND

2

K167 18BR/YL

SENSOR GROUND

CAV
1
2
3

CIRCUIT
K29 20WT/PK
Z1 20BK
V32 20YL/RD

FUNCTION
BRAKE SWITCH SENSE
GROUND
SPEED CONTROL ON/OFF SWITCH SENSE

4
5
6

V30 20DB/RD
F32 18PK/DB
L50 18WT/TN

SPEED CONTROL BRAKE SWITCH OUTPUT
FUSED B(+)
BRAKE LAMP SWITCH OUTPUT

CAV
1
2

CIRCUIT
K29 20WT/PK
G5 20DB/WT

FUNCTION
BRAKE SWITCH SENSE
FUSED IGNITION SWITCH OUTPUT (ST-RUN)

CAV
1
2

CIRCUIT
G9 20GY/BK
G99 20GY/WT

FUNCTION
RED BRAKE WARNING INDICATOR DRIVER
RED BRAKE WARNING INDICATOR DRIVER

CAV
1
2
3
4
5
6
7
8
9
10
11
12
13
14

CIRCUIT
F142 20OR/DG
K72 18DG/OR
A14 14RD/WT
B6 18WT/DB
B7 18WT
K226 18DB/LG
A141 18DG/WT
K167 20BR/YL
F12 20RD/LG
Z12 20BK/TN
Z12 20BK/LB
G7 20WT/OR
G107 20BK/RD
C3 20DB/BK

WHITE

2

1

BRAKE SHIFT
INTERLOCK
SOLENOID

BLACK
1

2

BRAKE WARNING
INDICATOR SWITCH

BLACK

7
14

1
8

C103

J998W-5

1
8

C103

ABS
DRL
LHD
RHD

CAV
1
2
3
4
BLACK
5
6
7
7
14
8
9
10
11
12
13
14

CIRCUIT
F142 18OR/DG
K72 18DG/OR
A14 14RD/WT
B6 18WT/DB
B7 18WT
K226 20DB/LG
A141 18DG/WT
K167 20BR/YL
F12 20RD/LG
Z12 20BK/TN
Z12 20BK/LB
G7 20WT/OR
G107 20BK/RD
C3 20DB/BK

TJI08006

TJ

8W-80 CONNECTOR PIN-OUTS

GREY

7
14

1
8

C104
(LHD)

BLACK

1
6

5
10

C104
(RHD)

BLACK
F1

F6

F7

F12

C106

CAV
1
2
3
4
5
6
7
8
9
10
11
12
13
14

CIRCUIT
C90 20LG
C22 18DB/WT
B4 18LG
B3 18LG/DB
T41 20BR/LB
B2 18YL
B1 18YL/DB
L1 20VT/BK
F20 20VT/WT
F42 18DG/LG
T40 12BR
F15 20DB
-

CAV
1
2
3
4
5
6
7
8
9
10

CIRCUIT
C90 20LG
C22 18DB/WT
F42 18DG/LG
T41 20BR/LB
T40 12BR
F15 20DB
L1 20VT/BK
F20 20VT/WT

CAV
F1

CIRCUIT
F30 12RD/PK

F2
F3
F4
F5
F6
F7
F8

L1 20VT/BK
F20 20VT/WT
F15 20DB
A1 14RD
A2 12PK/BK
A6 12RD/BK
C15 12BK/WT

F9

T141 14YL/RD

8W - 80 - 7

GREY
7
14

1
8

C104
(LHD)

BLACK

1

5

6

10

C104
(RHD)

BLACK
F6

F1

F12

F7

CAV
1
2
3
4
5
6
7
8
9
10
11
12
13
14

CIRCUIT
C90 20LG
C22 20DB/WT
B4 18LG
B3 18LG/DB
T41 20BR/LB
B2 18YL
B1 18YL/DB
L1 20VT/BK
F20 20VT/WT
F42 18DG/LG
T40 12BR
F15 18DB
-

CAV
1
2
3
4
5
6
7
8
9
10

CIRCUIT
C90 20LG
C22 20DB/WT
F42 18DG/LG
T41 20BR/LB
T40 12BR
F15 18DB
L1 20VT/BK
F20 20VT/WT

CAV
F1
F2

CIRCUIT
F30 12RD/PK
L1 20VT/BK

F3
F4
F5
F6
F7
F8

F20 20VT/WT
F15 20DB
A1 14RD
A2 12PK/BK
A6 12RD/BK
C15 12BK/WT
T141 14YL/RD
T141 14YL/RD
F12 20RD/LG
G9 20GY/BK
G9 20GY/BK
A111 12RD/LB

F9

C106

F10

F12 20RD/LG

F11

G9 20GY/BK

F11

F12

A111 12RD/LB

F12

F10

ABS
TJI08007

J998W-5

8W - 80 - 8

8W-80 CONNECTOR PIN-OUTS

CAV

YELLOW
E1

E7

E8

E14

C107

D8

CIRCUIT
L7 18BK/YL
L7 18BK/YL
L60 18TN
L61 18GY
L3 14RD/OR
L4 14VT/WT
Z12 20BK/LB
X3 20RD/YL
V10 18BR
Z12 20BK/TN
L39 18LB
V30 20DB/RD
-

E1

E2
E3
E4
E5
E6
E7
E8
E9
E10
E11
E12
E13

L60 18TN
L61 18GY
L3 16RD/OR
L4 16VT/WT
Z12 20BK/LB
X3 20RD/YL
V10 18BR
Z12 20BK/TN
L39 18LB
V30 20DB/RD
D20 18LG
D21 18PK
D21 20PK

E2
E3
E4
E5
E6
E7
E8
E9
E10
E11
E12
E13

D20 20LG

E14

D21 20PK

CAV
D1

CIRCUIT
V32 20YL/RD

D2

G19 20 LG/OR

D3

K167 20BR/YL
D1 20VT/BR

D7

D3
D4

CIRCUIT
V32 18YL/RD
G19 20LG/OR
G19 20LG/OR
K167 20BR/YL
D1 18VT/BR

D14

D5
D6

D2 18WT/BK
F61 18WT/OR

D2

YELLOW
E7

E1

E14

E8

C107

BLUE
D7
D14

D1
D8

D4
D5
D6

D2 20WT/BK
F61 18WT/OR

D7

G34 16RD/GY

D8

L20 16LG/WT
L50 18WT/TN
L50 18WT/TN
V37 20RD/LG
L9 16BK/WT
M1 20PK/WT
M1 20PK/WT
L22 20LG/DG
K29 20WT/PK
K29 20WT/PK

D8

G34 18RD/GY
L3 16RD/OR
L20 16LG/WT

D9

L50 18WT/TN

D9

D10
D11

V37 18RD/LG
L9 16BK/WT

D10
D11

D12
D13

M1 20PK/WT
M1 20PK/WT
L22 20LG/DG

D14

K29 18WT/PK

D7

C108

CAV

L7 18BK/YL

CAV
D1

D1

CIRCUIT

E1

E14

BLUE

TJ

C108

D12
D13
D14

DRL
EXCEPT DRL
LHD
SPEED CONTROL
FRONT FOG LAMPS
BUILT-UP-EXPORT
ABS

J998W-5

TJI08008

TJ

8W-80 CONNECTOR PIN-OUTS

BLACK

1
8

7
14

C110

CAV
1
2
3
4
5
6
7
8
9
10
11
12
13
14

CIRCUIT
L7 18BK/YL
L60 18TN
L61 18GY
L3 16RD/OR
L4 16VT/WT
X2 18WT/RD
V10 18BR
L22 20LG/DG
K52 20PK/BK
F12 20RD/LG
L39 18LB
L13 20BR/YL

CAV
1
2

CIRCUIT
Z1 20BK
L1 20VT/BK

3

T41 20BR/LB

4

F20 20VT/WT

8W - 80 - 9

BLACK

1

7

8

14

C110

CAV
1
2
3
4
5
6
7
8
9
10
11
12
13
14

CIRCUIT
L7 18BK/YL
L60 18TN
L61 18GY
L3 16RD/OR
L4 16VT/WT
X2 18WT/RD
V10 18BR
L22 20LG/DG
K52 18PK/BK
F12 20RD/LG
L39 18LB
L13 20BR/YL

CAV
1
2
3
3
4

CIRCUIT
Z1 20BK
L1 18VT/BK
T41 20BR/LB
Z1 20BK
F20 18VT/WT

BLACK
BLACK

4

1

C154

4

1

C154

M/T
A/T
BUILT-UP-EXPORT
FRONT FOG LAMPS

TJI08009

J998W-5

8W - 80 - 10

8W-80 CONNECTOR PIN-OUTS

CAV
1
2
3
4
5
6
7
8
9
10

LIGHT
GRAY

5
10

1
6

C170

TJ

CIRCUIT
L13 20BR/YL
C81 20LB/WT
G99 20GY/WT

BLACK

A3 14RD/WT
G107 20BK/RD
C90 20LG
-

1
6

5
10

C170

-

CIRCUIT
L13 20BR/YL
C81 20LB/WT
G99 20GY/WT

CAV
1
2
3

CIRCUIT
K105 20WT/OR
K106 20WT/DG
F142 20OR/DG

A3 14RD/WT
G107 20BK/RD
C90 20LG
-

BLACK

BLACK
2

CAV
1
2
3
4
5
6
7
8
9
10

1
CAV
1
2
3

3

CIRCUIT
K105 18WT/OR
K106 18WT/DG
F142 20OR/DG

1

3

C180

C180

CIRCUIT
F24 20RD/DG
F24 20RD/DG

CAV

A2

L20 16LG/WT

A2

A3
A4
A5

E1 18TN
E2 20OR
F81 20DB/RD

A6

Z12 20BK/LB

CAV
A1

GRAY
A6

A1

A12

A7

C202

2

A7

A1

GRAY
A6

A1

A12

A7

-

A3
A4
A5
A6
A7

C202

A8

L2 16LG

A9
A10

F38 16LB
G5 20DB/WT

A9
A10

A11

F34 18TN/BK

A11

A12

A111 12RD/LB

A12

A8

CIRCUIT
F24 20RD/DG
L20 16LG/WT
L20 14LG/WT
E1 18TN
E2 20OR
F81 20DB/RD
Z12 20BK/LB
Z12 20BK/LB
L2 14LG
L2 16LG
F38 16LB
G5 20DB/WT
F34 18TN/BK
F34 20TN/BK
A111 12RD/LB

EXCEPT DRL
REAR FOG LAMP
DRL
BUILT-UP-EXPORT
HARDTOP

J998W-5

TJI08010

TJ

8W-80 CONNECTOR PIN-OUTS

CAV

B7
B14

B8

B1

B2

L61 18GY

B2

B3

G26 20LB
G26 20LB

B4

G16 20BK/LB

B5

G34 16RD/GY

B7
B8
B9
B10
B11
B12
B13
B14

CAV
C1
C2
C3
C4

RED
C1

C7

C8

C14

CAV

L60 18TN

B6

C203

CIRCUIT

B1

GREEN
B1

8W - 80 - 11

C5
C6
C7

B3

B7
B8
B9
B10

G16 20BK/LB
G16 20BK/LB
G34 16RD/GY
G34 16RD/GY
L7 18BK/YL
L7 18BK/YL
M1 20PK/WT
D20 20LG
V20 18VT/OR
D21 20PK

B11

D1 20VT/BR

B12

D2 20WT/BK

B13
B14

L35 18BR/WT
G19 20LG/OR

CAV
C1
C2
C3
C4

CIRCUIT
L95 18DG/YL
V13 18BR/LG
G10 20LG/RD
Z12 20BK/TN
M2 20YL
V23 18BR/PK
-

B4
B7

B1

B14

B8

B5
B6

C203

CIRCUIT
L95 18DG/YL
V13 18BR/LG
G10 20LG/RD
Z12 20BK/TN
M2 20YL

RED
C7

C1

C14

C8

C5
C6
C7
C8

C8

L38 20BR/WT

C9

L22 20LG/DG

C9

C10
C11
C12
C13
C14

X12 20PK
X51 18BR/YL
X57 18BR/LB
X52 18DB/WT
X58 18DB/PK

C10
C11
C12
C13
C14

C204

G26 20LB

GREEN

L7 18BK/YL
L7 18BK/YL
M1 20PK/WT
D20 20LG
V20 18VT/OR
D21 20PK
D1 20VT/BR
D1 20VT/BR
D2 20WT/BK
D2 20WT/BK
L35 18BR/WT
G19 20LG/OR

V23 18BR/PK
-

CIRCUIT
L60 18TN
L60 18TN
L61 18GY
L61 18GY

C204

L38 20BR/WT
L38 20BR/WT
L22 20LG/DG
L22 20LG/DG
X12 20PK
X51 18BR/YL
X57 18BR/LB
X52 18DB/WT
X58 18DB/PK

REAR FOG LAMPS
HARD TOP
FRONT FOG LAMPS
BUILT-UP-EXPORT
EXCEPT BUILT-UP-EXPORT
LHD BUILT-UP-EXPORT
TJI08011

J998W-5

8W - 80 - 12

8W-80 CONNECTOR PIN-OUTS

BLACK
G1

G5

G6

G10

C322
(LHD)

BLACK

5
10

1
6

C322
(RHD)

RED
H1

H5

H6

H10

C323
(LHD)

TJ

CAV
G1
G2
G3
G4
G5
G6

CIRCUIT
L7 18BK/YL
L62 18BR/RD
L1 20VT/BK
L63 18DG/RD
Z1 12BK
G10 20LG/RD

G7

L50 18WT/TN

G8
G9
G10

L38 20BR/WT
G9 20GY/BK
V23 18BR/PK

G8
G9
G10

CIRCUIT
L7 18BK/YL
L62 18BR/RD
L1 20VT/BK
L63 18DG/RD
Z1 12BK
G10 20LG/RD
L50 18WT/TN
L50 18WT/TN
L38 20BR/WT
G9 20GY/BK
V23 18BR/PK

CAV
1
2
3
4
5
6
7

CIRCUIT
L7 18BK/YL
L62 18BR/RD
L1 20VT/BK
L63 18DG/RD
Z1 12BK
G10 20LG/RD
L50 18WT/TN

CAV
1
2
3
4
5
6
7

CIRCUIT
L7 18BK/YL
L62 18BR/RD
L1 20VT/BK
L63 18DG/RD
Z1 12BK
G10 20LG/RD
L50 18WT/TN

8
9
10

L38 20BR/WT
G9 20GY/BK
V23 18BR/PK

8
9
10

L38 20BR/WT
G9 20GY/BK
V23 18BR/PK

CAV
H1
H2
H3
H4
H5
H6
H7
H8
H9
H10

CIRCUIT
C15 12BK/WT
M1 20PK/WT
M2 20YL
V23 18BR/PK
V13 18BR/LG
V20 18VT/OR
X51 18BR/YL
X57 18BR/LB
X52 18DB/WT
X58 18DB/PK

CAV
H1
H2
H3
H4
H5
H6
H7
H8
H9
H10

CIRCUIT
C15 12BK/WT
M1 20PK/WT
M2 20YL
V23 18BR/PK
V13 18BR/LG
V20 18VT/OR
X51 18BR/YL
X57 18BR/LB
X52 18DB/WT
X58 18DB/PK

BLACK

G5

G1

G10

G6

C322
(LHD)

G7

BLACK
1
6

5
10

C322
(RHD)

RED
H5

H1

H10

H6

C323
(LHD)

CAV
G1
G2
G3
G4
G5
G6

HARD TOP
EXCEPT BUILT-UP-EXPORT
REAR FOG LAMP
4 SPEAKER SYSTEM
THE FEMALE SIDE OF C323 IS NOT PRESENT
IN SOFT-TOP 2 - SPEAKER SYSTEM VEHICLES
J998W-5

TJI08012

TJ

8W-80 CONNECTOR PIN-OUTS

Lt GRAY

5
10

1
6

C323
(RHD)

WHITE
1

6

C325
(4 SPKR SYS)

BLACK

5

1

10

6

C326
(HARD TOP)

CAV
1
2
3
4
5
6
7
8
9
10

CIRCUIT
C15 12BK/WT
M1 20PK/WT
M2 20YL
V23 18BR/PK
V13 18BR/LG
V20 18VT/OR
X51 18BR/YL
X57 18BR/LB
X52 18DB/WT
X58 18DB/PK

CAV
1
2
3
4
5
6

CIRCUIT
X57 18BR/LB
X51 18BR/YL
M1 20PK/WT
M2 20YL
X58 18DB/PK
X52 18DB/WT

CAV
1
2
3
4
5
6
7
8
9
10

CIRCUIT
C15 12BK/WT
V13 18BR/LG
V23 18BR/PK
V23 18BR/PK
Z1 12BK
M1 20PK/WT
M2 20YL
-

8W - 80 - 13

CIRCUIT
C15 12BK/WT
M1 20PK/WT
M2 20YL
V23 18BR/PK
V13 18BR/LG
V20 18VT/OR
X51 18BR/YL
X57 18BR/LB
X52 18DB/WT
X58 18DB/PK

CAV
1
2
Lt GRAY
3
4
5
5
10
6
7
8
9
10

1
6

C323
(RHD)

BLACK

6

1

C325
(4 SPKR SYS)

BLACK

5
10

1
6

C326
(HARD TOP)

CAV
1
2
3
4
5
6

CIRCUIT
X57 18BR/LB
X51 18BR/YL
M1 20PK/WT
M2 20YL
X58 18DB/PK
X52 18DB/WT

CAV
1
2
3
4
5
6
7
8
9
10

CIRCUIT
C15 12BK/WT
V13 18BR/LG
V23 18BR/PK
V23 18BR/PK
Z1 12BK
M1 20PK/WT
M2 18YL
-

4 SPEAKER SYSTEM
HARD TOP
THE MALE SIDE OF C323 IS NOT PRESENT
IN SOFT-TOP 2 - SPEAKER SYSTEM VEHICLES
TJI08013

J998W-5

8W - 80 - 14

8W-80 CONNECTOR PIN-OUTS

TJ

BLACK

BLACK
1
3

CAV
1
2
3

2

CIRCUIT
L38 20BR/WT
L7 18BK/YL
Z1 20BK

2

1
3

C329

CAV
1
2
3

CIRCUIT
L38 18BR/WT
L7 18BK/YL
Z1 20BK

CAV
1
2
3
4
5
6

CIRCUIT
X57 20BR/LB
X51 20BR/YL
M1 20PK/WT
M2 20YL
X58 20DB/PK
X52 20DB/WT

CAV
1
2
3
4
5
6
7
8
9
10

CIRCUIT
C15 12BK/WT
V13 18BK/LG
V23 18BR/PK
V23 18BR/PK
Z1 12BK
M1 20PK/WT
M2 20YL
-

C329

WHITE
1

6

C330
(4 SPKR SYS)

BLACK

5

1

10

6

C331
(HARD TOP)

CAV
1
2
3
4
5
6

CIRCUIT
X57 18BR/LB
X51 18BR/YL
M1 20PK/WT
M2 20YL
X58 18DB/PK
X52 18DB/WT

CAV
1
2
3
4
5
6
7
8
9
10

CIRCUIT
C15 12BK/WT
V13 18BR/LG
V23 18BR/PK
V23 18BR/PK
Z1 12BK
M1 20PK/WT
M2 18YL
-

BLACK

6

1

C330
(4 SPKR SYS)

BLACK

5
10

1
6

C331
(HARD TOP)

GRAY
1

3

CAV
1
2
3

CIRCUIT
K44 18TN/YL
K167 20BR/YL
K7 20OR

FUNCTION
CAMSHAFT POSITION SENSOR SIGNAL
SENSOR GROUND
5V SUPPLY

CAMSHAFT POSITION
SENSOR

J998W-5

TJI08014

TJ

8W-80 CONNECTOR PIN-OUTS

8W - 80 - 15

BLACK

1

5

2

4

CAV
1
2

CIRCUIT
F30 12RD/PK
A31 14BK/DG

FUNCTION
FUSED B(+)
IGNITION SWITCH OUTPUT (RUN-ACC)

3
4

F22 12WT/PK
Z1 20BK
Z1 20BK

CIGAR LIGHTER/ACCESSORY RELAY OUTPUT
GROUND
GROUND

5

CIGAR LIGHTER/
ACCESSORY RELAY
RED
2

1

CAV
1
2
3

3

CIRCUIT
F38 16LB
Z1 16BK

FUNCTION
FUSED B (+)
GROUND

CIGAR LIGHTER/
POWER OUTLET
YELLOW

2

CAV
1
2

1

CIRCUIT
R45 18DG/LB
R43 18BK/LB

FUNCTION
DRIVER AIRBAG LINE 2
DRIVER AIRBAG LINE 1

CLOCKSPRING - C1

NATURAL
4

1

CLOCKSPRING - C2

CIRCUIT
X3 20RD/YL

HORN RELAY CONTROL

4

V37 20RD/LG
K167 20BR/YL
-

SPEED CONTROL SWITCH SIGNAL
SENSOR GROUND
-

CAV
1
2

CIRCUIT
T141 14YL/RD
A41 14YL

FUNCTION
FUSED IGNITION SWITCH OUTPUT (ST)
FUSED IGNITION SWITCH OUTPUT (ST)

CAV
1
2
3
4
5
6
7
8
9

CIRCUIT
L32 16PK
Z1 20BK
L55 16RD/WT
-

FUNCTION
COMBINATION FLASHER OUTPUT
GROUND
COMBINATION FLASHER INPUT
-

CAV
1
2
3

FUNCTION

BLACK

1

2

CLUTCH PEDAL
POSITION SWITCH
(M/T)
BLACK

3

2

1

6

5

4

9

8

7

COMBINATION
FLASHER

TJI08015

J998W-5

8W - 80 - 16

8W-80 CONNECTOR PIN-OUTS

GRAY
1
6

5
12

CONTROLLER
ANTI-LOCK
BRAKE - C1

GRAY
1
9

8
18

CONTROLLER
ANTI-LOCK
BRAKE - C2

CAV
1
2
3
4
5
6
7
8
9
10
11
12

CIRCUIT
G19 20LG/OR
B43 20PK/OR
D21 20PK
F20 20VT/WT
B41 20YL/VT
B42 20TN/WT
L50 18WT/TN
B3 18LG/DB
B4 18LG
B1 18YL/DB
B2 18YL

FUNCTION
ABS WARNING INDICATOR DRIVER
G-SWITCH TEST SIGNAL
SCI TRANSMIT/ISO 9141K
FUSED IGNITION SWITCH OUTPUT (RUN)
G-SWITCH NO. 1 SENSE
G-SWITCH NO. 2 SENSE
BRAKE LAMP SWITCH OUTPUT
LEFT REAR WHEEL SPEED SENSOR (-)
LEFT REAR WHEEL SPEED SENSOR (+)
RIGHT REAR WHEEL SPEED SENSOR (-)
RIGHT REAR WHEEL SPEED SENSOR (+)

CAV
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18

CIRCUIT
B7 18WT
B6 18WT/DB
B120 16BR/WT
B251 20WT/BK
B48 20RD/YL
B248 20DG/WT
B116 20GY
B243 20DG/BK
B9 18RD
B8 18RD/DB
B58 20GY/LB
B254 20DG/OR
Z22 16BK/PK
Z22 16BK/PK
B249 20WT/DG
B245 20WT/LG

FUNCTION
RIGHT FRONT WHEEL SPEED SENSOR (+)
RIGHT FRONT WHEEL SPEED SENSOR (-)
ABS PUMP MOTOR RELAY OUTPUT
REAR INLET VALVE CONTROL
ABS MAIN RELAY OUTPUT
RIGHT FRONT OUTLET VALVE CONTROL
ABS PUMP MOTOR RELAY CONTROL
LEFT FRONT OUTLET VALVE CONTROL
LEFT FRONT WHEEL SPEED SENSOR (+)
LEFT FRONT WHEEL SPEED SENSOR (-)
ABS MAIN RELAY CONTROL
REAR OUTLET VALVE CONTROL
GROUND
GROUND
RIGHT FRONT INLET VALVE CONTROL
LEFT FRONT INLET VALVE CONTROL

CAV
1
2
3

CIRCUIT
K24 18GY/BK
K167 20BR/YL
K7 20OR

FUNCTION
CRANKSHAFT POSITION SENSOR SIGNAL
SENSOR GROUND
5V SUPPLY

TJ

BLACK

1

3

CRANKSHAFT
POSITION
SENSOR

J998W-5

TJI08016

TJ

8W-80 CONNECTOR PIN-OUTS

BLACK
1

8

9

16

DATA LINK
CONNECTOR

BLACK
5

1

10

6

DAYTIME RUNNING
LAMP MODULE
(EXCEPT BUILTUP-EXPORT)

TJI08017

CAV
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

CIRCUIT
D1 20VT/BR
Z12 20BK/LB
Z12 20BK/TN
D20 20LG
D21 20PK
D2 20WT/BK
M1 20PK/WT

CAV
1
2
3
4
5
6
7
8
9
10

CIRCUIT
L3 16RD/OR
G34 18RD/GY
F12 20RD/LG
L20 16LG/WT
G7 20WT/OR
Z1 18BK
L4 16VT/WT

8W - 80 - 17

FUNCTION
CCD BUS(+)
GROUND
GROUND
SCI RECEIVE
SCI TRANSMIT/ISO 9141K
CCD BUS(-)
FUSED B(+)

FUNCTION
DIMMER SWITCH HIGH BEAM OUTPUT
HIGH BEAM INDICATOR DRIVER
FUSED IGNITION SWITCH OUTPUT (ST-RUN)
FUSED B(+) OPTICAL HORN FEED
VEHICLE SPEED SENSOR SIGNAL
GROUND
DIMMER SWITCH LOW BEAM OUTPUT

J998W-5

8W - 80 - 18

8W-80 CONNECTOR PIN-OUTS

NATURAL

1

2

TJ

3

DRIVER DOOR
AJAR SWITCH

CAV
1
2
3

CIRCUIT
M23 20YL/BK
M2 20YL
G16 20BK/LB

FUNCTION
DOOR AJAR SWITCH OUTPUT
COURTESY LAMPS DRIVER
DRIVER DOOR AJAR SWITCH SENSE

CAV
1
2

CIRCUIT
K52 20PK/BK
F12 20RD/LG

FUNCTION
DUTY CYCLE EVAP/PURGE SOLENOID CONTROL
FUSED IGNITION SWITCH OUTPUT (ST-RUN)

CAV
1
2

CIRCUIT
K2 18TN/BK
K167 20BR/YL

FUNCTION
ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
SENSOR GROUND

CAV
1
2
3

CIRCUIT
K6 20VT/OR
G60 18GY/YL
K167 20BR/YL

FUNCTION
5V SUPPLY
ENGINE OIL PRESSURE SENSOR SIGNAL
SENSOR GROUND

BLACK

2

1

DUTY CYCLE
EVAP/PURGE
SOLENOID

BLACK
1

2

ENGINE COOLANT
TEMPERATURE
SENSOR

BLACK

1

3

ENGINE OIL
PRESSURE
SENSOR

J998W-5

TJI08018

TJ

8W-80 CONNECTOR PIN-OUTS

8W - 80 - 19

BLACK

2 4 1
5
3

FOG LAMP
RELAY NO. 1
(EXCEPT BUILTUP-EXPORT)

CAV
1
2
3
4
5

CIRCUIT
L35 18BR/WT
Z1 20BK
F61 18WT/OR
L39 18LB

FUNCTION
FOG LAMP SWITCH OUTPUT
GROUND
FUSED B(+)
FOG LAMP RELAY NO. 1 OUTPUT

CAV
1

3
4
5

CIRCUIT
G34 16RD/GY
Z1 20BK
Z1 20BK
L7 18BK/YL
L95 18DG/YL
-

FUNCTION
HIGH BEAM INDICATOR DRIVER
GROUND
GROUND
HEADLAMP SWITCH OUTPUT
FOG LAMP RELAY OUTPUT
-

CAV
1
2
3
4

CIRCUIT
E2 20OR
L35 18BR/WT
L95 18DG/YL
Z1 20BK

FUNCTION
FUSED PANEL LAMPS DIMMER SWITCH SIGNAL
FOG LAMP SWITCH OUTPUT
FOG LAMP RELAY OUTPUT
GROUND

CAV
1
2

CIRCUIT
F42 18DG/LG
K11 18WT/DB

FUNCTION
AUTOMATIC SHUT DOWN RELAY OUTPUT
FUEL INJECTOR NO. 1 DRIVER

CAV
1
2

CIRCUIT
F42 18DG/LG
K11 18WT/DB

FUNCTION
AUTOMATIC SHUT DOWN RELAY OUTPUT
FUEL INJECTOR NO. 1 DRIVER

BLACK

2 4 1
5

2

3

FOG LAMP
RELAY NO. 2
(EXCEPT BUILTUP-EXPORT)

BLACK

12 3 4

FRONT FOG
LAMP SWITCH
(EXCEPT BUILTUP-EXPORT)
BLACK

1

2

FUEL INJECTOR NO. 1
(2.5L)

2

1

BLACK

FUEL INJECTOR NO. 1
(4.0L)
TJI08019

J998W-5

8W - 80 - 20

8W-80 CONNECTOR PIN-OUTS

TJ

BLACK

1

2

CAV
1
2

CIRCUIT
F42 18DG/LG
K12 18TN

FUNCTION
AUTOMATIC SHUT DOWN RELAY OUTPUT
FUEL INJECTOR NO. 2 DRIVER

CAV
1
2

CIRCUIT
F42 18DG/LG
K12 18TN

FUNCTION
AUTOMATIC SHUT DOWN RELAY OUTPUT
FUEL INJECTOR NO. 2 DRIVER

CAV
1
2

CIRCUIT
F42 18DG/LG
K13 18YL/WT

FUNCTION
AUTOMATIC SHUT DOWN RELAY OUTPUT
FUEL INJECTOR NO. 3 DRIVER

CAV
1
2

CIRCUIT
F42 18DG/LG
K13 18YL/WT

FUNCTION
AUTOMATIC SHUT DOWN RELAY OUTPUT
FUEL INJECTOR NO. 3 DRIVER

CAV
1
2

CIRCUIT
F42 18DG/LG
K14 18LB/BR

FUNCTION
AUTOMATIC SHUT DOWN RELAY OUTPUT
FUEL INJECTOR NO. 4 DRIVER

FUEL INJECTOR NO. 2
(2.5L)

2

1

BLACK

FUEL INJECTOR NO. 2
(4.0L)

BLACK

1

2

FUEL INJECTOR NO. 3
(2.5L)

2

1

BLACK

FUEL INJECTOR NO. 3
(4.0L)

BLACK

1

2

FUEL INJECTOR NO. 4
(2.5L)

J998W-5

TJI08020

TJ

8W-80 CONNECTOR PIN-OUTS

2

8W - 80 - 21

BLACK

1

CAV
1
2

CIRCUIT
F42 18DG/LG
K14 18LB/BR

FUNCTION
AUTOMATIC SHUT DOWN RELAY OUTPUT
FUEL INJECTOR NO. 4 DRIVER

CAV
1
2

CIRCUIT
F42 18DG/LG
K15 18PK/BK

FUNCTION
AUTOMATIC SHUT DOWN RELAY OUTPUT
FUEL INJECTOR NO. 5 DRIVER

CAV
1
2

CIRCUIT
F42 18DG/LG
K16 18LG/BK

FUNCTION
AUTOMATIC SHUT DOWN RELAY OUTPUT
FUEL INJECTOR NO. 6 DRIVER

CAV
1
2
3
4
5
6

CIRCUIT
A141 18DG/WT
K226 20DB/LG
K167 20BR/YL
Z1 18BK

FUNCTION
FUEL PUMP RELAY OUTPUT
FUEL LEVEL SENSOR SIGNAL
SENSOR GROUND
GROUND

CAV
1
2
3

CIRCUIT
B42 20TN/WT

G-SWITCH NO.2 SENSE

B41 20YL/VT
B43 20PK/OR

G-SWITCH NO.1 SENSE
G-SWITCH TEST SIGNAL

CAV
1
2

CIRCUIT
K72 18DG/OR
K20 18DG

FUNCTION
VOLTAGE REGULATOR SIGNAL
GENERATOR FIELD DRIVER (+)

FUEL INJECTOR NO. 4
(4.0L)

2

BLACK

1

FUEL INJECTOR NO. 5
(4.0L)
2

BLACK

1

FUEL INJECTOR NO. 6
(4.0L)
BLACK

3

1

6

4

FUEL PUMP
MODULE
BLACK

1

3

FUNCTION

G SWITCH
BLACK
1

2

GENERATOR

TJI08021

J998W-5

8W - 80 - 22

8W-80 CONNECTOR PIN-OUTS

TJ

BLACK

4

1

HEADLAMP
DIMMER
SWITCH
WHITE

1

6

HEADLAMP
LEVELING
SWITCH
(BUILT-UP-EXPORT)

6

BLACK

8

5
7
9

4
2
3

1

HEADLAMP
SWITCH

CAV
1
2
3
4

CIRCUIT
L4 14VT/WT
L2 14LG
L3 14RD/OR
L20 14LG/WT

FUNCTION
DIMMER SWITCH LOW BEAM OUTPUT
HEADLAMP SWITCH OUTPUT
DIMMER SWITCH HIGH BEAM OUTPUT
FUSED B(+) OPTICAL HORN FEED

CAV
1
2

CIRCUIT
-

FUNCTION
-

L22 20LG/DG

HEADLAMP SWITCH FUSED OUTPUT

-

-

3
4
5
6

Z1 20BK
L13 20BR/YL
-

GROUND
HEADLAMP ADJUST SIGNAL

CAV
1
2
3
4
5
6
7
8
9

CIRCUIT
E1 18TN
L2 16LG
M2 20YL
F34 18TN/BK
G26 20LB
G16 20BK/LB
L20 16LG/WT
A3 14RD/WT
L7 18BK/YL

FUNCTION
PANEL LAMPS DIMMER SWITCH SIGNAL
HEADLAMP SWITCH OUTPUT
COURTESY LAMPS DRIVER
FUSED B(+)
KEY-IN IGNITION SWITCH SENSE
DRIVER AJAR SWITCH SENSE
FUSED B(+) OPTICAL HORN FEED
FUSED B(+)
HEADLAMP SWITCH OUTPUT

CAV
1
2

CIRCUIT
X2 18WT/RD
Z1 18BK

HORN RELAY OUTPUT
GROUND

CAV
1
2
3
4

CIRCUIT
Z11 20BK/WT
C4 16TN
C5 16LG/LB
C6 14LB
F24 20RD/DG
F24 20RD/DG
C36 20DB/RD
C7 12BR/TN
A111 12RD/LB
F24 20RD/DG
Z1 20BK

FUNCTION
GROUND
LOW SPEED BLOWER MOTOR
M1 SPEED BLOWER MOTOR
M2 SPEED BLOWER MOTOR
FUSED IGNITION SWITCH OUTPUT (RUN)
FUSED IGNITION SWITCH OUTPUT (RUN)
BLEND DOOR FEEDBACK SIGNAL
HIGH SPEED BLOWER MOTOR
FUSED B(+)
FUSED IGNITION SWITCH OUTPUT (RUN)
GROUND

-

BLACK
2
1

HIGH NOTE
HORN

GRAY

5
10

1
6

HVAC
UNIT

J998W-5

5
6
7
8
9
10

FUNCTION

TJI08022

TJ

8W-80 CONNECTOR PIN-OUTS

BLACK

5
10

1
6

HYDRAULIC
CONTROL
UNIT

1

4

CAV
1
2
3
4
5
6
7
8
9
10

CIRCUIT
B47 14RD/LB
B251 20WT/BK
B249 20WT/DG
B245 20WT/LG
B254 20DG/OR
B248 20DG/WT
B243 20DG/BK
B47 14RD/LB

FUNCTION
ABS SYSTEM RELAY OUTPUT
REAR INLET VALVE CONTROL
RIGHT FRONT INLET VALVE CONTROL
LEFT FRONT INLET VALVE CONTROL
REAR OUTLET VALVE CONTROL
RIGHT FRONT OUTLET VALVE CONTROL
LEFT FRONT OUTLET VALVE CONTROL
ABS SYSTEM RELAY OUTPUT

CAV
1
2
3
4

CIRCUIT
K59 18VT/BK
K40 18BR/WT
K60 18YL/BK
K39 18GY/RD

FUNCTION
IDLE AIR CONTROL NO. 4 DRIVER
IDLE AIR CONTROL NO. 3 DRIVER
IDLE AIR CONTROL NO. 2 DRIVER
IDLE AIR CONTROL NO. 1 DRIVER

CAV
1
2

CIRCUIT
F42 18DG/LG
K19 18GY

FUNCTION
AUTOMATIC SHUT DOWN RELAY OUTPUT
IGNITION COIL NO. 1 DRIVER

CAV
1
2
3
4
5
6
7
8
9
10

CIRCUIT
Z1 16BK
G9 20GY/BK
A2 12PK/BK
A22 12BK/OR
A1 14RD
A31 14BK/DG
A21 14DB
A41 14YL

FUNCTION
GROUND
RED BRAKE WARNING INDICATOR DRIVER
FUSED B(+)
IGNITION SWITCH OUTPUT (RUN)
FUSED B(+)
IGNITION SWITCH OUTPUT (RUN-ACC)
IGNITION SWITCH OUTPUT (ST-RUN)
IGNITION SWITCH OUTPUT (ST)

8W - 80 - 23

BLACK

IDLE AIR
CONTROL MOTOR

GRAY

1

2

IGNITION
COIL

GRAY
5

1

10

6

IGNITION
SWITCH

TJI08023

J998W-5

8W - 80 - 24

8W-80 CONNECTOR PIN-OUTS

GREEN

5

1

10

6

INSTRUMENT
CLUSTER - C1

BLUE

5

1

10

6

INSTRUMENT
CLUSTER - C2

TJ

CAV
1
2
3
4
5
6
7
8
9
10

CIRCUIT
D2 20WT/BK
D1 20VT/BR
C81 20LB/WT
C80 20DB/LG
G107 20BK/RD
L60 18TN
G26 20LB
Z2 18BK/LG
G10 20LG/RD

FUNCTION
CCD BUS(-)
CCD BUS(+)
REAR WINDOW DEFOGGER RELAY CONTROL
REAR WINDOW DEFOGGER SWITCH SENSE
4WD SENSE
RIGHT TURN SIGNAL
KEY-IN IGNITION SWITCH SENSE
GROUND
SEAT BELT SWITCH SENSE

CAV
1
2
3
4
5
6
7
8
9
10

CIRCUIT
G99 20GY/WT
E2 20OR
G19 20LG/OR
G34 16RD/GY
Z2 18BK/LG
G5 20DB/WT
M1 20PK/WT
L61 18GY

RED BRAKE WARNING INDICATOR DRIVER
FUSED PANEL LAMPS DIMMER SWITCH SIGNAL
ABS WARNING INDICATOR DRIVER
HIGH BEAM INDICATOR DRIVER
GROUND
FUSED IGNITION SWITCH OUTPUT (ST-RUN)
FUSED B(+)
LEFT TURN SIGNAL

CAV
1
2

CIRCUIT
K21 18BK/RD
K167 20BR/YL

FUNCTION
INTAKE AIR TEMPERATURE SENSOR SIGNAL
SENSOR GROUND

CAV
1
2

CIRCUIT
G16 20BK/LB
G26 20LB

FUNCTION
DRIVER AJAR SWITCH SENSE
KEY-IN IGNITION SWITCH SENSE

FUNCTION
-

GRAY
1

2

INTAKE AIR
TEMPERATURE
SENSOR

GREEN

2

1

KEY-IN
SWITCH

HARD TOP
J998W-5

TJI08024

TJ

8W-80 CONNECTOR PIN-OUTS

8W - 80 - 25

BLACK

4

1

LEAK
DETECTION PUMP
(EXCEPT BUILTUP-EXPORT)

CAV
1
2
3
4

CIRCUIT
F142 20OR/DG
K106 20WT/DG
K105 20WT/OR

FUNCTION
FUSED AUTOMATIC SHUTDOWN RELAY OUTPUT
LEAK DETECTION PUMP SOLENOID CONTROL
LEAK DETECTION PUMP SWITCH SENSE

CAV
1
2

CIRCUIT
L7 18BK/YL
Z1 18BK

FUNCTION
HEADLAMP SWITCH OUTPUT
GROUND

CAV
1
2

CIRCUIT
M1 20PK/WT
M2 20YL

FUSED B(+)
COURTESY LAMPS DRIVER

CAV
1
2

CIRCUIT
Z1 18BK
L39 18LB

FUNCTION
GROUND
FOG LAMP RELAY NO. 1 OUTPUT

CAV
1
2
3

CIRCUIT
L61 18GY
L7 18BK/YL
Z1 18BK

FUNCTION
LEFT TURN SIGNAL
HEADLAMP SWITCH OUTPUT
GROUND

CAV
1
2

CIRCUIT
X53 18DG
X55 18BR/RD

LEFT FRONT SPEAKER (+)
LEFT FRONT SPEAKER (-)

BLACK
2
1

LEFT CITY
LAMP
(BUILT-UP-EXPORT)

BLACK
1

2

FUNCTION

LEFT
COURTESY LAMP
BLACK
1

2

LEFT FOG
LAMP
(EXCEPT BUILT-UP
-EXPORT)
BLACK
3

1

LEFT FRONT PARK/
TURN SIGNAL LAMP
(EXCEPT BUILT-UP
-EXPORT)
BLACK
1

2

FUNCTION

LEFT
FRONT SPEAKER
TJI08025

J998W-5

8W - 80 - 26

8W-80 CONNECTOR PIN-OUTS

TJ

BLACK
1

3

LEFT FRONT
TURN SIGNAL LAMP
(BUILT-UP-EXPORT)

CAV
1
2
3

CIRCUIT
L61 18GY
Z1 18BK

FUNCTION
LEFT TURN SIGNAL
GROUND

BLACK

2

CAV
1
2

1

LEFT FRONT
WHEEL SPEED
SENSOR

CIRCUIT
B8 18RD/DB
B9 18RD

FUNCTION
LEFT FRONT WHEEL SPEED SENSOR (-)
LEFT FRONT WHEEL SPEED SENSOR (+)

BLACK

2

2
3

CIRCUIT
L3 16RD/OR
L3 16RD/OR
L4 16VT/WT
Z1 20BK

FUNCTION
DIMMER SWITCH HIGH BEAM OUTPUT
DIMMER SWITCH HIGH BEAM OUTPUT
DIMMER SWITCH LOW BEAM OUTPUT
GROUND

CAV
1
2
3

CIRCUIT
L22 20LG/DG
L13 20BR/YL
Z1 20BK

FUNCTION
HEADLAMP SWITCH FUSED OUTPUT
HEADLAMP ADJUST SIGNAL
GROUND

CAV
1
2

CIRCUIT
L7 18BK/YL
Z1 20BK

FUNCTION
HEADLAMP SWITCH OUTPUT
GROUND

CAV
1

3

LEFT HEADLAMP

1

BLACK

1

3

LEFT HEADLAMP
LEVELING MOTOR
(BUILT-UP-EXPORT)

GRAY
1

2

LEFT LICENSE
LAMP
(BUILT-UP-EXPORT)

J998W-5

TJI08026

TJ

8W-80 CONNECTOR PIN-OUTS
BLACK
1

2

3

4

4

CIRCUIT
L1 20VT/BK
L63 18DG/RD
L63 18DG/RD
L1 20VT/BK
L7 18BK/YL
L50 18WT/TN
L7 18BK/YL

BACK-UP LAMP FEED
LEFT TURN SIGNAL
LEFT TURN SIGNAL
BACK-UP LAMP FEED
HEADLAMP SWITCH OUTPUT
BRAKE LAMP SWITCH OUTPUT
HEADLAMP SWITCH OUTPUT

CAV
1
2

CIRCUIT
X51 20BR/YL
X57 20BR/LB

LEFT REAR SPEAKER (+)
LEFT REAR SPEAKER (-)

CAV
1
2

CIRCUIT
B3 18LG/DB
B4 18LG

FUNCTION
LEFT REAR WHEEL SPEED SENSOR (-)
LEFT REAR WHEEL SPEED SENSOR (+)

CAV
1
2

CIRCUIT
L61 18GY
Z1 18BK

FUNCTION
LEFT TURN SIGNAL
GROUND

CAV
1
2

CIRCUIT
L7 18BK/YL
L61 18GY

FUNCTION
HEADLAMP SWITCH OUTPUT
LEFT TURN SIGNAL

CAV
1
2

CIRCUIT
X2 18WT/RD
Z1 18BK

HORN RELAY OUTPUT
GROUND

CAV
1
2

LEFT REAR
LAMP ASSEMBLY

8W - 80 - 27

3

FUNCTION

BLACK

1

2

LEFT REAR
SPEAKER
(SOUND BAR)

FUNCTION

BLACK

2

1

LEFT REAR
WHEEL SPEED
SENSOR
GRAY
2
1

LEFT REPEATER
LAMP
(BUILT-UP-EXPORT)
GRAY
2
1

LEFT SIDE
MARKER LAMP
(EXCEPT BUILTUP-EXPORT)
BLACK
2
1

LOW NOTE
HORN
(EXCEPT BUILTUP-EXPORT)
TJI08027

FUNCTION

EXCEPT BUILT-UP-EXPORT
BUILT-UP-EXPORT
J998W-5

8W - 80 - 28

8W-80 CONNECTOR PIN-OUTS

TJ

BLACK

1

3

MANIFOLD
ABSOLUTE
PRESSURE
SENSOR

CAV
1
2
3

CIRCUIT
K167 20BR/YL
K1 18DG/RD
K7 20OR

FUNCTION
SENSOR GROUND
MANIFOLD ABSOLUTE PRESSURE SENSOR SIGNAL
5V SUPPLY

CAV
1
2
3
4

CIRCUIT
F142 18OR/DG
Z1 18BK
K167 20BR/YL
K41 18BK/DG

FUNCTION
FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT
GROUND
SENSOR GROUND
OXYGEN SENSOR 1/1 SIGNAL

CAV
1
2
3
4

CIRCUIT
F142 18OR/DG
Z1 18BK
K167 20BR/YL
K141 18TN/WT

FUNCTION
FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT
GROUND
SENSOR GROUND
OXYGEN SENSOR 1/2 SIGNAL

CAV
1
2
3

CIRCUIT
F20 18VT/WT
T41 20BR/LB
L1 18VT/BK

FUNCTION
FUSED IGNITION SWITCH OUTPUT (RUN)
PARK/NEUTRAL POSITION SWITCH SENSE
BACK-UP LAMP FEED

CAV
A
B

CIRCUIT
R44 18DG/YL
R42 18BK/YL

PASSENGER AIRBAG LINE 2
PASSENGER AIRBAG LINE 1

GRAY
1

2

3

4

OXYGEN SENSOR
1/1 UPSTREAM

BLACK
1

2

3

4

OXYGEN SENSOR
1/2 DOWNSTREAM

1

3

PARK/NEUTRAL
POSITION SWITCH
(A/T)

YELLOW

A

B

FUNCTION

PASSENGER
AIRBAG

J998W-5

TJI08028

TJ

8W-80 CONNECTOR PIN-OUTS

8W - 80 - 29

LIGHT
GRAY
1

2

CAV
1
2

CIRCUIT
F14 18LG/YL
Z6 20BK/PK

FUNCTION
FUSED IGNITION SWITCH OUTPUT (ST-RUN)
GROUND

CAV
1
2
3
4

CIRCUIT
R142 18BR/YL
R144 18VT/YL
R42 18BK/YL
R44 18DG/YL

FUNCTION
PASSENGER AIRBAG SQUIB LINE 1
PASSENGER AIRBAG SQUIB LINE 2
PASSENGER AIRBAG LINE 1
PASSENGER AIRBAG LINE 2

CAV
1
2

CIRCUIT
M23 20YL/BK
M2 20YL

FUNCTION
DOOR AJAR SWITCH OUTPUT
COURTESY LAMPS DRIVER

CAV
1
1
2

CIRCUIT
Z1 20BK
Z1 18BK
K10 18DB/BR

FUNCTION
GROUND
GROUND
POWER STEERING PRESSURE SWITCH SENSE

PASSENGER AIRBAG
ON/OFF SWITCH - C1

YELLOW

1

4

PASSENGER AIRBAG
ON/OFF SWITCH - C2

BLACK

1

2

PASSENGER
DOOR AJAR
SWITCH

BLACK

1

2

POWER STEERING
PRESSURE SWITCH
(2.5L)

LHD
RHD
TJI08029

J998W-5

8W - 80 - 30

8W-80 CONNECTOR PIN-OUTS

BLACK

11

1

32

22

POWERTRAIN
CONTROL
MODULE - C1

CAV
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
A13
A14
A15
A16
A17
A18
A19
A20
A21
A22
A23
A24
A25
A26
A27
A28
A29
A30
A31
A32

CIRCUIT
F15 18DB
K167 18BR/YL
T41 18BR/LB
K19 18GY
K24 18GY/BK
K60 18YL/BK
K40 18BR/WT
K10 18DB/BR
K21 18BK/RD
K2 18TN/BK
K7 18OR
K44 18TN/YL
K39 18GY/RD
K59 18VT/BK
A14 14RD/WT
K22 18OR/DB
K41 18BK/DG
K141 18TN/WT
K1 18DG/RD
Z12 14BK/TN
Z12 14BK/TN

TJ

FUNCTION
FUSED IGNITION SWITCH OUTPUT (ST-RUN)
SENSOR GROUND
PARK/NEUTRAL POSITION SWITCH SENSE
IGNITION COIL NO. 1 DRIVER
CRANKSHAFT POSITION SENSOR SIGNAL
IDLE AIR CONTROL NO. 2 DRIVER
IDLE AIR CONTROL NO. 3 DRIVER
POWER STEERING PRESSURE SWITCH SENSE
INTAKE AIR TEMPERATURE SENSOR SIGNAL
ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
5V SUPPLY
CAMSHAFT POSITION SENSOR SIGNAL
IDLE AIR CONTROL NO. 1 DRIVER
IDLE AIR CONTROL NO. 4 DRIVER
FUSED B(+)
THROTTLE POSITION SENSOR SIGNAL
OXYGEN SENSOR 1/1 SIGNAL
OXYGEN SENSOR 1/2 SIGNAL
MANIFOLD ABSOLUTE PRESSURE SENSOR SIGNAL
GROUND
GROUND

2.5L

J998W-5

TJI08030

TJ

8W-80 CONNECTOR PIN-OUTS

WHITE

11

1

32

22

POWERTRAIN
CONTROL
MODULE - C2

CAV
B1
B2
B3
B4
B5
B6
B7
B8
B9
B10
B11
B12
B13
B14
B15
B16
B17
B18
B19
B20
B21
B22
B23
B24
B25
B26
B27
B28
B29
B30
B31
B32

CIRCUIT
K11 18WT/DB
K13 18YL/WT
K15 18PK/BK
K20 18DG
T23 18OR/LG
K16 18LG/BK
K12 18TN
K14 18LB/BR
G60 18GY/YL
G7 18WT/OR
K6 18VT/OR
-

8W - 80 - 31

FUNCTION
FUEL INJECTOR NO. 1 DRIVER
FUEL INJECTOR NO. 3 DRIVER
FUEL INJECTOR NO. 5 DRIVER
GENERATOR FIELD DRIVER (+)
TRANSMISSION LOW/OVERDRIVE SOLENOID
FUEL INJECTOR NO. 6 DRIVER
FUEL INJECTOR NO. 2 DRIVER
FUEL INJECTOR NO. 4 DRIVER
ENGINE OIL PRESSURE SENSOR SIGNAL
VEHICLE SPEED SENSOR SIGNAL
5V SUPPLY
-

4.0L

TJI08031

J998W-5

8W - 80 - 32

8W-80 CONNECTOR PIN-OUTS

GRAY

11

1

32

22

POWERTRAIN
CONTROL
MODULE - C3

CAV
C1
C2
C3
C4
C5
C6
C7
C8
C9
C10
C11
C12
C13
C14
C15
C16
C17
C18
C19
C20
C21
C22
C23
C24
C25
C26
C27
C28
C29
C30
C31
C32

CIRCUIT
C13 18DB/OR
K51 18DB/YL
V36 18TN/RD
V35 18LG/RD
K106 18WT/DG
V32 18YL/RD
A142 14DG/PK
K105 18WT/OR
K118 18PK/YL
K31 18BR
K52 18PK/BK
C22 18DB/WT
C90 18LG
K29 18WT/PK
K72 18DG/OR
K226 18DB/LG
D21 18PK
D2 18WT/BK
D20 18LG
D1 18VT/BR
V37 18RD/LG

FUNCTION
A/C COMPRESSOR CLUTCH RELAY CONTROL
AUTOMATIC SHUT DOWN RELAY CONTROL
SPEED CONTROL VACUUM SOLENOID CONTROL
SPEED CONTROL VENT SOLENOID CONTROL
LEAK DETECTION PUMP SOLENOID CONTROL
SPEED CONTROL ON/OFF SWITCH SENSE
AUTOMATIC SHUT DOWN RELAY OUTPUT SENSE
LEAK DETECTION PUMP SWITCH SENSE
BATTERY TEMPERATURE SENSOR SIGNAL
FUEL PUMP RELAY CONTROL
DUTY CYCLE EVAP/PURGE SOLENOID CONTROL
A/C SWITCH SENSE
A/C SELECT INPUT
BRAKE SWITCH SENSE
VOLTAGE REGULATOR SIGNAL
FUEL LEVEL SENSOR SIGNAL
SCI TRANSMIT/ISO 9141K
CCD BUS(-)
SCI RECEIVE
CCD BUS(+)
SPEED CONTROL SWITCH SIGNAL

CAV
1
2

CIRCUIT
E2 20OR
Z1 20BK

FUNCTION
FUSED PANEL LAMPS DIMMER SWITCH SIGNAL
GROUND

TJ

BLACK

1

2

PRNDL LAMP

SPEED CONTROL
LEAK DETECTION

J998W-5

TJI08032

TJ

8W-80 CONNECTOR PIN-OUTS

GRAY

7

1

RADIO - C1

BLACK

7

1

RADIO - C2

8W - 80 - 33

CAV
1
2
3
4
5
6
7

CIRCUIT
X55 18BR/RD
X56 18DB
L7 18BK/YL
E2 20OR
X12 20PK
M1 20PK/WT

FUNCTION
-

CAV
1
2
3
4
5
6
7

CIRCUIT
X51 18BR/YL
X52 18DB/WT
X53 18DG
X54 18VT
X57 18BR/LB
X58 18DB/PK

LEFT REAR SPEAKER(+)
RIGHT REAR SPEAKER(+)
LEFT FRONT SPEAKER(+)
RIGHT FRONT SPEAKER(+)
LEFT REAR SPEAKER(-)
RIGHT REAR SPEAKER(-)

CAV
1
2

CIRCUIT
L38 18BR/WT
Z1 20BK

REAR FOG LAMP FEED
GROUND

CAV
1
2
3

CIRCUIT
L22 20LG/DG
L95 18DG/YL
Z1 20BK
L38 20BR/WT

FUNCTION
HEADLAMP SWITCH FUSED OUTPUT
REAR FOG LAMP RELAY CONTROL
GROUND
REAR FOG LAMP FEED

5

L38 20BR/WT
L22 20LG/DG

REAR FOG LAMP FEED
HEADLAMP SWITCH FUSED OUTPUT

CAV
1
2
3
4

CIRCUIT
Z1 20BK
L95 18DG/YL
L38 20BR/WT
E2 20OR

LEFT FRONT SPEAKER(-)
RIGHT FRONT SPEAKER(-)
HEADLAMP SWITCH OUTPUT
FUSED PANEL LAMPS DIMMER SWITCH SIGNAL
FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
FUSED B(+)

FUNCTION
-

BLACK

1

2

REAR FOG LAMP
(BUILT-UP-EXPORT)

FUNCTION
-

LIGHT GREEN
1 2

5

3

4

4

REAR FOG
LAMP RELAY
(BUILT-UP-EXPORT)

WHITE

1

4

REAR FOG
LAMP SWITCH
(BUILT-UP-EXPORT)

FUNCTION
GROUND
REAR FOG LAMP RELAY CONTROL
REAR FOG LAMP FEED
FUSED PANEL LAMPS DIMMER SWITCH SIGNAL

RHD
TJI08033

J998W-5

8W - 80 - 34

8W-80 CONNECTOR PIN-OUTS

TJ

BLACK

A

B

CAV
A
B

CIRCUIT
V20 18VT/OR
Z1 18BK

FUNCTION
REAR WASHER MOTOR CONTROL
GROUND

CAV
1
2
3
4

CIRCUIT
Z1 20BK
C80 20DB/LG
F81 20DB/RD
E2 20OR

FUNCTION
GROUND
REAR WINDOW DEFOGGER SWITCH SENSE
FUSED REAR WINDOW DEFOGGER RELAY OUTPUT
FUSED PANEL LAMPS DIMMER SWITCH SIGNAL

CAV
1
2
3

CIRCUIT
V23 18BR/PK
Z1 16BK
V13 18BK/LG

FUNCTION
FUSED IGNITION SWITCH OUTPUT (RUN)
GROUND
REAR WIPER MOTOR CONTROL

CAV
1
2
3
4
5
6

CIRCUIT
Z1 18BK/WT
V20 18VT/OR
E2 20OR
V13 18BR/LG
V23 18BR/PK
-

FUNCTION
GROUND
REAR WASHER MOTOR CONTROL
FUSED PANEL LAMPS DIMMER SWITCH SIGNAL
REAR WIPER MOTOR CONTROL
FUSED IGNITION SWITCH OUTPUT (RUN)
-

REAR WASHER
PUMP
(HARD TOP)

GRAY

1

4

REAR WINDOW
DEFOGGER
SWITCH
(HARD TOP)

BLACK

3

1

REAR WIPER
MOTOR
(HARD TOP)

WHITE
1

2

3

6

REAR WIPER/
WASHER SWITCH
(HARD TOP)

J998W-5

TJI08034

TJ

8W-80 CONNECTOR PIN-OUTS

BLACK
2
1

8W - 80 - 35

CAV
1
2

CIRCUIT
L7 18BK/YL
Z1 20BK

FUNCTION
HEADLAMP SWITCH OUTPUT
GROUND

CAV
1
2

CIRCUIT
M1 20PK/WT
M2 20YL

FUNCTION
FUSED B(+)
COURTESY LAMPS DRIVER

CAV
1
2

CIRCUIT
Z1 18BK
L39 18LB

FUNCTION
GROUND
FOG LAMP RELAY NO. 1 OUTPUT

CAV
1
2
3

CIRCUIT
L60 18TN
L7 18BK/YL
Z1 18BK

FUNCTION
RIGHT TURN SIGNAL
HEADLAMP SWITCH OUTPUT
GROUND

CAV
1
2

CIRCUIT
X54 18VT
X56 18DB

RIGHT FRONT SPEAKER (+)
RIGHT FRONT SPEAKER (-)

CAV
1
2
3

CIRCUIT
L60 18TN
Z1 18BK

RIGHT CITY
LAMP
(BUILT-UP-EXPORT)
BLACK

2

1

RIGHT
COURTESY
LAMP
BLACK
1

2

RIGHT FOG
LAMP
(EXCEPT BUILT-UP
-EXPORT)
1

BLACK

3

RIGHT FRONT PARK/
TURN SIGNAL LAMP
(EXCEPT BUILT-UP
-EXPORT)

BLACK
1

2

FUNCTION

RIGHT FRONT
SPEAKER

1

3

RIGHT FRONT TURN
SIGNAL LAMP
(BUILT-UP-EXPORT)

TJI08035

BLACK
FUNCTION
RIGHT TURN SIGNAL
GROUND

J998W-5

8W - 80 - 36

8W-80 CONNECTOR PIN-OUTS

TJ

BLACK
2

1

CAV
1
2

CIRCUIT
B6 18WT/DB
B7 18WT

FUNCTION
RIGHT FRONT WHEEL SPEED SENSOR (-)
RIGHT FRONT WHEEL SPEED SENSOR (+)

CAV
1
2
3

CIRCUIT
L3 16RD/OR
L4 16VT/WT
Z1 18BK

FUNCTION
DIMMER SWITCH HIGH BEAM OUTPUT
DIMMER SWITCH LOW BEAM OUTPUT
GROUND

CAV
1
2
3

CIRCUIT
L22 20LG/DG
L13 20BR/YL
Z1 18BK

FUNCTION
HEADLAMP SWITCH FUSED OUTPUT
HEADLAMP ADJUST SIGNAL
GROUND

CAV
1
2

CIRCUIT
L7 18BK/YL
Z1 20BK

FUNCTION
HEADLAMP SWITCH OUTPUT
GROUND

CAV

CIRCUIT
L1 20VT/BK
L62 18BR/RD
L62 18BR/RD
L1 20VT/BK
L7 18BK/YL
L50 18WT/TN
L63 18DG/RD
L7 18BK/YL

FUNCTION
BACK-UP LAMP FEED
RIGHT TURN SIGNAL
RIGHT TURN SIGNAL
BACK-UP LAMP FEED
HEADLAMP SWITCH OUTPUT
BRAKE LAMP SWITCH OUTPUT
LEFT TURN SIGNAL
HEADLAMP SWITCH OUTPUT

CIRCUIT
X52 20DB/WT
X58 20DB/PK

RIGHT REAR SPEAKER (+)
RIGHT REAR SPEAKER (-)

RIGHT FRONT
WHEEL SPEED
SENSOR
2

BLACK

1

3

RIGHT
HEADLAMP
BLACK

1

3

RIGHT HEADLAMP
LEVELING MOTOR
(BUILT-UP-EXPORT)
GRAY
1

2

RIGHT LICENSE
LAMP
(BUILT-UP-EXPORT)
BLACK

1
1

2

3

4

2
3

RIGHT REAR
LAMP ASSEMBLY

4

BLACK

1

2

RIGHT REAR
SPEAKER
(SOUND BAR)
J998W-5

CAV
1
2

FUNCTION

EXCEPT BUILT-UP-EXPORT
BUILT-UP-EXPORT

TJI08036

TJ

8W-80 CONNECTOR PIN-OUTS

8W - 80 - 37

BLACK

2

1

CAV
1
2

CIRCUIT
B1 18YL/DB
B2 18YL

FUNCTION
RIGHT REAR WHEEL SPEED SENSOR (-)
RIGHT REAR WHEEL SPEED SENSOR (+)

CAV
1
2

CIRCUIT
L60 18TN
Z1 18BK

RIGHT TURN SIGNAL
GROUND

CAV
1
2

CIRCUIT
L7 18BK/YL
L60 18TN

FUNCTION
HEADLAMP SWITCH OUTPUT
RIGHT TURN SIGNAL

CAV
1
2

CIRCUIT
G10 20LG/RD
Z1 20BK

SEAT BELT SWITCH SENSE
GROUND

CAV
1
2
3
4
5
6

CIRCUIT
F34 20TN/BK
Z1 20BK
F15 20DB

FUNCTION
FUSED B(+)
GROUND
FUSED IGNITION OUTPUT (ST-RUN)

Z12 20BK/LB
D2 20WT/BK
D1 20VT/BR

GROUND
CCD BUS(-)
CCD BUS(+)

CAV
1
2

CIRCUIT
M1 20PK/WT
M2 20YL

FUSED B(+)
COURTESY LAMPS DRIVER

RIGHT REAR
WHEEL SPEED
SENSOR
GRAY
2
1

FUNCTION

RIGHT REPEATER
LAMP
(BUILT-UP-EXPORT)
GRAY
2
1

RIGHT SIDE
MARKER LAMP
(EXCEPT BUILTUP-EXPORT)
BLACK
2

1

SEAT BELT
SWITCH
(EXCEPT LHD BUILT-UP-EXPORT)
BLACK

1

6

SENTRY KEY
IMMOBILIZER
MODULE

FUNCTION

BLACK

1

2

SOUND BAR
DOME LAMP
TJI08037

FUNCTION

J998W-5

8W - 80 - 38

8W-80 CONNECTOR PIN-OUTS

TJ

NATURAL
1

3

THROTTLE
POSITION
SENSOR

CAV
1
2
3

CIRCUIT
K167 20BR/YL
K22 18OR/DB
K7 20OR

FUNCTION
SENSOR GROUND
THROTTLE POSITION SENSOR SIGNAL
5V SUPPLY

CAV
A
B

CIRCUIT
F12 20RD/LG
T23 18OR/LG

FUNCTION
FUSED IGNITION SWITCH OUTPUT (ST-RUN)
TRANSMISSION LOW/OVERDRIVE SOLENOID

CAV
A
B

CIRCUIT
G107 20BK/RD
Z1 20BK

4WD SENSE
GROUND

CAV
1
2
3
4
5
6
7
8
9
10
11

CIRCUIT
L60 18TN
L50 18WT/TN
L62 18BR/RD
L32 16PK
L5 20BK/GY
L9 16BK/WT
L63 18DG/RD
L61 18GY
L55 16RD/WT

FUNCTION
RIGHT TURN SIGNAL
BRAKE LAMP SWITCH OUTPUT
RIGHT TURN SIGNAL
COMBINATION FLASHER OUTPUT
FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
FUSED FLASHER FEED
LEFT TURN SIGNAL
LEFT TURN SIGNAL
COMBINATION FLASHER INPUT

CAV
1

CIRCUIT
Z1 18BK

GROUND

2

M1 20PK/WT

FUSED B(+)

BLACK

B

A

TORQUE CONVERTOR
CLUTCH SOLENOID

BLACK

A

B

FUNCTION

TRANSFER
CASE SWITCH

BLACK

6

1

11

7

TURN SIGNAL/
HAZARD SWITCH

BLACK
2

1

UNDERHOOD
LAMP

FUNCTION

EXCEPT BUILT-UP-EXPORT
J998W-5

TJI08038

TJ

8W-80 CONNECTOR PIN-OUTS

BLACK
4

1

CAV
1
2
3
4

CIRCUIT
V36 18TN/RD
V35 18LG/RD
V30 20DB/RD
Z1 18BK

CAV
1
2
3

CIRCUIT
K6 20VT/OR
K167 20BR/YL
G7 20WT/OR

CAV
A
B

CIRCUIT
V10 18BR
Z1 18BK

FUNCTION
WASHER PUMP CONTROL SWITCH OUTPUT
GROUND

CAV
1
2
3
4
5
6

CIRCUIT
V6 18PK/BK
V5 18DG/YL
Z1 18BK
V3 18BR/WT
V4 18RD/YL

FUNCTION
FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
WIPER PARK SWITCH SENSE
GROUND
LOW SPEED WIPER SWITCH OUTPUT
WIPER SWITCH HIGH SPEED OUTPUT

CAV
1
2
3
4
5
6

CIRCUIT
Z1 20BK
V5 18DG/YL
V10 18BR
V3 18BR/WT
V6 18PK/BK
V4 18RD/YL

FUNCTION
GROUND
WIPER PARK SWITCH SENSE
WASHER PUMP CONTROL SWITCH OUTPUT
LOW SPEED WIPER SWITCH OUTPUT
FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
WIPER SWITCH HIGH SPEED OUTPUT

8W - 80 - 39

FUNCTION
SPEED CONTROL VACUUM SOLENOID CONTROL
SPEED CONTROL VENT SOLENOID CONTROL
SPEED CONTROL BRAKE SWITCH OUTPUT
GROUND

VEHICLE SPEED
CONTROL
SERVO

BLACK

3

1

FUNCTION
5V SUPPLY
SENSOR GROUND
VEHICLE SPEED SENSOR SIGNAL

VEHICLE SPEED
SENSOR

BLACK

A

B

WINDSHIELD
WASHER PUMP

BLACK

3
6

1
4

WINDSHIELD
WIPER MOTOR

NATURAL

6

1

WINDSHIELD
WIPER SWITCH
TJI08039

J998W-5

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Connector
Name/Number

Color

Location

Fig.

Connector
Name/Number

Color

Location

Fig.

A/C
Compressor
Clutch

BK

At A/C
Compressor
Clutch

12

C103

BK

Near T/O for
Fuel Injector
NO. 6

2, 3

A/C Heater
Control - C1

BK

Rear of Blower
Motor Switch

17, 18

C104 (LHD)

GY

Rear of Engine

2

C104 (RHD)

BK

Rear of Engine

3

A/C Heater
Control - C2

BK

Rear of Lamp

17, 18

C106 (LHD)

BK

Left Kick Panel

2, 15

A/C Heater
Control - C3

BK

Rear of A/C
Heater Control
Switch

17, 18

C106 (RHD)

BK

Right Kick
Panel

16

C107 (LHD)

YL

Left Kick Panel

2, 15

A/C High
Pressure Switch

BK

On A/C
Compressor

12

C107 (RHD)

YL

Right Kick
Panel

16

A/C Low
Pressure Switch

GY

Near T/O for
Powertrain
Control Module

N/S

C108 (LHD)

BL

Left Kick Panel

2, 15

C108 (RHD)

BL

Right Kick
Panel

16

ABS Diode

BK

Near T/O for
Controller
Anti-Lock Brake

2

C110

BK

Left Fender
Side Shield

3, 5

C154

BK

BK

Left Side of
Engine
Compartment
Near Grommet

6

Top Right Side
of Transmission

11, 14

ABS Pump
Motor

C170

LT
GY/
BK

Right Kick
Panel

2, 17,
18

Airbag Control
Module

YL

Front of Floor
Pan Tunnel

15, 16,
19

C180

BK

N/S

Back-up Lamp
Switch (M/T)

BK

Right Side of
Transmission

14

Engine
Compartment
Left Side

C202 (LHD)

GY

Left Kick Panel

15, 17

Battery
Temperature
Sensor

BK

Under Battery
Tray

3, 4

C202 (RHD)

GY

Right Kick
Panel

16, 18

C203 (LHD)

GN

Left Kick Panel

15, 17

Brake Lamp
Switch

GY

Top of Brake
Pedal Bracket

15, 16

C203 (RHD)

GN

Right Kick
Panel

16, 18

Brake Shift
Interlock
Solenoid

WT

Near Steering
Column

20

Brake Warning
Indicator Switch

BK

On Brake
Master Cylinder

2, 3

C204 (LHD)

RD

Left Kick Panel

15, 17

C204 (RHD)

RD

Right Kick
Panel

16, 18

C322

BK

Left Kick Panel

15, 16,
22

C323 (LHD)

RD

Left Kick Panel

15, 22

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Connector
Name/Number

Color

Location

Fig.

Connector
Name/Number

Color

Location

Fig.

C323 (RHD)

LT GY

Left Kick Panel

16

BK

WT/
BK

Left Side of
Sound Bar

22, 23

Bottom Left of
Instrument
Panel

17

C325 (4 Spkr
Sys)

Data Link
Connector
(LHD)

C326 (Hard
Top)

BK

Left Rear
Quarter Panel

22, 23

BK

BK

Left Side of
Rear Bumper

24

Bottom Right of
Instrument
Panel

18

C329 (LHD)

Data Link
Connector
(RHD)

BK

BK

Right Side of
Rear Bumper

25

Left Side of
Engine
Compartment

4

C329 (RHD)

Daytime
Running Lamp
Module (Except
Built-Up-Export)

C330 (4 Spkr
Sys)

WT/
BK

Left Side of
Sound Bar

22, 23

Driver Door Ajar
Switch

NAT

At 9A9 Pillar

15, 16

C331 (Hard
Top)

BK

Left Rear
Quarter Panel

22, 23

BK

Left Fender
Side Shield

5

Camshaft
Position Sensor

GY

Below
Distributor

11

Duty Cycle
Evap/Purge
solenoid

Bottom of
Instrument
Panel Near
Steering
Column

15, 22

On Thermostat
Housing

9, 10

BK

Engine Coolant
Temperature
Sensor

BK

Cigar Lighter/
Accessory
Relay (LHD)

Engine Oil
Pressure
Sensor

BK

Right Side of
Engine Block

11

Cigar Lighter/
Accessory
Relay (RHD)

BK

Bottom of
Instrument
Panel Near
Steering
Column

N/S

Fog Lamp
Relay NO.1
(Except
Built-Up-Export)

BK

Near Fuse
Block T/O

15

Cigar Lighter/
Power Outlet

RD

Rear of Cigar
Lighter

17, 18

BK

Near Fuse
Block T/O

15

Clockspring C1

YL

Rear of
Clockspring

20

Fog Lamp
Relay NO.2
(Except
Built-Up-Export)

At Switch

17

NAT

Rear of
Clockspring

20

Front Fog Lamp
Switch (Except
Built-Up-Export)

BK

Clockspring C2
Clutch Pedal
Position Switch
(M/T)

BK

Top of Clutch
Pedal Bracket

15, 16

Fuel Injector
NO.1

BK

At Injector

9, 10

At Injector

9, 10

BK

Bottom of
Instrument
Panel Near
Steering
Column

20

Fuel Injector
NO.2

BK

Combination
Flasher

Fuel Injector
NO.3

BK

At Injector

9, 10

Fuel Injector
NO.4

BK

At Injector

9, 10

Fuel Injector
NO.5

BK

At Injector

10

Fuel Injector
NO.6

BK

At Injector

10

Fuel Pump
Module

BK

Above Fuel
Tank

1

Controller
Anti-Lock Brake
- C1

GY

Near Grommet
Rear Left Side
of Dash Panel

2, 19

Controller
Anti-Lock Brake
- C2

GY

Near Grommet
Rear Left Side
of Dash Panel

2, 19

Crankshaft
Position Sensor

BK

At Rear of
Intake Manifold

9, 10,
13

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Connector
Name/Number

Color

_ `&arb c"as

Location

Fig.

Connector
Name/Number

Color

Location

Fig.

G100

Rear Center of
Engine
Compartment

2, 3

G Switch

BK

Near T/O for
Controller
Anti-Lock Brake

19

G101

Rear Center of
Engine
Compartment

2

Generator

BK

Rear of
Generator

12

5

G103

Right Radiator
Closure Panel

1

At Steering
Column Part of
Multifunction
Switch

20

Left Radiator
Closure Panel

Headlamp
Dimmer Switch

BK

G102

BK

Rear of
Generator

12

Right Side of
Instrument
Panel

17, 18

G104
G105

Right Rear of
Engine Block

12

Headlamp
Leveling Switch
(Built-UpExport)

BK

Rear of Switch

17, 18

G106

Right Rear of
Engine Block

12

Headlamp
Switch
High Note Horn

BK

5

G107

Right Rear of
Engine Block

12

Left Front
Fender Side
Shield

G200

Right Rear of
Instrument
Panel

17, 18

HVAC Unit
(LHD)

GY

Bottom Right of
Instrument
Panel

21

G201

Right Rear of
Instrument
Panel

17, 18

HVAC Unit
(RHD)

GY

Bottom Left of
Instrument
Panel

18

G202 (LHD)

Right Rear of
Instrument
Panel

21

Hydraulic
Control Unit

BK

Left Side of
Engine
Compartment

6

G202 (RHD)

Left Rear of
Instrument
Panel

18

Idle Air Control
Motor

BK

Side of Throttle
Body

9, 10

Ignition Coil

GY

Near Generator

12

G203 (LHD)

Right Rear of
Instrument
Panel

21

Ignition Switch

GY

Rear of Ignition
Switch

20

Rear of Cluster

17, 18

Left Rear of
Instrument
Panel

18

Instrument
Cluster - C1

GN

G203 (RHD)

Instrument
Cluster - C2

BL

Rear of Cluster

17, 18

G300 (LHD)

Left Kick Panel

15

GY

Right Kick
Panel

16

Rear of Intake
Manifold

9, 10

G300 (RHD)

Intake Air
Temperature
Sensor

G301 (LHD)

Right Kick
Panel

15

Key-In Switch

GN

At Key-In
Switch

20

G301 (RHD)

Left Kick Panel

16

BK

Left Kick Panel

15

Engine
Compartment
Left Side

N/S

G302 (LHD)

Leak Detection
Pump (Except
Built-Up-Export)

G302 (RHD)

Right Kick
Panel

16

Left City Lamp
(Built-UpExport)

BK

At Lamp

5

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ˆ%‰&Š ‹ Œ(Ž‘Ž
’ “”•“–—˜Ž™%’š ›
ž;Ÿ= =¡;¢"£¤=¥C£E¦G§I¨;§JžK¦G¤=Ÿ=¢;¨L¥C£E¦G§N©O¡;ªR«R¬U­V«X®R¯R°R±

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Connector
Name/Number

Color

Location

Fig.

Connector
Name/Number

Color

Location

Fig.

Left Courtesy
Lamp

BK

Left Side of
Instrument
Panel

17, 18

Low Note Horn
(Except
Built-Up-Export)

BK

Left Front
Fender Side
Shield

5

Left Fog Lamp
(Except
Built-Up-Export)

BK

At Lamp

N/S

BK

Side of Throttle
Body

9, 10

Left Front
Park/Turn
Signal Lamp
(Except
Built-Up-Export)

BK

At Lamp

N/S

Manifold
Absolute
Pressure
Sensor
Oxygen Sensor
1/1 Upstream

GY

On Front
Exhaust Pipe

9, 10

Oxygen Sensor
1/2 Downstream

BK

14

Left Front
Speaker

BK

At Speaker

17, 18

Rear of
Catalytic
Converter

At Lamp

N/S

Left of
Transmission

11

BK

Park/Neutral
Position Switch
(A/T)

BK

Left Front Turn
Signal Lamp
(Built-UpExport)

Passenger
Airbag

YL

Rear of Airbag

15, 16,
18, 21

Left Front
Wheel Speed
Sensor

BK

Passenger
Airbag On/Off
Switch - C1

LT GY

Near Fuse
Block T/O

15, 16

Passenger
Airbag On/Off
Switch - C2

YL

Near Fuse
Block T/O

15, 16

Passenger Door
Ajar Switch

BK

Near T/O for
G301

15, 16

Power Steering
Pressure Switch
(2.5L)

BK

Near Power
Steering Pump

9

Powertrain
Control Module
- C1

BK

Left Rear of
Engine
Compartment

3, 4

WT

Left Rear of
Engine
Compartment

3, 4

Left Side of
Engine
Compartment
Near Hydraulic
Control Unit

6

Left Headlamp

BK

Rear of Lamp

5

Left Headlamp
Leveling Motor
(Built-UpExport)

BK

At Lamp

5

Left License
Lamp
(Built-UpExport)

GY

Left Rear Lamp
Assembly

BK

At Lamp

24, 25

Left Rear
Speaker (Sound
Bar)

BK

At Sound Bar

N/S

Powertrain
Control Module
- C2

GY

BK

Near Vehicle
Speed Sensor
T/O

1

Left Rear of
Engine
Compartment

3, 4

Left Rear Wheel
Speed Sensor

Powertrain
Control Module
- C3
PRNDL Lamp

BK

Rear of Lamp

15, 16

Left Repeater
Lamp
(Built-UpExport)

GY

At Lamp

N/S

Radio - C1

GY

Rear of Radio

17, 18

Radio - C2

BK

Rear of Radio

17, 18

BK

At Lamp

24, 25

Left Side
Marker Lamp
(Except
Built-Up-Export)

GY

Rear Fog Lamp
(Built-UpExport)
Rear Fog Lamp
Relay
(Built-UpExport) (LHD)

LT GN

Near Fuse
Block T/O

N/S

At Lamp

At Lamp

24, 25

N/S

²^³
´%µ&¶ ·%¸¹º»»¼¹
½ º¾¿À¾ºÁ»Âú¹
Ä ½Å º»Æ
È;É=Ê=Ë;Ì"ÍÎ=ÏCÍEÐGÑIÒ;ÑJÈKÐGÎ=É=Ì;ÒLÏCÍEÐGÑNÓOË;ÔRÕRÖU×VÕXØRÙRÚRÛ

´ µ&¶r· ¸"¶Ç

Connector
Name/Number

Color

Location

Fig.

Connector
Name/Number

Color

Location

Fig.

Rear Fog Lamp
Relay
(Built-UpExport) (RHD)

LT GN

Near Fuse
Block T/O

16

Right License
Lamp
(Built-UpExport)

GY

At Lamp

24, 25

Rear Fog Lamp
Switch
(Built-UpExport)

WT

At Switch

17, 18

Right Rear
Lamp Assembly

BK

At Lamp

24, 25

BK

At Sound Bar

N/S

Rear Washer
Pump (Hard
Top)

BK

Rear Window
Defogger Switch
(Hard Top)

GY

Rear Wiper
Motor (Hard
Top)

BK

Rear Wiper/
Washer Switch
(Hard Top)

Under Washer
Fluid Reservoir

5

Right Rear
Speaker (Sound
Bar)

BK

17, 18

Near Vehicle
Speed Sensor
T/O

1

Behind Rear
Window
Defogger
Switch

Right Rear
Wheel Speed
Sensor

GY

At Lamp

1

At Rear Wiper
Motor

N/S

Right Repeater
Lamp
(Built-UpExport)

GY

At Lamp

1

WT

Behind Rear
Wiper/Washer
Switch

17, 18

Right Side
Marker Lamp
(Except
Built-Up-Export)

At Lamp

1

Near Park
Brake Switch
T/O

22, 23

BK

Seat Belt Switch
(Except LHD
Built-Up-Export)

BK

Right City Lamp
(Built-UpExport)

At Immobilizer

15, 16

BK

Right Side of
Instrument
Panel

18, 21

Sentry Key
Immobilizer
Module

BK

Right Courtesy
Lamp

At Sound Bar

N/S

BK

At Lamp

1

Sound Bar
Dome Lamp

BK

Right Fog Lamp
(Except
Built-Up-Export)

Throttle Position
Sensor

NAT

Side of Throttle
Body

9, 10

Right Front
Park/Turn
Signal Lamp
(Except
Built-Up-Export)

BK

Torque
Converter
Clutch Solenoid

BK

Left Side of
Transmission

N/S

BK

BK

At Speaker

18, 21

Left Side of
Transfer Case

14

Right Front
Speaker

Transfer Case
Switch

BK

BK

At Lamp

1

At Steering
Column Part of
Multifunction
Switch

20

Right Front Turn
Signal Lamp
(Built-UpExport)

Turn Signal/
Hazard Switch

BK

Under Hood

2, 3

Right Front
Wheel Speed
Sensor

BK

Rear of Engine

13

Underhood
Lamp

BK

BK

Rear of Lamp

1

Left Side of
Engine
Compartment

N/S

Right Headlamp

Vehicle Speed
Control Servo
(LHD)

Right Headlamp
Leveling Motor
(Built-UpExport)

BK

Near Lamp at
Motor

1

Vehicle Speed
Control Servo
(RHD)

BK

Right Side of
Engine
Compartment

N/S

Vehicle Speed
Sensor

BK

Left Rear of
Transfer Case

14

At Lamp

1

Ü ÝÞ ß à"Þ$á
Ü%Ý&Þ ß à(âãääåâ
æ ãçèéçãêäëìãâí%æî ãäï
ò;ó=ô=õ;ö"÷ø=ùC÷EúGûIü;ûJòKúGø=ó=ö;üLùC÷EúGûNýOõ;þRÿVÿ

ð8ñ

Connector
Name/Number

Color

Location

Fig.

Connector
Name/Number

Color

Location

Fig.

Windshield
Washer Pump

BK

Under Washer
Fluid Reservoir

5

Windshield
Wiper Switch

NAT

At Steering
Column

20

Windshield
Wiper Motor

BK

Center of Cowl
Panel

7, 8


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Fig. 1 Front End Wiring Connectors




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132545637.8$95:;8=<?>A@3>B1C<?952573@D:;8=<?>FEG63HIJKLIMNOP

gih

Fig. 2 Engine Compartment Connectors — Rear, LHD

QRTSUV.SWQ
QRSUVYXZ[[\X]Z^"_$`^"Za[b(cZXd]+e Z[f
j3k5l5m3n.o$p5q;o=r?sAt3sBjCr?p5k5n3tDq;o=r?sFuGm3vwxyLwz{|}

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Fig. 3 Engine Compartment Connectors — Rear, RHD

~ 
€‚ƒ„…†‡‡ˆ…‰†Š"‹$ŒŠ"†‡Ž(†…‰+‘ †‡’
“3”5•5–3—.˜$™5š;˜=›?œA3œB“C›?™5”5—3Dš;˜=›?œFžG–3Ÿ ¡¢L £¤¥¦

¼i½

Fig. 4 Engine Compartment Connectors—LHD

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§¨©ª«­®°¯¯±­²®³"´$µ³"®¶¯·(¸®­¹²+º ®¯»
¾3¿5À5Á3Â.Ã$Ä5Å;Ã=Æ?ÇAÈ3ÇB¾CÆ?Ä5¿5Â3ÈDÅ;Ã=Æ?ÇFÉGÁ3ÊËÌÍLËÎÏÐÑ

ÔÕÖ×Ø.Ö0çç

Fig. 5 Engine Compartment Connectors—Front Side

Ò Ó
ÔÕTÖ×ØYÙÚÛÛÜÙÝÚÞ"ß$àÞ"ÚáÛâ(ãÚÙäÝ+å ÚÛæ
è3é5ê5ë3ì.í$î5ï;í=ð?ñAò3ñBèCð?î5é5ì3òDï;í=ð?ñFóGë3ôõö÷Lõøùúû

üýTþÿ.þ

üýþÿ 


 
   


#%$'&'(%)+*,'-.*0/2143%15#6/2,'$')%37-.*0/2198:(%;=<=>?@<BA=C=D=E

Fig. 6 ABS Hydraulic Control Unit

Fig. 7 Windshield Wiper Motor—LHD

"!

FHG

IJLKNMOQPR S STP URVWXVR Y SZ[R P\U] R S ^

c%d'e'f%g+hi'j.h0k2l4m%l5c6k2i'd'g%m7j.h0k2l9n:f%o=p=qr@pBs=t=u=v

Fig. 8 Windshield Wiper Motor—RHD

IJ_KNMO+Ka`b

wxLyNz{+y|}

wx_yNz{~  € €~‚ƒ„…ƒ † €‡ˆ ~ ‰‚Š  € ‹

Œ"

Fig. 9 Engine Harness Connectors—2.5L Engine

Ž%''‘%’+“”'•.“0–2—4˜%—5Ž6–2”''’%˜7•.“0–2—9™:‘%š=›=œ@›Bž=Ÿ= =¡

¢H£

¤¥L¦N§¨Q©ª « «¬© ­ª®¯°®ª ± «²³ª ©´­µ ª « ¶

¤¥_¦N§¨+¦a·¸

Fig. 10 Engine Harness Connectors—4.0L Engine

¹%º'»'¼%½+¾¿'À.¾0Á2Â4Ã%Â5¹6Á2¿'º'½%Ã7À.¾0Á2Â9Ä:¼%Å=Æ=ÇÈ@ÆBÉ=Ê=Ë=Ì

ÍÎLÏNÐÑ+ÏÒÓ

ÍÎ_ÏNÐÑÔ Õ Ö Ö×ÔØÕÙÚÛÙÕ Ü ÖÝÞÕ Ô ßØà Õ Ö á

â"ã

Fig. 11 Engine and Automatic Transmission Connectors

ä%å'æ'ç%è+éê'ë.é0ì2í4î%í5ä6ì2ê'å'è%î7ë.é0ì2í9ï:ç%ð=ñ=òó@ñBô=õ=ö=÷

øHù

úûLüNýþQÿÿ
  ÿ 

úû_üNýþ+ü

Fig. 12 Engine Grounds

!#"
$%&"('*),+)-.'*$!+/%&"('*)102354568794;:5<5=5>

?@BADCE#AGF?

?@HADCEJIKMLLN8IOKP Q
RP KSLTUKIVOW KLX

Y[Z

Fig. 13 Crankshaft Position Sensor and Right Front Wheel Speed Sensor

\]^_`#a
bc&a(d*e,fe-\.d*b]`f/c&a(d*e1g2_h5i5j8k9i;l5m5n5o

prq

stBuDvwyxz{{|x}z~ 
€~ z{‚ƒzx„}… z{†

stHuDvw#u‡v

Fig. 14 Transmission and Transfer Case Connectors

ˆ‰Š‹Œ#
Ž&(*‘,’‘-ˆ.*Ž‰Œ’/&(*‘1“2‹”5•5–8—9•;˜5™5š5›

œBžDŸ #žG¡ 

œHžDŸ J¢£M¤¤¥8¢¦£§ ¨
©§ £ª¤«¬£¢­¦® £¤¯

°[±

Fig. 15 Dash Panel Connectors—LHD

²³´µ¶#·
¸¹&·(º*»,¼»-².º*¸³¶¼/¹&·(º*»1½2µ¾5¿5À8Á9¿;Â5Ã5Ä5Å

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ÔÒ ÎÕÏÖ×ÎÍØÑÙ ÎÏÚ

ÈÉHÊDËÌ#ÊÛÜ

Fig. 16 Dash Panel Connectors—RHD

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ãä&â(å*æ,çæ-Ý.å*ãÞáç/ä&â(å*æ1è2àé5ê5ë8ì9ê;í5î5ï5ð

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þü øÿùø÷û øù 


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Fig. 17 Instrument Panel Wiring Connectors—LHD

ñòBóDôõ#óGöö

576P8;:M<8RQ7S

Fig. 18 Instrument Panel Wiring Connectors—RHD

243
57698;:7<>=@? A ABC=D7?EGFHEG? I AJKC? =@LMDN ? A O
TUVWXYZ[Y\]^] T!\ZUX^"[Y\]$_%W`(a(b+c,a.d(e(f(g

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Fig. 19 Airbag Control Module and Controller, Antilock Brakes—LHD

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hMiPj;kMlqprts su+p@v7rwGxywGr z s{|Cr p}7v~ r s 
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Fig. 20 Steering Column Connectors

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­®¯°±²³´²µ¶·¶ ­!µ³®±·"´²µ¶$¸%°¹(º(»+¼,º.½(¾(¿(À

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ØÙÚÛÜÝÞßÝàáâá Ø!àÞÙÜâ"ßÝàá$ã%Ûä(å(æ+ç,å.è(é(ê(ë

Fig. 21 Instrument Panel Connectors—Right Side, LHD

Ö ×

ì4í

î7ï9ð;ñ7ò>ó@ô õ õöCó÷7ôøGùúøGô û õüýCô ó@þM÷ÿ ô õ

î7ïPð;ñMòð

Fig. 22 Body Connectors—LHD



 





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MON

Fig. 23 Rear Body Wiring Connectors—RHD

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+4,5-0/417698;::=<$6?>8=@BAC=@B8D:=EGFH869I>KJ 8:L
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R
STUV
WUXYZYPXV
Q
TZWUXY[S\!]!^$_%]'`!a!b!c

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|}
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Fig. 24 Rear Under Body Wiring Connectors—LHD

Fig. 25 Rear Under Body Wiring Connectors—RHD

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ÃÄÆÅÇÈǖɱʠËÌÅÎͱϤÐÑ ÍÓÒ?ÅÎÔÉ$ÇÈÅÎÕÕÎÖBǖËÓÑØ×ÙËÌÅÎͱÏBÇÈÅÎÔÙɱÏBËÌÅÎÚ Û?ÅÎÏBܦËÌÄBÉ
ÜÝÉ$ÏBɱÑØ×ÙÕKÕÎͱʠ×ÞËÌÅÍ$ÏßͱÚ;ËÌÄBÉ0ǖÐÕÎÅÎʠɱÇOÅÎÏßËÌÄBÅÎÇ!Ò?É$ÄBÅÎÊ ÕÎɱà$áâÇãÐÕÎÅÎÊ É
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ùKÍ$ѝǖÐÕÎÅÎʠɱÇÈËÓÄÆ×ÙËï×ÞÑ É7ÏBÍ$ËǖÄBÍÓëìÏúÅÎϤËÓÄBÉ7ÚÅÎÜûÖBѠɱÇÈÅÎÏ
ËÌÄBÅÎÇìÇãɱÊØËÓÅÎͱÏÆü;×ÞÏíýþÌÿ ÅÎÇìÐÕÎ×ÞÊ É$ÔêÅÎÏÈËÓÄBÉù ÅÎÜÝà;Ê Í$ÕÎÖBîÏBà

Splice
Number

Location

Fig.

Splice
Number

Location

Fig.

S101
(LHD)

Near T/O for Powertrain
Control Module

2

S119

Left Side Radiator Closure
Panel

1

S101
(RHD)

Near T/O for Power
Distribution Center

3

Near T/O for Left Front Turn
Signal Lamp At Grommet

N/S

S102

Near T/O for G100

2, 3

S122
(Built-UpExport)

S103
(LHD)

Near T/O for G101

2

Near T/O for Left Front
Park/Turn Signal Lamp

N/S

S103
(RHD)

Near T/O for Battery
Temperature Sensor

3

S122
(Except
Built-UpExport)

S104

Near T/O for C110

2

S123
(LHD)

Near T/O for G105

6

S105
(LHD)

Near Grommet on Left Side
of Dash Panel

2

Near T/O for C103

N/S

S105
(RHD)

Near T/O for C110

3

S123
(2.5L)
(RHD)

Near T/O for Ground G100

2

S123
(4.0L)
(RHD)

Near T/O for Fuel Injector
NO. 6

7

S106
S107

Near T/O for G101

2

S108
(LHD)

Near T/O for Underhood
Lamp

2

S124
(LHD)

Near T/O for G105

6

S108
(RHD)

Near T/O for C110

3

S124
(RHD)

Near T/O for C103

N/S

S109

Near T/O for C103 and C104

2

Near T/O for C103 and C104

2

S112

Near Controller Antilock
Brake

2

Near T/O for Right Front
Turn Signal Lamp At
Grommet

N/S

S110

S125
(Built-UpExport)

Near ABS Pump Motor T/O

2

Near T/O for Right Front
Park/Turn Signal Lamp At
Grommet

N/S

S114
S115
(Except
Built-UpExport)

Near T/O for Duty Cycle
Evap/Purge Solenoid

1

S125
(Except
Built-UpExport)
S126
(LHD)

Near T/Os for Fuel Injectors

6

S116
(Except
Built-UpExport)

Near T/O for High Note Horn

1

S126
(2.5L)
(RHD)

Near T/O for Fuel Injector
NO. 4

7

Near T/O for Windshield
Washer Pump Motor

1

Near T/O for Fuel Injector
NO. 6

7

S117

S126
(4.0L)
(RHD)

S118

Near Left Headlamp T/O

1

S127

Near T/O for Idle Air Control
Motor

4, 5

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-1/23. 14+
8:9<;<=:>"?A@<BC?EDGFIH:FJ8KDG@<9<>:HLBC?EDGFNMO=:PQRSTQUVWX

576

Splice
Number

Location

Fig.

Splice
Number

Location

Fig.

S127
(2.5L)
(RHD)

Between Fuel Injector NO. 2
and Fuel Injector NO. 3

5

S144

Near T/O for Right Front
Park/Turn Signal Lamp

N/S

S146
Between Fuel Injector NO. 2
and Fuel Injector NO. 3

4, 5

Near T/O for Powertrain
Control Module

2

S128

Near T/O for Fuel Injectors

6

S147
(LHD)

Near T/O for Powertrain
Control Module

2

S129
(LHD)

Near T/O for C104

7

S147
(RHD)

Right Side of Engine
Compartment Near Grommet

3

S129
(RHD)

Near T/O for Fuel Injectors

6

S150
(Built-UpExport)

Near T/O for Right Headlamp
Leveling Motor

1

S130
(LHD)
S130
(RHD)

Near T/O for C103

N/S

Near T/O for Left Headlamp
Ground

1

S131
(LHD)

Near T/O for ABS Pump
Motor

2

S151
(Built-UpExport)
S202

10, 11

S131
(RHD)

Near T/O for C110

3

Center Rear of Instrument
Panel

S204

10, 11

S132

Near T/O for Oxygen Sensor
1/2 Downstream

6, 7

Center Rear of Instrument
Panel

S206

10, 11

S133
(LHD)

Near T/O for G105

6

Center Rear of Instrument
Panel

S207

Near Cigar Lighter T/O

10, 11

S133
(RHD)

Near T/O For C104

7

S301
(LHD)

Near Grommeted T/O to
Windshield Wiper Motor

8

S134

Near T/O for Oxygen Sensor
1/2 Downstream

6, 7

S301
(RHD)

Near T/O for Passenger
Airbag

9

S135

Near T/O for Oxygen Sensor
1/2 Downstream

6, 7

S302

Near Grommeted T/O for
Windshield Wiper Motor

8, 9

S136

In Battery Harness Near
PDC

N/S

S303

Near Grommeted T/O for
Windshield Wiper Motor

8, 9

S138
(Built-UpExport)

Near T/O for Right Headlamp
Leveling Motor

1

S304

Near Grommeted T/O for
Windshield Wiper Motor

8, 9

S306
Near T/O for Left Front Turn
Signal Lamp

N/S

Near T/O for Airbag Control
Module

8, 9

S141
(Built-UpExport)

S307

Near T/O for Airbag Control
Module

8, 9

S141
(Except
Built-UpExport)

Near T/O for Left Front
Park/Turn Signal Lamp

N/S

S309

Front of Left Rear Wheel
Well

12, 13

S310

12, 13

S142
(Built-UpExport)

Near T/O for Right Front
Turn Signal Lamp At
Grommet

N/S

Left Rear Quarter Panel,
Near Body Grommet

S311

Near Left Tail Lamp
Connector

12, 13

S142
(Except
Built-UpExport)

Near T/O for Right Front
Park/Turn Signal Lamp at
Grommet

N/S

S313

Front of Left Rear Wheel
Well

12, 13

S314

Front of Left Rear Wheel
Well

12, 13

S143

Near T/O for Left Front
Park/Turn Signal Lamp

N/S

S315

Near Right Tail Lamp
Connetor

12, 13

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Splice
Number

Location

Fig.

S316

In T/O for Rear Fog Lamp

12, 13

S331

8, 9

S317

Near T/O for Left License
Lamp

12, 13

Near T/O for Airbag Control
Module

S332

8, 9

S320
(LHD)

Near T/O for 100 way
Connector

8

Near T/O for Cigar
Lighter/Accessory Relay

S335

12

S320
(RHD)

Near Passenger Airbag
On/Off Switch

9

Near Left Tail Lamp
Connector

S400

N/S

S330
(LHD)

In T/O for Fuse Block

8

Near T/O for Rear Window
Defogger Feed

S401
Near Passenger Airbag
On/Off Switch

9

Near T/O for Rear Window
Defogger Feed

N/S

S330
(RHD)

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Fig. 1 Engine Compartment Splices—Front

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Fig. 2 Engine Compartment Splices—Rear,LHD

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Fig. 3 Engine Compartment Splices—Rear,RHD

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Fig. 5 Engine Wiring Splices—RHD

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Fig. 7 Engine Wiring Splices—RHD

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Fig. 9 Dash Panel Wiring Splices—RHD

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Fig. 10 Instrument Panel Wiring Splices—LHD

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Fig. 11 Instrument Panel Wiring Splices—RHD

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Fig. 12 Body Wiring Splices—LHD

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Fig. 13 Body Wiring Splices—RHD

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ENGINE
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page

¿ÀÂÁÃÅÄÇÆÈRÉ%ÆÄ ÀÇÀÇÀÇÀÇÀÇÀÇÀÇÀÇÀÀÇÀÇÀÇÀÇÀÇÀÇÀÇÀÇÀÀÇÀÇÀÇÀÇÀÇÀÇÀÇÀÇÀÀËÊÍÌ
ÌÀÂÎÃÅÄÇÆÈRÉ%ÆÄ ÀÇÀÇÀÇÀÇÀÇÀÇÀÇÀÇÀÀÇÀÇÀÇÀÇÀÇÀÇÀÇÀÇÀÀÇÀÇÀÇÀÇÀÇÀÇÀÇÀÇÀÀ'ÁÇÏ

ÄÇÆÈRÉ%ÆÄÅÐÉ ÑNÈRÆÒÓ,É ÓÔÀÇÀÇÀÇÀÀÇÀÇÀÇÀÇÀÇÀÇÀÇÀÇÀÀÇÀÇÀÇÀÇÀÇÀÇÀÇÀÇÀÇÀ½Õ
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STANDARD SERVICE INFORMATION
É!ÆÐÄÍß
page
GENERAL INFORMATION
ENGINE OIL SERVICE . . . . .
ENGINE PERFORMANCE . .
FORM-IN-PLACE GASKETS .
HONING CYLINDER BORES

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HYDROSTATIC LOCK . . . . . . . . . . . . . . .
MEASURING WITH PLASTIGAGE . . . . . .
REPAIR DAMAGED OR WORN THREADS
SERVICE ENGINE
ASSEMBLY (SHORT BLOCK) . . . . . . . .

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CAUTION: Be sure that the tapped holes maintain
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CAUTION: DO NOT use the starter motor to rotate
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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.



 

  ! 
CAUTION: Do not use non-detergent or straight
mineral oil when adding or changing crankcase
lubricant. Engine failure can result.

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CAUTION: Do not overfill crankcase with engine oil,
oil foaming and oil pressure loss can result.

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CEDGFIH DIC

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ENGINE DIAGNOSIS
²³/´/µ¶

DIAGNOSIS AND TESTING
CYLINDER COMBUSTION PRESSURE
LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . .
CYLINDER COMPRESSION PRESSURE TEST
ENGINE CYLINDER HEAD GASKET FAILURE
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE OIL LEAK INSPECTION . . . . . . . . . . .

page

page

.. 8
.. 8

ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . . . 10
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 7
HYDRAULIC TAPPETS . . . . . . . . . . . . . . . . . . . . . 7
INTAKE MANIFOLD LEAKAGE DIAGNOSIS . . . . . 8
SERVICE DIAGNOSIS—MECHANICAL . . . . . . . . 12
SERVICE DIAGNOSIS—PERFORMANCE . . . . . . 10

.. 8
.. 9

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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.

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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

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CAUTION: Do not exceed 20.6 kPa (3 psi).

CONDITION
ENGINE WILL NOT CRANK

ENGINE CRANKS BUT
WILL NOT START

POSSIBLE CAUSES

CORRECTION

1. Weak or dead battery

1. Charge/Replace Battery. Refer to Group 8A,
Battery, for correct procedures. Check charging
system. Refer to Group 8C, Charging Systems,
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 Group 8B,
Starting Systems, 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 Group 9, Engine, for correct
diagnostics/procedures

1. No spark

1. Check for spark. Refer to Group 8D, Ignition
System, for correct procedures.

2. No fuel

2. Perform fuel pressure test, and if necessary,
inspect fuel injector(s) and driver circuits. Refer
to Group 14, Fuel System, for correct
procedures.

3. Low or no engine
compression

3. Perform cylinder compression pressure test.
Refer to Group 9, Engine, for correct
procedures.

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CONDITION
ENGINE LOSS OF POWER

ENGINE STALLS OR
ROUGH IDLE

ENGINE MISSES ON
ACCELERATION

POSSIBLE CAUSES

Öv×½Ø.Ù ×.Ö ÚsۆÜVÜ
CORRECTION

1. Worn or burned distributor
rotor

1. Install new distributor rotor

2. Worn distributor shaft

2. Remove and repair distributor (Refer to
group 8D, Ignition System

3. Worn or incorrect gapped
spark plugs

3. Clean plugs and set gap. (Refer to group
8D, Ignition System)

4. Dirt or water in fuel system

4. Clean system and replace fuel filter

5. Faulty fuel pump

5. Install new fuel pump

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

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 cables

11. Replace any cracked or shorted cables

12. Faulty ignition coil

12. Test and replace, as necessary (Refer to
Group 8D, ignition system)

1. Carbon build-up on throttle
plate

1. Remove throttle body and de-carbon. (Refer
to Group 14 for correct procedures)

2. Engine idle speed too low

2. Check Idle Air Control circuit. (Refer to
Group 14, Fuel System)

3. Worn or incorrectly gapped
spark plugs

3. Replace or clean and re-gap spark plugs
(Refer to group 8D, Ignition System)

4. Worn or burned distributor
rotor

4. Install new distributor rotor

5. Spark plug cables defective or
crossed

5. Check for correct firing order or replace
spark plug cables. (Refer to Group 8D, Ignition
System for correct procedures.)

6. Faulty coil

6. Test and replace, if necessary (Refer to
group 8D, Ignition System)

7. Intake manifold vacuum leak

7. Inspect intake manifold gasket and vacuum
hoses. Replace if necessary (Refer to Group
11, Exhaust System & Intake Manifold)

8. EGR valve leaking or stuck
open

8. Test and replace, if necessary (Refer to
group 25, Emission Control Systems)

1. Worn or incorrectly gapped
spark plugs

1. Replace spark plugs or clean and set gap.
(Refer to group 8D, Ignition System)

2. Spark plug cables defective or
crossed

2. Check Idle Air Control circuit. (Refer to
Group 14, Fuel System)

3. Dirt in fuel system

3. Clean fuel system

4. Burned, warped or pitted
valves

4. Install new valves

5. Faulty coil

5. Test and replace as necessary (refer to
group 8D, Ignition System)

  
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CONDITION
NOISY VALVES/LIFTERS

CONNECTING ROD NOISE

MAIN BEARING NOISE

POSSIBLE CAUSES

CORRECTION

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 Engine Oil Service in
this group)

3. Low oil pressure

3. Check engine oil level. If ok, Perform oil
pressure test. Refer to this group 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

1. Insufficient oil supply

1. Check engine oil level. (Refer to group 0,
Lubrication and Maintenance)

2. Low oil pressure

2. Check engine oil level. If ok, Perform oil
pressure test. Refer to this group for engine oil
pressure test/specifications

3. Thin or diluted oil

3. Change oil to correct viscosity. Refer to this
group 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

1. Insufficient oil supply

1. Check engine oil level. (Refer to group 0,
Lubrication and Maintenance)

2. Low oil pressure

2. Check engine oil level. If ok, Perform oil
pressure test. Refer to this group for engine oil
pressure test/specifications

3. Thin or diluted oil

3. Change oil to correct viscosity. Refer to this
group for correct procedure/engine oil
specifications

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

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T-U/V1W3X3Y3Z6U/Z7V1X3T9[(\(Z([6U;XW=]?^1_`aDbE`cdef
CONDITION

LOW OIL PRESSURE

OIL LEAKS

EXCESSIVE OIL
CONSUMPTION OR
SPARK PLUGS OIL
FOULED

L#M%N'O M'L

POSSIBLE CAUSES

PQR S

CORRECTION

7. Loose flywheel or torque
converter

7. Inspect crankshaft, flexplate/flywheel and
bolts for damage. Tighten to correct torque

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 worn gears or oil pump assy

5. Thin or diluted oil

5. Change oil to correct viscosity. Refer to this
group for correct procedure/engine oil
specifications

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 pump suction tube loose,
broken, bent or clogged

8. Inspect suction tube and clean or replace if
necessary

9. Oil pump cover warped or
cracked

9. Install new oil pump

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

1. PCV System malfunction

1. Refer to group 25, Emission Control System
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

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2.5L ENGINE
g;hijlk
page
DESCRIPTION AND OPERATION
ENGINE DESCRIPTION . . . . . . . . . . . . . .
LUBRICATION SYSTEM . . . . . . . . . . . . . .
OIL PUMP PRESSURE . . . . . . . . . . . . . . .
SERVICE PROCEDURES
FITTING CONNECTING ROD BEARINGS .
FITTING CRANKSHAFT MAIN BEARINGS
PISTON FITTING . . . . . . . . . . . . . . . . . . .
PISTON RING FITTING . . . . . . . . . . . . . .
VALVE TIMING . . . . . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . .
CAMSHAFT BEARINGS . . . . . . . . . . . . . .
CAMSHAFT PIN REPLACEMENT . . . . . . .
CRANKSHAFT MAIN BEARINGS . . . . . . .
CYLINDER HEAD . . . . . . . . . . . . . . . . . . .
CYLINDER HEAD COVER . . . . . . . . . . . .
ENGINE ASSEMBLY . . . . . . . . . . . . . . . . .
ENGINE MOUNTS—FRONT . . . . . . . . . . .
ENGINE MOUNT—REAR . . . . . . . . . . . . .
EXHAUST MANIFOLD—2.5L ENGINE . . . .
HYDRAULIC TAPPETS . . . . . . . . . . . . . . .
INTAKE MANIFOLD—2.5L ENGINE . . . . .
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . 14
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35
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page
OIL PUMP . . . . . . . . . . . . . . . . . . . .
PISTONS AND CONNECTING RODS
REAR MAIN OIL SEALS . . . . . . . . . .
ROCKER ARMS AND PUSH RODS .
TIMING CASE COVER . . . . . . . . . . .
TIMING CASE COVER OIL SEAL . .
TIMING CHAIN AND SPROCKETS . .
VALVE SPRINGS AND OIL SEALS . .
VIBRATION DAMPER . . . . . . . . . . . .
DISASSEMBLY AND ASSEMBLY
CYLINDER BLOCK . . . . . . . . . . . . . .
CYLINDER HEAD . . . . . . . . . . . . . . .
VALVE SERVICE . . . . . . . . . . . . . . .
CLEANING AND INSPECTION
CYLINDER BLOCK . . . . . . . . . . . . . .
ENGINE CYLINDER HEAD . . . . . . . .
HYDRAULIC TAPPETS . . . . . . . . . . .
ROCKER ARMS AND PUSH RODS .
SPECIFICATIONS
2.5L ENGINE . . . . . . . . . . . . . . . . . .
2.5L TORQUE SPECIFICATIONS . . .
SPECIAL TOOLS
2.5L ENGINE . . . . . . . . . . . . . . . . . .

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Fig. 12 Ring Gap Orientation

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Fig. 15 Scoring Caused by Insufficient Lubrication
or by Damaged Crankshaft Pin Journal

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Fig. 13 Connecting Rod Bearing Inspection

Fig. 16 Rod and Piston Assembly Installation

Fig. 14 Locking Tab Inspection

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Fig. 17 Measuring Bearing Clearance with
Plastigage

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CRANKSHAFT JOURNAL

CORRESPONDING CONNECTING ROD BEARING INSERT

Color Code

Diameter

Upper Insert Size

Lower Insert Size

Yellow

53.2257-53.2079 mm

Yellow - Standard

Yellow - Standard

Yellow - Standard

Blue - Undersize

(2.0955-2.0948 in.)
Orange

53.2079 - 53.1901 mm
(2.0948 - 2.0941 in.)

0.025 mm (0.001 in.)

0.0178 mm (0.0014 in.)
Undersize
Blue

53.1901 - 53.1724 mm

Blue - Undersize

Blue - Undersize

(2.0941 - 2.0934 in.)

0.025 mm (0.001 in.)

0.025 mm (0.001 in.)

0.0356 mm (0.0014 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

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Fig. 18 Checking Connecting Rod Side Clearace—
Typical



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Fig. 20 Bearing Insert Pairs
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).

“Mîù6ìóøìöì8õô6ê;îðfí·ø
õ EVìŽöì9ì8”
î ô6ú ì8ô6é Ltò)ê;óóBì9ëG2• ô6ú8ñ
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ÿ

Fig. 19 Main Bearing Wear Patterns
NOTE: If any of the crankshaft journals are scored,
remove the engine for crankshaft repair.

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NOTE: DO NOT rotate the crankshaft. This will
cause the Plastigage to shift, resulting in an inaccurate reading. Plastigage must not be permitted to
crumble. If brittle, obtain fresh stock.

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Û)Ò3Ý+×kënê
CAUTION: Never use a pair of inserts that differ
more than one bearing size as a pair.

Fig. 21 Measuring Bearing Clearance with
Plastigage

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CRANKSHAFT JOURNALS #1 - 4
Color Code
Yellow

Diameter
63.5025 - 63.4898 mm
(2.5001 - 2.4996 in.)

¨©

CORRESPONDING CRANKSHAFT BEARING INSERT
Upper Insert Size

Lower Insert Size

Yellow - Standard

Yellow - Standard

Yellow - Standard

Blue- Undersize
0.025 mm (0.001 in.)

Blue- Undersize
0.025 mm (0.001 in.)

Blue- Undersize
0.025 mm (0.001 in.)

Blue - Undersize
0.025 mm (0.001 in.)

Green - Undersize
0.051 mm (0.002 in.)

Red - Undersize
0.254 mm (0.010 in.)

Red - Undersize
0.254 mm (0.010 in.)

63.4898 - 63.4771mm
(2.4996 - 2.4991 in.)
Orange

0.0127 mm (0.0005 in.)
Undersize
63.4771 - 63.4644 mm
(2.4991 - 2.4986 in.)

Blue

0.0254 mm (0.001 in.)
Undersize
63.4644 - 63.4517 mm
(2.4986 - 2.4981 in.)

Green

0.0381 mm (0.0015 in.)
Undersize
63.2485 - 63.2358 mm
(2.4901 - 2.4896 in.)

Red

0.254 mm (0.010 in.)
Undersize

CRANKSHAFT JOURNAL #5 ONLY
Color Code
Yellow

Diameter
63.4873 - 63.4746 mm
(2.4995 - 2.4990 in.)

CORRESPONDING CRANKSHAFT BEARING INSERT
Upper Insert Size

Lower Insert Size

Yellow - Standard

Yellow - Standard

Yellow - Standard

Blue - Undersize
0.025 mm (0.001 in.)

Blue- Undersize
0.025 mm (0.001 in.)

Blue- Undersize
0.025 mm (0.001 in.)

Blue - Undersize
0.025 mm (0.001 in.)

Green - Undersize
0.051 mm (0.002 in.)

Red - Undersize
0.254 mm (0.010 in.)

Red - Undersize
0.254 mm (0.010 in.)

63.4746 - 63.4619 mm
(2.4990 - 2.4985 in.)
Orange

0.0127 mm (0.0005 in.
Undersize
63.4619 - 63.4492 mm
(2.4985 - 2.4980 in.)

Blue

0.0254 mm (0.001 in.)
Undersize
63.4492 - 63.4365 mm
(2.4980- 2.4975 in.)

Green

0.0381 mm (0.0015 in.)
Undersize
63.2333 - 63.2206 mm
(2.4895 - 2.4890 in.)

Red

0.254 mm (0.010 in.)
Undersize

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WARNING: THE COOLANT IN A RECENTLY OPERATED ENGINE IS HOT AND PRESSURIZED. USE
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CAREFULLY RELEASE THE PRESSURE BEFORE
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THE RADIATOR DRAIN COCK AND CAP.
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Fig. 28 Manual Transmission to Engine—2.5L

Fig. 26 Air Cleaner Resonator and Duct Work

Fig. 27 Automatic Transmission to Engine—2.5L
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CAUTION: When disconnecting the speed control
connector at the throttle body, DO NOT pry the connector off with pliers or screwdriver. Use finger
pressure only. Prying the connector off could break
it.

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Fig. 30 Air Inlet/CCV System—2.5L Engine

Fig. 31 Intake/Exhaust Manifold—2.5L Engine

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engine cylinder head cover. However, sections with
minor damage such as small cracks, cuts or chips
may be repaired with a hand held applicator. The
new material must be smoothed over to maintain
gasket height. Allow the gasket material to cure
prior to engine cylinder head cover installation.

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CAUTION: Install oil seals carefully to prevent damage from the sharp edges of the valve spring lock
grove.
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WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAIN COCK WITH THE SYSTEM HOT AND PRESSURIZED BECAUSE SERIOUS BURNS FROM THE
COOLANT CAN OCCUR.

Fig. 35 Rocker Arm Assembly

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Fig. 37 Fabricate Alignment Dowels

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NOTE: If valves, springs, or seals are to be inspected/replaced at this time, refer to Valves and Valve
Springs later in this section for proper procedures.

Fig. 38 Alignment Dowel Locations

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Fig. 36 Engine Cylinder Head Assembly

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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.

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á3Ë*ÐÚ Þ9á9ëÏÍEÎ87mË*ÝÍEÏÍIÉ
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ÚÚHÑÚÚHÎÉ*Ñ
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3 æ
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Ä;:Ç5ä?Ð×ÍIÑ
ÚÚHèOËæ ÷ ÑÐÓ5èXËæTÅ43 ÎÉ*ÑÓ-éËÚÍI×)æ

CAUTION: During the final tightening sequence,
bolt No.7 will be tightened to a lower torque than
theÄFÅ4rest
3Ç ÿ Ïof
Ô9Îthe
ÍEÉ*Ð bolts.
ÍEÎ(É6ÉDO
Ð(Ô0ÏÐNOT
É6Ý2Þ3overtighten
Ú"ÏÐÓ
É Û ÎÉ*Ñ
Ó bolt
éË*Ú"ÍINo.7.
×`ÏÐ

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ç:=Ç <
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ÍEË
ç 3 @
è ?¡Ê—ÄÆÆ Ù ÍIæRÚé×)æ ÇBÍIË Û 9ÖÉ*æ

üýIþÿ 

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†>€Ž£.{0‹Œ€[…*½Š€*ŽŒƒ{e…‚»5ŽŒ€½„0ƒ‹Œ€[ž}€—j




CAUTION: The accessory drive belt must be routed
correctly. Incorrect routing can cause the water
pump to turn in the opposite direction causing the
engine to overheat.

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€*‚†4{0…*‚"ž}#€UxŠ€„0
w;ŽŒ€›;€*ŽW…UÇDŽŒ…*‰#½b±Š»¤Ÿ …*…„e{0‚|j¾~¥.†4ž€—Ë›e…*Ž
}€[½ŽŒ…*½Š€*ŽU½ŽŒ…*‹=€*ª‰ŽŒ€žy=
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ª‰Ž=€¦y=
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}…†>€[ƒ@ž}#€b}€ŽŒ—j…*†4žƒ@}#…*‰†4{e‚#|
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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.

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º¦‚†4½€‹Œ•›;…Žb„e€ƒ¡#†‡ƒŠ‚#ªÕ‹Œ…*‚{0‚‰€)…½€*ŽŒƒ{0‚|}€)€*‚#|{0‚€
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Ø5Ù¨ÚWÛ5ܨÝWޓßràáNܨâ â ã“á“ä

Fig. 39 Engine cylinder head Bolt Tightening
Sequence

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Fig. 40 Hydraulic Valve Tappet Removal/Installation
Tool

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Fig. 49 Loading Timing Chain Tensioner

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änåMæMç èéCêcëTìWëTé\í•ìmîï3éCë6ðuñròó ñôŸï\õRöa÷œø€ï\ùKïCöZìWé3úëTêcìWöëTûròsü
ìWé\ö·ëTíìmîï ý€é\ó ñré\íïCíìø€ï\ó émþ‚õRð ÿ míêcìWõRðTð6õRìWëTé\í”êMï ìWëTé\íé\ù
öéCòñ Rú wô¢íëTìmëTéCí ‚êMìmïCó êc÷
ä Mç wíêMìmõRðTðiìmîsï ëTêMìmöëTûRòìWé\ö õRí 5ëTôŸíëTìWë6éCí ZëTöïCêc÷
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WARNING: DO NOT LOOSEN THE RADIATOR
DRAIN COCK WITH THE SYSTEM HOT AND PRESSURIZED BECAUSE SERIOUS BURNS FROM COOLANT CAN OCCUR.

Fig. 51 Timing Chain Alignment

nä åDç úëTê é\íísï ì!íïCôŸõRìWë þbï õrûRðTï,ùKöéCó ûRõRìmìWï\ö ¸÷
ä Mç úöõRëTí²ìmîsï öõ rë6õRìWé\öa÷†ú
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éCé\ðTõRíìm÷kúöõRëTí•ìWîï é\éCðTõrísì!ëTíìmé,õ ðTïCõrí éCíìmõRëTíïCöa÷
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ä Mç ø€ï\óZéwþ‚ï,ìWîï,õ ï\êMêcéCö röë þ‚ï,ûRï\ðTìm÷
ä Mç úëTê é\íísï ì!ìWîï,öõ ëTõRìméCö}émþ‚ïCöùKðTé ìWòûRï œöõ rë6õRìWé\ö
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CAUTION: DO NOT loosen or disconnect any air
conditioner system fittings. Move the condenser
and receiver/drier aside as a complete assembly.

ä Mç wùï RòëTññrï ZëTìWîŒõRëTö éCí ëTìWëTé\íëTíô :ø€ï\ó émþ‚ï ìWîï
€ÿaý é\í rï\íêMï\öŒõRìmìWõ îëTíôûRé\ðTìWê±õRí ²ó émþ‚ï ìWîï éCíü
ïCíêcïCö
õRí öï ïCë þ‚ï\ö—ÿ röëTï\ö
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ä Mç ø€ï\óZéwþ‚ï,ìWîï öõRí ˜êcîõRùKìþbëTûröõRìWëTé\í õRó ñïCöa÷
äKæMç ø€ï\óZéwþ‚ï·ìWîï·ìWëTó ëTíô õRêcï émþ‚ïCöa÷bý€ðTï\õRí–ìWîï·ôŸõRê sïCì
ó õRìWï\öëTõRð9ùKöéCó ìWîï éwþbï\öa÷
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Fig. 52 Camshaft and Crankshaft Sprocket and
Chain

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ìWîï·ûRöé\ü
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õRí õrönï\ùKòsð6ð *ñòðTðTëTíô–ìmîsï3ñrë6í|ùKöéCó ìWîï õRó êMîõrù6ìm÷
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CAUTION: The following procedural step must be
accomplished to prevent the camshaft from damaging the rear camshaft plug during pin installation.

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CAUTION: Cover the opened oil pan area to prevent metal chips from entering the pan.

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NOTE: It is not advisable to attempt to replace
camshaft bearings unless special removal and
installation tools are available.
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Fig. 60 Oil Pan Sealer Locations

Fig. 58 Fabrication of Alignment Dowels
‚ ¾Q„¿5“(–QŠ’'4ŠF±²ˆÀžˆ5±²†'–ÁŽ“¹ŠŒ(†ÀŠŽ‡²Ž“*Ÿo«’–Q†À«ˆ5‰S†—.˜
¿5“(–QŠ’' ŠŒ*†ÁˆŠŒ(†—)ŠF±²ˆÁžˆ5±²†'–EŽ'“ŠŒ*†Á«œ'Ž'“(ž$†—)ª'ˆ« 
‚
­@Ž'Ÿ˜¨¼ ÃQ„˜
Ž''Ž'«ˆ“*†0…G›*ªª †—Äž$Œ(†–IŽ ‰†
†’ 'É
‚
®Q„>Đ$ œÆÅLj’—
È Šˆ—†’ —A‡>’Ž'“+ª †’ —Ž'“(Ÿ0«’ E
È «ˆ—xÉ
’ “(Š²ˆ“Á«œS'Ž“*ž$†—Aª ˆt« Ê
“(†—–Ê’ “(žo«œS'Ž“*ž$†—\ª 'ˆ« ËŠˆ#”
—ˆ“(ŠB«ˆ5‰S†—-̈Ž'“(Š–E‚
”ˆ›(—
$'’ «†–}„˜

Fig. 59 Position of Dowels in Cylinder Block
‚ ¼Q„
Ž'ž†AŠŒ(† ˆ“(†É
$Ž'†«†AŸ°’–Q ¡†Šaˆ5‰S†—NŠŒ(† ž$ˆ±²†'–²’ “(ž
ˆ“*Šˆ ŠȌ(† ª ˆ« 8’ “(žŠŽ'‡>Ž'“(Ÿ¯«’ –I† «ˆ‰†—}˜
‚
ÍQ„Î@ˆ–QŽŠŽ'ˆ“ÁŠŒ(†ˆŽ'a$’ “Áˆ5‰S†—ÇŠŒ(†ž$ˆ5±-†'–4’ “(ž\ˆ“(Šˆ
ŠŒ(† Ÿ’ –I ¡†Š˜
‚
ÏQ„¿5“(–QŠ’'aŠŒ(†+ƒ}µ.®\Ž'“(«Œ#ˆŽ'$’ “Á”
’ –IŠ†“*†—–Q˜OºGŽ'ŸŒ(Š†“
ŠŒ(†–Q†-”
’ –IŠ†“*†—–!Šˆ-à ˜ ¼AÐÑ ‡¹‚
½ ®AŽ'“(˜ª –Q˜ „jŠˆ—Ò›(†˜Ó¿“(–IŠ’ 
ŠŒ(†Æ¼QµIƒQÍˎ“*«ŒÔˆŽ'4$’ “Ô”’–QŠ†“(†—–#‚
­@Ž'Ÿ˜AÍӃ}„˜!ºÕŽ'Ÿ°Œ(Š†“
ŠŒ(†–Q† ”
’ –IŠ†“*†—–²Šˆ0ƒQ¼<ÐaÑF‡Ö‚ƒQ¾ ¬<Ž'“(˜¨'ª –I˜ „VŠˆ—Ò ›(†˜

Fig. 61 Position of 5/16 inch Oil Pan Bolts
‚ ½Q„…†‡>ˆ‰†0ŠŒ(†0ž$ˆ±²†'–Q˜a¿5“(–QŠ’ 'VŠŒ(†0—†‡>’ Ž'“(Ž'“(ŸÆƒ}µ.®
Ž'“(«Œ0ˆŽ’“8”
’ –IŠ†“(†—–²’ “(ž<ŠŽ'ŸŒ*Š†“0Šˆ à ˜ ¼<ÐaÑF‡š‚
½ ®<Ž'“(˜
'ª –I˜ „˜
‚
ÃQ„×@ˆ5±²†—ŠŒ(†-†“(ŸŽ'“(†-›(“*ŠŽ'OŽ'Š:Ž'–V—ˆ$†— œ8'ˆ«’Š†žÇˆ“
ŠŒ(† †“(Ÿ°Ž“*†A‡²ˆ›(“(Š–Q˜
‚ƒQØQ„¿5“(–QŠ’ '@ŠŒ(†VŠŒ(—ˆ›(Ÿ°Œ4ª ˆ'Š–’ “(žAŠŽ'ŸŒ(Š†“¯ŠŒ(†V“(›(Š–I˜
‚ƒƒ}„×@ˆ5±-†—NŠŒ(†ÌL’« B–QŠ’ “(ž’ “(ž<—†‡>ˆ‰† ŠŒ(† Ž†«† ˆ”
±²ˆˆž$˜
‚ƒQ¬Q„¿5“(–QŠ’ '·ŠŒ(†Ù” œ±²Œ(††·’ “(ž´Šˆ—Ò ›(†Ú«ˆ“‰S†—Š†—
Œ(ˆ›(–IŽ'“(Ÿ¯’ ««†–Q–²«ˆ5‰S†—.˜
‚ƒQ¾Q„¿5“(–QŠ’ 'GŠŒ(† †“(Ÿ°Ž'“(† –IŠ’—Š†—-‡>ˆŠˆ—.˜
‚ƒQ®Q„™ˆ“(“*†«ŠŠŒ(†V†¶Œ(’ ›(–QŠ$Ž'$†VŠˆ!ŠŒ*†VŒ(’ “(Ÿ°†—¸’ “(ž³Šˆ
ŠŒ(† †“(Ÿ°Ž“*†A†¶Œ(’ ›(–QŠa‡>’ “(Ž'”
ˆž˜
‚ƒQ¼Q„¿5“(–QŠ’ 'ÙŠ—’ “(–I‡>Ž'–Q–IŽ'ˆ“ÛˆŽÚ«ˆˆ'Ž“*ŸÜ'Ž'“(†–‹‚
Ž'”
†Ò ›(Ž'$†žL„)’“*žËˆ5¶œSŸ†“Ý–I†“(–Iˆ—<±²Ž'—Ž'“(ŸÞ–Q›($$ˆ—Š–ÊŠŒ*’Š
’ ŠŠ’ «Œ0Šˆ ŠŒ(† ˆŽ'G$’ “0–IŠ›(ž$–Q˜
‚ƒQÍQ„¿5“(–QŠ’ '·ŠŒ*†ÙˆŽ·$’ “Rž$—’ Ž“R$'›(Ÿs‚­CŽ'Ÿ˜ÀÍӃ}„˜
ºGŽŸ°Œ(Š†“0ŠŒ(† ›*Ÿ4Šˆ ¾ ®<ÐÑ ‡‚¬¼4”
Š˜¨'ª –I˜ „VŠˆ—Ò ›(†˜
‚ƒQÏQ„×Cˆ±²†—NŠŒ(†‰†Œ*Ž«†˜
‚ƒQ½Q„™ˆ“(“*†«Ša“(†Ÿ’ ŠŽ ‰S† «’ª '† Šˆ ª ’ ŠŠ†—œ°˜
‚ƒQÃQ„­CŽ''CŠŒ(†NˆŽ@$’ “-±²Ž'ŠŒ4†“(ŸŽ'“(†NˆŽ'@ŠˆNŠŒ(†N–Q$†«Ž'”Ž†ž
'†5‰S†'˜

¤†¥
²(³-´Yµ¶Q·(¸B·(¹º^»¹¼-½­·(¸¸·~½=»µ¹¿¾?À(ÁÂÃ;Ä/ÂÅÆÇÈ

¦e§A¨Š©mªV«­¬® «ª

¯R°Q±#¨

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.

 
    ! "#$ %&(' )! *

+-,/.1032-450
6 7"8&!   9
;:# ! "#' 8$;<= 1>?: A@
"#B&;'C"#D<="E !
# 9FHG @I 8! GD &J! % KLM$H !=# 9FHG @I
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"#;!N!    & "#D<="CG&;V@*
6 U"#D<="W $&X"#& !YZ&[VD!N G'1"#;!N! D
;' ;%Q9F' 9F\ S&\'  <= <= ]
 <=D<^"#;!N! D\ S&\_a` b1)dce
b_="#!N ?*Ffgh i'  %e"#&;!N  &K j9
' 9
i"#<= !&;'a &
G @
"#! !k &;D>lm"#!N! >Cl 5"8D<="IG8&;V@n S&C 
 '  !  #&%j "#D<="#*
Oo 'M"#D<="n<=&S9
'=&;5"8'$;<= (LM ' 'M& h%%;$
\# !N  GD S&;k  <= IG;$D!N\ \# !N  GD S&;k8 9F
>;J;<=8 !M \<=! pLJ \ S$X8<=! % q*
rstiuvFwQx
X`/ yo \ S;> &;' *
  z3<M&g9
 & '"88*
{  z3<M&g9
n n"#D<="#: &:$|@
'  #;1G' &$)} S $ 
G&' !N*~z3<M&g9
k S "#D<="m!N! <=G' @\LM U>! ); Me >*
€  X*

Fig. 62 Oil Pump Assembly

b  yo \ S;> & ' *
›  z3<=&S9
 & '"#\ >!N)d *
œ  z3<=&S9
1 1$&;$  &ZG $"#!Y
 !N; !N*(žp8X)Ÿ I$"#!Y‡&8!hLM B I$|@
'  #;
G& ' &$ S &;* 6 E$&;$  ¡&#!}¢$"#!}
!N <="#;TLJ \k ALM&'   S;J$&;<=G8  &\…* € { X*

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.

‚
ƒ…„>w~xxw„P ui‚
X`/ fg! 8' '… (&;'…"#D<="&h S†$|@
'  #;-G'&;$)pD!N 
U;"#' $<=; >!N)d * 6  > ‡ HG8&;' S!C &Y{Uˆ‰A<
X` bk% S*Š'G! * ( &‹D;*
  fg! 8' ' & '"8H >!N)d; S*
{  …' ' &;'3"#pLJ \& ' & S! "#$ %; 'S9
;'*
03,/Œ3a+-Ž-ŒmiŽ-’‘3+-Ž-Ž-“a‘3a,/Ž-”’•-+--Œ
rstiuvFwQx
X`/ z3<M&g9
  $|@
'  #;J;8 $&S9
/*
  z3<M&g9
 &$)d;J<=!NKŠG8>!M "# 9
&; !N*
{  z3<M&g9
 "#D! H&;#! *
–  z3<M&g9
  $|@
'  #;J;88*
_  c…&!   &k J"8 !N &!—&(8 j S <=( JG& :
&<˜&%j ! S&;)d*Š™—!NR #>;<=( &<=&S9
 
 #C%X&<š  S&;"I;I&;%i  $|@
'  #;†LM' ' !N*Q™—! C
"#&; S;$  9F$' & H &$&' ' $  $D  >! *
 €  z3 !N —9
$' ;*

Fig. 63 Stamped Connecting Rods and Caps

X`   £e&SLMi -9F $' =D S 'P o !(G&D Qh%; o%X&<
%' &&;q*
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.

798;:<

=?>A@?BDCFEHGJI EJC

KML

NPO!Q RSUTPVTPWYX[ZWY\!]HTPV1V1T^]
ZRYW`_baPc1d1ef(d1g1h1i1j

ÉXÊ;ÊqË ÌiÍ Î
ÏYÍ8ÐWÍÑ ÑNÒ ÑNÓÍÐÓpÔ#ÕÑ ÖWÓSÖÏYÔ#Ò ÑNÓ×ÐWÍÐØnÙX×ÐÚ
ÐÏ;ÙÓSÒ ÐÛTÜ×ØpÍÑNÑ ÏÝ=Þß Ò ÏÑiÕÔpÍ8ÐØpÓÖÜ×ÕÛ>Ö ÓÖÏJÓS×;Ôh×;à­ÓÖÏ
Ù|á
ß Ò ÐØ8ÏÜJÞ×;ÜÏÑMÉâ…Ò Û>ãPäå ËXã

Fig. 65 Rod and Piston Assembly Installation

Fig. 64 Removal of Connecting Rod and Piston
Assembly

æç
è…é>ê~ëëêéPæ ìiç
ÉXÊ/Ë í3ß ÏÍÐ7ÓSÖÏUÙ|á
ß Ò ÐØ#ÏÜHÞ×ÜÏ;ÑmÓSÖ×Ü×;ÕÛ>Öß áîã3ï—Ô#Ô#ß á’Í
ß Ò Û>ÖÓàÒ ß Ýð×;àeÙßÏ;ÍÐRÏ;ÐÛ>Ò Ðφ×Ò ß…Ó׆ÓSÖφÞ×ÜÏ;Ñ­ñMÒ ÓSÖhÍTÙß ÏÍÐ
ß Ò ÐÓÚàÜÏ;ÏÙXß×;ÓSÖã
Éò Ë ógÐÑ ÓÍ8ß ßŸÓSÖÏôÔ#Ò ÑNÓ×;ÐõÜÒÐÛ>Ñ¢×;ÐõÓSÖÏôÔ#Ò ÑNÓ×;ÐÑ¢Ò à
ÜÏ;Ý=×gÎ
Ï;Ø#ã
Éö Ë ÷…ÕÞÜÒÙXÍ8ÓÏøÓSÖÏøÔ#Ò Ñ ÓS×;ÐùÍÐØúÜÒ ÐÛ>ÑBñMÒ ÓÖùÙß ÏÍÐ
ÏÐÛ>Ò ÐÏ×Ò ß ã
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.

Éû Ë ü—Ñ ÏJÍÔ8ÒÑ Ó×ÐkÜÒ ÐÛ=Ù×Ý=Ô8ÜÏÑ ÑN×;ÜÓ×JÒ ÐÑ ÓSÍß ßeÓSÖÏJÙ×;ÐÚ
ÐÏ;ÙÓSÒ ÐÛÜ×ØRÍ8ÐØkÔ#Ò Ñ ÓS×;Ð5ÍÑNÑ ÏÝ=Þß Ò ÏÑ(ÓSÖÜX×ÕÛ>ÖCÓSÖÏTÓ×ÔR×à
ÓÖÏÙ|á
ß Ò ÐØ#Ï;ÜJÞ×ÜÏ;ÑMÉâ…ÒÛãPäû ËXã
Éä Ë ý3ÐÑ ÕÜÏ\ÓÖÏ\Í8ÜXÜ×gñú×ÐnÓÖÏ\Ô#Ò ÑNÓ×ÐnÓ×ÔUÔ#×;Ò ÐÓSÑ Ó×
ÓÖÏàÜ×;ÐÓ×àjÓÖÏÏÐÛÒÐÏÉâeÒ Û>ãŠäûNË?ã
Éþ Ë ÿ3ÍÒ ÑNÏÓÖϗÎ
ÏÖÒÙß Ï;ã
É Ë ý3ÍÙÖWÞÏÍÜÒ ÐÛ1Ò ÐÑNÏ;ÜÓpÒÑ5àÒ ÓÓÏØnÓ×YÒ ÓSÑ5ÜÏÑ Ô#Ï;ÙÓSÒ Î
Ï

 ×;ÕÜÐÍß3Ó×T×ÞÓSÍÒ Ð5ÓSÖÏTÑ Ô#ÏÙÒ àÒÏ;Ø Ùß Ï;Í8ÜXÍ8ÐÙÏÞÏ;Ó ñJÏÏÐ5ÓÖÏ
ÞÏÍÜÒ ÐÛRÍÐØ5ÓÖÏ  ×ÕÜÐÍß ã­óSÐYÔ#Ü×;Ø#ÕÙÓÒ ×Ð ­ÓSÖÏÑNÏß Ï;ÙӗàÒ Ó
Ò Ñh×ÞÓSÍÒ ÐÏ;ØIÞ ánÕÑNÒ ÐÛÎ
ÍÜÒ ×ÕÑ ÚÑNÒ VÏ;Ø QÙ×;ß×;ÜXÚÙ×Ø#Ï;ØIÞÏ;Í8Ü?Ú
Ò ÐÛ5ÒÐÑNÏÜXÓSÑpÍÑhß Ò ÑNÓÏ;ØmÒ ÐUÓÖÏkí3×ÐÐÏ;ÙÓÒÐÛ\ÿ3×
Ø 3ÏÍÜÒ ÐÛ
â…ÒÓÓÒ ÐÛRí3ÖÍÜÓã
~ÖÏÙX×ß ×Ü(Ù×Ø#ÏÍÔ#Ô#Ï;ÍÜÑ=×;ÐHÓÖÏÏØ#ÛÏ×;à
ÓÖÏ(ÞÏ;Í8ÜÒ ÐÛMÒ ÐÑNÏ;ÜÓ ã
~ÖφÑNÒ VÏ(Ò ÑÐ×ÓÑ ÓSÍÝ=Ô#Ï;Ø×;ÐRÒ ÐÑNÏ;ÜÓÑ
ÕÑ ÏØ à×;ÜJÔ#Ü×;Ø#ÕÙÓÒ ×Ð\×àjÏÐÛ>Ò ÐÏÑ ã

É Ë
~ÖÏÜ×;Ø  ×ÕÜXÐÍ8ß3ÒÑMÒ Ø#Ï;ÐÓSÒ àÒÏ;ØCØ8ÕÜÒ ÐÛRÓÖÏÏÐÛ>Ò ÐÏ

Ô#Ü×;Ø#ÕÙÓÒ ×ÐmÞNá1Í5Ù×;ß×;ÜXÚÙ×Ø#Ï;ØHÔ8Í8Ò ÐӆÝ=ÍÜY×;ÐIÓÖÏhÍ8Ø  ÍÚ
ÙÏÐÓ-ÙÖÏÏ C×܆Ù×ÕÐÓSÏ;Ü|ñMÏÒ ÛÖÓ-ÓS×SñMÍÜØkÓSÖÏTàßÍÐÛÏÉÜÏÍÜ|Ë
ÏÐØY×àÓÖÏkÙÜÍÐ dÑNÖÍàÓSã
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ÙÍÓSÏ  ×;ÕÜÐÍ߆ÑNÒ VÏÑ ÍÜÏHß Ò ÑNÓÏØlÒ Ð‡ÓÖÏ\í3×ÐÐÏ;ÙÓÒÐÛIÿ3×Ø
3ÏÍÜÒ ÐÛhâ…ÒÓÓÒÐÛRí3ÖÍ8ÜÓã
ÉXÊ 
Ë 1ÖÏ;Ð ÜÏ 8ÕÒÜÏ;Ø WÕÔ8Ô#ÏÜ¢ÍÐØ ß ×gñMÏ;Ü¢ÞÏÍÜÒ ÐÛ
Ò ÐÑNÏ;ÜÓц×à­Ø8ÒààÏÜXÏÐÓ~ÑNÒ VÏÑiÝ=ÍNá5ÞÏMÕÑNÏ;ØhÍ8ÑiÍpÔ#ÍÒ Ü—ÉÜÏ;àÏÜ
Ó×1í3×ÐÐÏ;ÙÓÒÐ۝ÿ3×
Ø 3ÏÍÜÒ Ð۝â…ÒÓÓÒ Ð۝í3ÖÍÜÓ Ë?ã­ï ÑNÓÍÐÚ
Ø#ÍÜØWÑ Ò VÏUÒ ÐÑ ÏÜÓkÒÑYÑN×;Ý=ÏÓÒ Ý=ÏÑYÕÑNÏ;ØWÒ Ð7Ù×ÝMÞ8Ò ÐÍÓÒ ×Ð
ñMÒ ÓÖð
Í ã òûBÝ=Ý É 8ã aÊUÒ ÐÙXÖîËmÕÐØ8ÏÜÑ Ò VϝÒÐÑNÏ;ÜÓ\Ó×
ÜÏØ8ÕÙÏÙß ÏÍÜÍÐÙ
Ï ã …Ê ökÝ=ݘÉ ã ûkÒ ÐÙÖËXã
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.

ÉXÊÊ/Ë óSÐÑNÓÍßßÓÖÏUÙ×ÐÐÏÙÓÒ ÐÛnÜ×؟ÞÏ;Í8ÜXÒÐۇÙÍÔ#ÑmÍÐØ
Ò ÐÑNÏ;ÜÓÑMÒÐ\ÓÖÏÑNÍÝ=ÏÔ#×;ÑNÒ ÓÒ×;ÐÑMÍÑMÜÏÝ=×SÎ
ÏØ8ã

CAUTION: Verify that the oil squirt holes in the
rods face the camshaft and that the arrows on the
pistons face the front of the engine.

ÉXÊ ö Ë ógÐÑ ÓSÍß ßjÓÖÏp×;Ò ßjÔ#ÍÐYÍÐØCÛ>ÍÑdÏÓÑ=ÍÑT×;ÕÓßÒ ÐÏ;Ø5Ò Ð
ÓÖÏÒÐÑNÓÍßß ÍÓÒ×;ÐHÔ8Ü×ÙÏ;Ø#ÕÜÏ;ã
ÉXÊ å Ë ÷e×SñMÏÜ(ÓÖϗÎ
ÏÖÒÙXßÏ;ã
ÉXÊ û Ë ógÐÑ ÓSÍß ß=ÓSÖÏ1ÏÐÛ>Ò ÐÏ1Ù|áFß ÒÐØ#ÏÜ\ÖÏÍØ (Ô#ÕÑ ÖBÜ×;Ø#Ñ 
Ü×Ù Ï;Ü-ÍÜÝ=Ñ FÞÜÒ Ø#Û>Ï;Ñ FÔ8Ò ÎF×ÓÑÍÐØÏ;ÐÛ>Ò ÐφÙ|áFßÒ ÐØ8ÏÜoÖÏÍØ
Ù×gÎFÏÜ/ã
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NOTE: If the valve guides are reamed oversize, the
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Fig. 67 Valve Facing Margin

Fig. 68 Measurement of Valve Seat Runout

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Fig. 69 Measurement of Valve Guide Bore Diameter

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NOTE: Valve seats must be ground after reaming
the valve guides to ensure that the valve seat is
concentric to the valve guide.

Fig. 71 Valve Spring Tester

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Fig. 70 Measurement of Lateral Movement Of Valve
Stem

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4.0L ENGINE
Í6ÎnÏnÐ#Ñ
page
DESCRIPTION AND OPERATION
ENGINE DESCRIPTION . . . . . . . . . . . . . .
LUBRICATION SYSTEM . . . . . . . . . . . . . .
OIL PUMP PRESSURE. . . . . . . . . . . . . . .
SERVICE PROCEDURES
FITTING CONNECTING ROD BEARINGS.
FITTING CRANKSHAFT MAIN BEARINGS
PISTON FITTING . . . . . . . . . . . . . . . . . . .
PISTON RING FITTING . . . . . . . . . . . . . .
VALVE TIMING . . . . . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . .
CAMSHAFT BEARINGS . . . . . . . . . . . . . .
CRANKSHAFT MAIN BEARINGS . . . . . . .
CRANKSHAFT OIL SEALS—REAR. . . . . .
CYLINDER HEAD COVER . . . . . . . . . . . .
ENGINE ASSEMBLY. . . . . . . . . . . . . . . . .
ENGINE CYLINDER HEAD. . . . . . . . . . . .
ENGINE MOUNTS—FRONT. . . . . . . . . . .
ENGINE MOUNT—REAR . . . . . . . . . . . . .
EXHAUST MANIFOLD—4.0L ENGINE . . .
HYDRAULIC TAPPETS. . . . . . . . . . . . . . .
INTAKE MANIFOLD—4.0L ENGINE . . . . .

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page
OIL PAN . . . . . . . . . . . . . . . . . . . . . . .
OIL PUMP . . . . . . . . . . . . . . . . . . . . .
PISTONS AND CONNECTING RODS .
ROCKER ARMS AND PUSH RODS . .
TIMING CASE COVER . . . . . . . . . . . .
TIMING CASE COVER OIL SEAL . . . .
TIMING CHAIN AND SPROCKETS . . .
VALVE SPRINGS AND OIL SEALS . . .
VIBRATION DAMPER . . . . . . . . . . . . .
DISASSEMBLY AND ASSEMBLY
CYLINDER BLOCK. . . . . . . . . . . . . . .
VALVE SERVICE . . . . . . . . . . . . . . . .
VALVES AND VALVE SPRINGS . . . . .
CLEANING AND INSPECTION
CYLINDER BLOCK. . . . . . . . . . . . . . .
CYLINDER HEAD. . . . . . . . . . . . . . . .
HYDRAULIC TAPPETS. . . . . . . . . . . .
ROCKER ARMS AND PUSH RODS . .
SPECIFICATIONS
4.0L ENGINE SPECIFICATIONS . . . . .
4.0L TORQUE SPECIFICATIONS . . . .
SPECIAL TOOLS
4.0L ENGINE . . . . . . . . . . . . . . . . . . .

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Fig. 6 Ring Side Clearance Measurement

Fig. 7 Gap Measurement

Fig. 5 Piston Dimensions

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ëjçNö:ð@ûHèsò‘ìlížúBçNèü:ìlúBúìsðýìlû,úBçNèóMíNé‡óMîè©èlîôèö>íî4ö6îìsú
ìlí6úBçNè’úìsñ5ûHìlòPëjìlòjòjèsëjúóMíNé‡úBö:ùMùMö>úBóMìlí6ãHþWónôÿ åfÿ
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ð 
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ô Nñ›ãnþóMô{
ÿ ‡å‚ãHþWóMô{ÿ ‰å ÿ
ã å…éóMíNô(ö5òjóMíNô(óMíNéúö:ùMùMèlò óMíNéúö:ùMù"úçNèˆúìsñœëjìlðEñòjèlé 
éónìsí4òjóMíNô©ãnèlóMúçèlòPé‡óMî
è Nñå ÿ

Fig. 11 Compression Ring Installation

Fig. 8 Top Compression ring identification

sì ÿDCE\ìsð@ñòjèléé‡óMìsí#òjóMíNôFG=ö>ñH[email protected]ûHòjìlð÷úBìlñ™ìlóMù
òjö:•óMù.ô{B ö:ñÿ
ìsI
ÿ JE\ìlð@ñ>òjèléé‡óMìlí¢òjóMíNôK =‚ö:ñL[email protected]@ûnòjìlð B ìsÿGC
• ñB òjèléé‡óMìsí4òjóMíNô©ô{ö:ñÿ
ëjìlðE

Fig. 9 Second Compression Ring Identification

Fig. 10 Compression Ring Chamfer Location
Ring Gap Orientation
• "!$$1#&= %(')*+,!-'./%(*"0132 4#6> 57(8:9;5
• <
$ ?[email protected]
• <

Mó ù.éñö:ëjèlò ‚ö:ñ™ìsí4ëfèlíNúBèlòPùMóníèˆìsû"ñóMé‡úBìlí6é 7óMòjúBÿ
óMù*òjö>óMùMé \ôö>ñ
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Fig. 12 Ring Gap Orientation

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ghjik]l7monp ml

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Ÿ¡ •©.Ÿ › •¢½¹º›º©.¨.š•¢&¥® ©.¬¹I&©.¥±
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›ž¢&¥£ªš•¤)»Tš•£ªž·,› ©.š•§¨.¾•¥¥›±

Fig. 15 Scoring Caused by Insufficient Lubrication
or by Damaged Crankshaft Pin Journal

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ëô"ò(ëŽëô,èÚìê/óˆçù(ú"êî;ëŽô"ìó/èç¦ê/í3ëô,èÚî;ìõ)ç¦ûªò(ð;èÚëô"èJð;ò(ñ-çô"ò(ûªë
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Fig. 13 Connecting Rod Bearing Inspection

Fig. 16 Rod and Piston Assembly Installation

Fig. 14 Locking Tab Inspection

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Fig. 17 Measuring Bearing Clearance with
Plastigage

ìYíyîsîsï3ì-ð3ñjîžò]óYíyô¬õï3öYó-ñjîžò]÷Ûñ»ð3ð3ñøî×ò]ìùsöóð
CRANKSHAFT JOURNAL
Color Code
Yellow

Diameter
53.2257 - 53.2079 mm
(2.0955 - 2.0948 in.)

CORRESPONDING ROD BEARING INSERT
Upper Insert Size

Lower Insert Size

Yellow - Standard

Yellow - Standard

53.2079 - 53.1901 mm
Orange

(2.0948 - 2.0941 in.)
0.0178 mm (0.0007 in.)

Yellow - Standard

Blue - Undersize
0.025 mm (0.001 in.)

Undersize
53.1901 - 53.1724 mm
Blue

(2.0941 - 2.0934 in.)

Blue - Undersize

Blue - Undersize

0.0356 mm (0.0014 in.)

0.025 mm (0.001 in.)

0.025 mm (0.001 in.)

(2.0855 - 2.0848 in.)

Red - Undersize

Red - Undersize

0.254 mm (0.010 in.)

0.254 mm (0.010 in.)

0.254 mm (0.010 in.)

Undersize
52.9717 - 52.9539 mm
Red

Undersize

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²³
¨0³
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Fig. 18 Checking Connecting Rod Side Clearance—
Typical

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…ˆ‡‰„1‘ Š‰«®‹Œ‡‰‘ •…¤O•ƒ‘ Š‰ž„1„^Š‰“<¨Y å¼‡‰„1„^‘ I™š‘ €ƒŠÍ^–"£ Š‰‘ O¬‰€ƒ‹
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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).

ÿ Š‰„'…ˆ‡‰„'˜ „"‘ €ƒŠ‰ž‹C‡‰‘ÄDŽ—˜ „^„"Š¾‚F–"‚
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Y€OŠ   ©ªŠ‰‹…Ž‘ ƒƒ‘
…ˆ€ƒ–"Š  







 
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ƒ„"‘ ‘ Š‰„T‘ …@‘…ˆ€ƒ™š„" 
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¡,+ ™ ¤ * ï•…ˆ nƒ˜ ‹Œ  ¨1…Ž–^ñ £‰„" 
Fig. 19 Main Bearing Wear Patterns
NOTE: If any of the crankshaft journals are scored,
remove the engine for crankshaft repair.

©ªŠ‰‹‚F„"Y…œ…ˆ‡‰„š˜ ‘ «–^•…Ž‡ „š€ƒŠ‰‹Œ„^…ˆ‹P•–^o•‘ …Ž£ „"‹¬4‹‘ ‚F­
€ƒŠ‰ž‹¢–^€ƒ„^ž£‰ƒ‘  › „"‘ ‚F‘ …ˆ…ˆ„"Š‰‹ 
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€ƒŠ‰‹„"…ˆ‹¢‘
„T‹™š–"–^…Ž‡  

NOTE: DO NOT rotate the crankshaft. This will
cause the Plastigage to shift, resulting in an inaccurate reading. Plastigage must not be permitted to
crumble. If brittle, obtain fresh stock.

¯„"™š–ŽÄ$„T…ˆ‡‰„˜
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Fig. 20 Crankshaft Journal Size Paint I.D. Location

Fig. 21 Bearing Insert Pairs

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CAUTION: Never use a pair of inserts that differ
more than one bearing size as a pair.

Fig. 22 Measuring Bearing Clearance with
Plastigage

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ÝÞpßbàCátâKÞã2ßbàwäæåQß çQç€ßbàwäCèéTÞã?ç

Crankshaft Journals #1-6
Color Code
Yellow

Diameter
63.5025 -63.4898 mm
(2.5001 - 2.4996 in.)

Corresponding Crankshaft Bearing Insert
Upper Insert Size

Lower Insert Size

Yellow - Standard

Yellow - Standard

Yellow - Standard

Blue - Undersize
0.025 mm (0.001 in.)

Blue - Undersize
0.025 mm (0.001 in.)

Blue - Undersize
0.025 mm (0.001 in.)

Blue - Undersize
0.025 mm (0.001 in.)

Green - Undersize
0.051 mm (0.002 in.)

Red - Undersize
0.254 mm (0.010 in.)

Red - Undersize
0.254 mm (0.010 in.)

63.4898 - 63.4771 mm
(2.4996 - 2.4991 in.)
Orange

0.0127 mm (0.0015 in.)
Undersize
63.4771 - 63.4644 mm
(2.4991 - 2.4986 in.)

Blue

0.0254 mm (0.001 in.)
Undersize
63.4644 - 63.4517 mm
(2.4986 - 2.4981 in.)

Green

0.0381 mm (0.0015 in.)
Undersize
63.2485 - 63.2358 mm
(2.4901 - 2.4896 in.)

Red

0.254 mm (0.010 in.)
Undersize

Crankshaft Journal #7 Only
Color Code
Yellow

Diameter
63.4873 - 63.4746 mm
(2.4995 - 2.4990 in.)

Corresponding Bearing Insert
Upper Insert Size

Lower Insert Size

Yellow - Standard

Yellow - Standard

Yellow - Standard

Blue - Undersize
0.025 mm (0.001 in.)

Blue - Undersize
0.025 mm (0.001 in.)

Blue - Undersize
0.025 mm (0.001 in.)

Blue - Undersize
0.025 mm (0.001 in.)

Green - Undersize
0.051 mm (0.002 in.)

Red - Undersize
0.254 mm (0.010 in.)

Red - Undersize
0.254 mm (0.010 in.)

63.4746 - 63.4619 mm
(2.4996 - 2.4991 in.)
Orange

0.0127 mm (0.0005 in.)
Undersize
63.4619 - 63.4492 mm
(2.4985 - 2.4980 in.)

Blue

0.0254 mm (0.001 in.)
Undersize
63.4492 - 63.4365 mm
(2.4980 - 2.4975 in.)

Green

0.0381 mm (0.0015 in.)
Undersize
63.2333 - 63.2206 mm
(2.4895 - 2.4890 in.)

Red

0.254 mm (0.010 in.)
Undersize

džÈÆÉPÊ

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Fig. 23 Left Front Engine Mount

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Fig. 25 Rear Mount (Manual Transmission)

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 ÷rê 
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üPøEúQUñ 0Lî$õBVû êaÿÍ%ð +W!:_ì
N7OP

WARNING: THE COOLANT IN A RECENTLY OPERATED ENGINE IS HOT AND PRESSURIZED. USE
CARE TO PREVENT SCALDING BY HOT COOLANT.
CAREFULLY RELEASE THE PRESSURE BEFORE
REMOVING
RADIATOR
AND
ê _ì.;þô$÷Hî1xTHE
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õBöYüPðVöYñKî õ[üODRAIN
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Fig. 26 Rear Mount (AutomaticTransmission)

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CAUTION: Install oil seals carefully to prevent damage from the sharp edges of the valve spring lock
grove.

ðñòóSôõö÷ õô ø ù)úû

35 Valve and Valve Components
¤Ÿ ÆI¡¢ ceFig.
woc?hk]Ic+
hW[1_–^_ac?]Ž]Ifs_ac+hWisdÜd[o]Žb‰`eisisc?banLnpZsc+hW[1_
Zs`?]Žc?~ ¢ c?Œ6`ˆŠ…cnpZschWdhW^np`e_.1_a`eŒènpZsc]I^hW_a}^wofsr|Zs`?woc
hWisd[1i\]ŽnphWw1wNnqZsc']I^hW_a}Ñ^wofsrt~
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]Ž^k_a[oisrÇnq`'jWc'_aceŒ6`qŠxcedk~
Ÿ¤ËI¡ ‡ˆis]Inphkwow¼npZscm^fs]IZ _a`?d]I~…™Nis]Žf\_ac!npZscmjW`enpnp`eŒ²c?isd'`e
cehWbaZ›_a`ed[o] bacei\nqc?_aced[oinpZsc{^wofsisrtce_gbahW^L]IcehWn6`enpZsc
Z·u…d_ahWfswo[1b5ŠxhWw Šxc'nphk^k^cenp~
Ÿ¤ÖI¡ ‡ˆis]Inphkwow npZscS_a`eba}“c?_ÑhW_aŒ6]Ž^[ Šx`?nq]|hWisd–jk_a[odkr‘cShkn
npZsce[o_!`e_a[or‘[oishWw4wo`eb‰hknp[o`eis~
Ÿ¤ÛI¡ Y4[1rtZsnpceiLnpZscœjW_a[odr‘cœbahW^%]Iba_acˆl ].hkwonpce_ai\hknpcew u·5`?isc
hWn#hÇnp[1Œ cenq`6hIŠx`e[odœdkhkŒ6hWrt[1i\rgnqZ\c‹jW_a[odr‘c?~“Y4[or‘Zsnpcei{nqZsc
bahW^]Žba_acql ] nq` £WÛ ÕéŒ Ÿ¤£X  ¤np~¾wojW]Ž~ ¡ np`e_aÓWfsc?~
Ÿ¤ÏI¡ ‡ˆis]Inphkwow4npZsc'cei\r‘[oisc'bvuxwo[oisdc?_zZsc?hWd{ba`qŠxc?_®~
JXQ#R#P@Q#JLê…ëHG¼P@Q#T#JXOVì#JWFHT
Y)Z\[1].^k_a`ebac?dfs_ac bahWijkc dk`eisczlz[1npZnqZ\cœc?isr‘[oisc [oi`e_
`ef\n`ežnqZ\cHŠxceZs[obawoc?~
4€\‚4ƒ…„)†
Ÿ‰ @¡ Ú[o]Iba`eisi\cebanisc?r‘hWnq[ Š…c.b‰hkjWwoc'¤_a`?ŒíjWhWnqnpce_vu·~

Ÿ‰ @¡æ [1rtZsnpw u^f\]ŽZ nqZ\c)Š…hWw Š…cz]IcehWw`qŠxc?_npZsc5ŠxhWw Šxc!]ŽnpceŒ
hWisd'Š…hkw Šxc.r‘fs[odc.jW`e]Ž]I~çNcg]Ifs_acgnpZscg]IcehWwž[o]‹ba`?Œ6^wocenpcew u WARNING: DO NOT REMOVE THE CYLINDER
]IcehWnqc?d{`?i|nqZscHŠ…hkw Šxc'rtfs[odc'jW`e]Ž]I~
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
Ÿ¤£I¡ ‡ˆis]InphkwowxŠ…hkw Š…c.]I^_a[oisrÇhWisd_acenphW[1i\ce_®~
DRAIN COCK WITH THE SYSTEM HOT AND PRESŸ¤¥I¡Ì `eŒ ^_ace]I]ÑnpZscgŠxhWw Šxc]Ž^_a[oisrœl [onpZSØNhkw ŠxcÙ…^_a[oisr SURIZED BECAUSE SERIOUS BURNS FROM THE
Ì `eŒ ^_ace]I]Ž`?_'Y¼`e`ewzÍÇÚ)y ÏWÏWÛkÖWÖW£ ’ÃhWisd–[1i\]Žc?_anÇnqZ\c ŠxhWw Šxc COOLANT CAN OCCUR.
wo`eba}“]I~ ¢ cewocehW]IcšnpZsc¦]Ž^k_a[1i\rÄnpcei\]Ž[o`eiÜhWisd²_ac?Œ6`ˆŠ…cšnpZsc Ÿ¤£I¡ Ú_ahW[oiLnqZscœba`?`ewohWisnzhWisd%d[o]Žba`?isisc?banznqZ\cZ\`e]Ice]ghWn
np`e`?w1~xY¾hW^npZsc ]I^_a[oisr{1_a`eŒ¯]I[odcey1nq`?y¤]I[1dkc np` c?is]Žfs_‰c npZshWn pn Zsc6cei\r‘[oisc6npZsce_aŒ6`?]ŽnphWnZs`?fs]Ž[oisrt~Ú)ášÕHáYSlzhk]Inpc6_acefs]Iy
npZsc ]Ž^k_a[oisr{[o].]Žc?hWnqc?d^_a`e^kce_aw u”`einpZsc c?isr‘[oisc bvu…w1[oisdkce_ Wh jWw1c›ba`e`?wohki\nq~6‡qÇnpZsc›]Ž`ewofsnp[o`ei—[o]Lbawoc?hki—hki\d+[o]jkc?[oisr
Zsc?hkdk~
d _ahW[oisc?d{`?isw u%nq`']Ice_vŠ…[obac'nqZ\c'ceisr‘[oisc'`?_!ba`e`ewo[oisrÇ]@ux]Inqc?Œ6
d_ahW[oi|nqZsc'ba`?`ewohWisn[oisnp`.h bawocehWiba`?isnphk[oisc?_z1`e_!_acefs]Ice~

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O" ¥%('*Fig.
),+-M36
/1)žEngine
2435)k@A35Cylinder
-Pâ2M-MQ.); Head
@Ϡ$9<-Assembly
+ã2435)k:IC1;=7=>5JK),9
B8-,9<)@AD®*-682”2M3U) B8-9<),@ŒQ.7=243•:<;=)6L>Ÿ),>UGT7=>5)-,7=;=D
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2435)(>5_5+B8),9<@„† 6L:<7=>5GŸ_5PA% _5@&7=>5GŸ2M35)(68;=7=GT>5+)>52.JK-0Q?),;=@
7=>•2435):ICS; 7=>5JL),9BL;=-:<ZURi2M-PK-@A7=247=-,>Ÿ2M35)GH6L@&Z[),24D
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.

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JK-MQ.),;=@’_U@A)JÌ2M-•; -:<682M)«2435)«GH68@AZ[),24Dc')+-0/S)«2435)«246LPL)
†$9<-+xB8-,;=2 ¢ -,D–¥&FLD
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#8~&%OD

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.

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Í*-,;=24@‚¥‰2M359<-_5GT3å¥&¦‚2M-ˆ¥&FL› ¢”è +ê"O¥,¥&¦‚†$24D ;=B8@AD %
24-,9<•‡8_5)D
Í*-,;=2´¥¥.2M-’¥&# ¢cè +ž"O¥&¦8¦|†$24D®;=B8@AD %—2M-9<‡8_5),D
• Í*-,;=24@“¥A˜“24359<-_5GT3k¥&F“2M-¤¥&F8› ¢cè +ë"O¥¥A¦Ï†$2MD; B8@&D %
24-,9<•‡8_5)D

Ä-Å
ÑÒ
Ó[ÔSÕ"Ö׈ÖØÙÚØÛ
ÜbÖ× × Ö Ü
ÚÔØÝÞß à áâà ã ä å æ
 "!$#&%('*),+-'*."%0/"1- 243
POSITION

DESCRIPTION

1,4,5,12,13

1/2 in.-13 BOLT

8,9

1/2 in.-13 BOLT WITH
DOWEL POINT

2,3,6,7,10,11,14

1/2 in.-13 WITH 7/16
in.-14 STUD END

All bolts are 12 point drives for rocker cover clearance

57698;:*<=6?>A@CBEDFD GEH?DFIKJLMNJO6?PEQ=6?MR>A6SITHVUW6XALFY Z[IT<R6>\H?X]
XA6?>AI
ITHXAP^QR6?_
57Y 8a`TYbMRH?I BEDFXA6?BEcdZecfHM=6?gh>\D6BEMaBEM=cji
BEXA@k6?BE>A<;G^HDFI
F
L
l IK<mB,c^BEG,H?YnfBELFM=IjBEY7IK6?XaITLFop<=IT6M=LFM=oq_VrW<=HQ=DFcNZWH?Q
6?MR>AH?Q=M=IK6?XkG^HDFITJ l <=LF>A< l 6?XA6NnfBELMRIT6c,LFMsBEMs6?BEXADFLF6?X
Jt6XuUWLF>A6SH?n^6?XABEIKLHM=gvXA6nfDFBE>A6SIT<=6i
_

Fig. 37 Engine Cylinder Head Bolt Tightening
Sequence

75 wO8a`9M=JOIKB^DFD IK<=6SLFoqM=LFIKLFH?MN>AH?LFD BEM=caGEXAB^>\@R6IxBEJtJO6?i
GED Zp_
57yO8a:*H?MRM=6?>AIsIK<=6zIT6i
nf6?XABEIKQ=XA6zJt6M=cfLFM=o{Q=M=LFI l LFXA6
>AHM=M=6?>AIKHX|_
57}O8a`9M=JOIKB^DFD"IK<=6kJOnfBEXA@~n^DQRoqJBEM=cIKLFoq<=IK6M€ITH‚^yCƒV„ i
57…Ey;YIT_†DGEJO_ 8IKH?XAPEQ=6_v:*H?MRM=6?>AIxIK<=6SLFoqM=LFIKLFH?M l LFXA6?JO_
57‡O8a`9M=JOIKB^DFDjIK<=60LFM=IKBE@R60BEM=cˆ6?M=opLFM=6069‰W<RB^QRJtICi
BEM=LF]
Y7HDFcfJŠ57XA6Y76?X-ITHŒ‹(XAHQ=n€?Og†Ž4‰W<=BEQ=JOI
rpZWJtIK6?i{BEM=ca`TM=ITBE@6
 B^MRLYH?DFcaY7H?XIT<R6n^XAH?n^6?XŠn^XAH?>A6cfQ=XA6J|8_
5\O‘O8a`9M=JOITBEDFDvIT<R6
YQ=6?DvDFLFM=6?J-BEM=ckIK<=6(UWBE>AQ=Q=i’B^ctUWBEM=>A6
<=HJt6_
5\|8a`TY-6?PEQ=LFnfnf6cfg(B^IKIKB^>A<0IK<=6Cn^H l 6XkJOIK6?6?X\LMRo[nfQ=i
n
BEM=caG^X\B^>A@6IT_
5\O…O8a`9M=JOITBEDFDbIK<=6
n^Q=Jt<eXAHcfJtg“XAH?>\@R6X-BEXAi
JOg n^L U4H?IKJBEM=c
GEXALFcfoq6J”LFM•IK<=6–H?XAc^6?X,IK<=6TZ l 6XA6mXA6i
H9U46?c—57XA6?Y6?X,IKH
˜ H?>\@R6Xb™VXAi
JBEM=ceš“Q=JO< ˜ HcfJLFMIK<=LFJJt6>AITLFHM›8\_
5\OO8a`9M=JOITBEDFD IK<=6S6?M=opLFM=6S>uZWDFLFM=cf6XŠ<=6B^ca>AHTUW6?X_
5\OœO8
™VITIKBE>A<[IT<R6jBELX>AHM=cfLFIKLHM=6?X>AHi
nfXA6?JOJtHXi
H?Q=MRIT]
LFM=oGEXAB^>\@R6IjITH[IK<=6[6?MRoqLFM=6[>uZWDFLFM=cf6Xe<=6BEc”BEM=c0GEDFH?>A@_
ž Lop<=IK6?MNIT<R6GEHDIKJIKHœE‘;ƒx„ iŸ57E‘;YIT_†DGEJO_ 8-IKH?XAPEQ=6_
5\O O8
™VITIKBE>A<[IK<=6jBELFX>AH?M=c^LIKLFH?M=LFM=ok>AH?i
nfX\6?JtJOH?XIKHjIK<=6
GEXABE>A@R6IK_ ž LFoq<=IK6?M¡IT<=6”GEH?DFITJ¢IKHs…Ey£ƒx„ i¤57…E‘£YIT_SDFGEJt_ 8
IKH?XAPEQ=6_
CAUTION: The accessory drive belt must be routed
correctly. Incorrect routing can cause the water

Æ Ç$ȆÉ~ÊdËbÌxÍ ËxÊ

ÎkÏ"ÐfÐ

pump to turn in the opposite direction causing the
engine to overheat.

5\OwO8a`9M=JOITBEDFD&IK<=6CB^>A>\6?JtJOH?XuZscfX\L U46NGE6DIŒBEM=c>AHXAXA6?>AIKD Z
IK6?M=JOLFH?MkIT<R6G^6DFI¥57XA6Y76?X
IKH‹(XAH?QRny^g4:*H?HDLFM=o
rpZWJOIT6izYH?X
IK<=6SnfXAH?n^6?XnfXAH?>\6?cfQ=XA6T8\_
5\OyO8a`9M=JOITBEDFD IK<=6SBELX>ADF6?BEM=6XŠBEM=cacfQ=>AIKLFM=oq_
5\O}O8a`9M=JOITBEDFD IK<=6S6?M=opLFM=6S>uZWDFLFM=cf6XŠ<=6B^ca>AHTUW6?X_
5\O‡O8a:*H?M=MR6?>AIkIT<R6<=HJt6J[IKHIK<=6€6?M=oqLFM=6€IK<=6?XAi
HJtIKBEI
<=HQ=JtLFM=o~BEM=c¢YLDFD&IT<R6N>AH?HDLFM=o~JZWJOIT6iITHNIK<=6NJOnf6?>\LYLF6?c
DF69U46?DN57XA6?Y6?X–IKH¦‹(XAH?QRn{y^ga:*H?HDFLMRozrqZ4JtIK6?i
JmY7H?X–IK<=6
nfXAHnf6?XnfXAH>A6?c^Q=XA698_
57…E‘O8 ž <R60B^QRITHi
BEITLF>~IKXAB^MRJti
LFJOJtLFH?M—IK<=XAHITIKDF60DFLFM=@RBEop6
BEM=c•>ABEG^DF6£i
Q=JOI¢GE6£B^c|§Q=JOIT6c{BEYIT6X–>AHi
nfDF6?IKLFM=o¡IT<R6
6?MRoqLFM=6j>uZWDFLFM=cf6X
<R6?BEcCLMRJtIKB^DFDFBEIKLHM~5XA6?Y6?XITHj‹(X\H?Q=nC…htg
ž XABEM=Jti
LFJOJtLFH?MRJ
YH?XIT<R6n^XAH?nf6XŠn^XAH?>A6cfQ=XA6J|8\_
57…h8a`9M=JOITBEDFDbIK<=6
IT6i
nf6XAB^IKQ=XA6
JO6?M=c^LMRojQRM=LFI(B^MRc;>AHM=]
M=6>AIxIT<R6 l LFXA6>\H?M=M=6>AIKH?X|_
57…E…O8a:*H?M=MR6?>AIxIK<=6SY7Q=6D DFLFM=6?_
57…EO8a`9Y6PEQ=LFnfnf6c l LFIK<–BELFXa>AH?M=c^LIKLFH?MRLMRoqgVLFM=JtIKBEDFDB^LFX
>AH?infXA6?JOJtHX
BEM=c>A<RB^X\oq6v™*¨|:€J|Z4JtIK6?i—57XA6?Y6?X
IKH-‹(XAH?QRn…Eœ
© 6?BEIKLMRokBEM=c&™VLX:*H?M=c^LIKLFH?MRLMRoA8\_
57…EœO8a:*H?M=MR6?>AIxM=6oqBEIKL U46S>AB^GEDF6SITHSGEBEITIK6XuZp_
57…E O8a:*H?M=MR6?>AIjIK<=6[Q=nfnf6XeXABEcfLFBEIKH?Xe<RH?JO6~BEM=c0<=6B^IK6?X
<=HJt6SBEIxIT<R66M=oqLFM=6SIK<=6XAi
H?JOITBEIx<=HQ=JtLFM=op_
57…EwO8aª LFDFD IK<=6S>AH?HDFLMRokJZWJOIT6i
_v:*<=6>A@CY7HXŠDF6?BE@Jt_

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.

57…EyO8a«(nf6XABEIT6‚IK<=6‚6?M=opLFM=6 l LFIT<~IK<=6‚XABEcfLFB^IKH?X
>ABEnNH?Y7Y_
`9M=JOnf6>AIY7HXD6BE@RJjB^MRc~>AH?M=IKLFM=Q=6aHnf6?XABEIKLFM=oNIK<=6a6?MRoqLFM=6
Q=M=IKLFDIK<=606M=oqLFM=6,IK<=6?XAi
HJtIKBEIeH?nf6M=Jt_ ™Vcfc¬>AH?HDBEM=IKg
LFY
XA6?PEQ=LFXA6cf_
­v®V¯
°v±V²
³h´µm¶d±V·*·*¸h¶h¹
˜ 6?IKBELM¬B^DFD
IT<R6>AH?i
n^H?M=6M=IKJ[LFMˆIK<=6JOB^i
6€H?XAcf6XNBEJ
XA6i
H9UW6cf_
º »R¼&½ ¾4¿"À
5\8 ˜ 6?i
HTUW6SIK<=6S6?M=opLFM=6S>uZWDFLFM=cf6XŠ<=6B^ca>AHTUW6?X_
57…O8 ˜ 6?i
HTUW6IT<R6¢GEXALFcfoq6BEM=cmnfL UWHI;B^JOJt6i
GEDLF6J~BEM=c
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J¦GOZÁXA6i
H9U4LMRoÂIK<=6z>ABEnfJt>\XA6 l J¦BEIs6?BE>A<
GEXALFcfoq6_p™VDFIK6?XAM=BEIK6?D ZDFHH?Jt6MC6?BE>A<e>AB^n^Jt>AXA6 l g H?M=6
ITQ=X\MCB^I
B;IKLFi
6?gvIKHSBOUWH?LFcacfBEi
BEoqLFM=o‚IK<=6SG^XALFc^oq6?JO_
57O8 ˜ 6?i
HTUW6SIK<=6SnfQ=JO<XAHcfJO_
57œO8 ˜ 6?i
HTUW6S>uZ4DLFM=c^6?X<=6?BEcaB^MRceopB^JO@6?IK_
57 O8 ˜ 6?i
HTUW6&IK<=6&ITBEnfn^6?IKJxIK<=XAHQ=oq<jIT<R6-n^Q=Jt<jXAH?cŒH?n^6?M=]
LFM=oqJ€LFM—IK<=6,>uZWDFLFM=cf6X~GEDFH?>A@ l LFIK<—B © ZWcfXABEQ=DFLF>kÃ*BED UW6
ž B^n^nf6?I ˜ 6i
H9U4BED ¨|`9MRJtIKB^DFDFBEIKLHM ž H?H?D*57ª LFop_vE}t8_

ƒs„†…5‡

ˆ‚‰‹Š‚ŒŽ’‘“ 

”r•

–.—w˜~™(šœ›.ž›.Ÿv n¡9Ÿv¢w£’›.ii›N£:¡9™vŸ¥¤¦.§i¨i©ª
¨i«i¬i­i®

Fig. 38 Hydraulic Valve Tappet Removal—
Installation Tool

ç7èWé“êqë ìRì?ëRêvç í&è
î9ïðñ–ò=ó?ïò=ôõAô?ñOñtöE÷uøùïKó£õAú=öE÷Aûpô£ïKú=ô£ïKö^ü^üfô?ïKñ€ýŠðFïTú
ô?òRûqðFò=ôó?ðFþFÿ ú=ôTø
ýðFþþ“õAú=öE÷AûqôïKú=ô 
ñtôþ 4ô?ñ*ýŠðïKú=ðFòkö Wô÷uø
ñOú=ó?÷Aïxü^ô?÷AðFó aó ¥ôò=ûqðFò=ôSó?ü^ô?÷AöEïKðóò=ÿ

 ðFü€ôö^õAú,ïKöEüfüfôï
ðF
ò ‚óüföE
÷ *òRûqðFò=
ô (ðFþ =ü^üfþFô 

ôò=ï †ó?÷ô =ð WöEþFô?ò=ïKÿ
! " ñO$
ô #¥%ø f÷Aö =þFðF'
õ &*öEþ W(
ô vö^ü^üfô?*
ï )*ô 
+ó 4ö^þ ,|î9ò=ñOïKö^þFþFö 
ïKðFó?'
ò ó?óþ ïKóŠðFò=ñOïKö^þFþ“ô?öEõAú;ïKöEüfüfôï¥ðFò;ïKú=ôñOö 
.
ô -^ó÷A.ô 7÷Aó 
ýúRô?÷AôSðFïbýöEñó?÷AðFûqðFò=öEþFþ ø[÷Aô 
ó Wô ^ÿ
/! î9ò=ñOïKö^þFþ õuø4þFð0
ò fô?÷ú=ô?ö aöE1ò aûqöE3ñ 2ô?ïKÿ
4! î9ò=ñOïKö^þFþ ïKú=ô5
ü Rñtúk÷Aó ^ñVðòkïKú=ô?ðF÷
ó?÷AðFûqðFò=öEþ þFóõAöEïTðFó?òRñtÿ
6! î9ò=ñOïKö^þFþŠïKú=ô~÷Aó7õ 2ô?÷eöE7÷ 
ñCö^1
ò 8-E÷A9ð ^ûqô~öE1ò 0üfð Wóï
öEñtñOô :-EþFðFô?ñ
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ïKú=ôSõAöEüfñtõA÷\ô9ýñöEïxô?öEõA=
ú -E÷A>ð fûqôÿ
?! ðûpú=ïKô?ò€ïKú=ôkõAöEüfñOõA÷Aô9ýñSö^þFïKô?÷AòRö^ïKô?þ @ø ¥óò=ôkAï =÷Aò€öEï
ö~ïT>ð 
ô 
ïKóC!ö Wó9ð B^Cö ö^ûpðòRû[ïTúR$
ô -E÷A9ð ^ûqô?ñODÿ ¥ðFûqúRïTôò0ïTú=ô
õAöEüfñOõA÷Aô9ýŠñ
ïKó EGFH  I
7ïKÿv>þ -Eñtÿ ïTó7÷ =ô?ÿ
J! K ó =÷
ïKú=ôj÷Aô 
öEðFò=ðFò=G
û ‚ó?ü^ö^L
÷ *ò=ûqðFò=M
ô (ðFNþ =ü^üfþFô 

ôò=ï 
ó÷kô =ð 4ö^þFôò=ïSó Wô÷kïTúRôNôò=ïTðF÷A(
ô WöEþ WôCö^õ\ï =öEïKðFò=û
öEñtñOô :-Eþ øp(
ÿ "úRO
ô jó?ü^ö^P
÷ *ò=ûqðFò=Q
ô "ðFR
þ RüfüfþFô 
ôò=Aï Nó?÷
ô =ð 4ö^þFôò=G
ï :Rñtïk÷Aô 
öEðFò¢ýðFïKúˆïKú=ôôò=ûqðFò=ô€ó?ðF*
þ ó?÷NöEï
þFô?öEñOï
B?CST 2U
 SSS 
ðFþôñ ÿ ú=ô”óðFþ‚!ñ =üfüfþFô 
ô?ò=ï
ò=ôô zòRó?R
ï -^V
ô f÷AöEðFò=ô ORò=ïKðþaïKú=ô¬òR+ô WWï~ñtõAúRô 5Rþô zó?ðFþ
õAú=öEò=ûpô?ÿ
E! î9ò=ñOïKö^þFþ ïKú=ôSô?òRûqðFò=ôSõuøWþFðF1
ò fô÷Šú=ôö eõAó Wô÷|ÿ
XY
Z\[<]_^IY
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gih0j&íik4ë"ì

 ðFñOõAó?ò=òRô?õAïxò=ôûqöEïKð 4ôSõAöC-EþFô(7÷Aól-EöEïTïKô?÷uø›ÿ
! *
) ô
 ó+W
 ôùïKú=ôùñOô?÷Aü^ô?ò=ïKðFò=ômf
 ÷\ð 4
 ômE
- ô?þFï—öEò1nö^ò
ñOú=÷Aó1^ ÿ
/! *
) ô
 ó+W
 ôˆïKú=ô4
 ð9E
- ÷AöEïKðóòl^
 öC
 ü^ô?÷s÷AôïTöEðFò=ðFò=ûc^
- óþFï
öEò1
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& ð>E
- ÷Aö^ïKðFó?ò  ö
 üfô÷o*
) ô
 óW
 öEþ ó?óþ J?CTJ ïKó
÷Aô
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 ôSïKú=ô(f
 ö
 üfô÷' ÷AóÂ
 ïTú=ôSõA÷AöEò1
2 ñOú=ö7 ï p ðFûqÿ /T! ÿ

ç7èWé“êqë ìRì?ëRêvç í&è

:q üfü^þ =
ø jó?ü^ö^÷r4ðFþðFõAóò=ô:)\1--Eô?÷ q ^ú=ô?ñOð Wô:4ô?öEþFö^òRï
ïKókïKú=s
ô 2ô9øpýöOø¢ðFò€ïKú=ôkõA÷AöE1ò 2ñtúRCö ïöEò1ðFò=ñOô?÷Aï-ïKú=ôs2ô9ø›ÿ
tðïKúmïKú=R
ô 2ô9ø¬ðòmü^ó?ñOðïKðFó?1ò &öEþFðFûqòmïKú=ôR2ô9øpýöOøˆó?òmïKú=ô

Fig. 39 Vibration Damper Removal Tool 7697

Wð>-E÷AöEïTðFóòufö
üfô÷;ú11-aýðFïKúsïKú=ôõA÷AöEò12ñOú=ö7ïv2ôTømöEò1
ïKö^üaïKú=ô(f ö
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2 ñtú=ö7 ïKÿ
! î9ò=ñOïKö^þFþvïTú=ôw4
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- ÷AöEïKðFó?òf
 ö
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- óþï"öEò1

ýöEñOú=ô?÷|ÿ
/! ðûpú=ïKô?ò€ïKú=ôs^öC
ü^ô?÷Œ÷AôïTöEðFò=ðFò=û-Eóþï-ïKó
!SCE$FH 
ES ïTÿ†9þ -EñOÿ ïKó?÷7=ôÿ
4! î9ò=ñOïKö^þFþ*ïKú=ôSñOô?÷Aü^ô?ò=ïKðFò=*
ô f÷Að W*
ô -^ôþFï
ö^0ò aïKðûpú=ïKô?òNïKó
ïKú=ôkñOüfôõA9ð ðFô ïKô?òRñtðFó?ò ÷Aô ô?÷ŒïK
ó x(÷Aó Rü J iy*ó?ó?þFðFò=ûqø4ñ3
ïKô 
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ñ 7ó÷ŠïKú=ôSüf÷Aóüfô?÷ñtü^ô?õA>ð 7ðFõAöEïKðóò=ñöE1ò aüf÷Aó?õAô 5=÷Aôñ ÿ
6! y*ó?òRò=ô?õAïxòRô?ûqöEïKð WôSõA
ö -^þFôSïKv
ó -EöEïKïTô÷uøpÿ
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 ðFñOõAó?ò=òRô?õAïxò=ôûqöEïTð 4ôõ\öC-EþFô(7÷Aól-EöEïTïKô?÷uø›ÿ
! *
) ô
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 ôSïKú=ôW
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/! *
) ô
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 ú11k
- öEñtñOô:E
- þ ø[öEò1a
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ó+4ô
ïKú=ô(7 öEòñOú=÷Aó1f ÿ
4! *
) ô
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2 ô?ïKñaïTú=öEïSöE÷Aô
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y õAó
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- ó?þFïKñ
öEò1a
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Fig. 40 Timing Case Cover Components

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Fig. 41 Timing Case Cover Alignment and Seal
Installation Tool 6139

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Fig. 42 Crankshaft—Camshaft Alignment

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Fig. 43 Camshaft Sprocket and Thrust Plate

WARNING: THE COOLANT IN A RECENTLY OPERATED ENGINE IS HOT AND PRESSURIZED.
RELEASE THE PRESSURE BEFORE REMOVING
THE DRAIN COCK, CAP AND DRAIN PLUGS.

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1999 TJ Wrangler
Publication No. 81-370-9148
TSB 26-11-98 November, 1998

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45 Timing Case Cover Components
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NOTE: During installation, lubricate the hydraulic
valve tappets and all valve components with Mopar
Engine Oil Supplement, or equivalent. The Mopar
Engine Oil Supplement, or equivalent must remain
with the engine oil for at least 1609 km (1,000
miles). The oil supplement need not be drained until
the next scheduled oil change.

d^e&f=gihkjmlon joh

pq9rEs

1999 TJ Wrangler
Publication No. 81-370-9148
TSB 26-11-98 November, 1998



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CAUTION: Both service valves must be opened
before the air conditioning system is operated.


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1999 TJ Wrangler
Publication No. 81-370-9148
TSB 26-11-98 November, 1998

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ÊXÎD½E³ ´­Ä

NOTE: It is not advisable to attempt to replace
camshaft bearings unless special removal and
installation tools are available, such as recommended tool 8544 Camshaft Bushing Remover
Installer.

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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 bearing bore. Failure to do so will cause inadequate oil
supply for the sprockets and timing chain.

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Fig. 47 Verify Crankshaft—Camshaft Installation—
Typical

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Fig. 48 Fabrication of Alignment Dowels

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Fig. 49 Position of Dowels in Cylinder Block

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Fig. 50 Oil Pan Sealer Location

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.

Fig. 51 Position of 5/16 inch Oil Pan Bolts

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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.
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Fig. 53 Main Bearing Caps and Brace.

Fig. 54 Removing Main Bearing Caps and Lower
Inserts

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Fig.
  55 Removing Upper Inserts
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kŠNav57«kMain
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–X_¶a 58~pkStamped
r$egjlk>«kWjlConnecting
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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.

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Fig. 60 Rod and Piston Assembly Installation

Fig. 59 Removal of Connecting Rod and Piston
Assembly

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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.

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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.

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þ$ $
B 
  h6n"þ  þ ,þ 
  
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CAUTION: Verify that the oil squirt holes in the
rods face the camshaft and that the arrows on the
pistons face the front of the engine.

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Fig. 61 Rear Main Bearing Oil Seal

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Stem



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Valve Spring Compressor Tool MD-998772A

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Timing Case Cover Alignment and Seal installation
Tool 6139
Vibration Damper Removal Tool 7697

Hydraulic Valve Tappet Removal/Installation Tool
C-4129–A

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WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH.
THEREFORE, NEVER ATTEMPT TO SERVICE ANY
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COOLED. SPECIAL CARE SHOULD BE TAKEN
WHEN WORKING NEAR THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER
RISES TO A HIGH LEVEL AFTER A SHORT PERIOD
OF ENGINE OPERATION TIME.

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CAUTION: Avoid application of rust prevention
compounds or undercoating materials to exhaust
system floor pan exhaust heat shields. Light over
spray near the edges is permitted. Application of
coating will result in excessive floor pan temperatures and objectionable fumes.

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Fig. 1 Exhaust System—2.5L Engine

Fig. 2 Exhaust System—4.0L Engine

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CONDITION
EXCESSIVE EXHAUST NOISE OR
LEAKING EXHAUST GASES

POSSIBLE CAUSE

CORRECTION

1. Leaks at pipe joints.

1. Tighten clamps/bolts 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.

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.

D
EFG" HI  J HKHA L 
M J%"NO&"%P MQMR$S T UA%U VW "!$#%XPYX
WARNING: THE NORMAL OPERATING TEMPERATURE 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 CONVERTER. THE TEMPERATURE OF THE CONVERTER
RISES TO A HIGH LEVEL AFTER A SHORT PERIOD
OF ENGINE OPERATION TIME.
WARNING: IF TORCHES ARE USED WHEN WORKING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
CAUTION: When servicing exhaust system components, disconnect the oxygen sensor connector(s).
Allowing the exhaust system to hang by the oxygen
sensor harness will damage the wiring and/or sensor.

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WARNING: THE NORMAL OPERATING TEMPERATURE 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 CONVERTER. THE TEMPERATURE OF THE CONVERTER
RISES TO A HIGH LEVEL AFTER A SHORT PERIOD
OF ENGINE OPERATION TIME.
WARNING: IF TORCHES ARE USED WHEN WORKING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
CAUTION: When servicing exhaust system components, disconnect the oxygen sensor connector(s).
Allowing the exhaust system to hang by the oxygen
sensor harness will damage the wiring and/or sensor.

Fig. 3 Exhaust Pipe with Catalytic Converter—2.5L
Engine

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Fig. 4 Exhaust Pipe with Catalytic Converter—4.0L
Engine

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× WÙLô—Û î0Ý}þKß{àq
Ý 'Ý}àqækÞOêkÝì

Fig. 5 Catalytic Converter to Muffler Connection

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FRAME
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page

GENERAL INFORMATION
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 3
SERVICE PROCEDURES
FRAME SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . 4
REMOVAL AND INSTALLATION
FUEL TANK SKID PLATE . . . . . . . . . . . . . . . . . . . 6

TRANSFER CASE SKID PLATE . . . . . . . . . . . . . . 5
SPECIFICATIONS
FRAME DIMENSIONS . . . . . . . . . . . . . . . . . . . . . 7
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . 9


 


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WARNING: USE EYE PROTECTION WHEN GRINDING OR WELDING METAL, SERIOUS EYE INJURY
CAN RESULT. BEFORE PROCEEDING WITH FRAME
REPAIR INVOLVING GRINDING OR WELDING, VERIFY 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.

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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. 3). Reinforcing this area
may effect energy management.
NOTE: If a reinforcement is required, it should
completely 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 indicated (Fig. 2).

Fig. 2 Frame Reinforcement

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Fig. 4 Transmission Mount—Automatic
Transmission
Fig. 3 Energy Management Holes
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Fig. 5 Transmission Mount—Manual Transmission

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WARNING: THE TRANSFER CASE AND TRANSMISSION ARE SUPPORTED BY THE TRANSFER CASE
SKID PLATE. BEFORE REMOVING THE TRANSFER
CASE SKID PLATE, ENSURE THAT THE TRANSMISSION IS PROPERLY SUPPORTED.
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FUEL DELIVERY SYSTEM
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DESCRIPTION AND OPERATION
FUEL DELIVERY SYSTEM . . . . . . . . . . . . . . . . . . 2
FUEL FILTER/FUEL PRESSURE REGULATOR . . . 4
FUEL GAUGE SENDING UNIT . . . . . . . . . . . . . . . 4
FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . 5
FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUEL PUMP MODULE . . . . . . . . . . . . . . . . . . . . . 3
FUEL RAIL/FUEL DAMPER—2.5L ENGINE . . . . . . 5
FUEL RAIL—4.0L ENGINE . . . . . . . . . . . . . . . . . . 5
FUEL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . 1
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUEL TANK FILLER TUBE CAP . . . . . . . . . . . . . . 6
QUICK-CONNECT FITTINGS . . . . . . . . . . . . . . . . 6
ROLLOVER VALVE(S) . . . . . . . . . . . . . . . . . . . . . 5
DIAGNOSIS AND TESTING
FUEL GAUGE SENDING UNIT . . . . . . . . . . . . . . 10
FUEL INJECTOR TEST . . . . . . . . . . . . . . . . . . . 10
FUEL PRESSURE LEAK DOWN TEST . . . . . . . . . 7
FUEL PUMP AMPERAGE TEST . . . . . . . . . . . . . . 8
FUEL PUMP CAPACITY TEST . . . . . . . . . . . . . . . 7
FUEL PUMP PRESSURE TEST—ALL ENGINES
WITH PRESSURE TEST PORT . . . . . . . . . . . . . 6

SERVICE PROCEDURES
FUEL SYSTEM PRESSURE RELEASE
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL TUBES/LINES/HOSES AND CLAMPS . . . .
QUICK-CONNECT FITTINGS . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION
ACCELERATOR PEDAL . . . . . . . . . . . . . . . . . . .
FUEL FILTER/FUEL PRESSURE REGULATOR . .
FUEL GAUGE SENDING UNIT . . . . . . . . . . . . . .
FUEL INJECTOR RAIL—2.5L ENGINE . . . . . . . .
FUEL INJECTOR RAIL—4.0L ENGINE . . . . . . . .
FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . .
FUEL PUMP INLET FILTER . . . . . . . . . . . . . . . .
FUEL PUMP MODULE . . . . . . . . . . . . . . . . . . . .
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL TANK FILLER TUBE CAP . . . . . . . . . . . . .
THROTTLE CABLE . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS
FUEL SYSTEM PRESSURE . . . . . . . . . . . . . . . .
FUEL TANK CAPACITY . . . . . . . . . . . . . . . . . . .
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . .

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CAUTION: DO NOT use gasoline containing METHANOL. Gasoline containing methanol may damage
critical fuel system components.

CAUTION: Follow these guidelines to maintain your
vehicle’s performance:

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Fig. 3 Fuel Filter/Fuel Pressure Regulator

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[Wm ”uX_ik[!` j˜i-m€a` Y„jlv

Fig. 5 Fuel Rail/Fuel Damper—2.5L Engine

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ØKÙ\Ú&Û ÜÝ:ÞKßOàáà?âdÞã
æçèéêOë,ìíRë8îoïñðïBæÆîoìçêðhíRë8îoïóòœéôõö÷õ øùúû

Fig. 6 Fuel Rail—4.0L Engine


 !"#
$&%('*),+-.-/+01325460879'):+<;>=?13@A+<;B+<79CD+008EF)F)F'<;B29'<GIHJE,@K;I'L=?'29CL'MON.4PCQ%9'R79-S'R+<0 1/@K;I'-.-S79;I'T =?13GI7979UV087('<)WCQ1329H
08EF)F)F'<;XCQ79N3'YGI1A@AZP[ '),EF'0\=?13) =?'<-]EF29-SEFMK'YCQ%9'YGI13@_^DEF)F)
;I'),'13-.'0879')\CL1329H`@A;I'<-S-.79;I'13Ca@K;I'MK'<CQ'<;bURE,2('<M@K;I'<-ST
-S79;I'<-SZc79'<)dCL1329H=?13GI7979U^DEF)F)e13)F-.+fN3'f;I'<)F'1A-S'<Mg13Ch@A;I'<T
MK'CL';IUREF29'<M\=?13),7('<-SZi$h%9EF-\GI13@UR79-SCjN3'k;b'<@K)F13GI'<MNS4l1
-SE,UREF)F13;m792(E,CgEF0D;I'<@A)F1AGI'UR'<29CgEF-k29'GI'<-S-.13;n45Z$&%(E,-kEF-kEF2
+<;bMK'<;08+<;CQ%9'o-p4?-SCQ'<UqCL+o;I'UR1AEF2P'<0,08'<GICQE =?'Z
CAUTION: Remove fuel tank filler tube cap before
servicing any fuel system component. This is done
to help relieve tank pressure. If equipped with a
California emissions package and a Leak Detection
Pump (LDP), the secondary seal below the fill cap
must be pressed (opened) to relieve fuel tank pressure.

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WARNING: THE FUEL SYSTEM IS UNDER CONSTANT FUEL PRESSURE EVEN WITH THE ENGINE
OFF. BEFORE DISCONNECTING FUEL LINE AT
FUEL RAIL, THIS PRESSURE MUST BE RELEASED.
REFER TO THE FUEL SYSTEM PRESSURE
RELEASE PROCEDURE.

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EF2908+;IUR13CLEF+29Z
CAUTION: The interior components (o-rings, spacers) of quick-connect fitting are not serviced separately, but new pull tabs are available for some
types. Do not attempt to repair damaged fittings or
fuel lines/tubes. If repair is necessary, replace the
complete fuel tube assembly.

Fig. 7 Fuel Pressure Test Gauge (Typical Gauge
Installation at Test Port)

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WARNING: BEFORE PROCEEDING TO NEXT STEP,
NOTE THE FUEL PUMP WILL BE ACTIVATED AND
SYSTEM PRESSURE WILL BE PRESENT. THIS WILL
OCCUR AFTER CONNECTING TEST LEADS FROM
LCS ADAPTER INTO FUEL PUMP RELAY CAVITIES.
THE FUEL PUMP WILL OPERATE EVEN WITH IGNITION KEY IN OFF POSITION. BEFORE ATTACHING
TEST LEADS, BE SURE ALL FUEL LINES AND FUEL
SYSTEM COMPONENTS ARE CONNECTED.

Fig. 11 Type–1 Relay

CAUTION: TO PREVENT POSSIBLE DAMAGE TO
THE VEHICLE ELECTRICAL SYSTEM AND LCS
ADAPTER, THE TEST LEADS MUST BE CONNECTED INTO RELAY CAVITIES EXACTLY AS
SHOWN IN FOLLOWING STEPS.

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not attempt to use following steps to relieve this
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seconds will permanently damage the injector.

Fig. 14 Fuel Injector Internal Components—Typical









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WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING ANY FUEL SYSTEM HOSES,
FITTINGS OR LINES, THE FUEL SYSTEM PRESSURE MUST BE RELEASED. REFER TO THE FUEL
SYSTEM PRESSURE RELEASE PROCEDURE IN
THIS GROUP.

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Fig. 15 Single-Tab Type Fitting

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WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING ANY FUEL SYSTEM HOSES,
FITTINGS OR LINES, THE FUEL SYSTEM PRESSURE MUST BE RELEASED. REFER TO THE FUEL
SYSTEM PRESSURE RELEASE PROCEDURE IN
THIS GROUP.

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CAUTION: If this release tab is not pressed prior to
releasing
the pull tab, the pull tab will be damaged.
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CAUTION: The interior components (o-rings, spacers) of this type of quick-connect fitting are not serviced separately, but new pull tabs are available. Do
not attempt to repair damaged fittings or fuel lines/
tubes. If repair is necessary, replace the complete
fuel tube assembly.

Fig. 16 Disconnecting Single-Tab Type Fitting

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Fig. 18 Typical Two-Tab Type Quick-Connect Fitting
Fig. 17 Removing Pull Tab

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CAUTION: The interior components (o-rings, spacers) of this type of quick-connect fitting are not serviced separately, but new plastic retainers are
available. Do not attempt to repair damaged fittings
or fuel lines/tubes. If repair is necessary, replace
the complete fuel tube assembly.

WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING ANY FUEL SYSTEM HOSES,
FITTINGS OR LINES, THE FUEL SYSTEM PRESSURE MUST BE RELEASED. REFER TO THE FUEL
PRESSURE RELEASE PROCEDURE IN THIS
GROUP.

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CAUTION: When the quick-connect fitting was disconnected, the plastic retainer will remain on the
component being serviced. If this retainer must be
removed, very carefully release the retainer from
the component with two small screwdrivers. After
removal, inspect the retainer for cracks or any damage.

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Fig. 19 Plastic Retainer Ring Type Fitting

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CAUTION: The interior components (o-rings, spacers, retainers) of this type of quick-connect fitting
are not serviced separately. Do not attempt to repair
damaged fittings or fuel lines/tubes. If repair is necessary, replace the complete fuel tube assembly.
WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING ANY FUEL SYSTEM HOSES,
FITTINGS OR LINES, THE FUEL SYSTEM PRESSURE MUST BE RELEASED. REFER TO THE FUEL
SYSTEM PRESSURE RELEASE PROCEDURE IN
THIS GROUP.

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Fig. 20 Latch Clip Removal

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Fig. 21 Fuel Line Disconnection
CAUTION: The interior components (o-rings, spacers, retainers) of this type of quick-connect fitting
are not serviced separately. Do not attempt to repair
damaged fittings or fuel lines/tubes. If repair is necessary, replace the complete fuel tube assembly.
WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING ANY FUEL SYSTEM HOSES,
FITTINGS OR LINES, THE FUEL SYSTEM PRESSURE MUST BE RELEASED. REFER TO THE FUEL
SYSTEM PRESSURE RELEASE PROCEDURE IN
THIS GROUP.

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Fig. 22 Fuel Filter/Fuel Pressure Regulator

‡

‘’h“”(•Q–Q•e—-“˜

™uš(›œ™

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Fig. 23 Fuel Filter/Fuel Pressure Regulator Gasket

WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING THE FUEL PUMP MODULE,
THE FUEL SYSTEM PRESSURE MUST BE
RELEASED.
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Fig. 24 Fuel Filter/Fuel Pressure Regulator O-Rings
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Fig. 25 Top View of Fuel Tank and Fuel Pump
Module


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Fig. 26 Locknut Removal/Installation—Typical

¸¹eº‹»ˆ¼b½:½¼:»†¸ ¾*¹

CAUTION: Whenever the fuel pump module is serviced, the module gasket must be replaced.

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Fig. 32 Injector Mounting

Fig. 33 Injector Retaining Clips—Typical Injector

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Fig. 35 Fuel Tank Connections

Fig. 34 Fuel Filler Hoses/Fuel Fill Cap
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Fig. 37 Fuel Tank Mounting Nuts—Front

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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.

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CAUTION: Be careful not to damage or kink the
cable core wire (within the cable sheathing) while
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Fig. 39 Throttle Cable Routing

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FUEL INJECTION SYSTEM

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page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . .
MODES OF OPERATION . . . . . . . . . . . . . . . . . .
DESCRIPTION AND OPERATION
AIR CONDITIONING (A/C) CLUTCH RELAY—
PCM OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . .
AIR CONDITIONING (A/C) CONTROLS—
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUTO SHUTDOWN (ASD) RELAY—
PCM OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . .
AUTOMATIC SHUTDOWN (ASD) RELAY
SENSE—PCM INPUT . . . . . . . . . . . . . . . . . . .
BATTERY TEMPERATURE SENSOR—
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . .
BATTERY VOLTAGE—PCM INPUT . . . . . . . . . . .
BRAKE SWITCH—PCM INPUT . . . . . . . . . . . . . .
CAMSHAFT POSITION SENSOR—
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . .
CCD BUS (+/-) CIRCUITS-PCM OUTPUTS . . . . .
CRANKSHAFT POSITION SENSOR—PCM
INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DATA LINK CONNECTOR—PCM INPUT AND
OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DUTY CYCLE EVAP PURGE SOLENOID
VALVE-PCM OUTPUT . . . . . . . . . . . . . . . . . . .
ENGINE COOLANT TEMPERATURE SENSOR—
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIVE VOLT SENSOR SUPPLY—PRIMARY . . . . .
FIVE VOLT SENSOR SUPPLY—SECONDARY . .
FUEL INJECTORS—PCM OUTPUT . . . . . . . . . .
FUEL LEVEL SENSOR—PCM INPUT . . . . . . . . .
FUEL PUMP RELAY-PCM OUTPUT . . . . . . . . . .
GENERATOR FIELD DRIVER (-)—
PCM OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . .
GENERATOR FIELD SOURCE (+)—
PCM OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . .
GENERATOR OUTPUT—PCM INPUT . . . . . . . . .
IDLE AIR CONTROL (IAC) MOTOR—
PCM OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . .
IGNITION CIRCUIT SENSE—PCM INPUT . . . . .
IGNITION COIL—PCM OUTPUT . . . . . . . . . . . . .
INTAKE MANIFOLD AIR TEMPERATURE
SENSOR—PCM INPUT . . . . . . . . . . . . . . . . . .
LEAK DETECTION PUMP (SWITCH) SENSE—
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . .
LEAK DETECTION PUMP—PCM OUTPUT . . . . .
MALFUNCTION INDICATOR LAMP—ECM/PCM
OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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24

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28
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page
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSOR—PCM INPUT . . . . . . . . . . . . . . . . . .
OIL PRESSURE SENSOR—PCM INPUT . . . . . .
OXYGEN SENSOR (O2S)—PCM INPUT . . . . . . .
POWER GROUND . . . . . . . . . . . . . . . . . . . . . . .
POWER STEERING PRESSURE SWITCH—
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWERTRAIN CONTROL MODULE (PCM) . . . .
SENSOR RETURN—PCM INPUT . . . . . . . . . . . .
SPEED CONTROL SOLENOIDS—
PCM OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . .
SPEED CONTROL SWITCHES—PCM INPUT . . .
TACHOMETER—PCM OUTPUT . . . . . . . . . . . . .
THROTTLE BODY . . . . . . . . . . . . . . . . . . . . . . .
THROTTLE POSITION SENSOR (TPS)—
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION PARK/NEUTRAL SWITCH—
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . .
VEHICLE SPEED AND DISTANCE SENSOR—
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS AND TESTING
ASD AND FUEL PUMP RELAYS . . . . . . . . . . . . .
ENGINE COOLANT TEMPERATURE
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IDLE AIR CONTROL (IAC) MOTOR . . . . . . . . . . .
INTAKE MANIFOLD AIR TEMPERATURE
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSOR TEST . . . . . . . . . . . . . . . . . . . . . . . .
OXYGEN (O2S) SENSORS . . . . . . . . . . . . . . . .
POWER STEERING PRESSURE SWITCH . . . . .
THROTTLE BODY MINIMUM AIR FLOW CHECK
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . .
THROTTLE POSITION SENSOR (TPS) . . . . . . .
VEHICLE SPEED SENSOR . . . . . . . . . . . . . . . .
VISUAL INSPECTION . . . . . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION
AIR CLEANER ELEMENT . . . . . . . . . . . . . . . . . .
AUTOMATIC SHUTDOWN (ASD) RELAY . . . . . .
DUTY CYCLE EVAP CANISTER PURGE
SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE COOLANT TEMPERATURE SENSOR . .
FUEL PUMP RELAY . . . . . . . . . . . . . . . . . . . . . .
IDLE AIR CONTROL (IAC) MOTOR . . . . . . . . . . .
INTAKE MANIFOLD AIR TEMPERATURE
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OXYGEN SENSOR . . . . . . . . . . . . . . . . . . . . . . .

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46

’W“•”–W“

—™˜`šW›•œt/œtžBš™Ÿ

POWER STEERING PRESSURE SWITCH—2.5L
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWERTRAIN CONTROL MODULE (PCM) . . . .
THROTTLE BODY . . . . . . . . . . . . . . . . . . . . . . .
THROTTLE POSITION SENSOR (TPS) . . . . . . .

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46
46
44
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VEHICLE SPEED SENSOR . . . . . . . . . . . . . . . . 49
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 49
SPECIAL TOOLS
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 50

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Fig. 7 Intake Man. Air Temp. Sensor Location—4.0L
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Fig. 19 Intake Manifold Air Temp. Sensor Location—
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Fig. 18 Ignition Coil—4.0L Engine

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Fig. 27 ASD and Fuel Pump Relay Terminals

Fig. 25 Vehicle Speed Sensor—Typical

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ž"~$~Öv ×®„‹-š*w"Ø y…/v%×Ƅ‹-š
w"Ù y:š

Fig. 26 ASD and Fuel Pump Relay Terminals

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æÉçgè éê

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bdcegf \h]ikjl]m\kSWPnSWY\k]m\opUmqrUTSS3Yjls%SWj e \ht
WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST.

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KL@9 z †‡TIJ† zš‰™“ C z ADCFC9›EWCFˆ |x‰_z CFEL…D†. | ˆ‡GDŠ vxyœ| T€k–Z˜ZM
u Š wk †‡GxKL@FTJCFK z ƒIT…(?CFEAD†‡ELC9GHM
u!žxwkŸ CF?hˆ | KLC z }TC#ELCFˆ |x‰ †‡‚‹† z €†‡€„T@ z ? | GHG z }TC#KL@F z †‡TIT
† zš‰R| T€ELC9GH†‡G zB| TKLC z C9G z GHM B‚ z }TCDELC9ˆ |H‰ ? | GHGxCF€ z }TC z CFG z Gx¡
† z @9?CFE |hz CFGV?EL@F?hCFELˆ ‰ M¢£}TC9KL¤ z }TC#ELCF… | †‡T€C9E@F‚ z }TC yV¥
| T€œ‚!ITC9ˆ„?hIT…(?œELCFˆ |x‰ KL†‡ELKLIT† z GxM Ÿ C9‚!C9E z @ z }TCn¦™†‡EL†‡T§
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| T€_† z G„KL†‡ELKLIT† z E ‰ ¡ELCF‚.CFE z @ aŸ£Â GHK |  z @F@Fˆ | T€ | ??EL@9
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z CFG zz }JC/¼ yV¾ GxCFTGx@FE#@FTˆ ‰ ¡‹ELC9‚!CFE z @ z }TC%‚!@9ˆ‡ˆ.@BAD†‡T§dÃ
uWÄ:w  ‘TGx?C9K z EWI “Z“ C9EÅƐ!GH} | ?hCF€
‚.† zBz †‡T§„‚.EL@F…Ǽ yV¾ GHC9T
Gx@FE z @ z }TEL@ z{z ˆ.C “ @F€ ‰_u.¿ †‡§dMÁ žHw M Ÿ CF? | †‡E | GDJCFKLCFGxG | E ‰ M

Fig. 29 Rubber L-Shaped Fitting—MAP Sensor-toThrottle Body

Fig. 30 MAP Sensor Connector Terminals—Typical

Fig. 28 Sensor Location (4.0L Engine Shown)
CAUTION: When testing the MAP sensor, be sure
that the harness wires are not damaged by the test
meter probes.

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z @F!ÁZM Ä Ž¹@Fˆ z GaA»† z } | }T@ z ¡TCFI z E | ˆ6†‡€ˆ‡C%GH?hCFCF€kKL@9T€† z †.@9TM

u – w OC9G zо @BADCFE z E | †‡—¢£@F z EL@Fˆ¼„@F€IJˆ.C u!¾ ¢£¼ w K | Ž† zš‰
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} | ELTC9GHGDKL@9T€† z †.@9TM Ÿ C9? | †.E | GDTCFKLC9GHG | E ‰ M
u Î w OC9G z ¼ yV¾ GxCFJGH@FE»GxIT??ˆ ‰ Ž@9ˆ zB| §dC |Zz GxCFJGH@9EDKL@9T
TC9K z @9E “ C z ADCFC9 z CFEL…(†‡ | ˆ‡G yr| T€/¢ u!¿ †‡§dM¹–Z˜ w AD† z }g†‡§ÀT†‡
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y 6 Äxv @9‚ z }JC ¾ ¢£¼ÓAD†‡6
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ELCF?hˆ | KLCVA»†.ELC%} | ELJCFGHG | GDTC9KLCFGxG | E ‰ M
u Ï w OC9G z(z }JCR¼ yV¾ GHC9TGH@9E§dEL@9ITT€[KL†‡ELKLIT† z(|Zz GxCFJGH@FE
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Fig. 33 Engine Coolant Temperature Sensor—
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TEMPERATURE

RESISTANCE (OHMS)

°CEL.

°FAHR.

MIN.

MAX.

-40

-40

291,490

381,710

-20

-4

85,850

108,390

-10

14

49,250

61,430

0

32

29,330

35,990

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50

17,990

21,810

20

68

11,370

13,610

25

77

9,120

10,880

30

86

7,370

8,750

40

104

4,900

5,750

50

122

3,330

3,880

60

140

2,310

2,670

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Fig. 49 Upstream Oxygen Sensor Location


 






Fig. 50 Downstream Oxygen Sensor Location

š›œžŸ  

WARNING: THE EXHAUST MANIFOLD, EXHAUST
PIPES AND CATALYTIC CONVERTER BECOME
VERY HOT DURING ENGINE OPERATION. ALLOW
ENGINE TO COOL BEFORE REMOVING OXYGEN
SENSOR.

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connector, do not pull directly on wire going into
sensor.

Fig. 51 Air Cleaner Element

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WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING. COOLING SYSTEM
MUST BE PARTIALLY DRAINED BEFORE REMOVING THE COOLANT TEMPERATURE SENSOR.
REFER TO GROUP 7, COOLING.

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Fig. 53 IAT Sensor Location—4.0L Engine

Fig. 52 Engine Coolant Temperature Sensor—
Typical

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Fig. 55 Vehicle Speed Sensor Location—Typical

Fig. 56 Sensor Removal/Installation

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354




 


O2S (Oxygen Sensor) Remover/Installer—C-4907
Spanner Wrench—6856

Adapters, Fuel Pressure Test—6539 and/or 6631

Test Kit, Fuel Pressure—5069

Fitting, Air Metering—6714
Test Kit, Fuel Pressure—C-4799-B

Fuel Line Removal Tool—6782

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STEERING
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POWER STEERING

MONDhDEji
page

page

DESCRIPTION AND OPERATION
STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING
POWER STEERING FLOW AND PRESSURE . . . . 4

POWER STEERING SYSTEM DIAGNOSIS
CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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Fig. 1 Power Steering Gear & Pump – 4.0L

Fig. 2 Power Steering Gear & Pump – 2.5L

G/HJI.K

LMON/N/PQ RS

TU

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$Ž%þ 
CONDITION
OBJECTIONAL HISS OR
WHISTLE

RATTLE OR CLUNK

POSSIBLE CAUSES

CORRECTION

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.

1. Gear mounting bolts loose.

1. Tighten bolts to specification.

2. Loose or damaged suspension
components.

2. Inspect and repair suspension.

3. Loose or damaged steering linkage.

3. Inspect and repair steering
linkage.

4. Internal gear noise.

4. Replace gear.

5. Pressure hose in contact with other
components.

5. Reposition hose.

CHIRP OR SQUEAL

1. Loose belt.

1. Adjust or replace.

WHINE OR GROWL

1. Low fluid level.

1. Fill to proper level.

2. Pressure hose in contact with other
components.

2. Reposition hose.

3. Internal pump noise.

3. Replace pump.

1. Loose return line clamp.

1. Replace clamp.

2. O-ring missing or damaged on hose
fitting.

2. Replace o-ring.

SUCKING AIR SOUND

SCRUBBING OR
KNOCKING

3. Low fluid level.

3. Fill to proper level.

4. Air leak between pump and reservoir.

4. Repair as necessary.

1. Wrong tire size.

1. Verify tire size.

2. Wrong gear.

2. Verify gear.

uv
‚>ƒD„&…†‡ˆƒDˆ‰„&†‚‹Š;Œ;ˆ;Šƒ†(…Ž&‘?’?“%”•’?–?—?˜?™
V@WFXYWCX(Z\[!XY^]5_#WC`aWCX4Z
CONDITION

w7xpy/y/z{ |}

POSSIBLE CAUSE

DIFFICULT TO TURN WHEEL
STICKS OR BINDS

~/f€.

CORRECTION

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. Repair or replace gear.

8. Ball joints binding.

8. Inspect and repair as necessary.

WCX]5bdc c.WC`WCe#X(_f[!]#]5_hg ij^k#iij^j.e5_#bdj.Xl_min`!e#X(_me#j
CONDITION

POSSIBLE CAUSE

HARD TURNING OR MOMENTARY
INCREASE IN TURNING EFFORT

STEERING WHEEL
DOES NOT WANT TO RETURN TO
CENTER POSITION

CORRECTION

1. Tire pressure.

1. Adjust tire pressure.

2. Low fluid level.

2. Fill to proper level.

3. Loose belt.

3. Adjust or replace.

4. Lack of lubrication.

4. Inspect and lubricate steering and
suspension compnents.

5. Low pump pressure.

5. Pressure test and repair as
necessary.

6. Internal gear leak.

6. Pressure and flow test, and repair
as necessary.

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.

opii]#eq]5_me#e#jWCX(Z\[!XYsrpe#t4WC`!o eqo e#[!Y
CONDITION
EXCESSIVE PLAY IN STEERING
WHEEL

POSSIBLE CAUSE

CORRECTION

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.

NOQP5R SUTVVW0X Y0Z
^
_a`bLcLdLef_aeg`cL^ihkjkekhf_lcmbonpqsrstu9rsvswsxsy
CONDITION
VEHICLE PULLS OR LEADS TO
ONE SIDE

[]\

POSSIBLE CAUSE

CORRECTION

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 or
suspension components.

6. Repair as necessary.

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CAUTION: This next step involves testing maximum pump pressure output and flow control valve
operation. Do not leave test valve closed for more
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CAUTION: Do not force the pump to operate
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ENGINE

RELIEF PRESSURE 6 50

2.5L

9653 kPa (1400 psi)

4.0L

9653 kPa (1400 psi)

FLOW RATE (GPM)
1500 RPM 2.4 - 2.8 GPM

“”•5–






 



POWER STEERING PUMP
ªl«s¬s­*®
page
DESCRIPTION AND OPERATION
POWER STEERING PUMP . . . . . . .
DIAGNOSIS AND TESTING
PUMP LEAKAGE DIAGNOSIS . . . . .
SERVICE PROCEDURES
POWER STEERING PUMP – INITIAL
OPERATION . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION
POWER STEERING PUMP . . . . . . .

.......... 6
.......... 7

.......... 7
.......... 7

page
PUMP REMOTE RESERVOIR – 2.5L . . . . . . . . . . 7
DISASSEMBLY AND ASSEMBLY
FLOW CONTROL VALVE . . . . . . . . . . . . . . . . . . . 9
PUMP PULLEY . . . . . . . . . . . . . . . . . . . . . . . . . . 8
PUMP RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . 9
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 10
SPECIAL TOOLS
POWER STEERING PUMP . . . . . . . . . . . . . . . . . 10

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NOTE: Power steering pumps have different pressure rates and are not interchangeable with other

Fig. 1 Pump With Integral Reservoir
pumps.

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Adapters, Power Steering Flow/Pressure Tester
6893

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Puller C-4333

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Installer, Power Steering Pulley C-4063–B

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POWER STEERING GEAR

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page
DESCRIPTION AND OPERATION
POWER STEERING GEAR . . . . . . . . . . . . . . . . .
DIAGNOSIS AND TESTING
POWER STEERING GEAR LEAKAGE
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION
POWER STEERING GEAR . . . . . . . . . . . . . . . . .
DISASSEMBLY AND ASSEMBLY
HOUSING END PLUG . . . . . . . . . . . . . . . . . . . .
PITMAN SHAFT/SEALS/BEARING . . . . . . . . . . .

11

13
13
13
14

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RACK PISTON AND WORM SHAFT
SPOOL VALVE . . . . . . . . . . . . . . . .
ADJUSTMENTS
STEERING GEAR . . . . . . . . . . . . . .
SPECIFICATIONS
POWER STEERING GEAR . . . . . . .
TORQUE CHART . . . . . . . . . . . . . .
SPECIAL TOOLS
POWER STEERING GEAR . . . . . . .

. . . . . . . . . . 17
. . . . . . . . . . 15
. . . . . . . . . . 19
. . . . . . . . . . 21
. . . . . . . . . . 21
. . . . . . . . . . 21


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'< J7? 'FL#0 ÿ[%'
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J7X B'FL='#S%'
' '  
'N"'M^0
CAUTION: Components attached with a nut and
cotter pin must be torqued to specification. Then if
the slot in the nut does not line up with the cotter
pin hole, tighten nut until it is aligned. Never loosen
the nut to align the cotter pin hole.

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xzy;{;|z}N~;€7~L‚„ƒz‚Px…;y;}zƒ5€7~L‚‡†ˆ|z‰‹Š‹Œ4ŠŽ‹‹‘‹’

Fig. 1 Recirculating Ball Type Gear

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ª4«;¬¨¬;¤­¦¨®)¤­¯Z­¬;¤E°;ª ­¬;«; ;§¡ª4§

Fig. 2 Steering Gear Mounting

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½$¾4¿GêRË'ÍBÆÃ!ÁÁ Ñ ÊRÌ(Å ÉIÍBÆ ÅÅ ÉÎË'ÏVÇÊ ÍBÅ Í4ÖÆÕ'×Å ÍSÆ ÊYÍÆÅ ÅÉÎË'Ï
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¿ Ë'ÍBÅ ÃÆÃ!ËÐIÉÅ Ø7Ê ÛÅ<ÉÅÆ ÃÎË'ÎË'ÏQÉÎË'ÏNÈLÉÊ Ø ÏëÉÊ Ê ÛÅ
ÌÎÆÇ¨Ã Ñ Õ'Ë'Ä$Ç¨Æ ÇÉÊ Õ'ÏëǨÆÇ'śÇ'ÊÁśÎ˨ÆÇ'śÅË'ÐÞÊÈCÆÇ'Å
Ç'ÊÕ'ÍÎË'ÏC½LãÂÎÏÒ£ÙB¿$Ò

Fig. 3 End Plug Retaining Ring

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CAUTION: Do not turn stub shaft any further than


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necessary. The rack piston balls will drop out of the


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stub
b  piston
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:*,$D]f
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97$D572 <=isB7[eturned
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NOTE: The pitman shaft will not clear the housing
if it is not centered.

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m>w Q 5760*,<%Cm/Z-1 GP *,<=B7[ &x<%-9y@$'&(1.* 24-1D1.*,<%B_[t:"=57<=Xz/0B7X
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b  U B72 -/Z"="*,1.-'/0<=B7<=B7[‚*,<=B7[‚24$8$DB_1A1.B7Xƒ$D:g-'9_1A*,<=B7[
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Fig. 4 End Plug Components

Cover and Pitman Shaft
   O 1D]€Fig.
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<=-]€/0B3
2 97/0:-L:*m$D]^-971g2 <%XZ1gC,$dc 1.*œ`
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@<=C,Ey%hR<=[a`¦4¥`
CAUTION: Use care not to score the housing bore
when prying out seals and washer.

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©  O 1D]€$'c 1Œ&(/02 971D*:*,$.]^-971g97$D5_24<=B7[a`
m> ª  O 1D]€$'c 1t$.<="q2 1D/0" :*,$.]«-971t97$.5724<=B7[x&(<=-9ž/241D/0"
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m>.>œ O 1.]€$dc#1ƒ@<=-]€/ZB¬2 97/0:-36Z1./0*,<%B_[­:*,$.]®9_$D572 <=B7[
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Fig. 5 Installing The Retaining Ring

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Fig. 7 Pitman Shaft Seals & Bearing

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Fig. 8 Needle Bearing Removal












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Fig. 10 Thrust Support Assembly

Fig. 12 Stub Shaft

Fig. 11 Valve Assembly With Stub Shaft
†ˆ‡‡Š‰#‹ŒˆŽ

NOTE: Clean and dry all components, then lubricate with power steering fluid.
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NOTE: Notch in stub shaft cap must fully engage
valve body pin and seat against valve body shoulder.
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Fig. 13 Spool Valve
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NOTE: The thrust support is serviced as an assembly. If any component of the thrust support is damaged the assembly must be replaced.
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Fig. 16 Stub Shaft Cap O-Ring

Fig. 14 Valve Seals

Fig. 17 Rack Piston End Plug

Fig. 15 Stub Shaft Installation

 ºû

Cú 6û


ú6û ü'ýÿþ

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Fig. 18 Rack Piston with Arbor

Fig. 20 Rack Piston Teflon Ring and O-Ring

Fig. 19 Rack Piston

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·CÌÉ9ËAÍ\θº$Í
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NOTE: Clean and dry all components and lubricate
with power steering fluid.

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Á2¾4ÞR¼1·RÌÉ9ËAÍiÎOÎDº$Í

CAUTION: The rack piston balls must be installed
alternately into the rack piston and ball guide. This
maintains worm shaft preload. There are 12 black
balls and 12 silver (Chrome) balls. The black balls
are smaller than the silver balls.

Fig. 21 Worm Shaft

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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.

Fig. 22 Installing Balls in Rack Piston

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CAUTION: Do not overtighten the vise on the gear
case. This may affect the adjustment

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Fig. 23 Balls in the Return Guide

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M2P=OT bU=$1457=$TTUM$5A6F5AI:14^ 57M$TU‘9@4=O_

Fig. 24 Adjuster Lock Nut

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Fig. 25 Alignment Marking On Housing
Fig. 27 Aligning To The Second Mark

Fig. 26 Second Marking On Housing

ê!ëŽìDí!îðï¶ìDñQò‰ìDí

NOTE: Before performing this procedure, the worm
bearing preload adjustment must be performed.

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Fig. 28 Steering Gear Centered
NOTE: The stub shaft must rotate smoothly without
sticking or binding.

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Fig. 29 Checking Over-center Rotation Torque

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turn the screw CLOCKWISE.

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Remover/Installer Steering Rack Piston C-4175

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STEERING LINKAGE
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page
DESCRIPTION AND OPERATION
STEERING LINKAGE . . . . . . . .
SERVICE PROCEDURES
LUBRICATION . . . . . . . . . . . . .
STEERING LINKAGE . . . . . . . .
REMOVAL AND INSTALLATION
DRAG LINK . . . . . . . . . . . . . . .

. . . . . . . . . . . . . 22
. . . . . . . . . . . . . 22
. . . . . . . . . . . . . 22
. . . . . . . . . . . . . 23

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page
PITMAN ARM . . . . . . . .
STEERING DAMPENER
TIE ROD . . . . . . . . . . .
SPECIFICATIONS
TORQUE CHART . . . . .
SPECIAL TOOLS
STEERING LINKAGE . .

. . . . . . . . . . . . . . . . . . . 23
. . . . . . . . . . . . . . . . . . . 23
. . . . . . . . . . . . . . . . . . . 22
. . . . . . . . . . . . . . . . . . . 24
. . . . . . . . . . . . . . . . . . . 24

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CAUTION: If any steering components are replaced
or serviced an alignment must be performed, to
ensure the vehicle meets all alignment specifications.
CAUTION: Components attached with a nut and
cotter pin must be torqued to specification. Then if
the slot in the nut does not line up with the cotter
pin hole, tighten nut until it is aligned. Never loosen
the nut to align the cotter pin hole.

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Î]Ó]Ó]Ð0/2103546/107Ö3}Ó

Puller C-3894–A

Remover Pitman C-4150A

ï¹ð

ñ’òóóôDõ öD÷

ø¢ùú=ûü

STEERING COLUMN
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page

page

DESCRIPTION AND OPERATION
STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . 25
REMOVAL AND INSTALLATION
STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . 25

SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 27

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WARNING: BEFORE SERVICING THE STEERING
COLUMN THE AIRBAG SYSTEM MUST BE DISARMED. REFER TO GROUP 8M RESTRAINT SYSTEMS FOR SERVICE PROCEDURES. FAILURE TO
DO SO MAY RESULT IN ACCIDENTAL DEPLOYMENT OF THE AIRBAG AND POSSIBLE PERSONAL
INJURY.

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CAUTION: Keep clock spring from turning during
removal and installation. Failure to do so may damage the clock spring.

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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 DISCHARGE. 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 COATINGS 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.

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NOTE: If equipped with cruise control, disconnect
clock spring harness from the cruise switch harness on the steering wheel.
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CAUTION: Ensure the puller bolts are fully engaged
into the steering wheel before attempting to remove
the wheel. Failure to do so may damage the steering wheel.
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Fig. 1 Steering Wheel

Fig. 3 Column Shrouds

Release Access Hole
Fig.
 2
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NOTE: If vehicle is equipped with automatic transmission, remove shifter interlock cable. Refer to
Group 21 Transmission and Transfer Case for procedure.

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AB v 8 #%,  z(W( )‰!"#%QR ‡WU
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NOTE: If vehicle is equipped with automatic transmission, install shifter interlock cable. Refer to
Group 21 Transmission and Transfer Case for procedure.

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Spring
Aº ×8è8¼½ ¾¿8ÀÁ"ÂÂ5ÂÈ Fig.
é3ÅÆê7 ÇClock
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NOTE: If equipped with cruise control, connect
clock spring harness to cruise switch harness on
the steering wheel.

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TRANSMISSION AND TRANSFER CASE
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AX5 MANUAL TRANSMISSION
‚b†e¡e•“
page
GENERAL INFORMATION
AX5 MANUAL TRANSMISSION . . . . . . . . . .
GEAR RATIOS . . . . . . . . . . . . . . . . . . . . . . .
RECOMMENDED LUBRICANT . . . . . . . . . . .
TRANSMISSION ASSEMBLY INFORMATION
TRANSMISSION IDENTIFICATION . . . . . . . .
DIAGNOSIS AND TESTING
HARD SHIFTING . . . . . . . . . . . . . . . . . . . . .
LOW LUBRICANT LEVEL . . . . . . . . . . . . . . .
TRANSMISSION NOISE . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION
ADAPTER HOUSING SEAL . . . . . . . . . . . . .
EXTENSION HOUSING SEAL . . . . . . . . . . .
FRONT BEARING RETAINER SEAL . . . . . . .
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . .

.
.
.
.
.

.
.
.
.
.

.
.
.
.
.

.
.
.
.
.

1
1
1
2
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.... 4
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.
.

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.

7
7
6
4

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page
DISASSEMBLY AND ASSEMBLY
ADAPTER/EXTENSION HOUSING AND FRONT
BEARING RETAINER . . . . . . . . . . . . . . . . . . . . 8
COUNTERSHAFT . . . . . . . . . . . . . . . . . . . . . . . . 27
INPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 27
OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . 28
SEMI-SYNCHRONIZED REVERSE IDLER
GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
SHIFT MECHANISM AND GEARTRAIN . . . . . . . . 16
CLEANING AND INSPECTION
AX5 MANUAL TRANSMISSION COMPONENTS . 33
SPECIFICATIONS
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
SPECIAL TOOLS
AX5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

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Fig. 20 Remove Detent Spring

Fig. 18 Clutch Housing

Fig. 21 Remove Detent Ball

Fig. 19 Remove Detent Ball Plug

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ÒaÓZԃÕԃԃփ×4؈Ù-Ú^ÕÛfÒ^Õԃԃփ×BØÙ-ڌÜÝÞßàá ßâãäå

Fig. 22 Shift Arm Retainer Bolt Removal

Fig. 24 Removing Shift Lever Shaft Plug

Fig. 23 Shift Arm Rstrictor Pins

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ž¥2œª4—X¨"žš –Z¬>¥A¦L®N¯"²@˜®

Fig. 25 Remove Shifter Shaft

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hjikaclm\kac_b_bdbenfchjiporqcsTtTuv*tTwTxTyTz

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Fig. 26 Loosen Adapter/Extension Housing

Fig. 29 Remove Front Bearing Retainer

Fig. 27 Remove Adapter/Extension Housing–Typical




 

  

  



Fig. 30 Remove Input Shaft Bearing Snap-ring

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þ è éý
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ó&ùXö"ð0ô@ìïAôô@ïAíð Xö"ô@ë æZü­ïAúPý þ çéý

Fig. 28 Speedometer Drive Gear Assembly




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Fig. 31 Separate Intermediate Plate and
Transmission Case

ÈAÉ

Fig. 34 Install Transmission Gear Case to the
Intermediate Plate

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ƒ#ˆ›‰‹ƒ#‚„Ž”{`œ‚„0|§9}r

Fig. 32 Remove Intermediate Plate from
Transmission Case

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ŠŒ‚‡#ŠŒ†ƒ¦!–ŠŽ”ŠŒ–Lª9«.¬€­ •k{®ª
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Ž
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ƒ#ˆ›µ‰‹ƒ#‚
–ƒ#ŠŒ––·Š›·ŠQŽ
#ˆ‘Š
Fig. 33 Apply Sealer to Transmission Gear Case

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åšæ*Install
ç,ßèŒé[ê9Front
ç
æ
ëLìí#Bearing
î‹ï.ð”ìñò^Retainer
ó!òå!ñéô0õï#ö‹òòó!÷
éíñ t ø ìùú#ìñgûžåü
ýVòèMõ8þ€æ9ÿßFæç¸ßê
êßMèŒé[ü
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ú#ö‹ôåî‹ò¸éôšåñåâèŒòö%ç,ò
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Þ 9
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ì
í LóéãèŒü^èŒé.ê
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à éü
ìèŒìéínü9ï#ìô`è³åö …ìínü9ï#ìô`èŒòö”èŒé'ð
òö”éâ!òí#ì í [éô
åñåâèŒòö)éö)ò
jèòí#ü9ìéí ï#éú#ü
ì í .Þ !ì ¢ê 
"à ¢þ¢ò^ü9ú#ö‹ò^èŒï#åè
èŒï#òü
ï#ìôèòö
åö kìü”ò í „å „òñ—ìí#èŒéèŒï#òü
ï#ìô`èQörå!ìãü 

Fig. 38 Install Adapter/Extension Housing–Typical

Fig. 39 Position Shift Arm in Adapter or Extension
Housing

Fig. 37 Speedometer Drive Gear Assembly

Þrææ*
à #jèŒå!ö‹è“ü9ï#ìô`èŒòö å!ö  ü
ï#åô`è“ìíï#éãò ìíóå!î‹ý¸éô
åñåâèŒòögéögò
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éôMèŒï#òåñåâèŒòö
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ì í ^Þ ì & 9à 
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ï#ìôèòö”åö …ü9ï#åô`è€úí#èìãMèŒï#òmï#éãòìí
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ï#ìô`èbå!ö  ìü”å!ãì „íòñ)ð”ìèïèŒï#òï#éãòìígèŒï#òü9ï#åô`è 
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Fig. 42 Shifter Arm Shaft Plug Installation
Fig. 40 Install Shifter Arm Shaft

Fig. 43 Install Shifter Restrictor Pins

Fig. 41 Install Shift Arm Retainer Bolt

ijlmn op%qrr:ow uz!p{ xcop{ u‘ p‚{’Bun o€unow uzpp%‚%“’xc{’q
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Ù ÈÚ&ÊÛÇÚ Ä-Á܍ÐÏÚ&ØÝÄÚ

Fig. 46 Install Detent Ball Plug
Fig. 44 Install Detent Ball

Fig. 47 Install Shift Tower

Fig. 45 Install Detent Spring

ÁÂÓÄÅÆ ÇÈ%ÉÊÊÇÑ Ð Ù È)ÈÒޒÌcßVÏÉ
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Fig. 48 Install Backup Lamp Switch

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_htji  auvcGifdX{Oik|~}I–9Y.Z(}

Fig. 51 Remove Shift Fork Retainer Bolt

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_htjc  acG_h_bmpwxlGd ‡sifaqt Pgjdkdfm-u¡OyGe—G¢£Xk{Pif|…}¤–e”bZŸ}

Fig. 49 Positioning Intermediate Plate In Vise

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uvif]`|X{Oif|…}I–G—bZ(}

Fig. 52 Remove Fifth Gear Blocker Ring

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 uvo-w!ƒvo-g`]`aWmpuv_bt`c  aXk{Pif|…}¤–ebZ(}
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_htjc  aX{Oik|~}I–G–bZ(}
XªbZ\•5mpwxoq‰‹m  i  aWtœ|…mpcGu$aWt`uvgj_ha\uvif]`|«dko-ƒv›¬lGcedfd  uvopw
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Fig. 50 Remove Fifth Gear Snap-ring

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Fig. 53 Remove Fifth Gear Synchro Ring

Fig. 55 Remove Fifth Gear Thrust Ring

Fig. 54 Remove Fifth Gear and Synchro Assembly

Fig. 56 Remove Fifth Gear Thrust Ring Lock Ball

NOTE: There are many lock balls, check balls,
interlock balls, and interlock pins used in various
places in the transmission. Whenever a pin or ball
is removed, it should be identified in such a way
that it can be reinstalled in the same location from
which it was removed.

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ÝfÚpèvé=êeÝfæeÞW؄ÞqڄÞWß`؄áfâ`ÞWØpävÙxØ-à áfæeÞW؄ê ÝfæGÞqØ-ë
Ô(ìbíbÖ\×5ØpÙxÚqۋ؝ävØ^ۋØ-ävåh؝áfà ÝfØpä£ã~ØpæGä£åbß`æGçބæeâjàävØqۋØpävåbØ
áfà ÝfØpäã…Ø-æeäæGåhåbØpÙxÜGÝ îšÔkïPáfã…ë¤ðGñh֟ë

NOTE: Be sure to retrieve the pin and compression
spring from the reverse idler shaft.

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áfâ`ã«ävØpÞWæGáfâ`ØpäÞWڏÞWß`Øáfâ`ÞWØpävَØpà áfæGÞqØêeÝkæGÞWØæGâ`à™ävØpÙxÚqۋØ
ävØ-ÞqæGáfâ`ØpäÔïOáfã…ëIðGôbÖ(ë
Ô(ìbõbÖ\×5ØpÙxÚqۋØ#ÜeÚ-ÝfÞqåxß`Ú-Ýkàeákâjã¨ìböGõ\æeâjà=÷GöGø\åhß`áfçÞBçÚ-ävéå
ÞWڄÞqß`؄åbß`áfçÞävæGáfÝfåxÔkïPáfã…ë¤ðGÕhÖnæGâ`à\à áfåhèvæGävà\ÜGÚpÝfÞWåhë

Fig. 57 Remove Reverse Idler Shaft

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ÜGävæGèvéjØ-ÞÞWÚ#áfâ`ÞWØpä(ÙxØpà áfæGÞWØ#êeÝkæGÞW؄ÔïOákã~ëIþGíbÖ(ë

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Fig. 58 Remove Output Shaft Rear Bearing Retainer

Fig. 60 Remove Reverse Shift Arm Bracket Bolts

Fig. 59 Remove Shift Fork To Shift Rail Bolts

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RF`VXi%g'VdT_cIu]N=fTgkJMZ]RF`VXi%gkn|}VdWhNMTgQ`J~Z]J=VdZNMigQ`_JlLOVX\eTY
RF`VXi%gVXTcu]NMfT_gQJ=Z]RU`VXi[g€\egk`IV3RUf_\[gkV j b[J.WbeVXRUgk\eu‚LOVXb[beJ=gQn
|ƒ`\eR€\ebeb'Z]JMbeJ=VXRUJhgk`Jhu]NMf_TgQJ=Z]RU`_Vdi[g.i%Z]N=L„gk`Jhu]N=fTgkJMZsY
RF`VXi%gZ]J=VXZ j J=VXZ]\eT^…VXTc†gk`J‡LVd\eTRF`VXi%g#Z]JMVXZ j JMVXZ]\eT^
i%Z]N=Lˆgk`J\[T_gQJ=Z]LOJMcd\[VXgkJ…Wdb[VXgkJMn‰|ƒ`Ju]NMfT_gQJ=Z]RU`_Vdi[g~€.\eb[b
Z]J=b[J=VXRUJi%Z]N=L6gk`Ju]NMfT_gQJ=Z]RU`VXi[g j J=VdZ8\[T_^{i[\[Z]RFg~VXTcSu]VdT
j JzZ]JMLONQP JMc jFŠ LONQP \eT^.gk`Ju8NMfTgkJMZ8RU`VXi%gKZ]J=VXZ‹€VXZ]clVXTc
cNQ€TŒ€.VdZ]cIC%mr\e^on}pXFG8n
C8DFŽFGIHKJMLONQP J4gQ`J4LOVX\eTRU`_Vdi[g jFŠ LONP \eT^Sgk`J{LOVX\eTY
RF`VXi%g,i%N=Z‹€VXZ]cf_Tgk\[bgk`J†LOVX\eTRU`_Vdi[g,Z]JMVXZ j J=VdZ8\[T_^\eR
u]beJMVXZNMigk`J~\eTgkJMZ]LOJ=c\eVXgQJ~WdbeVdgkJ~VXTchgk`JMTZ]N=gQVXgk\[T_^gQ`J
LOVX\eTRU`_Vdi[gcN€.TŒ€VXZ]cINMfgN=igQ`JlRF`\ei%gi%N=Z]‘RC%m\e^’n}pX“UGsn

Fig. 61 Remove Output Shaft Rear Bearing
Snap-ring

C8DF”FGIHKJMLONQP J#gQ`_J“X•XERU`\ei[g(i[NMZ]‘4i[Z]NML–gk`J#“X•dERF`\ei%g
Z]VX\ebC%mr\e^on}pXEFG8n
C8DF—FGIHKJMLONQP J‡gk`J‡RFTVXWY%Z]\eT^…i[Z]NML˜TJMVXZgk`J‡JMT_c†NMi
gk`JxDF•d™RU`\ei[gZ]VX\ebOgkN‡VdbebeN€šgk`J‡Z]J=LONP0VdbNMi~gk`JxDF•X
RU`_\[i[gi%N=Z]‘_n

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Fig. 62 Remove Countershaft and Countershaft
Rear Bearing

Fig. 64 Remove 3–4 Shift Fork

Fig. 63 Remove Mainshaft

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ËkÌÇlØdÎXÙhÏFÌÐeÑ%ËÒ]ÕXÐeÚeρÂ%ÛrÐ[ܒÝ}ÞXßFÅ8Ý
Â%ÃÍ>ÅIÆKÇMÈOÉQÊ ÇàËkÌÒ]Ç=Õd×dÇM×âáÚeãܒÏäÑ%Ò]É=ÈåÐ[Ö_ËQÇ=Ò]ÈOÇM×dÐ[ÕXËkÇ
áÚeÕXËkÇMÝKæÌÇ=ÖçÒ]ÇMÈOÉQÊ Ç4ÚeÉ=è]ӆéXÕXÚ[Ú(ÕXÖיÏUádÒ]ÐeÖÜSÑ%Ò]É=ÈâáÚeãÜ
ÌÉ=Ú[Ç=ÏKêÐeËkÌháÇ=Öè]ÐeÚÈOÕXÜoÖ_ÇMËÂ%ÛrÐeÜoÝ ÞXÞFÅ8Ý ëÉMËkÇ(ËQÌÕXËËkÌÇ(éXÉMËkì
ËkÉMÈ6ÏUádÒ]ÐeÖÜ{ÐeÏIÏFÌÉMÒ]ËkÇMÒÐeÖaÚeÇMÖܒËQÌaËkÌÕXÖaËkÌÇíÉMËkÌÇ=ÒhËîêÉ
ÏFáÒ]ÐeÖÜoÏFÝ
Â%ÃXÃFÅIÆKÇMÈOÉQÊ ÇËQÌ_Ç#ÐeÖËkÇ=Ò]ÈOÇM×ÐeÕXËkÇ#ádÚ[ÕXËkÇÑ%Ò]ÉMÈäËQÌ_Ç(Ê0ÐeÏUÇ=ï
Ò]É=ËQÕXËkÇIËkÌÇIáÚeÕXËkÇSÍFðXÄdñQïƒÕXÖ×{Ò]Ç=Ð[Ö_ÏUËkÕdÚeÚ'ËkÌÇIáÚeÕXËkÇIÐeÖËkÌÇ
Ê ÐeÏFǦãÏFÐeÖÜ,ËkÌǦÏFÕXÈOǦéXÉMÚeˁÕXÖ×hêÕXÏFÌÇMÒȁÉMãÖËkÐeÖÜ,ÏFÇMËkì
ãádÝ

Fig. 65 Remove 1–2 Shift Fork
CAUTION: The interlock balls and pins are different
sizes and shapes. Be sure to correctly identify
which position an item is removed from to ensure
that it is reinstalled in the same location.

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Fig. 68 Remove Fifth Gear Check Ball

Fig. 66 Remove Lock Ball And Spring

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Fig. 69 Remove Reverse Shift Head And Rail
Assembly

Fig. 67 Remove Fifth Gear Shift Rail

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>?`J@B36GKM?76Y[cb>?`JQ
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>?`J@B7=>O`k@:3%GK5836a>?F.@B3=bM?FL@B36Q
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< 7%GK[oF.`Ja]F.GK5pF.H0HI3%58\LM e<OGK765q>O`k@:3%GK5836aL>OF.@B3rbM?F.@:3r+ONP>?CEQ
T.s0/Q

Fig. 70 Remove Reverse Shift Rail

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+ Nf>?CEQgTzy&/Q
+ ,.h0/21436587:9;3G3w9;3%GKHI336M?76`kCEF.@:3%axYKAJ3%YK[\.F.M?MP+ NP>?C{QzT.,0/Q

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ð ñòññóôõö÷òøïòññóôõö÷ùúû"ü"ý%þ&ü"ÿ

Fig. 71 Remove Interlock Pin From Reverse Shift
Rail
Fig. 73 Remove 1–2 Shift Rail Interlock Pin

Fig. 74 Remove 1–2 Check Ball

Fig. 72 Remove Reverse Check Ball

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Fig. 75 Shift Rail Components

Fig. 76 Install 1–2 Check Ball

 


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Fig. 77 Install 1–2 Shift Rail Interlock Pin

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Fig. 80 Install Reverse Arm Bracket to Fork

Fig. 78 Install Reverse Check Ball

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Fig. 81 Install Reverse Shift Rail

Fig. 79 Install Reverse Interlock Pin

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Fig. 82 Install Reverse Snap-ring

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Fig. 83 Install Fifth Gear Check Ball

Fig. 85 Install 1–2 Shift Fork

Fig. 84 Install Fifth Gear Shift Rail

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Fig. 87 Install Shift Fork Bolts

Fig. 89 Install Compression Spring And Pin

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Fig. 94 Install Fifth Gear Thrust Ring

Fig. 91 Align Idler Shaft Pin

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Fig. 95 Install Fifth Gear Retainer Bolt

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Fig. 96 Countershaft Front Bearing Snap-ring

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Fig. 98 Input Shaft Components

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Fig. 100 Install Output Shaft Pilot Bearing Rollers






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Fig. 101 Check Output Shaft Gear Thrust Clearance

Fig. 99 Select Input Shaft Bearing Snap-ring

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Fig. 102 Remove Fifth Gear Snap-ring

Fig. 103 Remove Fifth Gear, First Gear Bearing, And
Race

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Fig. 104 Remove First Gear Bearing Inner Race
Lock Ball

Fig. 105 Remove Second Gear, Reverse Gear, And
1–2 Synchronizer

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Fig. 106 Remove 3–4 Synchronizer Snap Ring

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Fig. 108 Synchronizer Identification

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Fig. 107 Remove 3–4 Synchronizer And Third Gear



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Fig. 109 Select 3–4 Synchronizer Snap-ring

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Fig. 111 Install First Gear Bearing Inner Race Lock
Ball

Fig. 110 Check Third Gear Clearance

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Fig. 113 Check First–Second Gear Thrust Clearance

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Fig. 124 Check Fork–To–Hub Clearance

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Fig. 123 Check Synchronizer Ring Wear

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8212 Installer, Seal

C-3339 Dial Indicator Set

8208 Installer, Seal

C-3995-A Installer, Extension Housing Seal

P-334 Splitter, Bearing

8109 Cup, Installer
C-4171 Handle, Universal Tool

8211 Installer, Seal

L-4507 Tube, Driver



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AX15 MANUAL TRANSMISSION
HJIKLNM
page
GENERAL INFORMATION
AX15 MANUAL TRANSMISSION . . . . . . . . . .
RECOMMENDED LUBRICANT . . . . . . . . . . .
TRANSMISSION ASSEMBLY INFORMATION
TRANSMISSION GEAR RATIOS . . . . . . . . . .
TRANSMISSION IDENTIFICATION . . . . . . . .
DIAGNOSIS AND TESTING
HARD SHIFTING . . . . . . . . . . . . . . . . . . . . .
LOW LUBRICANT LEVEL . . . . . . . . . . . . . . .
TRANSMISSION NOISE . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION
ADAPTER HOUSING SEAL . . . . . . . . . . . . .
EXTENSION HOUSING SEAL . . . . . . . . . . . .
FRONT BEARING RETAINER SEAL . . . . . . .
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . .

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. . . 41
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page
DISASSEMBLY AND ASSEMBLY
ADAPTER/EXTENSION HOUSING AND FRONT
BEARING RETAINER . . . . . . . . . . . . . . . . . .
COUNTERSHAFT . . . . . . . . . . . . . . . . . . . . . . .
INPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . .
OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . .
SHIFT MECHANISM AND GEARTRAIN . . . . . . .
CLEANING AND INSPECTION
AX15 MANUAL TRANSMISSION
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS
AX15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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. 73

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Fig. 1 AX15 Manual Transmission

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Fig. 2 Identification Code Number Location

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Fig. 3 Fill Plug Location

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Fig. 5 Output Shaft and Gears

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Fig. 8 Crankshaft Position Sensor —4.0L Engine

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CAUTION: It is important that the crankshaft position sensor be removed prior to transmission
removal. The sensor can easily be damaged if left
in place during removal operations.

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Fig. 14 Install Extension Housing Seal

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d‘gfiÆxgy|r+‹p7xz}yRƒp~Rjœ¿;uÖsсŒm^m ~|Âm uip7xg~Ry|{;jœ†+plUlUj u
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Fig. 13 Remove Extension Housing Seal

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Fig. 15 Remove Adapter Housing Seal

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Fig. 17 Remove Shift Tower

Fig. 16 Install Adapter Housing Seal

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Fig. 18 Remove Shift Tower Gasket

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Fig. 21 Remove Detent Spring

Fig. 19 Clutch Housing

Fig. 22 Remove Detent Ball

Fig. 20 Remove Detent Ball Plug

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Fig. 23 Shift Arm Retainer Bolt Removal

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Fig. 24 Shift Arm Rstrictor Pins

Fig. 25 Removing Shift Lever Shaft Plug

Fig. 26 Remove Shifter Shaft
Fig. 27 Adapter/Extension Housing Bolts

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Fig. 28 Loosen Adapter/Extension Housing

Fig. 30 Speedometer Drive Gear Assembly

Fig. 29 Remove Adapter/Extension Housing

Fig. 31 Remove Front Bearing Retainer

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Fig. 33 Remove Cluster Gear Snap-ring

Fig. 36 Apply Sealer to Transmission Gear Case

Fig. 34 Separate Intermediate Plate and
Transmission Case

Fig. 37 Install Transmission Gear Case to the
Intermediate Plate

Fig. 35 Remove Intermediate Plate from
Transmission Case

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Fig. 40 Speedometer Drive Gear Assembly

Fig. 38 Install Front Bearing Snap-rings

Fig. 41 Install Adapter/Extension Housing

Fig. 39 Install Front Bearing Retainer

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Fig. 42 Position Shift Arm in Transmission Case

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Fig. 43 Install Shifter Arm Shaft
Fig. 45 Shifter Arm Shaft Plug Installation

Fig. 44 Install Shift Arm Retainer Bolt

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Fig. 47 Install Detent Ball

Fig. 50 Installing Shift Tower And Backup Lamp
Switch

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Fig. 48 Install Detent Spring

Fig. 49 Install Detent Ball Plug

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Fig. 51 Positioning Intermediate Plate In Vise

Fig. 52 Remove Fifth Gear Snap-ring

Fig. 54 Remove Fifth Gear Shift Fork

Fig. 53 Remove Fifth Gear Shift Fork Retainer Bolt

Fig. 55 Remove Reverse Shift Head Assembly

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Fig. 58 Remove Fifth Gear And Synchro Assembly

Fig. 56 Remove Fifth Gear Blocker Ring

Fig. 59 Remove Fifth Gear Thrust Ring

Fig. 57 Remove Fifth Gear Synchro Ring

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places in the transmission. Whenever a pin or ball
is removed, it should be identified in such a way
that it can be reinstalled in the same location from
which it was removed.

Fig. 60 Remove Fifth Gear Thrust Ring Lock Ball

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Fig. 63 Remove Reverse Idler Shaft And Gear

Fig. 61 Remove Output Shaft Rear Bearing Retainer
Bolts

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Fig. 64 Reverse Shift Arm Components

Fig. 62 Remove Output Shaft Rear Bearing Retainer

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Fig. 65 Lock Ball Plug Locations

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Fig. 68 Remove Fifth Gear Shift Rail Lock Ball

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Fig. 66 Remove Lock Ball And Spring

Fig. 67 Shift Rail Identification

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Fig. 71 Remove 3–4 Shift Rail

Fig. 69 Remove Shift Rail C-rings

Fig. 72 Remove 3–4 Shift Rail Interlock Plug

Fig. 70 Remove Shift Fork To Shift Rail Bolts

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Fig. 75 Remove 1–2 Shift Rail Interlock Pin

Fig. 73 Remove Shift Forks

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Fig. 76 Remove 1–2 Shift Rail Interlock Plug

Fig. 74 Remove 1–2 Shift Rail

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¼-½¾]¿@À`ÁàÀ]Àh Ä@¿e¾]¿Å ¼-½¾]¿@ÀcÆ?Ç#½ È`¾]ÀhÇ É#Ê3ËWÌ?Í
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Fig. 79 Remove Reverse Shift Rail Interlock Pin

Fig. 77 Remove Reverse Shift Rail C-ring

Fig. 80 Remove Output Shaft Rear Bearing
Snap-ring

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NOTE: Coat all shift components with petroleum
jelly during assembly. Petroleum jelly will hold components in position during installation.

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Fig. 84 Install Shift Forks
Fig. 82 Install Reverse Shift Rail Interlock Pin

Fig. 83 Install Reverse Shift Rail

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Fig. 86 Install 1–2 Shift Rail Interlock Pin

Fig. 89 Install 3–4 Shift Rail

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Fig. 87 Install 1–2 Shift Rail

Fig. 90 Install Shift Fork To Shift Rail Bolts

Fig. 88 Install 3–4 Shift Rail Interlock Plug

Fig. 91 Install Shift Rail C-rings

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Fig. 94 Install Fifth Gear Shift Rail Lock Ball

Fig. 92 Install Reverse Idler Gear And Shaft

Fig. 95 Install Fifth Gear Thrust Ring Lock Ball










Fig. 93 Install Output Shaft Rear Bearing Retainer

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Fig. 96 Install Fifth Gear Thrust Ring

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Fig. 98 Install Countershaft Fifth Gear Assembly

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Fig. 99 Install Fifth Gear Synchronizer Ring

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Fig. 101 Install Reverse Shift Head And Rail
Assembly

Fig. 102 Install Fifth Gear Shift Fork

Fig. 103 Install Fifth Gear Shift Fork Retainer Bolt

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Fig. 107 Remove Output Shaft Pilot Bearing

Fig. 105 Countershaft Front Bearing Snap-ring

idjNkmlNnpomqArstn

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Fig. 106 Separate Input and Output Shafts


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Fig. 110 Output Shaft And Gears

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Fig. 112 Check Output Shaft Gear Thrust Clearance

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Fig. 113 Remove Fifth Gear Snap-ring

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Fig. 114 Remove Fifth Gear, First Gear Bearing, And
Thrust Washer

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Fig. 115 Remove Second Gear And 1–2
Synchronizer/Reverse Gear

Fig. 117 Remove 3–4 Synchronizer And Third Gear

Fig. 118 Synchronizer Identification

Fig. 116 Remove 3–4 Synchronizer Snap Ring

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Fig. 119 Select 3–4 Synchronizer Snap-ring

Fig. 120 Check Third Gear Clearance


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Fig. 121 Second Gear And Synchronizer Assembly

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Fig. 122 First And Fifth Gear Components

Fig. 124 Select/Install Fifth Gear Snap Ring

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Fig. 123 Check First–Second Gear Thrust Clearance

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AUTOMATIC TRANSMISSION—30/32RH
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GENERAL INFORMATION
30/32RH AUTOMATIC TRANSMISSION . . . . . . . 76
CAUSES OF BURNT FLUID . . . . . . . . . . . . . . . . 76
EFFECTS OF INCORRECT FLUID LEVEL . . . . . 76
FLUID CONTAMINATION . . . . . . . . . . . . . . . . . . 76
GEARSHIFT MECHANISM . . . . . . . . . . . . . . . . . 78
RECOMMENDED FLUID . . . . . . . . . . . . . . . . . . . 76
TORQUE CONVERTER—ELECTRONIC
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
TRANSMISSION GEAR RATIOS . . . . . . . . . . . . . 78
TRANSMISSION IDENTIFICATION . . . . . . . . . . . 76
DESCRIPTION AND OPERATION
BRAKE TRANSMISSION SHIFT INTERLOCK
MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . 79
CONVERTER CLUTCH ENGAGEMENT . . . . . . . 79
CONVERTER DRAINBACK VALVE . . . . . . . . . . . 79
HYDRAULIC CONTROL SYSTEM . . . . . . . . . . . . 78
DIAGNOSIS AND TESTING
AIR TESTING TRANSMISSION CLUTCH AND
BAND OPERATION . . . . . . . . . . . . . . . . . . . . . 84
ANALYZING ROAD TEST . . . . . . . . . . . . . . . . . . 81
AUTOMATIC TRANSMISSION DIAGNOSIS . . . . . 80
CONVERTER HOUSING FLUID LEAK
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
CONVERTER STALL TEST . . . . . . . . . . . . . . . . . 83
DIAGNOSIS CHARTS . . . . . . . . . . . . . . . . . . . . . 86
GEARSHIFT CABLE . . . . . . . . . . . . . . . . . . . . . . 81
HYDRAULIC PRESSURE TEST . . . . . . . . . . . . . 82
PARK/NEUTRAL POSITION SWITCH . . . . . . . . . 81
PRELIMINARY DIAGNOSIS . . . . . . . . . . . . . . . . 80
ROAD TESTING . . . . . . . . . . . . . . . . . . . . . . . . . 81
STALL TEST ANALYSIS . . . . . . . . . . . . . . . . . . . 84
THROTTLE VALVE CABLE . . . . . . . . . . . . . . . . . 81
SERVICE PROCEDURES
ALUMINUM THREAD REPAIR . . . . . . . . . . . . . . 96
CONVERTER DRAINBACK CHECK VALVE
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
FLUID AND FILTER REPLACEMENT . . . . . . . . . 94
FLUID LEVEL CHECK . . . . . . . . . . . . . . . . . . . . 94
FLUSHING COOLERS AND TUBES . . . . . . . . . . 96
OIL PUMP VOLUME CHECK . . . . . . . . . . . . . . . 95
TRANSMISSION FILL PROCEDURE . . . . . . . . . . 95
REMOVAL AND INSTALLATION
BRAKE TRANSMISSION SHIFT INTERLOCK . . 102
EXTENSION HOUSING . . . . . . . . . . . . . . . . . . 100
GEARSHIFT CABLE . . . . . . . . . . . . . . . . . . . . . 102
GOVERNOR AND PARK GEAR . . . . . . . . . . . . 104
OUTPUT SHAFT REAR BEARING . . . . . . . . . . 104

PARK LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
PARK/NEUTRAL POSITION SWITCH . . . . . . . . 101
SPEEDOMETER ADAPTER . . . . . . . . . . . . . . . 100
TORQUE CONVERTER . . . . . . . . . . . . . . . . . . . 99
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . 97
VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . 103
DISASSEMBLY AND ASSEMBLY
FRONT CLUTCH . . . . . . . . . . . . . . . . . . . . . . . 129
FRONT SERVO PISTON . . . . . . . . . . . . . . . . . . 124
GOVERNOR AND PARK GEAR . . . . . . . . . . . . 106
OIL PUMP AND REACTION SHAFT SUPPORT . 126
OVERRUNNING CLUTCH/LOW-REVERSE
DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
PLANETARY GEARTRAIN/OUTPUT SHAFT . . . 133
REAR CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . 130
REAR SERVO PISTON . . . . . . . . . . . . . . . . . . . 125
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . 114
VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . 107
CLEANING AND INSPECTION
EXTENSION HOUSING AND PARK LOCK . . . . 137
FRONT CLUTCH . . . . . . . . . . . . . . . . . . . . . . . 142
FRONT SERVO . . . . . . . . . . . . . . . . . . . . . . . . 141
GOVERNOR AND PARK GEAR . . . . . . . . . . . . 137
OIL PUMP AND REACTION SHAFT SUPPORT . 141
OVERRUNNING CLUTCH/LOW-REVERSE
DRUM/OVERDRIVE PISTON RETAINER . . . . 141
PLANETARY GEARTRAIN/OUTPUT SHAFT . . . 143
REAR CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . 142
REAR SERVO . . . . . . . . . . . . . . . . . . . . . . . . . 141
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . 140
VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . 139
ADJUSTMENTS
BRAKE TRANSMISSION SHIFT INTERLOCK
CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . 144
FRONT BAND ADJUSTMENT . . . . . . . . . . . . . . 145
GEARSHIFT CABLE . . . . . . . . . . . . . . . . . . . . . 143
REAR BAND ADJUSTMENT . . . . . . . . . . . . . . . 146
TRANSMISSION THROTTLE VALVE CABLE
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 144
VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . 146
SCHEMATICS AND DIAGRAMS
HYDRAULIC SCHEMATICS . . . . . . . . . . . . . . . 147
SPECIFICATIONS
30/32RH AUTOMATIC TRANSMISSION . . . . . . 160
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
SPECIAL TOOLS
30/32RH TRANSMISSIONS . . . . . . . . . . . . . . . 161

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CAUTION: Stalling the converter causes a rapid
increase in fluid temperature. To avoid fluid overheating, hold the engine at maximum rpm for no
more than 5 seconds. If engine exceeds 2500 rpm
during the test, release the accelerator pedal immediately; transmission clutch slippage is occurring.

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Fig. 9 Pressure Test Analysis
WARNING: NEVER ALLOW ANYONE TO STAND
DIRECTLY IN LINE WITH THE VEHICLE FRONT OR
REAR DURING A STALL TEST. ALWAYS BLOCK
THE WHEELS AND FULLY APPLY THE SERVICE
AND PARKING BRAKES DURING THE TEST.

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Fig. 12 Converter Leak Points—Typical

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ÖkהØkÙÚÛ
ܩהÜÝ)Þ
Ø)ß6à
CONDITION
HARSH ENGAGEMENT
FROM NEUTRAL TO
DRIVE OR REVERSE

POSSIBLE CAUSES

CORRECTION

1. Fluid Level Low.

1. Add Fluid.

2. Throttle Linkage Misadjusted.

2. Adjust linkage - setting may be too long.

3. Mount and Driveline Bolts Loose.

3. Check engine mount, transmission
mount, propeller shaft, rear spring to body
bolts, rear control arms, crossmember and
axle bolt torque. Tighten loose bolts and
replace missing bolts.

4. U-Joint Worn/Broken.

4. Remove propeller shaft and replace
U-Joint.

5. Axle Backlash Incorrect.

5. Check per Service Manual. Correct as
needed.

6. Hydraulic Pressure Incorrect.

6. Check pressure. Remove, overhaul or
adjust valve body as needed.

7. Band Misadjusted.

7. Adjust rear band.

8. Valve Body Check Balls Missing.

8. Inspect valve body for proper check ball
installation.

9. Axle Pinion Flange Loose.

9. Replace nut and check pinion threads
before installing new nut. Replace pinion
gear if threads are damaged.

10. Clutch, band or planetary
component Damaged.

10. Remove, disassemble and repair
transmission as necessary.

11. Converter Clutch (if equipped)
Faulty.

11. Replace converter and flush cooler and
line before installing new converter.



,.-0/214345467-068/234,:9<;<6<97-=3>1@?BA2CDEFDGHIJ
CONDITION
DELAYED ENGAGEMENT
FROM NEUTRAL TO
DRIVE OR REVERSE

NO DRIVE RANGE
(REVERSE OK)

  
"!#$!

POSSIBLE CAUSES

%#&('*)"+

CORRECTION

1. Fluid Level Low.

1. Correct level and check for leaks.

2. Filter Clogged.

2. Change filter.

3. Gearshift Linkage Misadjusted.

3. Adjust linkage and repair linkage if worn
or damaged.

4. Rear Band Misadjusted.

4. Adjust band.

5. Valve Body Filter Plugged.

5. Replace fluid and filter. If oil pan and old
fluid were full of clutch disc material and/or
metal particles, overhaul will be necessary.

6. Oil Pump Gears Worn/Damaged.

6. Remove transmission and replace oil
pump.

7. Hydraulic Pressure Incorrect.

7. Perform pressure test, remove
transmission and repair as needed.

8. Reaction Shaft Seal Rings
Worn/Broken.

8. Remove transmission, remove oil pump
and replace seal rings.

9. Rear Clutch/Input Shaft, Rear
Clutch Seal Rings Damaged.

9. Remove and disassemble transmission
and repair as necessary.

10. Governor Valve Stuck.

10. Remove and inspect governor
components. Replace worn or damaged
parts.

11. Regulator Valve Stuck.

11. Clean.

12. Cooler Plugged.

12. Flush transmission cooler and inspect
convertor drainback valve.

1. Fluid Level Low.

1. Add fluid and check for leaks if drive is
restored.

2. Gearshift Linkage/Cable
Loose/Misadjusted.

2. Repair or replace linkage components.

3. Rear Clutch Burnt.

3. Remove and disassemble transmission
and rear clutch and seals. Repair/replace
worn or damaged parts as needed.

4. Valve Body Malfunction.

4. Remove and disassemble valve body.
Replace assembly if any valves or bores
are damaged.

5. Transmission Overrunning Clutch
Broken.

5. Remove and disassemble transmission.
Replace overrunning clutch.

6. Input Shaft Seal Rings Worn/
Damaged.

6. Remove and disassemble transmission.
Replace seal rings and any other worn or
damaged parts.

7. Front Planetary Failed Broken.

7. Remove and repair.

K#LNM*O#O
PQRSTUWV TTV XSRSYPQRSZT[#\"Q]RT\
`.a0b2c4d4e4f7a0f8b2d4`:g<h<f<g7a=d>c@iBj2klmnlopqr
CONDITION
NO DRIVE OR REVERSE
(VEHICLE WILL NOT
MOVE)

POSSIBLE CAUSES

^ _

CORRECTION

1. Fluid Level Low.

1. Add fluid and check for leaks if drive is
restored.

2. Gearshift Linkage/Cable
Loose/Misadjusted.

2. Inspect, adjust and reassemble linkage
as needed. Replace worn/damaged parts.

3. U-Joint/Axle/Transfer Case
Broken.

3. Perform preliminary inspection procedure
for vehicle that will not move. Refer to
procedure in diagnosis section.

4. Filter Plugged.

4. Remove and disassemble transmission.
Repair or replace failed components as
needed. Replace filter. If filter and fluid
contained clutch material or metal particles,
an overhaul may be necessary. Perform
lube flow test. Flush oil. Replace cooler as
necessary.

5. Oil Pump Damaged.

5. Perform pressure test to confirm low
pressure. Replace pump body assembly if
necessary.

6. Valve Body Malfunctioned.

6. Check press and inspect valve body.
Replace valve body (as assembly) if any
valve or bore is damaged. Clean and
reassemble correctly if all parts are in good
condition.

7. Transmission Internal Component
Damaged.

7. Remove and disassemble transmission.
Repair or replace failed components as
needed. Remove and disassemble
transmission. Repair or replace failed
components as needed.

8. Park Sprag not Releasing.

8. Remove, disassemble, repair.

9. Torque Converter Damage.

9. Check Stall Speed, Worn/Damaged/
Stuck. Inspect and replace as required.

s t
†.‡0ˆ2‰4Š4‹4Œ7‡0Œ8ˆ2Š4†:<Ž<Œ<7‡=Š>‰@B2‘’“”’•–—˜
CONDITION
SHIFTS DELAYED OR
ERRATIC (SHIFTS ALSO
HARSH AT TIMES)

NO REVERSE (D RANGES
OK)

HAS FIRST/REVERSE
ONLY (NO 1-2 OR 2-3
UPSHIFT)

MOVES IN 2ND OR 3RD
GEAR, ABRUPTLY
DOWNSHIFTS TO LOW

uvwxyz{ yy{ |xwx}uvwxy~"#v€wy

POSSIBLE CAUSES

#‚(ƒ*„"…

CORRECTION

1. Fluid Level Low/High.

1. Correct fluid level and check for leaks if
low.

2. Throttle Linkage Misadjusted.

2. Adjust linkage as described in service
section.

3. Throttle Linkage Binding.

3. Check cable for binding. Check for return
to closed throttle at transmission.

4. Gearshift Linkage/Cable
Misadjusted.

4. Adjust linkage/cable as described in
service section.

5. Fluid Filter Clogged.

5. Replace filter. If filter and fluid contained
clutch material or metal particles, an
overhaul may be necessary. Perform lube
flow test.

6. Governor Valve Sticking.

6. Inspect, clean or repair.

7. Governor Seal Rings Worn/
Damaged.

7. Inspect/replace.

8. Clutch or Servo Failure.

8. Remove valve body and air test clutch,
and band servo operation. Disassemble
and repair transmission as needed.

9. Front Band Misadjusted.

9. Adjust band.

10. Pump Suction Passage Leak.

10. Check for excessive foam on dipstick
after normal driving. Check for loose pump
bolts, defective gasket. Replace pump
assembly if needed.

1. Gearshift Linkage/Cable
Misadjusted/Damaged.

1. Repair or replace linkage parts as
needed.

2. Park Sprag Sticking.

2. Inspect and replace as necessary.

3. Rear Band Misadjusted/Worn.

3. Adjust band; replace.

4. Valve Body Malfunction.

4. Remove and service valve body. Replace
valve body if any valves or valve bores are
worn or damaged.

5. Rear Servo Malfunction.

5. Remove and disassemble transmission.
Replace worn/damaged servo parts as
necessary.

6. Front Clutch Burnt.

6. Remove and disassemble transmission.
Replace worn, damaged clutch parts as
required.

1. Governor Valve, Shaft, Weights or
Body Damaged/Stuck.

1. Remove governor assembly and clean or
repair as necessary.

2. Valve Body Malfunction.

2. Stuck 1-2 shift valve or governor plug.

3. Front Servo/Kickdown Band
Damaged/Burned.

3. Repair/replace.

1. Valve Body Malfunction.

1. Remove, clean and inspect. Look for
stuck 1-2 valve or governor plug.

2. Governor Valve Sticking.

2. Remove, clean and inspect. Replace
faulty parts.

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CONDITION
NO LOW GEAR (MOVES
IN 2ND OR 3RD GEAR
ONLY)

NO KICKDOWN OR
NORMAL DOWNSHIFT

STUCK IN LOW GEAR
(WILL NOT UPSHIFT)

CREEPS IN NEUTRAL

POSSIBLE CAUSES

ª «

CORRECTION

1. Governor Valve Sticking.

1. Remove governor, clean, inspect and
repair as required.

2. Valve Body Malfunction.

2. Remove, clean and inspect. Look for
sticking 1-2 shift valve, 2-3 shift valve,
governor plug or broken springs.

3. Front Servo Piston Cocked in
Bore.

3. Inspect servo and repair as required.

4. Front Band Linkage Malfunction.

4. Inspect linkage and look for bind in
linkage.

1. Throttle Linkage Misadjusted.

1. Adjust linkage.

2. Accelerator Pedal Travel
Restricted.

2. Floor mat under pedal, accelerator cable
worn or brackets bent.

3. Governor/Valve Body Hydraulic
Pressures Too High or Too Low Due
to Sticking Governor, Valve Body
Malfunction or Incorrect Hydraulic
Control Pressure Adjustments.

3. Perform hydraulic pressure tests to
determine cause and repair as required.
Correct valve body pressure adjustments as
required.

4. Valve Body Malfunction.

4. Perform hydraulic pressure tests to
determine cause and repair as required.
Correct valve body pressure adjustments as
required.

5. Valve Body Malfunction.

5. Sticking 1-2, 2-3 shift valves, or governor
plugs.

1. Throttle Linkage Misadjusted/
Stuck.

1. Adjust linkage and repair linkage if worn
or damaged. Check for binding cable or
missing return spring.

2. Gearshift Linkage Misadjusted.

2. Adjust linkage and repair linkage if worn
or damaged.

3. Governor/Valve Body, Governor
Valve Stuck Closed; Loose Output
Shaft Support or Governor Housing
Bolts, Leaking Seal Rings or Valve
Body Problem (i.e., Stuck 1- 2 Shift
Valve/Gov. Plug).

3. Check line and governor pressures to
determine cause. Correct as required.

4. Front Band Out of Adjustment.

4. Adjust Band.

5. Clutch or Servo Malfunction.

5. Air pressure check operation of clutches
and bands. Repair faulty component.

1. Gearshift Linkage Misadjusted.

1. Adjust linkage.

2. Rear Clutch Dragging/Warped
Welded.

2. Disassemble and repair.

3. Valve Body Malfunction.

3. Perform hydraulic pressure test to
determine cause and repair as required.

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CONDITION
BUZZING NOISE

SLIPS IN REVERSE ONLY

SLIPS IN FORWARD
DRIVE RANGES

SLIPS IN LOW GEAR 9D9
ONLY, BUT NOT IN 1
POSITION

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POSSIBLE CAUSES

Í#Î(Ï*Ð"Î

CORRECTION

1. Fluid Level Low.

1. Add fluid and check for leaks.

2. Shift Cable Misassembled.

2. Route cable away from engine and bell
housing.

3. Valve Body Misassembled.

3. Remove, disassemble, inspect valve
body. Reassemble correctly if necessary.
Replace assembly if valves or springs are
damaged. Check for loose bolts or screws.

4. Pump Passages Leaking.

4. Check pump for porous casting, scores
on mating surfaces and excess rotor
clearance. Repair as required. Loose pump
bolts.

5. Cooling System Cooler Plugged.

5. Flow check cooler circuit. Repair as
needed.

6.Overrunning Clutch Damaged.

6. Replace clutch.

1. Fluid Level Low.

1. Add fluid and check for leaks.

2. Gearshift Linkage Misadjusted.

2. Adjust linkage.

3. Rear Band Misadjusted.

3. Adjust band.

4. Rear Band Worn.

4. Replace as required.

5. Hydraulic Pressure Too Low.

5. Perform hydraulic pressure tests to
determine cause.

6. Rear Servo Leaking.

6. Air pressure check clutch-servo operation
and repair as required.

7. Band Linkage Binding.

7. Inspect and repair as required.

1. Fluid Level Low.

1. Add fluid and check for leaks.

2. Fluid Foaming.

2. Check for high oil level, bad pump
gasket or seals, dirt between pump halves
and loose pump bolts. Replace pump if
necessary.

3. Throttle Linkage Misadjusted.

3. Adjust linkage.

4. Gearshift Linkage Misadjusted.

4. Adjust linkage.

5. Rear Clutch Worn.

5. Inspect and replace as needed.

6. Low Hydraulic Pressure Due to
Worn Pump, Incorrect Control
Pressure Adjustments, Valve Body
Warpage or Malfunction, Sticking
Governor, Leaking Seal Rings,
Clutch Seals Leaking, Servo Leaks,
Clogged Filter or Cooler Lines.

6. Perform hydraulic and air pressure tests
to determine cause.

7. Rear Clutch Malfunction, Leaking
Seals or Worn Plates.

7. Air pressure check clutch-servo operation
and repair as required.

8. Overrunning Clutch Worn, Not
Holding (Slips in 1 Only).

8. Replace Clutch.

Overrunning Clutch Faulty.

Replace overrunning clutch.

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CONDITION
GROWLING, GRATING OR
SCRAPING NOISES

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POSSIBLE CAUSES

CORRECTION

1. Drive Plate Broken.

1. Replace.

2. Torque Converter Bolts Hitting
Dust Shield.

2. Dust shield bent. Replace or repair.

3. Planetary Gear Set Broken/
Seized.

3. Check for debris in oil pan and repair as
required.

4. Overrunning Clutch Worn/Broken.

4. Inspect and check for debris in oil pan.
Repair as required.

5. Oil Pump Components Scored/
Binding.

5. Remove, inspect and repair as required.

6. Output Shaft Bearing or Bushing
Damaged.

6. Remove, inspect and repair as required.

7. Clutch Operation Faulty.

7. Perform air pressure check and repair as
required.

8. Front and Rear Bands
Misadjusted.

8. Adjust bands.

1. Fluid Level Low.

1. Check and adjust level.

2. Clutch Dragging/Failed.

2. Air pressure check clutch operation and
repair as required.

3. Front or Rear Band Misadjusted.

3. Adjust bands.

4. Case Leaks Internally.

4. Check for leakage between passages in
case.

5. Servo Band or Linkage
Malfunction.

5. Air pressure check servo operation and
repair as required.

6. Overrunning Clutch Worn.

6. Remove and inspect clutch. Repair as
required.

7. Planetary Gears Broken.

7. Remove, inspect and repair as required
(look for debris in oil pan).

8. Converter Clutch Dragging.

8. Check for plugged cooler. Perform flow
check. Inspect pump for excessive side
clearance. Replace pump as required.

1. Fluid Level Low.

1. Add fluid and check for leaks.

2. Shift Cable Incorrect Routing.

2. Check shift cable for correct routing.
Should not touch engine or bell housing.

TORQUE CONVERTER
LOCKS UP IN SECOND
AND/OR THIRD GEAR

Lockup Solenoid, Relay or Wiring
Shorted/Open.

Test solenoid, relay and wiring for
continuity, shorts or grounds. Replace
solenoid and relay if faulty. Repair wiring
and connectors as necessary.

HARSH 1-2 OR 2-3
SHIFTS

Lockup Solenoid Malfunction.

Remove valve body and replace solenoid
assembly.

DRAGS OR LOCKS UP

WHINE/NOISE RELATED
TO ENGINE SPEED



  

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CONDITION
NO START IN PARK OR
NEUTRAL

NO REVERSE (OR SLIPS
IN REVERSE)

OIL LEAKS (ITEMS
LISTED REPRESENT
POSSIBLE LEAK POINTS
AND SHOULD ALL BE
CHECKED.

POSSIBLE CAUSES

CORRECTION

1. Gearshift Linkage/Cable
Misadjusted.

1. Adjust linkage/cable.

2. Neutral Switch Wire Open/Cut.

2. Check continuity with test lamp. Repair
as required.

3. Neutral Switch Faulty.

3. Refer to service section for test and
replacement procedure.

4. Neutral Switch Connect Faulty.

4. Connectors spread open. Repair.

5. Valve Body Manual Lever
Assembly Bent/Worn/Broken.

5. Inspect lever assembly and replace if
damaged.

1. Direct Clutch Pack (front clutch)
Worn.

1. Disassemble unit and rebuild clutch
pack.

2. Rear Band Misadjusted.

2. Adjust band.

3. Front Clutch Malfunctioned/Burnt.

3. Air pressure test clutch operation.
Remove and rebuild if necessary.

1. Speedometer Adapter Leaks.

1. Replace both adapter seals.

2. Fluid Lines and Fittings Loose/
Leaks/Damaged.

2. Tighten fittings. If leaks persist, replace
fittings and lines if necessary.

3. Filler Tube (where tube enters
case) Leaks/Damaged.

3. Replace O-ring seal. Inspect tube for
cracks in tube.

4. Pressure Port Plug Loose
Loose/Damaged.

4. Tighten to correct torque. Replace plug
or reseal if leak persists.

5. Pan Gasket Leaks.

5. Tighten pan screws to 150 inch pounds.
If leaks persist, replace gasket. Do no over
tighten screws.

6. Valve Body Manual Lever Shaft
Seal Leaks/Worn.

6. Replace shaft seal.

7. Rear Bearing Access Plate Leaks.

7. Replace gasket. Tighten screws.

8. Gasket Damaged or Bolts are
Loose.

8. Replace bolts or gasket or tighten both.

9. Adapter/Extension Gasket
Damaged Leaks/Damaged.

9. Replace gasket.

10. Neutral Switch Leaks/Damaged.

10. Replace switch and gasket.

11. Converter Housing Area Leaks.

11. Check for leaks at seal caused by worn
seal or burr on converter hub (cutting seal),
worn bushing, missing oil return, oil in front
pump housing or hole plugged. Check for
leaks past O-ring seal on pump or past
pump-to-case bolts; pump housing porous,
oil coming out vent due to overfill or leak
past front band shaft access plug.

12. Pump Seal Leaks/Worn/
Damaged.

12. Replace seal.

13. Torque Converter Weld
Leak/Cracked Hub.

13. Replace converter.

14. Case Porosity Leaks.

14. Replace case.

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CAUTION: Do not overfill transmission, fluid foaming and shifting problems can result.

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CAUTION: The drainback valve is a one-way flow
device. It must be properly oriented in terms of flow
direction for the cooler to function properly. The
valve must be installed in the pressure line. Otherwise flow will be blocked and would cause an overheating condition and eventual transmission failure.

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CAUTION: With the fluid set at the proper level,
fluid collection should not exceed (1) quart or internal damage to the transmission may occur.

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WARNING: WEAR PROTECTIVE EYEWEAR THAT
MEETS THE REQUIREMENTS OF OSHA AND ANSI
Z87.1–1968. WEAR STANDARD INDUSTRIAL RUBBER GLOVES.
KEEP LIGHTED CIGARETTES, SPARKS, FLAMES,
AND OTHER IGNITION SOURCES AWAY FROM THE
AREA TO PREVENT THE IGNITION OF COMBUSTIBLE LIQUIDS AND GASES. KEEP A CLASS (B) FIRE
EXTINGUISHER IN THE AREA WHERE THE
FLUSHER WILL BE USED.
KEEP THE AREA WELL VENTILATED.
DO NOT LET FLUSHING SOLVENT COME IN CONTACT WITH YOUR EYES OR SKIN: IF EYE CONTAMINATION OCCURS, FLUSH EYES WITH WATER FOR
15 TO 20 SECONDS. REMOVE CONTAMINATED
CLOTHING AND WASH AFFECTED SKIN WITH
SOAP AND WATER. SEEK MEDICAL ATTENTION.

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NOTE: When flushing transmission cooler and
lines, ALWAYS reverse flush.
NOTE: The converter drainback valve must be
removed and an appropriate replacement hose
installed to bridge the space between the transmission cooler line and the cooler fitting. Failure to
remove the drainback valve will preventreverse
flushing the system.

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CAUTION: The transmission and torque converter
must be removed as an assembly to avoid component damage. The converter drive plate, pump
bushing, or oil seal can be damaged if the converter is left attached to the driveplate during
removal.

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damaged during transmission removal (or installation) if the sensor is still bolted to the engine block.
To avoid damage, remove the sensor before removing the transmission.

Fig. 16 Crankshaft Position Sensor—2.5L Engine

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è ìå&æßà&×"Ù æ—à&Ù ã†Úc× å&Ý × å›Ü ìäzÞ
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Fig. 18 Typical Method Of Checking Converter
Seating

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CAUTION: Be sure the converter housing is fully
seated on the engine block dowels before tightening any bolts.

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lifting device or work surface, the center of gravity
of the transmission will shift when the torque converter is removed creating an unstable condition.
The torque converter is a heavy unit. Use caution
when separating the torque converter from the
transmission.

CAUTION: Do not damage oil pump seal or bushing
while inserting torque converter into the front of the
transmission.
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33 Governor Body
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Fig. 34 Park Lock
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Fig. 36 Snap Ring, Washer, and Outer Weight
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CAUTION: Exercise care when installing the rings.
They are easily broken if overspread or twisted during installation.

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CAUTION: Do not clamp any part of the valve body
assembly (Fig. 39) in a vise. This practice will distort the valve body and transfer plate resulting in
valve bind. Slide valves and plugs out carefully. Do
not use force at any time. The valves and valve
body will be damaged if force is used. Also tag or
mark the valve body springs for reference as they
are removed. Do not allow them to become intermixed.

Fig. 37 Inner Weight Snap Ring

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t`jv ]_KZX;cn‡K]_KDRnWYMOfKZax¼cDcZe YŠYYu [¼ PoKZf—alKZX;cn‡KWYfV
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]_KZX;cn‡K/RTPalcZRTRTeOK4eOKn‡KZa MONQ[ [

Fig. 38 Intermediate and Inner Governor Weights

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39 Valve Body Assembly
st ¨j¹jv ]_KZX;cnFig.
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Fig. 40 Adjusting Screw Bracket, Springs, Valve
Removal

Fig. 41 Securing Detent Ball And Spring With
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Fig. 43 Manual Valve

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Fig. 45 Converter Clutch Solenoid

Fig. 48 Valve Body Transfer Plate Screws

Fig. 46 Clutch Module And Connecting Tube

Fig. 47 Converter Clutch and Fail Safe Valves

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Fig. 51 Shuttle Valve End Plate

Fig. 52 Shuttle Valve E-Clip And Secondary Spring

CAUTION: Do not force valves or plugs into place
during reassembly. If the valve body bores, valves,
and plugs are free of distortion or burrs, the valve
body components should all slide into place easily.
In addition, do not overtighten the transfer plate
and valve body screws during reassembly. Overtightening can distort the valve body resulting in
valve sticking, cross leakage and unsatisfactory
operation. Tighten valve body screws to recommended torque only.

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Fig. 56 Rear Servo and Rear Clutch Check Balls

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Fig. 59 Valve Body Transfer Plate Screws

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Fig. 64 Securing Detent Ball And Spring With
Retainer Tool

Fig. 67 Manual Valve And Throttle Lever Alignment

Fig. 65 Manual Valve

Fig. 68 Adjusting Screw Bracket, Springs, and
Valves

Fig. 66 Manual And Throttle Levers

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NOTE: The 32RH is equipped with an additional
spring under the accumulator piston.

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Fig. 69 Repair Stand

Fig. 72 Front Band Adjusting Screw Lock Nut

Fig. 70 Park/Neutral Position Switch

Fig. 73 Oil Pump/Reaction Shaft Support

Fig. 71 Accumulator Piston And Spring

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Fig. 74 Front Band Strut
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;X>#%$'&)(+*-,.&%&ZY.14&C268IL*)C[72*)0\68ILC2K]:<=*)(^1-<=9;C26>(+IL686>IL*)C
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Fig. 76 Separating Front Clutch From Rear Clutch

;g>#%$'&)(+*-,.&h*021435021i687\9A:B1j9;C2Dk35@L9AC\&)149A<baKV&9A<=14<=9;ILC
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6>S=<=9;1-S=72&D5M

Fig. 77 Output Shaft Thrust Plate and Washer
;x>#%yJ**)6>&)Cl<=&)9;<]F;9;C2Dz9;D|{026>1-ILC2K}68S=<&ZE~_AvBg1-0\<=C26
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D5<=0\(~1-*<=&)9;<R6>023535*<=1o7202F;„i72*ZE
&Z,.&<RD5*C2*)1o<=&)(+*-,.&

Fig. 75 Front/Rear Clutch Assemblies

D5<=0\(
HUILKVMPW"!#M

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Fig. 78 Front Band

Fig. 80 Rear Band Adjuster Location

Fig. 79 Planetary Geartrain

Fig. 81 Low-Reverse Drum Snap Ring

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Fig. 82 Rear Support

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Fig. 85 Rear Band and Link—30RH

Fig. 83 Overrunning Clutch Cam Bolt Locations

Fig. 86 Rear Band and Link—30RH
2I—68j„UYWXHJb˜UYHJEF]/egBDWXHJbu]0cXWg9Bik
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]/W ?A=S„rBD=;
S`BDEFHJUY;>WXUVUYWX=<HZmDEFUY9C2x#WXbdK}–FQV6K
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;>WXUYUVWX=<HJK

Fig. 84 Low- Reverse Band and Drum—32RH
!#"%$&"')(+*-,/.0!1
2354687:9<;>=@?A9CBD9EFBG0EFHJI0KMLONJ9P30QF7:RTS@BDEFHJUV;>WXUYUVWX=<HZWXU
9<[F\JWX]0]/9<I>^_WXS`NEaUVWXHJbdcX9e ^_BDEF]8G0EFHJI>^_WXS`NEfcgWXHJh-G0EFBiK
2EV68j!UVWgHMb8UVHJEF]/eBDWXHJba]/cXWX9<Bik:]/\McgcOBD9EFB>GFE0HJIlEFHJmDNJ=B
]/WXHn2cX=mDE0S`9<Il=<HnS`NJ9oUV9<Bp?A=qUYWXI/9q=<rsS`NJ9oBD9EFBPUV\J]/]0=<BDSt6
rBD=;
S`BDEFHJUY;>WXUVUYWX=HmDEFUY9K

Fig. 87 Front Band Reaction Pin Access Plug

2GV687:9<;>=@?A9nBD9EFBlGFEFHJIuEFHJIucXWXHJhvrBD=<;wS`BDEFHJUY;>WXUVe
UYWX=H2gxyWXbdK&z0{V6K
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cX9? 9<BDUVKJ…+cXcS@BDEFHJUV;>WXUYUVWg=H†m=<;>]/=HJ9<HMS@UomDEFH‡G098UV9<Bp? WgmD9I
^_WXS`NJ=<\MS„BD9<;>=@?AWXHJboS@NM9ˆcX9@?A9BDUYK
2EV68j!UVWgHMb
E4i‰iŠ‹WXHJmDNŒI/BDW ? 99@ŽAS`9<HJUVWX=<HŒBD9<;>=@?A9
rBD=HJS„GFEFHJI-BD9EFmDS@WX=H]0WgHZEFmDmD9<UVU_]/cX\Jbo2x#WgbK}zFV6K
2GV687:9<;>=@?A9lrBD=HJSPG0EFHJI‘BD9<EFmDS`WX=<Hu]0WgHZ^_WXS`Nu]/9HJmDWXc
;>EFbdHJ9S@K+’#WgH“WXUZEFmDmD9UYUVWXG0cX9nrgBD=<;wmD=H”?A9<BS@9BlNM=<\JUVWXHJb
UYWXI/9C=rOmE0UV9C2xyWXbK}zFzY6•K
2mp687:9;>=?A9CrgBD=<HJS„GFEFHJI8cX9?A9B
2gxyWXbdK&z0–V6K

Fig. 88 Front Band Reaction Pin

5*6
78:9<;>=@?.A =<=BA C>;D9<;FEG78:9<;H=JIKL8GM@9<=JK
SUTVXW(VXVXYXZ[]\^_W(`aS_W(VXVXYXZb[(\^dcfe(gBhBikj hBlBmBnBo

NLOPQOOLR

Fig. 89 Front Band Lever

Fig. 91 Compressing Front Servo

Fig. 90 Rear Band Servo Lever Pin
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Fig. 92 Compressing Rear Servo Spring
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Fig. 93 Clutch Cam Alignment

Fig. 94 Rear Support

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Fig. 98 Front and Rear Clutches

Fig. 96 Output Shaft And Planetary Geartrain

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Fig. 99 Output Shaft Thrust Plate

Fig. 97 Input Shaft Seal Ring Location

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Fig. 100 Assembling Front And Rear Clutch Units

Fig. 103 Front Band

Fig. 101 Output Shaft Thrust Washer
Fig. 104 Installing Front/Rear Clutch

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Fig. 102 Aligning Rear Clutch Disc Lugs

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æçè é3êlëì/íYîïXð(ð ñxòIóì/ô~ëõJõ íYö"÷ð&íYøAù/ð&ï5úEù/û5íYõn÷ëù/ô~ëü5ø
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CAUTION: The thrust washer bore (I.D.), is chamfered on one side. Make sure the chamfered side is
installed so it faces the pump.

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eJ˜2‘`h©
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uoyz§‰|Š‰ ˆ uozqi?yŒj0qlo‡ ˆ uozq}±nzq}l"km‡0nq}l"z ¥¨y‡²pynŒ–uo‡0nz
‰nqq}l"km‡quŽ„’*³•´ ŠTeŸ‘µ*‹Jq¢z ˆ  h[

Fig. 105 Front Band Linkage Installation

Fig. 108 Installing Pilot Studs And Oil Pump Gasket

Fig. 106 Reaction Shaft Support Seal Rings

Fig. 107 Front Clutch Thrust Washer Installation

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ˆ uozq<j0u"zlovy‡u"yz?‰|0Š‰‹Jzn‡0ŒlŽe.yŒ‘’gh[
eJf“h”•zyŒ–‡n‡0py‡0q}nzz?uoyz?‰|0Š‰Œn—Aloq<e.yŒ‘’gh[

Fig. 109 Installing Oil Pump And Reaction Shaft
Support

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™}š

NOTE: If end play is incorrect, transmission is
incorrectly assembled, or output shaft thrust
washer and/or thrust plate are worn and need to be
changed.

ÜJÝÞߕàà}Ýámâ#ãäÝå¬äæ0ãäámÝàçoè¨ÜJéƒêëëëìÞ«à}çámçoæîíïoèmàïoè
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ÜJüÞýHç}í6ïMäæ0öð0à%ñâ0Ýøà%äæ¬Ýæ0ã­ç"ð0à%Ýæã­èmïoá[çoèmã­è[ïoÝãê
äæ0òó<þƒæ0ã=öåÝÿ$ñâ0çoð0åã=üï ó ¨ê ó ë
Ü ó =ê
ó ì väæ0ó Þ[ó



   




Fig. 111 Removing Overrunning Clutch From
Low-Reverse Drum

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üå ÿ®ç"æ¨åçRêJèmï}í6ïoèmñï¬ãèmðI

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 êJèmï
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o(qsrte d rutv o bGj f>oX] j r h o d q
bGcaqad fwe rtuxdIh4v iMh4jlq k ] jm_aj e]Lnp
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j h d iIb"| j j k d k d h}dMk iMbGj~

 Fig. 110 Checking

Input Shaft
 End
 Play

 
 
 
 

 

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àâ0ïŽç
íïoèmèmðæ0æ0äæ0òHámåð0à}á[âèmÝámï"ó
Fig. 112 Overrunning Clutch Rollers, Springs,
Retainer
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Fig. 113 Assembling Overrunning Clutch And Cam

Fig. 115 Assembled Overrunning Clutch

ê$ëì"ê+í0ë ê î^ï+ð0Fig.
ñ(í0ò 116
ï$ó Front Servo
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Fig. 114 Temporary Assembly Of Clutch And Drum
To Check Operation

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Fig. 117 Rear Servo Components

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k)‘c}€ ’+lAl¡ym¢’

Fig. 120 Separating Pump Housing From Reaction
Shaft Support

Fig. 121 Pump Gear Removal
Fig. 118 Removing Pump Seal Ring

Fig. 122 Support Hub Thrust Washer

Fig. 119 Pump Support Bolts

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Fig. 123 Removing Oil Pump Bushing
Fig. 125 Replacing Reaction Shaft Support Bushing
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Fig. 124 Staking Oil Pump Bushing
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CAUTION: The pump inner gear is a one way fit.
The bore on one side of the gear inside diameter
(I.D.) is chamfered. Be sure the chamfered side
faces forward (to front of pump).
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Fig. 126 Supporting Pump And Installing Outer Gear
Fig. 129 Assembling Reaction Shaft Support And
Pump Housing
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Fig. 127 Pump Inner Gear Installation
CAUTION: The reaction shaft support seal rings
will break if overspread, or twisted. If new rings are
being installed, spread them only enough for installation. Also be very sure the ring ends are securely
hooked together after installation. Otherwise, the
rings will either prevent pump installation, or break
during installation.

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Fig. 130 Pump Oil Seal Installation
Fig. 128 Hub Seal Ring Position

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Fig. 131 Front Clutch Components

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Fig. 132 Compressing Front Clutch Piston Spring

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Fig. 133 Front Clutch Piston Installation

Fig. 134 Clutch Piston Spring Installation
Fig. 136 Measuring Front Clutch Pack Clearance

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Fig. 135 Correct Spring Retainer Installed Position

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Fig. 137 Rear Clutch Components

åæ ç èkéêtë}ì™érí6î"ï ï0ðñòí6óï ô0ðñ õ5ë3î$ñ éí6öñ÷
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ñ ð é3ïrô0óé3ññnõë3ëö[õ5ë„ñ ù"ô0ôëóõkõ5úé„óéõí6ðî"éóší6ñnòöëñ é„õë„õú"é
ðî"ô0ùõnñú"í6ûõní6ñtô0ë3ññ ð öé3÷

Fig. 138 Removing/Installing Input Shaft Snap-Ring

 
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This will fold the seals over causing leakage and
clutch slip. In addition, never use any type of metal
tool to help ease the piston seals into place. Metal
tools will cut, shave, or score the seals.
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Fig. 140 Input Shaft Seal Ring Identification

Fig. 139 Rear Clutch Retainer And Input Shaft Seal
Ring Installation

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Fig. 141 Pressing Input Shaft Into Rear Clutch
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Fig. 146 Front Planetary Snap Ring Removal

Fig. 147 Front Planetary And Annulus Gear
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Fig. 149 Assembling Rear Annulus And Planetary
Gear

Fig. 148 Removing Driving Shell, Rear Planetary
And Rear Annulus

Fig. 150 Installing Rear Annulus And Planetary On
Output Shaft

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Fig. 151 Installing Rear Planetary Front Thrust
Washer

Fig. 154 Installing Driving Shell Rear Thrust Plate

Fig. 152 Installing Spacer On Sun Gear

Fig. 155 Supporting Sun Gear On Wood Block

Fig. 153 Installing Driving Shell Front Thrust Plate
On Sun Gear

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Fig. 156 Installing Sun Gear Lock Ring

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Shell On Output Shaft

Fig. 159 Installing Front Planetary And Annulus
Gears

Fig. 158 Installing Rear Thrust Washer On Front
Planetary Gear

Fig. 160 Positioning Thrust Plate On Front Annulus
Support

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Fig. 161 Installing Front Annulus Thrust Washer

Fig. 162 Installing Front Annulus Snap Ring

Fig. 163 Installing Planetary Selective Snap Ring

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Fig. 167 Park Sprag, Shaft And Spring

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Fig. 168 Park Sprag Reaction Plug And Spring
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Fig. 170 Valve Body Components

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NOTE: Inspect the clutch retainer bushings carefully (Fig. 174). The retainer bushings are NOT serviceable. It will be necessary to replace the retainer
if either bushing is scored, or worn.

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Location

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Fig. 175 Shift Cable Attachment At
Transmission–Typical

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Fig. 176 Park Lock Cable Attachment

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Fig. 177 Throttle Cable Attachment At Engine

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NOTE: Be sure that as the cable is pulled forward
and centered on the throttle lever stud, the cable
housing moves smoothly with the cable. Due to the
angle at which the cable housing enters the spring
housing, the cable housing may bind slightly and
create an incorrect adjustment.

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ë Gí ñ9üGô ð@÷Nô Bò;ñ9ò;ñ9ó ;ò;ûfõNñ9ô>õ ;÷ 9õIïmüEò;ñ9óý
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ë GíFî ònó 9ô>÷Iñ Bñ ï9üEô>ò;ñ9óŽü @ð@÷ ¢ôeõ
™ë Bþ-ònñmý
BüEý í ô>õNð ]ïm÷ ònô ñ
iõIï9ñ îpõNð ]ïm÷ Jð@÷Nñ
ò;ñ9ý÷ Xô>÷IñmüEò;õIñ Bñ Eì ŽüGõ @ö÷Iô>ý
CAUTION: If Adapter C-3705 is needed to reach the
adjusting screw (Fig. 180), tighten the screw to only
5 N·m (47-50 in. lbs.) torque.
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ë Gí @ö—õ ð@õNñ9ô ]ñ ï9üEô>ò;ñ9óˆü @ð@÷ …þ 4ì
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õNðô 9÷ ]ÿ ]ñ fþ 4ì Žô>ï9ð@ñ9ü õNðô 9÷ BþBÿ Šý
ë Gí õ
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;õ @öñ9ï9ô)ô>õ ì ¢ë ô>ý BüEý íŠôeõNð Bï9÷Iý
ë Gí iõ U÷Nð ,÷ 9ò ;÷Iý

Fig. 179 Front Band Adjustment Screw Location

NPORQOPSPT

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YZ[ Y7Y5[ \
X]W7X_^`UV/W7X
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Fig. 180 Band Adjustment Adapter Tool
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å:æTç(è Ó!×Õ3Ð݊Ð
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å éç(è ÐÖ"Ø݊ÐÑÒ Ó!Ô#Õ3Ö×ÕÕ3×ØÔtØ×Ù1ÚÓ!ÔxÓ!Ô#Þ(ÞÒ Ó!×ÔxßÙÛ×Þ*ä
å êç(ë ØØÕÐÔwÜ!Ó!Ô#Þ;Ó*ÞKá
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Fig. 181 Rear Band Adjustment Screw Location
make it necessary to vary from this dimension to
obtain desired pressure.
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Fig. 182 Line Pressure Adjustment

NOTE: The 33.4 mm (1-5/16 in.) setting is an
approximate setting. Manufacturing tolerances may

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NOTE: The kickdown valve spring must be fully
compressed and the kickdown valve completely
bottomed to obtain correct adjustment.

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¿ÀÁoÂÃÄoÅ7ÆÈÇÊÉÇ¿oË7ÌlÃ5Í7ÆÈÇÉ
Fig. 183 Throttle Pressure Adjustment

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COMPONENT

METRIC

INCH

Oil pump gear tip clearance

0.089-0.190 mm

0.0035-0.0075 in.

Planetary end play

0.125-1.19 mm

0.001-0.047 in.

Input shaft end play

0.56-2.31 mm

0.022-0.091 in.

Clutch pack clearance/Front 4-disc.

1.70-3.40 mm

0.067-0.134 in.

Clutch pack clearance/Rear 4-disc.

0.559-0.940 mm

0.022-0.037 in.

Front clutch spring usage
32RH-Front Band adjustment from 72 in. lbs.

1 spring
Back off 2.25 turns

32RH-Rear Band adjustment from 72 in. lbs.

Back off 4 turns

30RH-Front Band adjustment from 72 in. lbs.

Back off 2.5 turns

30RH-Rear Band adjustment from 41 in. lbs.

Back off 7 turns

Recommended fluid

SET NUPV S-W OXV T JYNPZV\[]O_^RJMNPZVRLPO\[`NabLPIdcHae$JMLPVRa fKLPV
COMPONENT

MoparT, ATF Plus 3, Type 7176

METRIC

INCH

Front clutch thrust washer (reaction shaft support hub)

1.55 mm

0.061 in.

Rear clutch thrust washer (clutch retainer)

1.55 mm

0.061 in.

Output shaft thrust plate (output shaft pilot hub)

1.5-1.6mm

0.060-0.063 in.

Output shaft thrust washer (rear clutch hub)

1.3-1.4 mm

0.052-0.054 in.

1.7-1.8 mm

0.068-0.070 in.

2.1-2.2 mm

0.083-0.086 in.

1.5-1.6 mm

0.06-0.062 in.

1.7-1.8 mm

0.068-0.070 in.

1.9-2.0 mm

0.076-0.078 in.

1.0-1.1 mm

0.040-0.044 in.

1.6-1.7 mm

0.062-0.066 in.

2.1-2.2 mm

0.082-0.086 in.

Rear clutch pack snap ring

Planetary geartrain snap ring
(at front of output shaft)

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ITEM

RANGE

PRESSURE

Line pressure (at
accumulator)

Closed throttle

372-414 kPa (54-60 psi).

Front servo

Third gear only

No more than 21 kPa (3 psi) lower than line pressure.

Rear servo

1 range

No more than 21 kPa (3 psi) lower than line pressure.

R range

1103 kPa (160 psi) at idle, builds to 1862 kPa (270 psi)
at 1600 rpm.

D range closed throttle

Pressure should respond smoothly to changes in mph
and return to 0-7 kPa (0-1.5 psi) when stopped with
transmission in D, 1, 2. Pressure above 7 kPa (1.5 psi)
at stand still will prevent transmission from
downshifting.

Governor

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Installer—6951

Retainer, Detent Ball and Spring—6583

Remover—6957

Snap-ring Plier—6823

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Pilot Stud—C-3288-B

Pressure Gauge—C-3292

Pressure Gauge—C-3293SP

Dial Indicator—C-3339

EGF

Spring Compressor—C-3422-B

Fixture, Engine Support—C-3487-A

Spring Compressor—C-3575-A

Spring Compressor—C-3863-A

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Adapter, Band Adjuster—C-3705

Seal Installer—C-3860-A

Transmission Repair Stand—C-3750-B

Bushing Remover/Installer—C-3887-J

Puller, Slide Hammer—C-3752

Cup, Remover—SP-3633

Gauge, Throttle Setting—C-3763

Remover, Bushing—SP-5301

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Installer, Bushing—SP-5118

Installer, Bushing—SP-5511

Installer, Bushing—SP-5302

Snap-ring Plier—C-3915

Remover, Bushing—SP-3550
Seal Remover—C-3985-B

Remover, Bushing—SP-3629
Bushing, Remover—6957

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Flusher, Oil Cooler—6906

Universal Handle—C-4171

Installer—C-3995-A

Remover/Installer—C-4470

Nut, Bushing Remover—SP-1191

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NV231 TRANSFER CASE

ÌÍ#Î#ÏÑÐ
page
GENERAL INFORMATION
NV231 TRANSFER CASE . . . . . . . . . . . . . . . .
RECOMMENDED LUBRICANT AND FILL LEVEL
TRANSFER CASE IDENTIFICATION . . . . . . . .
DIAGNOSIS AND TESTING
NV231 DIAGNOSIS . . . . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION
FRONT OUTPUT SHAFT SEAL . . . . . . . . . . .
SHIFT LEVER . . . . . . . . . . . . . . . . . . . . . . . . .
SPEEDOMETER . . . . . . . . . . . . . . . . . . . . . . .
TRANSFER CASE . . . . . . . . . . . . . . . . . . . . .

. 166
. 167
. 166
. 167
.
.
.
.

169
168
169
168

page
DISASSEMBLY AND ASSEMBLY
NV231 TRANSFER CASE . . . . .
CLEANING AND INSPECTION
NV231 TRANSFER CASE . . . . .
ADJUSTMENTS
SHIFT LINKAGE ADJUSTMENT
SPECIFICATIONS
TORQUE . . . . . . . . . . . . . . . . .
SPECIAL TOOLS
NV231 . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . 170
. . . . . . . . . . . . 185
. . . . . . . . . . . . 187
. . . . . . . . . . . . 189
. . . . . . . . . . . . 189

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Condition
Transfer case difficult to shift or will
not shift into desired range.

ìíCîïlðñsòuíCòMótôsîtõ-ö
Possible Cause

Correction

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.

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.

1) Extended operation in 4H mode
on dry surfaces.

1) Operate vehicle in 2H mode on
dry surfaces.

Lubricant leaking from transfer case
seals or vent.

Abnormal tire wear.

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Fig. 5 Location Of Index Numbers On Speedometer
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Fig. 8 Rear Slinger Removal

Fig. 11 Output Shaft Rear Bearing Retaining Ring

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Fig. 9 Slinger Stop Spacer and Snap-ring

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Fig. 15 Yoke Nut Removal

Fig. 13 Oil Pump Removal

Fig. 16 Yoke Removal

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Fig. 20 Oil Pickup Tube Removal

Fig. 18 Rear Case Alignment Bolt Locations

Fig. 21 Mode Fork Spring Removal

Fig. 19 Loosening Rear Case

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Fig. 22 Remove Front Output Shaft And Chain

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Fig. 23 Detent Plug, Spring And Plunger Removal

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Fig. 25 Range Fork And Hub Removal

Fig. 26 Shift Sector Removal

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Fig. 27 Sector Bushing And O-Ring Removal

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ëlì3írîŸï'ð8ñ ïrïñ òŸî`írî[óRëlì3írîgïFô*õ‡ìRö'írïFõ ÷‡øMùkø*ú‡û
ü9ýþOÿþOþ²ÿ
zü²ÿþOþ 



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× Ä"ÄØ;ÂIÙ$ÎBÊNÚÜÛ*ÈÕÔ5ÊKÄÄ × Û*ÄØ;ÎBÊKÎ7ÄÉ3Â"ÝÎBÉØ × ÄÊNØ$Í2ÊIÂÍQÞ ÚÂ"É3ÝÄ"Æ
È.ÂÊNÍ2ÎBÉ3Â"Ⱦß@ÎBÏDÑgà2¿À Ñ

Fig. 28 Mode Hub Retaining Ring Removal

Fig. 31 Front Bearing Retainer Bolts

Fig. 29 Mode Hub Removal

¾ àÀÁ Fig.
Â"Ã(ÄN32Å'Â0Front
ÆÈ.Ä"ÉVÊBearing
Ë2Â"Í2È.ÎBÉ3ÏÌRetainer
È.Â"ÊKÍQÎBÉVÂ"ÈRemoval
Ø;ÂÍ × ÑkágÍ2ÛaØ;ÂÍ ×
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¾çÀÓ × Í2Þ.ÂÌÆÈ.ÄÉ3ʓÞ.Í2ØÂjÎBÉcÚ3Ä"È Î7è^ÄÉ3ÊKÍ × Û*Ä"ØÎBÊNÎBÄÉ3Ñ[áYÚ3Â"É
È.ÂÃ(Ä&Å'ÂzÎBÉ3Û*â3ÊIÏDÂÍ2È$Í2É3Ý × Ä&ÙfÈ.Í2É3ÏDÂzÏDÂ"Í2È$Í2Ø(ÍQÉÍQØØ;ÂÃ(æ
Ë × ÔǾß@ÎBÏDÑà2ãÀ ÑYágÍ2ÛäÏDÂÍ2ÈÜÄ"â3ÊMÄÆZË2Â"Í2È.ÎBÉ3ϓÙ$ÎBÊKÚ`Û × Í2Ø;ÊKÎBÞ
Ã(Í ×B× ÂÊ[ÎBÆYÉVÂ"Þ.ÂØ;ØÍQÈÕÔvÑ
Fig. 30 Drive Sprocket Removal

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Fig. 33 Removing Input Gear Retaining Ring

Fig. 35 Input Gear Snap-Ring Removal

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Fig. 34 Input Gear And Planetary Carrier Removal

Fig. 36 Input Gear Retainer Removal

CAUTION: The bearing bores in various transfer
case components contain oil feed holes. Make sure
replacement bearings do not block the holes.

Fig. 37 Front Tabbed Thrust Washer Removal





   
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Fig. 38 Input Gear Removal

Fig. 40 Front Output Seal Removal

Fig. 39 Rear Tabbed Thrust Washer Removal

Fig. 41 Front Output Shaft Bearing Retaining Ring
Removal

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Fig. 42 Front Output Shaft Bearing Removal

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º+»-¼½/¼¼¾¿3À5Á7Â8½/Ã:º8½/¼¼¾¿;À/Á7Â=Ä?Å/ÆÇÈDÉEÇÊËÌÍ

Fig. 43 Front Output Shaft Bearing Installation

Fig. 46 Output Shaft Rear Bearing Removal

Fig. 44 Installing Output Shaft Front Bearing
Retaining Ring

Fig. 47 Output Shaft Rear Bearing Installation

Fig. 45 Front Output Seal Installation

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ùúûüýþÿ ýýÿ üûüùúûüý!úûý

÷ ø



 

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܂ÓDÝjޙÝjØäŽäeÞh× Ö×mØܔÛ^æÓ5àjÓSÝjÞh×mØܔÕDÚÛçU×mÛ[æ|Û^æÓ5äeÞh×må-ېÝjØäŽÝ
æÝjÔYÔYÓDÞ5Î-èy×m܂éêÏEÑ?é
Î?ÏMëMÑOìWØâMÛ[ÝjßmߙØÓ[çíÙe×mßfÕDÛYàjÓSÝjÞh×mØ܎çU×mÛ[æ‹ìWØâMÛ^ÝeßmßmÓSގêjîeïjê
ÝjØäOð ÝjØäeßfӖñQòfëyÏMóÏUÎ-èy×m܂éêjôMÑ?é

Fig. 48 Output Shaft Rear Bearing Installation Depth

Fig. 51 Remove Input Gear Pilot Bearing

Fig. 49 Input Shaft Bearing Removal

Fig. 52 Install Input Gear Pilot Bearing

Fig. 50 Seating Input Shaft Bearing

?Î ÏMÐMÑOÒQÓSÔYÕ[ÖÓ&×mØÙÚÛ/܂ÓDÝjޖÙ×mßmÕSÛ/àjÓSÝjÞh×mØÜàMá‹×mØâMÓSÞhÛ^×mØÜ
ÝYâMÚ×mÛ[Ýjàjß á|âM×mãvÓSä”äÞh×må-ÛQ×mØÛ^Õ Û^æÓpâaÙeßm×fØcÓSä”ÓSØä”ÕSåyÛ[æcÓ ×mØÙeÚÛ

?Î ÏMêMÑOÒQÓSÔYÕ[Öӎå-ÞhÕDØÛpàjÓSÝjÞh×mØÜ|ÞhÓDÛ[Ýj×mØÓDÞYâMÓSÝjßyç5×fÛ^æ;âaÚc×fÛ^ò
ÝjàjßfӖÙÞ-áˆÛ^ÕSÕDßmé
Î?ÏMïMÑOìWØâMÛ[ÝjßmßYØÓ[çõå-Þ?ÕSØÛ&àjÓSÝjÞh×mØ܋ÞhÓSÛ^Ýj×fØcÓSޕâMÓSÝjßç5×fÛ^æ
ìWØâMÛ^ÝeßmßmÓSÞ/ójöeöjë|Îfè×m܂é êeÐMÑ?é

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Fig. 55 Installing Rear Bearing In Retainer

Fig. 53 Install Front Bearing Retainer Seal

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MVUTOPTZWn;>EGJMNDYHNPTFVF _$D7;>EGZ[;>xb
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EGJK;|OJK?>O^;>JKF _$EGFNMVW…UT;>x:MVUW…;>EGJUT?.Z[œKRT;>D7b
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JKMVUTWnb

Fig. 54 Oil Pump Seal Installation

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{<}qv576v5YEGUTxƒdBUTDjZ[EGFVFN;.JoGG„Gqf4l~MNW…b†oGo78(b
‡ ˆT‰GŠŒ‹zvˆTŽ.Œ‘“’ŒvˆT”T•z”T•B~’€v–^–G•.—™˜GVš
4(5/8:›~PT]GJKMNœ(E^Z[;Wn;.EGJKDEGUTx‚Z[RTJKPTD7ZXYEGD7RT;>JKDt4l~MNW…boG„78
XYMVZ[RJ(;>œK?>=Y=@;>UTx;.x:ZBJKEGUTD7=@MVDjD7MN?.UtHFVPTMVxb
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4l~MVWnbTo^„78(bTŸ<;€DjPQJK;XYEGDjRQ;>J™ZBEG]GDEGJK;€OJK?.O;.JKF _fEGFVMVWnUT;.x|MNU
Wn;.EGJUT?.ZBœKRQ;>D7b

Fig. 56 Input/Low Range Gear Components

‡ ˆT‰GŠŒ‹#”T•ev’€~ˆQŽ.Œ‘“’ŒvˆT”T•z”T•B~’¦‡ ˆT–7‹K~.e.‹Q‡ Tˆ
4(5/8@§¤FVMVWnUkEGUTxMVUTD7ZBEGFVFFN?BX¨JKEGUTW…;e©£MVUTOPTZYWn;.E^J¦EGD7Dj;.=@}
]GF _SMVU‚HNJK?>UTZ|œKEGD7;4NlmMVWnbo^678(bŸ<;D7PTJK;tFN?BX&J(E^UQWn;tWn;>EGJ
OMVUTMV?>UQD|EGJK;;.UTWnEGWn;.xtMVUaE^UQUTPTFVPTD|W…;>EGJ@EGUTxtZBRQE^ZzMVUTOPTZ
Wn;.EGJD7RTE^HNZMVDYHPTFVF _aD7;>EGZ[;>x:MVUHNJK?>UTZ]G;.E^JKMVUTW…b
4w78:deUTD7Z[E^FVFDjUTEGO}NJKMVUTWZB?ƒRQ?>FVxMVUTOPTZª©£FV?eX¨JKEGUTWn;:Wn;>EGJ
MVUTZ[?#HNJK?>UTZ]^;.EGJKMNUQW
4NlmMVWnbpo^c78«b

8:9
W(XZY%[\Y%Y%]%^`_badce[\fWe[\Y%Y%]%^-_\adchgji\kElEmn2lEoEpEqEr

Fig. 57 Input/Low Range Gear Installation

;=<
>?A@7BDC @@EC FA?G>?IHJ;=<
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QORTSURNVOR

Fig. 59 Install Front Bearing Retainer

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ßKØ.ÞBÙGàVÚTàVÚTÛßKàVÚTÛàNÜYãNâT×V× í$Ü7Ø>ÙGÞBØ.á:àNÚtå@ÙGàVÚTÜjéQÙ^ãNÞÛnßKä.äeõCØ.ê

 !#"
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)*!+!# #
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ÚTØeø Ü7Ø>èKÞ[ä>ßÜjéQÙ^ãNÞ-,.NßKàNÚQÛuÙ^ÚQáiòGâTÜ7éTàVÚTÛ
Óû~àVÛnê†ù /7Õ(ê

Fig. 58 Install Snap-Ring

Ó Ô7Õ:Ö<×VØ>ÙGÚsÛnÙGÜ7ÝQØ.ÞÜ7Ø>ÙG×VØ>ß|ßKØ>Ü7àVáâTØfãNßKä>åæßKØ>Þ[ÙGàVÚTØ>ß|ÙGÚTá
àVÚTÜ7çØ>èKÞßKØ.Þ[Ù^àVÚTØ.ßãNä>ßè(ßKÙ^èKÝ ÜYä.ßä>Þ[éTØ.ßáÙGå@ÙGÛnØ.ê
Óë7Õ@ì¤çç^× íaكÔ:å@åîÓ«ï/ð[ñ:àVÚTê ÕòGØ>ÙGáä>ãó¦ä>ç^Ù^ß ÛnÙGÜ7ÝQØ.Þ
å@ÙGÝ Ø>ßôä>ß\ÜjàV×VàNè(ä>ÚTؓÙ^á^éTØ>Ü7à õCØhÞ[ähÜ7Ø>ÙG×VàVÚTÛ!Ü7âTtßKãÙGèKؓä>ã
ßKØ.ÞBÙGàVÚTØ>ß/ê
Óö7Õ@ì¤×VàVÛnÚèKÙ7õCàVÞªí÷àVÚkÜ7Ø>ÙG×ßKØ>Þ[ÙGàNÚQØ>ßzøYàVÞ[éã×VâTàVáaßKØ>Þ[âTßKÚ
éTä.×NØ|àVÚtãßKä.ÚTÞä>ãèKÙGÜjØ.ê
CAUTION: Do not block fluid return cavity on sealing surface of retainer when applying MoparT gasket maker or silicone adhesive sealer. Seal failure
and fluid leak can result.

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Fig. 64 Mainshaft Assembly Installation

Fig. 61 Shift Sector Installation

Fig. 62 Range Lever Installation

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Fig. 65 Assembling Mode Fork And Sleeve

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Fig. 66 Mode Fork And Sleeve Installation

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Fig. 69 Install Mode Fork Spring

Fig. 67 Shift Detent Components

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Fig. 70 Installing Case Magnet

Fig. 68 Installing Drive Chain And Front Output
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Fig. 71 Pickup Tube O-Ring Position

Fig. 74 Range Lever Installation

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Fig. 72 Oil Pump And Pickup Tube Installation

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Fig. 75 Output Shaft Yoke Installation

Fig. 73 Alignment Bolt Location

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Fig. 76 Yoke Seal Washer Installation

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Fig. 77 Output Shaft Seal and Protector

Fig. 78 Rear Seal Installation

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DESCRIPTION AND OPERATION
RADIAL-PLY TIRES . . . . . . . . . . . . .
REPLACEMENT TIRES . . . . . . . . . .
SPARE TIRE–TEMPORARY . . . . . . .
TIRE INFLATION PRESSURES . . . .
TIRE PRESSURE FOR HIGH SPEED
OPERATION . . . . . . . . . . . . . . . . .
TIRES . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS AND TESTING
PRESSURE GAUGES . . . . . . . . . . .
TIRE NOISE OR VIBRATION . . . . . .

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TIRE WEAR PATTERNS . . . .
TREAD WEAR INDICATORS
SERVICE PROCEDURES
MATCH MOUNTING . . . . . . .
REPAIRING LEAKS . . . . . . .
ROTATION . . . . . . . . . . . . . .
CLEANING AND INSPECTION
CLEANING TIRES . . . . . . . .
SPECIFICATIONS
TIRE SIZE . . . . . . . . . . . . . .

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Fig. 2 Under Inflation Wear

ÁɊŒ…„µ{;”}|y!ƒ{|‰XL{|}|}ª˜ry,–H† …Ÿ„ry,_{|z ˜r…Hƒ…„cL…y!„µy,Hz
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Fig. 1 Tire Identification

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xpy,z_{|y!}|~_} €‚ƒ{|„r…†B{‡ˆ!„r‰‹ŠŒ…ŽHy,Hz_}|{|H’‘1ƒ„r…y!z“}|{”…Žy,Hz
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xpy,z_{|y!}|~_} €œƒ{|„r…†Ž‡ˆ–;†™y,} Ly €@†Žž,…Ÿ–H† …z {|¡† …ƒ†Ž‰”
”‰–H„› ¢[Hz_…„jH‰L˜r{|„r˜r–H‡ˆ†™ƒy,H˜r…†£† H‰–;}zšƒH…‹€ž,…ˆ–H† …zš‰
ƒH…¤”„r‰;‰H} €>›T¥e;…‹€¦‡ˆy €§ž,…¤‡ˆ{ ¨@…zL{|ƒ“ƒ…‡ˆ_‰„ry,„©€
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–H† …«H…† y,‡ˆ…´„0…˜r‰‡L‡ˆ…Hz!…z={;”}|y,«{|‰¤_„r…†™† –H„r…† ›
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„r…y!„¶‰”p«;…lŠ@…H{|˜r}|…‘ ˜ry,¸˜ry!–;†™…lŠŒ…H{|˜r}|…ˆz!„r{ ŠŒ…ˆƒ„ry,{¸”y!{|}|~
–H„r…›l¥e;{†¹˜r‰–H}|z y,}|†™‰º˜ry,–H†™…º{|Hy,˜r˜r–H„ry,ƒ…¤L;……}´†™_……z
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_„r…†™† –H„r…†™;‰–H}|z=ž,…´‡ˆy,{|Hƒy,{;…z=‰¤y,}}p”‰–H„£ƒ{„0…†™›
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Fig. 3 Over Inflation Wear

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Fig. 5 Tire Wear Patterns

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TIRE SIZE

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WHEELS
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page

page

DESCRIPTION AND OPERATION
WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DIAGNOSIS AND TESTING
TIRE AND WHEEL RUNOUT . . . . . . . . . . . . . . . . 7
WHEEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . 7

SERVICE PROCEDURES
TIRE AND WHEEL BALANCE . . . . . . . . . . . . . . . . 9
WHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . 8
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 10

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WARNING: FAILURE
TO
USE
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SERVICE HISTORY OF THE WHEEL MAY HAVE
INCLUDED SEVERE TREATMENT OR VERY HIGH
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Fig. 3 Radial Runout
Fig. 2 Checking Tire/Wheel/Hub Runout

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NOTE: Rotating the tire on wheel is particularly
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wheel.

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Fig. 4 Lateral Runout

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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.

6

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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 alignment equipment.

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Fig. 7 Dynamic Unbalance & Balance
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GENERAL SERVICE INFORMATION
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GENERAL INFORMATION
SAFETY PRECAUTIONS AND WARNINGS . . . . . . 1

‚„ƒ†…„ƒ†‡AˆŠ‰Œ‹v…„Ž„‡h)ˆ’‘†‹vŽ„…
“•”–˜—˜™ šœ›ž-—˜Ÿ•”  ™˜¡¢ £ “¤”£ ¥)¦¤”-£ ¡£ § “
WARNING: EYE PROTECTION SHOULD BE USED
WHEN SERVICING GLASS COMPONENTS. PERSONAL INJURY CAN RESULT.
USE A 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 components. 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 solvents 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.

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GENERAL INFORMATION
AFTERMARKET PAINT REPAIR PRODUCTS . . . . 3
BASE COAT/CLEAR COAT FINISH . . . . . . . . . . . . 2
FINESSE SANDING, BUFFING, AND
POLISHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

PAINT CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
PAINTED SURFACE TOUCH-UP . . . . . . . . . . . . . 2
SERVICE PROCEDURES
HARD TOP REPAIR . . . . . . . . . . . . . . . . . . . . . . . 4

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EXTERIOR
COLOR

CHRY
CODE
*

PPG

DuPONT

S-W**
M-S**

AKZO
NOBEL
SIKKENS

ICI**

Flame Red
Clear Coat

PR4

4679

B9326

46916

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Chili Pepper
Red

VEA

5361

B9823

54470

CHA98:VEA

HMT3B

Medium Fern
Pearl Coat

RJP

4969

B9524

50270

CHA99:RJP

7CD6B

Deep Amethyst
Pearl Coat

TCN

5246

B9736

52566

CHA97:TCN

FNE4B

Forest Green
Pearl Coat

SG8

5065

B9609

51062

CHA95:SG8

7MR8B

Desert Sand

WTD

5474

B9884

56153

CHA99:WTD

KGC7B

Intense Blue
Pearl Coat

VB3

5357

B9822

54468

CHA98:VB3

HMR9B

Gun Metal
Pearl Coat

TQ7

5248

B9735

52952

CHA97:TQ7

ERA9B

Black Clear
Coat

DX8

9700

99

34858
90-5950

CHA85:DX8

TC60B

Stone White
Clear Coat

SW1

83542

B9622

51539

CHA96:SW1

8KY5B

ðñEë]ò*ê íFó
HARD TOP

CHRY
CODE*

PPG

DuPONT

S-W**
M-S**

AKZO
NOBEL
SIKKENS

Spice

LTB

27315

C9523

46487

CHA90:LTB

FPP6

Carmel

VK9

28589

C9846

58115

CHAVK9M

NVM9

Black

BX7

9418

44219

58115

CHABX7M

NVN1

Stone
White

SW1

5072

C9622

52779

CHASWM1

NNV6

ICI**

ì8ôêmè ë]ì íFë3î^íFïíFë
INTERIOR
COLOR

CHRY
CODE*

PPG

DuPONT

S-W**
M-S**

AKZO
NOBEL
SIKKENS

ICI**

Agate

AZ

9856 / 2-1461

C9208

45994

CHALAZI

7WC8

Camel

K5

27731 / 2-1584

C9603

51541

CHARJ5I

7VX6

Camel / Dark
Green

KG

N/A

N/A

N/A

N/A

K5/G8

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NOTE: *Herberts Standox, Spies Hecker, and BASF
use the Chrysler paint code as listed on the Body
Code Plate and the Vehicle Safety Certification
label. ** S-W = Sherwin-Williams, M-S = Martin
Senour, ICI = ICI Autocolor.

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STATIONARY GLASS
ä å
æ
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page

page

GENERAL INFORMATION
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . 5
REMOVAL AND INSTALLATION
QUARTER GLASS . . . . . . . . . . . . . . . . . . . . . . . . 7

WINDSHIELD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

é2ê&ë2ê&ìífîœï-ë2ðkñ2ì+ò»í)ó&ï-ñ2ë
ôrõ9ö>÷>øNùºú«ûd÷>ürõ9ýø>þDÿô
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, STRUCTURAL
INTEGRITY COULD BE COMPROMISED.
CHRYSLER DOES NOT RECOMMEND GLASS
ADHESIVE BY BRAND. TECHNICIANS SHOULD
REVIEW PRODUCT LABELS AND TECHNICAL 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 MANUFACTURER’S DIRECTIONS FOR CURING TIME
SPECIFICATIONS, AND DO NOT USE ADHESIVE
AFTER ITS EXPIRATION DATE.
VAPORS THAT ARE EMITTED FROM THE URETHANE ADHESIVE OR PRIMER COULD CAUSE
PERSONAL INJURY. USE THEM IN A WELL-VENTILATED 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.




 
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Fig. 1 Cutting Urethane Around Windshield—Typical

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Fig. 2 Windshield

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DO NOT USE SOLVENT BASED GLASS
TO CLEAN WINDSHIELD BEFORE
GLASS PREP AND PRIMER. POOR
CAN RESULT.

Fig. 3 Work Surface Set up and Molding Installation

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Fig. 4 Urethane Bead

 


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WARNING: DO NOT USE SOLVENT BASED GLASS
CLEANER TO CLEAN QUARTER GLASS BEFORE
APPLYING GLASS PREP AND PRIMER. POOR
ADHESION CAN RESULT.

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CAUTION: Be prepared to install the quarter glass
immediately after applying the adhesive. The adhesive begins to cure within 10-15 minutes.

Fig. 5 Hard Top Quarter Glass

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page

page

REMOVAL AND INSTALLATION
BUCKET SEAT CUSHION COVER . . . . . . . . . . . . 9
BUCKET SEATBACK . . . . . . . . . . . . . . . . . . . . . . 8
BUCKET SEATBACK COVER . . . . . . . . . . . . . . . . 8

REAR SEAT CUSHION COVER . . . . . . . . . . . . . 10
REAR SEATBACK . . . . . . . . . . . . . . . . . . . . . . . . 9
REAR SEATBACK COVER . . . . . . . . . . . . . . . . . 10
RECLINER RELEASE CABLE . . . . . . . . . . . . . . . . 9

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Fig. 5 Rear Seat Components

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Fig. 7 Hook And Loop Fasteners
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Fig. 6 Seat Back Cover
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BODY COMPONENT SERVICE
[\K]K^(_

page
SERVICE PROCEDURES
BODY LUBRICATION . . . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION
ADD-A-TRUNK . . . . . . . . . . . . . . . . . . . . . . . .
BODY DECALS . . . . . . . . . . . . . . . . . . . . . . .
BODY SIDE MOLDING . . . . . . . . . . . . . . . . . .
BUCKET SEAT . . . . . . . . . . . . . . . . . . . . . . . .
CARGO AREA CARPET . . . . . . . . . . . . . . . . .
CENTER CARPET . . . . . . . . . . . . . . . . . . . . .
CONSOLE LOCK CYLINDER . . . . . . . . . . . . .
COWL GRILLE AND SCREEN . . . . . . . . . . . .
COWL WEATHERSTRIP . . . . . . . . . . . . . . . . .
DOOR OPENING FRAME . . . . . . . . . . . . . . . .
FENDER FLARE . . . . . . . . . . . . . . . . . . . . . . .
FRONT CARPET . . . . . . . . . . . . . . . . . . . . . .
FRONT FENDER . . . . . . . . . . . . . . . . . . . . . .
FRONT SHOULDER/LAP BELT AND BUCKLE
FULL DOOR . . . . . . . . . . . . . . . . . . . . . . . . . .
FULL DOOR GLASS . . . . . . . . . . . . . . . . . . . .
FULL DOOR GLASS RUN CHANNEL
WEATHERSTRIP . . . . . . . . . . . . . . . . . . . . .
FULL DOOR HINGE . . . . . . . . . . . . . . . . . . . .
FULL DOOR INNER BELT WEATHERSTRIP . .
FULL DOOR INSIDE HANDLE ACTUATOR . . .
FULL DOOR LATCH . . . . . . . . . . . . . . . . . . . .
FULL DOOR LATCH STRIKER . . . . . . . . . . . .
FULL DOOR LOCK CYLINDER . . . . . . . . . . . .
FULL DOOR OUTER BELT SEAL . . . . . . . . . .
FULL DOOR OUTSIDE RELEASE HANDLE . .
FULL DOOR TRIM PANEL . . . . . . . . . . . . . . .
FULL DOOR WEATHERSTRIP . . . . . . . . . . . .
FULL DOOR WINDOW REGULATOR . . . . . . .
FULL FLOOR CONSOLE . . . . . . . . . . . . . . . .
HALF DOOR . . . . . . . . . . . . . . . . . . . . . . . . .
HALF DOOR HINGE . . . . . . . . . . . . . . . . . . . .
HALF DOOR INSIDE HANDLE ACTUATOR . . .
HALF DOOR LATCH . . . . . . . . . . . . . . . . . . . .
HALF DOOR LATCH STRIKER . . . . . . . . . . . .
HALF DOOR LOCK CYLINDER . . . . . . . . . . .
HALF DOOR OUTSIDE HANDLE . . . . . . . . . .
HALF DOOR TRIM PANEL . . . . . . . . . . . . . . .
HALF DOOR WEATHERSTRIP . . . . . . . . . . . .
HALF DOOR WINDOW . . . . . . . . . . . . . . . . . .
HARD TOP . . . . . . . . . . . . . . . . . . . . . . . . . . .
HARD TOP AIR EXHAUSTER . . . . . . . . . . . . .
HARD/SOFT TOP LATCH . . . . . . . . . . . . . . . .

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page
HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOOD HINGE . . . . . . . . . . . . . . . . . . . . . . .
HOOD SAFETY LATCH . . . . . . . . . . . . . . . .
LICENSE PLATE BRACKET . . . . . . . . . . . . .
LIFTGATE GLASS . . . . . . . . . . . . . . . . . . . .
LIFTGATE GLASS HINGE . . . . . . . . . . . . . . .
LIFTGATE GLASS SUPPORT CYLINDER . . .
LIFTGATE GLASS WEATHERSTRIP . . . . . . .
MINI FLOOR CONSOLE . . . . . . . . . . . . . . . .
RADIATOR GRILLE PANEL . . . . . . . . . . . . .
REAR SEAT . . . . . . . . . . . . . . . . . . . . . . . . .
REAR SHOULDER/LAP BELT AND BUCKLE .
REAR VIEW MIRROR . . . . . . . . . . . . . . . . . .
REARVIEW MIRROR SUPPORT BRACKET .
SHIFT BOOT . . . . . . . . . . . . . . . . . . . . . . . .
SIDE STEP . . . . . . . . . . . . . . . . . . . . . . . . .
SIDE VIEW MIRROR . . . . . . . . . . . . . . . . . .
SOFT TOP . . . . . . . . . . . . . . . . . . . . . . . . . .
SOFT TOP FABRIC . . . . . . . . . . . . . . . . . . .
SPARE TIRE CARRIER . . . . . . . . . . . . . . . .
SPORT BAR . . . . . . . . . . . . . . . . . . . . . . . . .
SUNVISOR . . . . . . . . . . . . . . . . . . . . . . . . . .
TAILGATE . . . . . . . . . . . . . . . . . . . . . . . . . .
TAILGATE HINGE . . . . . . . . . . . . . . . . . . . . .
TAILGATE LATCH . . . . . . . . . . . . . . . . . . . . .
TAILGATE LATCH STRIKER . . . . . . . . . . . . .
TAILGATE LOCK CYLINDER . . . . . . . . . . . .
TAILGATE OUTSIDE HANDLE . . . . . . . . . . .
TAILGATE WEATHERSTRIP AND CHANNEL
WHEELHOUSE CARPET . . . . . . . . . . . . . . .
WHEELHOUSE SPLASH SHIELD . . . . . . . . .
WINDSHIELD FRAME . . . . . . . . . . . . . . . . .
WINDSHIELD FRAME WEATHERSTRIP . . . .
WINDSHIELD HINGE . . . . . . . . . . . . . . . . . .
ADJUSTMENTS
DOOR ADJUSTMENT . . . . . . . . . . . . . . . . . .
HOOD ADJUSTMENT . . . . . . . . . . . . . . . . . .
TAILGATE ADJUSTMENT . . . . . . . . . . . . . . .
SPECIFICATIONS
BODY LUBRICANTS . . . . . . . . . . . . . . . . . .
BODY OPENING DIMENSIONS . . . . . . . . . .
SEALER LOCATIONS . . . . . . . . . . . . . . . . . .
TORQUE SPECIFICATIONS . . . . . . . . . . . . .
WELD LOCATIONS . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS
BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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. . . 83

 







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NOTE: When installing the cowl grille, ensure the
foam seals on the cowl (Fig. 6) are positioned cor-

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Fig. 7 Windshield Frame

S TVUXWZYC[\[]Y\WS ^/T
_a`NbcXd]egf>hif d]jkhl\mnof j,pegl,f m]q pr sutwvDmd]jkhl,mxym]l,f zuq m]{
_ |gb}j,eghit~q q4hil,mhidMs€egzusumn‚eƒtwhihtwzul,f j,„…hl\m†nof j\p‡
egl,f m]q pˆl\f>j\„Zmhdhil,mnof j,p~e‰l,f mMq>pr sutwvDmM{
_ ŠgbD‹Bf>q hŒhil,mnof j,p~e‰l,f mMq>psumMt~sn‚t~sap{
_ gb}j,eghit~q qŽhl,mohid]s €kegzusumn…zuq dMe‰mMe‰h&hidohil,mol,f j,„Zmo~f xyd]h
dMf j,htwj,p;q d]zu‘hl\mCnof j,pegl,f m]q p;f j’hil,m“,suf „”l,hdMe‰f hif d]j,{
_ •gb}j,eghit~q qBhil,mnof j,p~e‰l,f mMq>pDnof mMs‚twsuvDeg{
_ –gb}j,eghit~q qhil,m;—wd]q hieDt~hihit~zal,f j,„’hl,m;egd]suhŒ—~tws‚hd;hil,m
nof j,p~e‰l,f mMq>pr sutwvDmM{
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«B¬X¬­\®°¯\®VYC±‘­³²´­]Y\WµB­\®VUXW®BS ¬¶®B­·±¸^B¹yYC[
_a`Nbº»f egzud]j,j\m]zuhŒhil,mhdMr sud]v¼hil,mnof j,pegl,f m]q pr sutwvDm]{
_ |gbº»f egm]j,„”t~„”mhl,m“\e‰l,‡>f>j´r tweghmMj,m]sue½twhihtwzul,f j,„khil,m
nomMtwhl,mMsue‰hisuf hdhil,mnof j,pegl,f m]q pr sutwvDm]{
_ ŠgbcXm]m]q¡hl\m/n‚m]twhil,m]sueghsuf r sudMv¾hil,mr sutwvDmM{
«B¬X¬­\®°¯\®VYC±‘­³²´­]Y\WµB­\®VUXW®BS ¬¶S>TVUW”Y&[\[MY\WS ^/T
_a`Nb¿¡q m]twjÀhil,m†egm]twq’zudMj,hit~zahÁe‰“\sur twzum†dMjÀhl,mÁnof j,p‡
egl,f m]q pˆr>sutwvDmnof hlkf e‰dMsud]‰ÂVqBtwq zud]l\d]qBdMs‚mMÃ~“,f xyt~q mMj,h{
NOTE: Ensure that the contact surface is dry and
free from any residue, poor adhesion will result.

_ |gbcXd]egf>hif d]j¾hl,mÄnomMtwhl,mMsue‰hisuf ÅdMjÆhil,mÄnof j,pegl,f m]q p
r sutwvDmMÇ&twq f „Zj´hl\m“,egl,‡ f j´r twe‰him]j,mMsue½twj,pȏsumMe‰e½f hof j,hid
q twzum_ ÉXf>„”{Êgba{
_ ŠgbË¡m]vodxVmÈtwpl,m]egf xVmȗ~twzu·f j,„Är>sud]vÌhil,m¶—wdMhhid]vÌdMr
hil,mnom]twhil,mMsue‰hisuf {
_ gbÍegf j,„Dr dMsuzum]r>“,ql,twj,p;~sum]ege‰“,sumMÇye‰m]twhBhl,m¸t~p~l,m]egf xVm
d]jkhil,mzud]j,hitwzuhŒeg“,sur twzum]{

NOTE: If tape surface becomes contaminated, it
will not adhere to the windshield frame.

_ •gb¿¡d]j\j,m]zuhŒhil,mhid]hid;hil,mnof j,p~e‰l,f mMq>pr sutwvDmM{

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Fig. 8 Windshield Frame Weatherstrip

[]^B²´­\®°¯\®VYC±‘­³²´­]Y\WµB­\®VUXW®BS ¬¶®B­\±/^B¹yYC[
‹&l\mÎq dnomMs;nof j,pegl,f m]q pÏr sutwvDmn‚m]twhil,m]sueghsaf>Ïzutwj8—wm
sumMvDdxVmMpn‚f>hil‘hl,m/r>sut~vDm/hif q>himMpr dMsnotwsup³hd/hil,m/r “,q q l,dMsa‡
f ÐÑd]j,hitwqBdMe‰f hif d]j,{
_a`Nbґt~suÓhl,m¾~d]e‰f hif d]jÔd]r†hil,mÕnof mMs…twsuvDeÖtwj,p
sumMvDdxVmhil,mtwsuvDe‰{
_ |gbº»f egzud]j,j\m]zuhŒhil,mhdMr sud]v¼hil,mnof j,pegl,f m]q pr sutwvDm]{
_ ŠgbË¡m]vDdxVmhil,mzudn‚qB„Zsuf q q m]{
_ gbË¡m]vDdxVmÄhl\m×hid]s€e‰zusumnoeÎdMjmMt~zulÕe‰f pmÄd]r½hil,m
nof j,p~e‰l,f mMq>p°r>sutwvDmÈtwq q>dnof j,„´hil,m’n‚f j,pegl,f m]q p°r sutwvDmÈhid
hif>q hŒhidhl\mr “,q qBl,dMsuf ÐÑd]j,hitwqBdMe‰f hf dMj,{
_ •gbº»f egm]j,„”t~„”mÏhl\mØdM“,hi—wd]twsup“,egl,‡ f j…r twe‰him]j,mMsue×twh
hil,m½hdMÁdMrzudnoq&twj,pk“,j,egzusumnÆhil,m½r twe‰him]j,mMsuehl\t~h¸l\d]q p
hil,mnom]twhil,m]sae‰hisuf ˆdMjÁmMt~zalÁl,f j,„”mf q>q tws_ Éf „”{Êgba{
_ –gbº»f egm]j,„”t~„”mohl\mo“,egl,‡ f jr twe‰him]j,mMst~hChl,mozumMj,him]sd]r
zudnoq {
_ ˜gbË¡m]vDdxVmhil,mnomMt~hil,mMsue‰hisuf ˆr>sud]v¼hl\m;zudnoq {
[]^B²´­\®°¯\®VYC±‘­³²´­]Y\WµB­\®VUXW®BS ¬¶S>TVUW”Y&[\[]Y·WS ^/T
_a`NbcXd]e‰f hif d]j’hil,mnom]twhil,m]sueghisuf ;d]j’hil,m¸zudnoq Çytwq f>„”j’hil,m
zumMj,hmMs‚~“,e‰l,‡>f jÁr tweghmMj,m]stwj,psum]egeof hŒf>j\hdq twzum]{
_ |gbDÙq f „ZjÎhl\m$d]“,him]s“,egl,‡ f jÎr tweghmMj,m]sue‘twj,p4~sum]ege‘f>h
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_ Šgb}j,eghit~q qŽhl\moe‰zasumnoe/twhhitwzul,f j,„hil,moq dnom]s¡n‚m]twhl\m]sH‡
eghsuf hdhil,ml,f j,„Zm~f>q q twsue‰{
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xVmMsuhif>zutwqB~d]egf>hif d]j,{
_ •gb}j,eghit~q qˆhl\m8hid]s€Æegzusumn‚eÏdMj¼m]twzul¼e‰f p~m8d]rkhil,m
nof j,p~e‰l,f mMq>pegm]zu“,suf j,„½hil,mnof j,pegl,f m]q pr sutwvDm]{
_ –gb¿¡d]j\j,m]zuhŒhil,mhid]hdhil,mnof j,p~e‰l,f m]q pr sutwvDmM{
_ ˜gb}j,eghit~q qBzudnoqB„”suf q>q mtwj,pDnof m]stwsuvDe‰{
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Fig. 9 Windshield Hinge

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apply heat to area and slowly peel the decal from
panel.

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CAUTION: Always remove the carrier from the tape
stripe/decal, never remove the tape stripe/decal
from the carrier.

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Fig. 12 FENDER FLARES

Fig. 13 Body Side Molding

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Fig. 14 Front Fender

  
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Fig. 15 Body Side Molding

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Fig. 16 Side Step

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Fig. 17 Full Door Trim Panel

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Fig. 18 Restraint Strap

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NOTE: When removing the door or hinge DO NOT
discard the plastic shims or the hinge pin.

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Fig. 19 Full Door Hinge

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Fig. 20 Grab Handle Support Bracket

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Fig. 21 Latch Rods

Fig. 22 Outside Door Handle Removal

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Fig. 23 Latch Rods

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Fig. 24 Full Door Latch

Fig. 26 Inside Handle Actuator

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Fig. 25 Latch Striker

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Fig. 27 Door Sail Screws

Fig. 29 Full Door Outer Belt Seal

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Fig. 28 Door Sail Removal

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Fig. 30 Full Door Glass Run Channel Weatherstrip

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NOTE: Ensure that the glass is seated properly.
Improperly seated door glass will result in high
glass roll-up/roll-down effort.

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Fig. 32 Window Regulator Bolts

Fig. 31 Full Door Weatherstrip


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Fig. 36 Half Door Latch Rods

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Fig. 51 Front Retractor

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WARNING: INSPECT
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OR DAMAGED. REPLACE THE BELT IF THE
RETRACTOR IS INOPERATIVE.

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Fig. 54 Turning Loop Cover

Fig. 56 Rear Belt Assembly

í îeïðWñòeó.ôgóhñõônöEFig.
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Fig. 58 Bucket Seat

Fig. 60 Mini Floor Console

åæ(çCè=¿"À+À¿+è>å ½/æ

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‹¬9Ž9‘’V““9”›ž‘ –˜˜]‘ëꮛÈV›Wš4’V‘˜Ÿ^–•Ï̕“¢

Fig. 59 Bucket Seat Removal

‹Œ9Ž9‘’V““‘”+•—–˜“‘™’‘‘’š”›œ‘”•—žWŸ˜+‘`˜ž,•]’V‘

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Fig. 62 Console Lock Cylinder

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Fig. 61 Full Floor Console

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Fig. 63 Shift Boot

  
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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 SUPPORT RODS.

Fig. 71 Sunvisor

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ATTEMPT TO DISASSEMBLE OR REPAIR THE SUPPORT RODS.

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à &I
â 'tê'ìRóHíBóHç-ê
ç-é6êñ9æ K%ç ióHç?(
ê FñóHåI)
å KíBä  ç-é6êé6óHíBî¯ç-ä'ì+ô

Fig. 73 Support Rod Cylinder

Fig. 75 Rear Defroster Connectors

Fig. 74 Support Rod Cylinder Removal

ÙKÚe۞ÜiÝÞNÞ'ÝN܇٠ßqÚ
à)á âWãžä'åIæç-æ9ä'èoç-é6ê¯å`ë6ì+ìRä'íBçíBäîbï2ðeñ9æ9è6îRêíBåäèoç-é6ênòHóHñ9ñ
åIç?ë6î+å`ô
àKõIâWökè6åIç-ó+ñ9ñç-é6êåIë6ìRìRäíBçgíBä'îWï2ðeñ9æ9è6î+ê'í.í)ê'ç-ó+æ9è6êí.ïBñ9æ9ìRåIô
÷¦ø ù¦ú¦û‡ü¢ú¦ýbû÷+ü>þ„þ
ÿqßtÝÞ
à)á âWö gê +ëNæì+ìRê'î
î+æåIïBä'èNè6ê'ïBç ç?éNêíBê'óHíîRêKíBä'åIç-ê'íé6óHí
è6êå`åXïBäè6è6ê'ïBç-äíBåXà
 æ Fô `âô
àKõIâWö 
ê Hë6æ9ìRìRêî Xî+æåIïBä'èNè6ê'ïBçWç-é6
ê Xæ9ìRê'
í ä'ç-ä'íéNó+í
è6êå`åXïBäè6è6ê'ïBç-äíBå`ô
WARNING: DO NOT REMOVE THE LIFTGATE SUPPORT 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

Fig. 76 Liftgate Glass

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î }æ9è6åIç-ó+ñ9ñmå`ëNìRìRäíBç~íBäî”òHóHññmåIç?ëNîRå`ô
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ç-ä'3í Hë6êô
à !IâWãžä'å`æ9ç-æ9ä'èoç-é6ê¯å`ë6ì+ìRä'íBçíBäîbï2ðeñ9æ9è6îRêíBåäèoç-é6ênòHóHñ9ñ
åIç?ë6î+åXó+èNî¯æ9è6åIç?óHñ9ñç-é6êïBñ9æ9ìRå`ô

×Ø-ÙCÚ×
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ßyà

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Fig. 78 Spare Tire

Fig. 77 Liftgate Hinge

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Fig. 79 Spare Tire Bracket

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Fig. 80 License Plate Bracket

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COMPONENT
Door Latches
Hood Latch, Release Mechanism &
Safety Latch

SERVICE INTERVAL
As Required
As Required
(When Performing Other
Underhood Service)

LUBRICANT
Multi-Purpose Grease NLGI GC-LB
(Water Resistant) (1)
Multi-Purpose Grease NLGI GC-LB 2
EP (2)

Hood Hinges

As Required

Engine Oil

Seat Track & Release Mechanism

As Required

Multi-Purpose Grease NLGI GC-LB 2
EP (2)

Tailgate Hinge

As Required

Multi-Purpose Grease NLGI GC-LB 2
EP (2)

Liftgate Support Arms

As Required

Engine Oil

Tailgate Latches

As Required

White Spray Lubricant (3)

Tailgate Release Handle

As Required

Multi-Purpose Grease NLGI GC-LB 2
EP (2)

Window System Components

As Required

White Spray Lubricant (3)

Lock Cylinders

Twice A Year

Lock Cylinder Lubricant (4)

Parking Brake Mechanism

As Required

Multi-Purpose Grease NLGI GC-LB 2
EP (1)

1 = Mopar
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2 = Mopar
3 = Mopar
4 = Mopar

Wheel Bering Grease (High
Multi-Mileage Lubricant
Spray White Lube
Lock Cylinder Lubricant

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Fig. 1 Common Blend-Air Heater-Air Conditioner
System - Typical

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‚„ƒ…„ƒ†ˆ‡‰‹Š2…Œ7Ž„†'‡ $ŠŽ„…’‘”“•@–7—P˜ –7™7š7›7œ
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WARNING:
• THE AIR CONDITIONING SYSTEM CONTAINS
REFRIGERANT UNDER HIGH PRESSURE. SEVERE
PERSONAL INJURY MAY RESULT FROM IMPROPER
SERVICE PROCEDURES. REPAIRS SHOULD ONLY
BE PERFORMED BY QUALIFIED SERVICE PERSONNEL.
• 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 REFRIGERANT. IF EYE CONTACT OCCURS, SEEK MEDICAL ATTENTION IMMEDIATELY.
• DO NOT EXPOSE THE REFRIGERANT TO
OPEN FLAME. POISONOUS GAS IS CREATED
WHEN REFRIGERANT IS BURNED. AN ELECTRONIC LEAK DETECTOR IS RECOMMENDED.
• IF
ACCIDENTAL
SYSTEM
DISCHARGE
OCCURS, VENTILATE THE WORK AREA BEFORE
RESUMING SERVICE. LARGE AMOUNTS OF
REFRIGERANT RELEASED IN A CLOSED WORK
AREA WILL DISPLACE THE OXYGEN AND CAUSE
SUFFOCATION.
• THE EVAPORATION RATE OF R-134a 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 REFRIGERANT 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 ELEVATED PRESSURES. THESE MIXTURES ARE
POTENTIALLY DANGEROUS, AND MAY RESULT IN
FIRE OR EXPLOSION CAUSING INJURY OR PROPERTY DAMAGE.
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. Damage to the system will
result.
• R-12 refrigerant oil must not be mixed with
R-134a refrigerant oil. They are not compatible.
• Do not use R-12 equipment or parts on the
R-134a system. Damage to the system will result.

• Do not overcharge the refrigerant system. This
will cause excessive compressor head pressure
and can cause noise and system failure.
• Recover the refrigerant before opening any fitting or connection. Open the fittings with caution,
even after the system has been discharged. Never
open or loosen a connection before recovering the
refrigerant.
• Do not remove the secondary retention clip
from any spring-lock coupler connection while the
refrigerant system is under pressure. Recover the
refrigerant before removing the secondary retention
clip. Open the fittings with caution, even after the
system has been discharged. Never open or loosen
a connection before recovering the refrigerant.
• The refrigerant system must always be evacuated before charging.
• Do not open the refrigerant system or uncap a
replacement component until you are ready to service the system. This will prevent contamination in
the system.
• Before disconnecting a component, clean the
outside of the fittings thoroughly to prevent contamination from entering the refrigerant system.
• Immediately after disconnecting a component
from the refrigerant system, seal the open fittings
with a cap or plug.
• Before connecting an open refrigerant fitting,
always install a new seal or gasket. Coat the fitting
and seal with clean refrigerant oil before connecting.
• Do not remove the sealing caps from a replacement component until it is to be installed.
• When installing a refrigerant line, avoid sharp
bends that may restrict refrigerant flow. Position the
refrigerant lines away from exhaust system components or any sharp edges, which may damage the
line.
• Tighten refrigerant fittings only to the specified
torque. The aluminum fittings used in the refrigerant system will not tolerate overtightening.
• When disconnecting a refrigerant fitting, use a
wrench on both halves of the fitting. This will prevent twisting of the refrigerant lines or tubes.
• Refrigerant oil will absorb moisture from the
atmosphere 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.
• Keep service tools and the work area clean.
Contamination of the refrigerant system through
careless work habits must be avoided.


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Item

Description

VEHICLE

TJ Wrangler

Notes

SYSTEM

R134a w/orifice tube

COMPRESSOR

Nippondenso
10PA17

ND-8 PAG oil

Freeze–up Control

Low Pressure
cycling cutout switch

accumulator
mounted

Low psi Control

opens < 20.5 psi resets 38 psi

High psi Control

switch - opens >
450-490 psi - resets
< 270-330 psi

CONTROL HEAD

manual type

Mode Door

vacuum

Blend Air Door

electric actuator

Fresh/Recirc door

vacuum

Blower Motor

hardwired to control
head

COOLING FAN

viscous fan

discharge line
mounted
switch

resistor block

CLUTCH
Control

relay

PCM

Draw

2–3.9 amps @ 12V

6 0.5V @
70° F

Gap

0.0169–0.0319

DRB IIIT
Reads

TPS, RPM, A/C
switch test

Actuators

clutch relay

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ALL VALVES ON THE EQUIPMENT BEING USED
BEFORE CONNECTING TO, OR DISCONNECTING
FROM THE REFRIGERANT SYSTEM. FAILURE TO
OBSERVE THESE WARNINGS MAY RESULT IN PERSONAL INJURY.

Fig. 5 Spring-Lock Coupler - Typical

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Fig. 7 Low Pressure Cycling Clutch Switch - Typical

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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)

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)

Compressor
Discharge
Pressure

Condition
Rapid compressor clutch
cycling (ten or more cycles per
minute).
Equal pressures, but the
compressor clutch does not
engage.

Normal pressures, but A/C
Performance Test air
temperatures at center panel
outlet are too high.

Pressure Diagnosis
Possible Causes
Correction
1. See Refrigerant System Leaks in this group.
1. Low refrigerant system
Test the refrigerant system for leaks. Repair,
charge.
evacuate and charge the refrigerant system, if
required.
1. No refrigerant in the
1. See Refrigerant System Leaks in this group.
refrigerant system.
Test the refrigerant system for leaks. Repair,
2. Faulty fuse.
evacuate and charge the refrigerant system, if
3. Faulty compressor clutch
required.
coil.
2. Check the fuses in the Power Distribution Center
4. Faulty compressor clutch
and the fuseblock module. Repair the shorted
relay.
circuit or component and replace the fuses, if
5. Improperly installed or
required.
faulty low pressure cycling
3. See Compressor Clutch Coil in this group. Test
clutch switch.
the compressor clutch coil and replace, if required.
6. Faulty high pressure cut-off 4. See Compressor Clutch Relay in this group. Test
switch.
the compressor clutch relay and relay circuits.
7. Faulty Powertrain Control
Repair the circuits or replace the relay, if required.
Module (PCM).
5. See Low Pressure Cycling Clutch Switch in this
group. Test the low pressure cycling clutch switch
and tighten or replace, if required.
6. See High Pressure Cut-Off Switch in this group.
Test the high pressure cut-off switch and replace, if
required.
7. Refer to the proper Diagnostic Procedures
manual for testing of the PCM. Test the PCM and
replace, if required.
1. See Refrigerant Oil Level in this group. Recover
1. Excessive refrigerant oil in
the refrigerant from the refrigerant system and
system.
inspect the refrigerant oil content. Restore the
2. Temperature control cable
refrigerant oil to the proper level, if required.
improperly installed or faulty.
2. See Temperature Control Cable in this group.
3. Blend-air door inoperative
Inspect the temperature control cable for proper
or sealing improperly.
routing and operation and correct, if required.
3. See Blend-Air Door under Heater-A/C Housing
Door in this group. Inspect the blend-air door for
proper operation and sealing and correct, if
required.

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Condition
The low side pressure is
normal or slightly low, and the
high side pressure is too low.

The low side pressure is
normal or slightly high, and
the high side pressure is too
high.

The low side pressure is too
high, and the high side
pressure is too low.

The low side pressure is too
low, and the high side
pressure is too high.

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Pressure Diagnosis
Possible Causes
Correction
1. Low refrigerant system
1. See Refrigerant System Leaks in this group.
charge.
Test the refrigerant system for leaks. Repair,
2. Refrigerant flow through
evacuate and charge the refrigerant system, if
the accumulator is restricted.
required.
3. Refrigerant flow through
2. See Accumulator in this group. Replace the
the evaporator coil is
restricted accumulator, if required.
restricted.
3. See Evaporator Coil in this group. Replace the
4. Faulty compressor.
restricted evaporator coil, if required.
4. See Compressor in this group. Replace the
compressor, if required.
1. Condenser air flow
1. Check the condenser for damaged fins, foreign
restricted.
objects obstructing air flow through the condenser
2. Inoperative cooling fan.
fins, and missing or improperly installed air seals.
3. Refrigerant system
Refer to Group 7 - Cooling System for more
overcharged.
information on air seals. Clean, repair, or replace
4. Air in the refrigerant
components as required.
system.
2. Refer to Group 7 - Cooling System for more
5. Engine overheating.
information. Test the cooling fan and replace, if
required.
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. See Refrigerant System Leaks in this group.
Test the refrigerant system for leaks. Repair,
evacuate and charge the refrigerant system, if
required.
5. Refer to Group 7 - Cooling System for more
information. Test the cooling system and repair, if
required.
1. Accessory drive belt
1. Refer to Group 7 - Cooling System for more
slipping.
information. Inspect the accessory drive belt
2. Fixed orifice tube not
condition and tension. Tighten or replace the
installed.
accessory drive belt, if required.
3. Faulty compressor.
2. See Fixed Orifice Tube in this group. Install the
missing fixed orifice tube, if required.
3. See Compressor in this group. Replace the
compressor, if required.
1. Restricted refrigerant flow
1. See Liquid Line and Suction and Discharge Line
through the refrigerant lines.
in this group. Inspect the refrigerant lines for kinks,
2. Restricted refrigerant flow
tight bends or improper routing. Correct the routing
through the fixed orifice tube.
or replace the refrigerant line, if required.
3. Restricted refrigerant flow
2. See Fixed Orifice Tube in this group. Replace
through the condenser.
the restricted fixed orifice tube, if required.
3. See Condenser in this group. Replace the
restricted condenser, if required.

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˜#¤?™L™+š9™L©@¡E¤—L¡6¦%¸)¬)™+-› ´0š2—o¡E¢@—4¡E—+¦<¡K¡E¢@—Lš29™+9—L¡6—Lš9š2—L´:²:žŸ7 
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Temperature Reference
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)

 





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Refrigerant Oil Capacities
Component

ml

fl oz

A/C System

240

8.1

Accumulator

120

4

Condenser

30

1

Evaporator

60

2

Compressor

drain and measure
the oil from the old
compressor - see
text.

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NEAR THE FRONT OF THIS GROUP BEFORE PERFORMING THE FOLLOWING OPERATION.

EF GHI

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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.
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Fig. 14 Refrigerant Line Spring-Lock Coupler
Disconnect

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NOTE: The garter spring may not release if the A/C
line disconnect tool is cocked while pushing it into
the coupler cage opening.
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!

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 recommended for the compressor in the vehicle.

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Fig. 19 Clutch Nut Remove

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Fig. 22 Shaft Protector and Puller

Fig. 20 Clutch Plate Remove

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Fig. 23 Install Puller Plate

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YRFXDXDE^Z€?APiPSE6@agTX Z BDPaPSE'?TGJE6\Tb

Fig. 24 Clutch Coil Lead Wire Harness

Fig. 26 Clutch Pulley Install

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BDPaYLMO6YTE6LMX Z PSE'?AG^E'\qBDC~G^IfEl™LMO6O^j1E6b

Fig. 25 Clutch Field Coil Snap Ring Remove

CAUTION: If the snap ring is not fully seated in the
groove it will vibrate out, resulting in a clutch failure and severe damage to the front housing of the
compressor.

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Fig. 27 Clutch Plate Driver

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Fig. 29 Power Distribution Center

Fig. 28 Check Clutch Air Gap
NOTE: The air gap is determined by the spacer
shims. When installing an original, or a new clutch
assembly, try the original shims first. When installing a new clutch onto a compressor that previously
did not have a clutch, use 1.0, 0.50, and 0.13 millimeter (0.040, 0.020, and 0.005 inch) shims from the
clutch hardware package that is provided with the
new clutch.

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Fig. 30 Liquid Line Remove/Install

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31 Fixed Orifice Tube - Typical
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Fig. 32 Low Pressure Cycling Clutch Switch
Remove/Install - Typical

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NOTE: If the accumulator is replaced, add 120 milliliters (4 fluid ounces) of refrigerant oil to the
refrigerant system. Use only refrigerant oil of the
type recommended for the compressor in the vehicle.
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WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT OF THIS GROUP BEFORE
PERFORMING THE FOLLOWING OPERATION.

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CAUTION: Before removing the condenser, note the
location of each of the radiator and condenser air
seals. These seals are used to direct air through the
condenser and radiator. The air seals must be reinstalled in their proper locations in order for the air
conditioning and engine cooling systems to perform as designed.
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Fig. 36 Powertrain Control Module (PCM) Remove/
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Fig. 35 Vacuum Reservoir Remove/Install

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Fig. 37 Blower Motor Remove/Install

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Fig. 39 Heater-A/C Control Connections

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Fig. 38 Heater-A/C Control Remove/Install

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Fig. 40 Blower Motor Switch Remove/Install

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WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO GROUP 8M - PASSIVE
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WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
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Fig. 42 Blower Motor Relay Remove/Install

Fig. 43 Kick Cover Remove/Install

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€‚„ƒ†…@‡$‡ˆ…$ƒ2 ‰%€

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WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, 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 PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.

WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, 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 PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
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Fig. 44 Blower Motor Resistor Remove/Install

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WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, 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 PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.

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Fig. 45 Defrost, Floor, and Panel/Demist Door
Vacuum Actuators

Fig. 46 Vacuum Actuator Remove/Install - Typical

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RESTRAINT SYSTEMS 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.




 



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Fig. 55 Recirculation Air Door



 
 

WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, 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 PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
ÈÉÊË

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Fig. 54 Floor Door

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NOTE: If the evaporator is replaced, add 60 milliliters (2 fluid ounces) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type
recommended for the compressor in the vehicle.


 


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STEERING WHEEL, STEERING COLUMN, OR
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WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO GROUP 8M - PASSIVE
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INJURY.

Fig. 56 Evaporator Coil Remove/Install

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Heater-A/C Housing Ducts Remove/Install

Fig. 57 Heater Core Remove/Install

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ON-BOARD DIAGNOSTICS
Ú.Ý]ä]Óè
page

page

GENERAL INFORMATION
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION AND OPERATION
DIAGNOSTIC TROUBLE CODES . . . . . . . . . . . . . 2

MALFUNCTION INDICATOR LAMP (MIL) . . . . . . . 2
MONITORED SYSTEMS . . . . . . . . . . . . . . . . . . . . 5

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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 (check engine lamp).

Fig. 1 Data Link (Diagnostic) Connector Location

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*02

Generic
Scan Tool
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NOTE: For a list of DTC’s, refer to the charts in this
section.

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WARNING: APPLY PARKING BRAKE AND/OR
BLOCK WHEELS BEFORE PERFORMING ANY TEST
ON AN OPERATING ENGINE.

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DRB Scan Tool Display

Description of Diagnostic Trouble Code

P0340

No Cam Signal at PCM

No camshaft signal detected during engine
cranking.

P0601

Internal Controller Failure

PCM Internal fault condition detected.

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Hex
Code

Generic
Scan Tool
Code

ª|«9¬ ­­O¬ ®‚¯„°®‚¯‚±!² ®ˆ³<­´Q­±!ª|«4­

µ%¶<·q¸

DRB Scan Tool Display

Description of Diagnostic Trouble Code

Charging System Voltage Too Low

Battery voltage sense input below target charging
during engine operation. Also, no significant
change detected in battery voltage during active
test of generator output circuit.

Charging System Voltage Too High

Battery voltage sense input above target charging
voltage during engine operation.

0A

Auto Shutdown Relay Control
Circuit

An open or shorted condition detected in the auto
shutdown relay circuit.

0B

Generator Field Not Switching
Properly

An open or shorted condition detected in the
generator field control circuit.

Torque Converter Clutch Soleniod/
Trans Relay Circuit

An open or shorted condition detected in the
torque converter part throttle unlock solenoid
control circuit (3 speed auto RH trans. only).

Speed Control Solenoid Circuits

An open or shorted condition detected in the
Speed Control vacuum or vent solenoid circuits.

A/C Clutch Relay Circuit

An open or shorted condition detected in the A/C
clutch relay circuit.

P0443

EVAP Purge Solenoid Circuit

An open or shorted condition detected in the duty
cycle purge solenoid circuit.

P0203

Injector #3 Control Circuit

Injector #3 output driver does not respond
properly to the control signal.

Injector #2 Control Circuit

Injector #2 output driver does not respond
properly to the control signal.

P0201

Injector #1 Control Circuit

Injector #1 output driver does not respond
properly to the control signal.

P0505

Idle Air Control Motor Circuits

A shorted or open condition detected in one or
more of the idle air control motor circuits.

P0122

Throttle Position Sensor Voltage
Low

Throttle position sensor input below the minimum
acceptable voltage

P0123

Throttle Position Sensor Voltage
High

Throttle position sensor input above the maximum
acceptable voltage.

P0117

ECT Sensor Voltage Too Low

Engine coolant temperature sensor input below
minimum acceptable voltage.

P0118

ECT Sensor Voltage Too High

Engine coolant temperature sensor input above
maximum acceptable voltage.

P0500

No Vehicle Speed Sensor Signal

No vehicle speed sensor signal detected during
road load conditions.

P0107

MAP Sensor Voltage Too Low

MAP sensor input below minimum acceptable
voltage.

05

06

*0C
P0743
0F
10
*12
*13

or
*14

P0202
or

*15
*19
*1A

or
*1B
*1E

or
*1F
*23
*24

or

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Hex
Code
*25

Generic
Scan Tool
Code

DRB Scan Tool Display

Description of Diagnostic Trouble Code

P0108

MAP Sensor Voltage Too High

MAP sensor input above maximum acceptable
voltage.

P1297

No Change in MAP From Start to
Run

No difference recognized between the engine
MAP reading and the barometric (atmospheric)
pressure reading from start-up.

P0320

No Crank Reference Signal at
PCM

No crank reference signal detected during engine
cranking.

P0351

Ignition Coil #1 Primary Circuit

Peak primary circuit current not achieved with
maximum dwell time.

P1389

No ASD Relay Output Voltage at
PCM

An Open condition Detected In The ASD Relay
Output Circuit.

P1696

PCM Failure EEPROM Write
Denied

Unsuccessful attempt to write to an EEPROM
location by the PCM.

P0112

Intake Air Temp Sensor Voltage
Low

Intake air temperature sensor input below the
maximum acceptable voltage.

P0113

Intake Air Temp Sensor Voltage
High

Intake air temperature sensor input above the
minimum acceptable voltage.

P0204

Injector #4 Control Circuit

Injector #4 output driver does not respond
properly to the control signal.

P0132

1/1 O2 Sensor Shorted to Voltage

Left oxygen sensor input voltage maintained
above the normal operating range.

P0600

PCM Failure SPI Communications

PCM Internal fault condition detected.

P0205

Injector #5 Control Circuit

Injector #5 output driver does not respond
properly to the control signal.

Injector #6 Control Circuit

Injector #6 output driver does not respond
properly to the control signal.

Speed Control Power Relay or
Speed Control 12V Driver Circuit

Malfunction detected with power feed to speed
control servo solenoids.

Speed Control Switch Always Low

Speed control switch input below the minimum
acceptable voltage.

*27

28
2B
2C
31
*39
*3A
*3D
*3E
44
*45

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or
*46

P0206

52
57
60

P1698

65
*72
*73
*76
*77
*7E
*80

No CCD/PCI message from TCM
Fuel Pump Relay Control Circuit

An open or shorted condition detected in the fuel
pump relay control circuit.

P1899

Park/Neutral Switch Stuck In Park
or In Gear

Incorrect input state detected for the Park/Neutral
switch, auto. trans. only.

P0551

Power Steering Switch Failure

Power steering high pressure seen at high speed.

P0172

Fuel System Rich 1/1 Rich

A rich air/fuel mixture has been indicated by an
abnormally lean correction factor.

P0171

Fuel System Lean 1/1 Lean

A lean air/fuel mixture has been indicated by an
abnormally rich correction factor.

P0138

1/2 O2 Sensor Shorted to Voltage

Downstream oxygen sensor input voltage
maintained above the normal operating range.

P0125

Closed Loop Temp Not Reached

Engine does not reach 20°F within 5 minutes with
a vehicle speed signal.

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Hex
Code
*84
89

Generic
Scan Tool
Code
P0121

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DRB Scan Tool Display

Description of Diagnostic Trouble Code

TPS Voltage Does Not Agree With
MAP

TPS signal does not correlate to MAP sensor

P0700

Aisin AW4 transmission DTC present
Torq Conv Clu, No RPM Drop At
Lockup

Relationship between engine speed and vehicle
speed indicates no torque converter clutch
engagement (auto. trans. only).

Fuel Level Sending Unit Volts Too
Low

Open circuit between PCM and fuel gauge
sending unit.

Fuel Level Sending Unit Volts Too
High

Circuit shorted to voltage between PCM and fuel
gauge sending unit.

Battery Temp Sensor Voltage Too
Low

Battery temperature sensor input voltage below
an acceptable range.

P1492

Battery Temp Sensor Voltage Too
High

Battery temperature sensor input voltage above
an acceptable range.

P0131

Upstream O2s Voltage Shorted to
Ground

O2 sensor voltage too low, tested after cold start.

P0137

Downstream O2s Voltage Shorted
to Ground

O2 sensor voltage too low, tested after cold start.

P1391

Intermittent Loss of CMP or CKP

Intermittent loss of either camshaft or crankshaft
position sensor

94
P0740
95
or
96
*99

P1493
or

*9A
*9B

or
*9C
*9D

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EVAPORATIVE EMISSION CONTROLS
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DESCRIPTION AND OPERATION
EVAPORATION CONTROL SYSTEM . . . . . . . . . . 8

VEHICLE EMISSION CONTROL INFORMATION
(VECI) LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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VECI LABEL

NOTE: The evaporative system uses specially manufactured hoses. If replacement becomes necessary, only use fuel resistant hose.

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EMISSION CONTROL SYSTEMS
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¸a¾ŒÅ8Æ2¸Œ¶¹ŒÇ™ÇŒ» ¶È¾/¸Œ½º» ¿T½˜Á+Á+Á+Á+Á+Á+Á+Á+ÁoÁ+Á+Á+Á+Á+Á+Á+Á+Á„É

ON-BOARD DIAGNOSTICS
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page

page

DESCRIPTION AND OPERATION
CIRCUIT ACTUATION TEST MODE . . . . . . . . . . . 2
COMPONENT MONITORS . . . . . . . . . . . . . . . . . 18
DIAGNOSTIC TROUBLE
CODE DESCRIPTIONS . . . . . . . . . . . . . . . . . . . 3
DIAGNOSTIC TROUBLE CODES . . . . . . . . . . . . . 2
HIGH AND LOW LIMITS . . . . . . . . . . . . . . . . . . . 19

LOAD VALUE . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
MALFUNCTION INDICATOR LAMP (MIL) . . . . . . . 1
MONITORED SYSTEMS . . . . . . . . . . . . . . . . . . . 15
NON-MONITORED CIRCUITS . . . . . . . . . . . . . . 18
STATE DISPLAY TEST MODE . . . . . . . . . . . . . . . 2
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . 1
TRIP DEFINITION . . . . . . . . . . . . . . . . . . . . . . . . 17

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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 (check engine lamp).

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WARNING: APPLY PARKING BRAKE AND/OR
BLOCK WHEELS BEFORE PERFORMING ANY TEST
ON AN OPERATING ENGINE.

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NOTE: For a list of DTC’s, refer to the following
charts.

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Generic
Scan Tool
P-Code

DRB Scan Tool Display

Brief Description of DTC

P0030 (M)

1/1 O2 Sensor Heater Relay Circuit

Problem detected in oxygen sensor heater relay circuit.

P0036 (M)

1/2 O2 Sensor Heater Relay Circuit

Problem detected in oxygen sensor heater relay circuit.

P0106

Barometric Pressure Out of Range

MAP sensor input voltage out of an acceptable range
detected during reading of barometric pressure at key-on.

P0107 (M)

Map Sensor Voltage Too Low

MAP sensor input below minimum acceptable voltage.

P0108 (M)

Map Sensor Voltage Too High

MAP sensor input above maximum acceptable voltage.

P0112 (M)

Intake Air Temp Sensor Voltage Low

Intake air (charge) temperature sensor input below the
minimum acceptable voltage.

P0113 (M)

Intake Air Temp Sensor Voltage High

Intake air (charge) temperature sensor input above the
maximum acceptable voltage.

P0116

A rationatilty error has been detected in the coolant temp
sensor.

P0117 (M)

ECT Sensor Voltage Too Low

Engine coolant temperature sensor input below the
minimum acceptable voltage.

P0118 (M)

ECT Sensor Voltage Too High

Engine coolant temperature sensor input above the
maximum acceptable voltage.

P0121 (M)

TPS Voltage Does Not Agree With
MAP

TPS signal does not correlate to MAP sensor signal.

P0121 (M)

Accelerator Position Sensor (APPS)
Signal Voltage Too Low

APPS voltage input below the minimum acceptable
voltage.

P0122 (M)

Throttle Position Sensor Voltage Low

Throttle position sensor input below the acceptable
voltage range.

P0122 (M)

Accelerator Position Sensor (APPS)
Signal Voltage Too Low

APPS voltage input below the minimum acceptable
voltage.

P0123 (M)

Throttle Position Sensor Voltage
High

Throttle position sensor input above the maximum
acceptable voltage.

P0123 (M)

Accelerator Position Sensor (APPS)
Signal Voltage Too High

APPS voltage input above the maximum acceptable
voltage.

P0125 (M)

Closed Loop Temp Not Reached

Time to enter Closed Loop Operation (Fuel Control) is
excessive.

P0125 (M)

Engine is Cold Too Long

Engine does not reach operating temperature.

P0131 (M)

1/1 O2 Sensor Shorted To Ground

Oxygen sensor input voltage maintained below normal
operating range.

P0132 (M)

1/1 O2 Sensor Shorted To Voltage

Oxygen sensor input voltage maintained above normal
operating range.

P0133 (M)

1/1 O2 Sensor Slow Response

Oxygen sensor response slower than minimum required
switching frequency.

P0134 (M)

1/1 O2 Sensor Stays at Center

Neither rich or lean condition is detected from the oxygen
sensor input.

P0135 (M)

1/1 O2 Sensor Heater Failure

Oxygen sensor heater element malfunction.

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Generic
Scan Tool
P-Code

DRB Scan Tool Display

Brief Description of DTC

P0137 (M)

1/2 O2 Sensor Shorted To Ground

Oxygen sensor input voltage maintained below normal
operating range.

P0138 (M)

1/2 O2 Sensor Shorted To Voltage

Oxygen sensor input voltage maintained above normal
operating range.

P0139 (M)

1/2 O2 Sensor Slow Response

Oxygen sensor response not as expected.

P0140 (M)

1/2 O2 Sensor Stays at Center

Neither rich or lean condition is detected from the oxygen
sensor.

P0141 (M)

1/2 O2 Sensor Heater Failure

Oxygen sensor heater element malfunction.

P0143 (M)

1/3 O2 Sensor Shorted To Ground

Oxygen sensor input voltage maintained below normal
operating range.

P0144 (M)

1/3 O2 Sensor Shorted To Voltage

Oxygen sensor input voltage maintained above normal
operating range.

P0145 (M)

1/3 O2 Sensor Slow Response

Oxygen sensor response slower than minimum required
switching frequency.

P0146 (M)

1/3 O2 Sensor Stays at Center

Neither rich or lean condition is detected from the oxygen
sensor.

P0147 (M)

1/3 O2 Sensor Heater Failure

Oxygen sensor heater element malfunction.

P0151 (M)

2/1 O2 Sensor Shorted To Ground

Oxygen sensor input voltage maintained below normal
operating range.

P0152 (M)

2/1 O2 Sensor Shorted To Voltage

Oxygen sensor input voltage sustained above normal
operating range.

P0153 (M)

2/1 O2 Sensor Slow Response

Oxygen sensor response slower than minimum required
switching frequency.

P0154 (M)

2/1 O2 Sensor Stays at Center

Neither rich or lean condition is detected from the oxygen
sensor.

P0155 (M)

2/1 O2 Sensor Heater Failure

Oxygen sensor heater element malfunction.

P0157 (M)

2/2 O2 Sensor Shorted To Ground

Oxygen sensor input voltage maintained below normal
operating range.

P0158 (M)

2/2 O2 Sensor Shorted To Voltage

Oxygen sensor input voltage maintained above normal
operating range.

P0159

2/2 O2 Sensor Slow Response

Oxygen sensor response slower than minimum required
switching frequency.

P0160 (M)

2/2 O2 Sensor Stays at Center

Neither rich or lean condition is detected from the oxygen
sensor.

P0161 (M)

2/2 O2 Sensor Heater Failure

Oxygen sensor heater element malfunction.

P0168

Decreased Engine Performance Due
To High Injection Pump Fuel Temp

Fuel temperature is above the engine protection limit.
Engine power will be derated.

P0171 (M)

1/1 Fuel System Lean

A lean air/fuel mixture has been indicated by an
abnormally rich correction factor.

P0172 (M)

1/1 Fuel System Rich

A rich air/fuel mixture has been indicated by an
abnormally lean correction factor.

P0174 (M)

2/1 Fuel System Lean

A lean air/fuel mixture has been indicated by an
abnormally rich correction factor.

P0175 (M)

2/1 Fuel System Rich

A rich air/fuel mixture has been indicated by an
abnormally lean correction factor.

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Generic
Scan Tool
P-Code

DRB Scan Tool Display

Brief Description of DTC

P0176

Loss of Flex Fuel Calibration Signal

No calibration voltage present from flex fuel sensor.

P0177

Water In Fuel

Excess water found in fuel by water-in-fuel sensor.

P0178

Flex Fuel Sensor Volts Too Low

Flex fuel sensor input below minimum acceptable voltage.

P0178

Water In Fuel Sensor Voltage Too
Low

Loss of water-in-fuel circuit or sensor.

P0179

Flex Fuel Sensor Volts Too High

Flex fuel sensor input above maximum acceptable
voltage.

P0181

Fuel Injection Pump Failure

Low power, engine derated, or engine stops.

P0182 (M)

CNG Temp Sensor Voltage Too Low

Compressed natural gas temperature sensor voltage
below acceptable voltage.

P0183 (M)

CNG Temp Sensor Voltage Too High

Compressed natural gas temperature sensor voltage
above acceptable voltage.

P0201 (M)

Injector #1 Control Circuit

An open or shorted condition detected in control circuit for
injector #1 or the INJ 1 injector bank.

P0202 (M)

Injector #2 Control Circuit

An open or shorted condition detected in control circuit for
injector #2 or the INJ 2 injector bank.

P0203 (M)

Injector #3 Control Circuit

An open or shorted condition detected in control circuit for
injector #3 or the INJ 3 injector bank.

P0204 (M)

Injector #4 Control Circuit

Injector #4 or INJ 4 injector bank output driver stage does
not respond properly to the control signal.

P0205 (M)

Injector #5 Control Circuit

Injector #5 output driver stage does not respond properly
to the control signal.

P0206 (M)

Injector #6 Control Circuit

Injector #6 output driver stage does not respond properly
to the control signal.

P0207 (M)

Injector #7 Control Circuit

Injector #7 output driver stage does not respond properly
to the control signal.

P0208 (M)

Injector #8 Control Circuit

Injector #8 output driver stage does not respond properly
to the control signal.

P0209 (M)

Injector #9 Control Circuit

Injector #9 output driver stage does not respond properly
to the control signal.

P0210 (M)

Injector #10 Control Circuit

Injector #10 output driver stage does not respond properly
to the control signal.

P0215

Fuel Injection Pump Control Circuit

Failure in fuel pump relay control circuit.

P0216 (M)

Fuel Injection Pump Timing Failure

High fuel supply restriction, low fuel pressure or possible
wrong or incorrectly installed pump keyway.

P0217

Decreased Engine Performance Due
To Engine Overheat Condition

Engine overheating. ECM will derate engine performance.

P0219

Crankshaft Position Sensor
Overspeed Signal

Engine has exceeded rpm limits.

P0222 (M)

Idle Validation Signals Both Low

Problem detected with idle validation circuits within APPS.

P0223 (M)

Idle Validation Signals Both High
(Above 5 Volts)

Problem detected with idle validation circuits within APPS.

P0230

Transfer Pump (Lift Pump) Circuit
Out of Range

Problem detected in fuel transfer pump circuits.

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Generic
Scan Tool
P-Code

DRB Scan Tool Display

Brief Description of DTC

P0232

Fuel Shutoff Signal Voltage Too High

Fuel shut-off signal voltage too high from ECM to fuel
injection pump.

P0234 (M)

Turbo Boost Limit Exceeded

Problem detected in turbocharger wastegate.

P0236 (M)

Map Sensor Too High Too Long

Problem detected in turbocharger wastegate.

P0237 (M)

Map Sensor Voltage Too Low

MAP sensor voltage input below the minimum acceptable
voltage.

P0238 (M)

Map Sensor Voltage Too High

MAP sensor voltage input above the maximum
acceptable voltage.

P0251 (M)

Fuel Inj. Pump Mech. Failure Fuel
Valve Feedback Circuit

Problem sensed with fuel circuit internal to fuel injection
pump.

P0253 (M)

Fuel Injection Pump Fuel Valve
Open Circuit

Problem sensed with fuel circuit internal to fuel injection
pump.

P0254

Fuel Injection Pump Fuel Valve
Current Too High

Problem caused by internal fuel injection pump failure.

P0300 (M)

Multiple Cylinder Mis-fire

Misfire detected in multiple cylinders.

P0301 (M)

CYLINDER #1 MISFIRE

Misfire detected in cylinder #1.

P0302 (M)

CYLINDER #2 MISFIRE

Misfire detected in cylinder #2.

P0303 (M)

CYLINDER #3 MISFIRE

Misfire detected in cylinder #3.

P0304 (M)

CYLINDER #4 MISFIRE

Misfire detected in cylinder #4.

P0305 (M)

CYLINDER #5 MISFIRE

Misfire detected in cylinder #5.

P0306 (M)

CYLINDER #6 MISFIRE

Misfire detected in cylinder #6.

P0307 (M)

CYLINDER #7 MISFIRE

Misfire detected in cylinder #7

P0308 (M)

CYLINDER #8 MISFIRE

Misfire detected in cylinder #8.

P0309 (M)

CYLINDER #9 MISFIRE

Misfire detected in cylinder #9.

P0310 (M)

CYLINDER #10 MISFIRE

Misfire detected in cylinder #10.

P0320 (M)

No Crank Referance Signal at PCM

No reference signal (crankshaft position sensor) detected
during engine cranking.

P0320 (M)

No RPM Signal to PCM (Crankshaft
Position Sensor Signal to JTEC)

A CKP signal has not been detected at the PCM.

P0325

Knock Sensor #1 Circuit

Knock sensor (#1) signal above or below minimum
acceptable threshold voltage at particular engine speeds.

P0330

Knock Sensor #2 Circuit

Knock sensor (#2) signal above or below minimum
acceptable threshold voltage at particular engine speeds.

P0336 (M)

Crankshaft Position (CKP) Sensor
Signal

Problem with voltage signal from CKP.

P0340 (M)

No Cam Signal At PCM

No fuel sync

P0341 (M)

Camshaft Position (CMP) Sensor
Signal

Problem with voltage signal from CMP.

P0350

Ignition Coil Draws Too Much
Current

A coil (1-5) is drawing too much current.

P0351 (M)

Ignition Coil # 1 Primary Circuit

Peak primary circuit current not achieved with maximum
dwell time.

P0352 (M)

Ignition Coil # 2 Primary Circuit

Peak primary circuit current not achieved with maximum
dwell time.

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Generic
Scan Tool
P-Code

DRB Scan Tool Display

Brief Description of DTC

P0353 (M)

Ignition Coil # 3 Primary Circuit

Peak primary circuit current not achieved with maximum
dwell time.

P0354 (M)

Ignition Coil # 4 Primary Circuit

Peak primary circuit current not achieved with maximum
dwell time (High Impedance).

P0355 (M)

Ignition Coil # 5 Primary Circuit

Peak primary circuit current not achieved with maximum
dwell time (High Impedance).

P0356 (M)

Ignition Coil # 6 Primary Circuit

Peak primary circuit current not achieved with maximum
dwell time (high impedance).

P0357 (M)

Ignition Coil # 7 Primary Circuit

Peak primary circuit current not achieved with maximum
dwell time (high impedance).

P0358 (M)

Ignition Coil # 8 Primary Circuit

Peak primary circuit current not achieved with maximum
dwell time (high impedance).

P0370

Fuel Injection Pump Speed/Position
Sensor Sig Lost

Problem caused by internal fuel injection pump failure.

P0380 (M)

Intake Air Heater Relay #1 Control
Circuit

Problem detected in #1 air heater solenoid/relay circuit
(not heater element)

P0381 (M)

Wait To Start Lamp Inoperative

Problem detected in wait-to-start bulb circuit.

P0382 (M)

Intake Air Heater Relay #2 Control
Circuit

Problem detected in #2 air heater solenoid/relay circuit
(not heater element)

P0387

Crankshaft Position Sensor Supply
Voltage Too Low

CKP sensor voltage input below the minimum acceptable
voltage.

P0388

Crankshaft Position Sensor Supply
Voltage Too High

CKP sensor voltage input above the maximum acceptable
voltage.

P0401

EGR System Failure

Required change in air/fuel ration not detected during
diagnostic test.

P0403

EGR Solenoid Circuit

An open or shorted condition detected in the EGR
solenoid control circuit.

P0404

EGR Position Sensor Rationality

EGR position sensor signal does not correlate to EGR
duty cycle.

P0405

EGR Position Sensor Volts Too Low

EGR position sensor input below the acceptable voltage
range.

P0406

EGR Position Sensor Volts Too High

EGR position sensor input above the acceptable voltage
range.

P0412

Secondary Air Solenoid Circuit

An open or shorted condition detected in the secondary
air (air switching/aspirator) solenoid control circuit.

P0420 (M)

1/1 Catalytic Converter Efficiency

Catalyst 1/1 efficiency below required level.

P0432 (M)

1/2 Catalytic Converter Efficiency

Catalyst 2/1 efficiency below required level.

P0441 (M)

Evap Purge Flow Monitor

Insufficient or excessive vapor flow detected during
evaporative emission system operation.

P0442 (M)

Evap Leak Monitor Medium Leak
Detected

A small leak has been detected in the evaporative
system.

P0443 (M)

Evap Purge Solenoid Circuit

An open or shorted condition detected in the EVAP purge
solenoid control circuit.

P0455 (M)

Evap Leak Monitor Large Leak
Detected

A large leak has been detected in the evaporative system.

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Generic
Scan Tool
P-Code

DRB Scan Tool Display

Brief Description of DTC

P0456 (M)

Evap Leak Monitor Small Leak
Detected

Leak has been detected in the evaporative system.

P0460

Fuel Level Unit No Change Over
Miles

During low fuel

P0460

Fuel Level Unit No Change Over
Miles

Fuel level sending unit voltage does not change for more
than 40 miles.

P0462

Fuel Level Sending Unit Volts Too
Low

Fuel level sensor input below acceptable voltage.

P0462 (M)

Fuel Level Sending Unit Volts Too
Low

Open circuit between PCM and fuel gauge sending unit.

P0463

Fuel Level Sending Unit Volts Too
High

Fuel level sensor input above acceptable voltage.

P0463 (M)

Fuel Level Sending Unit Volts Too
High

Circuit shorted to voltage between PCM and fuel gauge
sending unit.

P0500 (M)

No Vehicle Speed Sensor Signal

No vehicle speed sensor signal detected during road load
conditions.

P0500 (M)

No Vehicle Speed Sensor Signal

A vehicle speed signal was not detected.

P0505 (M)

Idle Air Control Motor Circuits

SBEC II

P0522

Oil Pressure Voltage Too Low

Oil pressure sending unit (sensor) voltage input below the
minimum acceptable voltage.

P0523

Oil Pressure Voltage Too High

Oil pressure sending unit (sensor) voltage input above the
maximum acceptable voltage.

P0524

Oil Pressure Too Low

Engine oil pressure is low. Engine power derated.

P0545

A/C Clutch Relay Circuit

Problem detected in air conditioning clutch relay control
circuit.

P0551

Power Steering Switch Failure

Incorrect input state detected for the power steering
switch circuit. PL: High pressure seen at high speed.

P0562

Charging System Voltage Too Low

Supply voltage sensed at ECM too low.

P0563

Charging System Voltage Too High

Supply voltage sensed at ECM too high.

P0600

PCM Failure SPI Communications

No communication detected between co-processors in the
control module.

P0601 (M)

Internal Controller Failure

Internal control module fault condition (check sum)
detected.

P0602 (M)

ECM Fueling Calibration Error

ECM Internal fault condition detected.

P0604

RAM Check Failure

Transmission control module RAM self test fault detected.
-Aisin transmission

P0605

ROM Check Falure

Transmission control module ROM self test fault detected
-Aisin transmission

P0606 (M)

ECM Failure

ECM Internal fault condition detected.

P0615

Starter Relay Control Circuit

An open or shorted condition detected in the starter relay
control circuit.

P0622 (G)

Generator Field Not Switching
Properly

An open or shorted condition detected in the generator
field control circuit.

P0645

A/C Clutch Relay Circuit

An open or shorted condition detected in the A/C clutch
relay control circuit.

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Generic
Scan Tool
P-Code

DRB Scan Tool Display

Brief Description of DTC

P0700

EATX Controller DTC Present

This SBEC III or JTEC DTC indicates that the EATX or
Aisin controller has an active fault and has illuminated the
MIL via a CCD (EATX) or SCI (Aisin) message. The
specific fault must be acquired from the EATX via CCD or
from the Aisin via ISO-9141.

P0703

Brake Switch Stuck Pressed or
Released

Incorrect input state detected in the brake switch circuit.
(Changed from P1595)

P0711 (M)

Trans Temp Sensor, No Temp Rise
After Start

Relationship between the transmission temperature and
overdrive operation and/or TCC operation indicates a
failure of the Transmission Temperature Sensor. OBD II
Rationality. Was MIL code 37.

P0712

Trans Temp Sensor Voltage Too Low

Transmission fluid temperature sensor input below
acceptable voltage. Was MIL code 37.

P0712 (M)

Trans Temp Sensor Voltage Too Low

Voltage less than 1.55 volts (4-speed auto. trans. only).

P0713

Trans Temp Sensor Voltage Too
High

Transmission fluid temperature sensor input above
acceptable voltage. Was MIL code 37.

P0713 (M)

Trans Temp Sensor Voltage Too
High

Voltage greater than 3.76 volts (4-speed auto. trans.
only).

P0720 (M)

Low Output SPD Sensor RPM,
Above 15 MPH

The relationship between the Output Shaft Speed Sensor
and vehicle speed is not within acceptable limits.

P0720 (M)

Low Output Spd Sensor RPM Above
15 mph

Output shaft speed is less than 60 rpm with vehicle speed
above 15 mph (4-speed auto. trans. only).

P0740 (M)

Torq Con Clu, No RPM Drop at
Lockup

Relationship between engine and vehicle speeds
indicated failure of torque convertor clutch lock-up system
(TCC/PTU solenoid)

P0743 (M)

Torque Converter Clutch Solenoid/
Trans Relay Circuits

An open or shorted condition detected in the torque
converter clutch (part throttle unlock) solenoid control
circuit. Shift solenoid C electrical fault - Aisin transmission

P0743 (M)

Torque Converter Clutch Solenoid/
Trans Relay Circuits

An open or shorted condition detected in the torque
converter part throttle unlock solenoid control circuit (3 or
4-speed auto. trans. only).

P0748 (M)

Governor Pressur Sol Control/Trans
Relay Circuits

An open or shorted condition detected in the Governor
Pressure Solenoid circuit or Trans Relay Circuit in JTEC
RE transmissions.

P0748 (M)

Governor Pressure Sol Control/Trans
Relay Circuits

An open or shorted condition detected in the governor
pressure solenoid or relay circuits (4-speed auto. trans.
only).

P0751 (M)

O/D Switch Pressed (Lo) More Than
5 Minutes

Overdrive override switch input is in a prolonged
depressed state.

P0751 (M)

O/D Switch Pressed (LO) More Than
5 Min

Overdrive Off switch input too low for more than 5
minutes (4-speed auto. trans. only).

P0753 (M)

Trans 3-4 Shift Sol/Trans Relay
Circuits

An open or shorted condition detected in the overdrive
solenoid control circuit or Trans Relay Circuit in JTEC RE
transmissions. Was MIL code 45.

P0753 (M)

Trans 3-4 Shift Sol/Trans Relay
Circuits

An open or shorted condition detected in the transmission
2-4 shift solenoid circuit (4-speed auto. trans. only).

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Generic
Scan Tool
P-Code

DRB Scan Tool Display

Brief Description of DTC

P0756

AW4 Shift Sol B (2-3) Functional
Failure

Shift solenoid B (2-3) functional fault - Aisin transmission

P0783 (M)

3-4 Shift Sol, No RPM Drop at
Lockup

The overdrive solenoid is unable to engage the gear
change from 3rd gear to the overdrive gear.

P0801

Reverse Gear Lockout Circuit Open
or Short

An open or shorted condition detected in the transmission
reverse gear lock-out solenoid control circuit.

P0830

Clutch Depressed Switch Circuit

Problem detected in clutch switch circuit.

P0833

Clutch Released Switch Circuit

Problem detected in clutch switch circuit.

P1110

Decrease Engine Performance Due
To High Intake Air Temperature

Intake manifold air temperature is above the engine
protection limit. Engine power will be derated.

P1180

Decreased Engine Performance Due
To High Injection Pump Fuel Temp

Fuel temperature is above the engine protection limit.
Engine power will be derated.

P1195 (M)

1/1 O2 Sensor Slow During Catalyst
Monitor

A slow switching oxygen sensor has been detected in
bank 1/1 during catalyst monitor test. (Also see SCI DTC
$66) (was P0133)

P1196 (M)

2/1 O2 Sensor Slow During Catalyst
Monitor

A slow switching oxygen sensor has been detected in
bank 2/1 during catalyst monitor test. (Also see SCI DTC
$7A) (was P0153)

P1197

1/2 O2 Sensor Slow During Catalyst
Monitor

A slow switching oxygen sensor has been detected in
bank 1/2 during catalyst monitor test. (Also see SCI DTC
$68) (was P0139)

P1198

Radiator Temperature Sensor Volts
Too High

Radiator coolant temperature sensor input above the
maximum acceptable voltage.

P1199

Radiator Temperature Sensor Volts
Too Low

Radiator coolant temperature sensor input below the
minimum acceptable voltage.

P1281

Engine is Cold Too Long

Engine coolant temperature remains below normal
operating temperatures during vehicle travel (Thermostat).

P1282

Fuel Pump Relay Control Circuit

An open or shorted condition detected in the fuel pump
relay control circuit.

P1283

Idle Select Signal Invalid

ECM or fuel injection pump module internal fault condition
detected.

P1284 (M)

Fuel Injection Pump Battery Voltage
Out-Of-Range

Fuel injection pump module internal fault condition
detected. Engine power will be derated.

P1285 (M)

Fuel Injection Pump Controller
Always On

Fuel injection pump module relay circuit failure detected.
Engine power will be derated.

P1286

Accelerator Position Sensor (APPS)
Supply Voltage Too High

High voltage detected at APPS.

P1287

Fuel Injection Pump Controller
Supply Voltage Low

ECM or fuel injection pump module internal fault condition
detected. Engine power will be derated.

P1288

Intake Manifold Short Runner
Solenoid Circuit

An open or shorted condition detected in the short runner
tuning valve circuit.

P1289

Manifold Tune Valve Solenoid Circuit

An open or shorted condition detected in the manifold
tuning valve solenoid control circuit.

P1290

CNG Fuel System Pressure Too
High

Compressed natural gas system pressure above normal
operating range.

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Generic
Scan Tool
P-Code

DRB Scan Tool Display

Brief Description of DTC

P1291

No Temp Rise Seen From Intake
Heaters

Energizing Heated Air Intake does not change intake air
temperature sensor an acceptable amount.

P1291 (M)

No Temperature Rise Seen From
Intake Air Heaters

Problem detected in intake manifold air heating system.

P1292

CNG Pressure Sensor Voltage Too
High

Compressed natural gas pressure sensor reading above
acceptable voltage.

P1293

CNG Pressure Sensor Voltage Too
Low

Compressed natural gas pressure sensor reading below
acceptable voltage.

P1294 (M)

Target Idle Not Reached

Target RPM not achieved during drive idle condition.
Possible vacuum leak or IAC (AIS) lost steps.

P1295 (M)

No 5 Volts to TP Sensor

Loss of a 5 volt feed to the Throttle Position Sensor has
been detected.

P1295 (M)

Accelerator Position Sensor (APPS)
Supply Voltage Too Low

APPS supply voltage input below the minimum
acceptable voltage.

P1296

No 5 Volts to MAP Sensor

Loss of a 5 volt feed to the MAP Sensor has been
detected.

P1297 (M)

No Change in MAP From Start To
Run

No difference is recognized between the MAP reading at
engine idle and the stored barometric pressure reading.

P1298

Lean Operation at Wide Open
Throttle

A prolonged lean condition is detected during Wide Open
Throttle

P1299

Vacuum Leak Found (IAC Fully
Seated)

MAP Sensor signal does not correlate to Throttle Position
Sensor signal. Possible vacuum leak.

P1388

Auto Shutdown Relay Control Circuit

An open or shorted condition detected in the ASD or CNG
shutoff relay control ckt.

P1388

Auto Shutdown Relay Control Circuit

An open or shorted condition detected in the auto
shutdown relay circuit.

P1389

No ASD Relay Output Voltage At
PCM

No Z1 or Z2 voltage sensed when the auto shutdown
relay is energized.

P1389 (M)

No ASD Relay Output Voltage at
PCM

An open condition detected In the ASD relay output
circuit.

P1390

Timing Belt Skipped 1 Tooth or More

Relationship between Cam and Crank signals not correct

P1391 (M)

Intermittent Loss of CMP or CKP

Loss of the Cam Position Sensor or Crank Position
sensor has occurred. For PL 2.0L

P1398 (M)

Mis-Fire Adaptive Numerator at Limit

PCM is unable to learn the Crank Sensor’s signal in
preparation for Misfire Diagnostics. Probable defective
Crank Sensor

P1399

Wait To Start Lamp Cicuit

An open or shorted condition detected in the Wait to Start
Lamp circuit.

P1403

No 5V to EGR Sens

Loss of 5v feed to the EGR position sensor.

P01475

Aux 5 Volt Supply Voltage High

Sensor supply voltage for ECM sensors is too high.

P1476

Too Little Secondary Air

Insufficient flow of secondary air injection detected during
aspirator test (was P0411)

P1477

Too Much Secondary Air

Excessive flow of secondary air injection detected during
aspirator test (was P0411).

P1478

Battery Temp Sensor Volts Out of
Limit

Internal temperature sensor input voltage out of an
acceptable range.

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Generic
Scan Tool
P-Code

DRB Scan Tool Display

Brief Description of DTC

P1479

Transmission Fan Relay Circuit

An open or shorted condition detected in the transmission
fan relay circuit.

P1480

PCV Solenoid Circuit

An open or shorted condition detected in the PCV
solenoid circuit.

P1481

EATX RPM Pulse Perf

EATX RPM pulse generator signal for misfire detection
does not correlate with expected value.

P1482

Catalyst Temperature Sensor Circuit
Shorted Low

Catalyst temperature sensor circuit shorted low.

P1483

Catalyst Temperature Sensor Circuit
Shorted High.

Catalyst temperature sensor circuit shorted high.

P1484

Catalytic Converter Overheat
Detected

A catalyst overheat condition has been detected by the
catalyst temperature sensor.

P1485

Air Injection Solenoid Circuit

An open or shorted condition detected in the air assist
solenoid circuit.

P1486

Evap Leak Monitor Pinched Hose
Found

LDP has detected a pinched hose in the evaporative hose
system.

P1487

Hi Speed Rad Fan CTRL Relay
Circuit

An open or shorted condition detected in the control
circuit of the #2 high speed radiator fan control relay.

P1488

Auxiliary 5 Volt Supply Output Too
Low

Auxiliary 5 volt sensor feed is sensed to be below an
acceptable limit.

P1488

5 Volt Supply Voltage Low

Sensor supply voltage for ECM sensors is too low.

P1489

High Speed Fan CTRL Relay Circuit

An open or shorted condition detected in the control
circuit of the high speed radiator fan control relay.

P1490

Low Speed Fan CTRL Relay Circuit

An open or shorted condition detected in control circuit of
the low speed radiator fan control relay.

P1491

Rad Fan Control Relay Circuit

An open or shorted condition detected in the radiator fan
control relay control circuit. This includes PWM solid state
relays.

P1492

Ambient/Batt Temp Sen Volts Too
High

External temperature sensor input above acceptable
voltage.

P1492 (M)

Ambient/Batt Temp Sensor Volts Too
High

Battery temperature sensor input voltage above an
acceptable range.

P1493 (M)

Ambient/Batt Temp Sen Volts Too
Low

External temperature sensor input below acceptable
voltage.

P1493 (M)

Ambient/Batt Temp Sen Volts Too
Low

Battery temperature sensor input voltage below an
acceptable range.

P1494 (M)

Leak Detection Pump Sw or
Mechanical Fault

Incorrect input state detected for the Leak Detection
Pump (LDP) pressure switch.

P1495

Leak Detection Pump Solenoid
Circuit

An open or shorted condition detected in the Leak
Detection Pump (LDP) solenoid circuit.

P1496

5 Volt Supply, Output Too Low

5 volt sensor feed is sensed to be below an acceptable
limit. ( less than 4v for 4 sec )

P1498

High Speed Rad Fan Ground CTRL
Rly Circuit

An open or shorted condition detected in the control
circuit of the #3 high speed radiator fan control relay.

P1594 (G)

Charging System Voltage Too High

Battery voltage sense input above target charging voltage
during engine operation.

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Generic
Scan Tool
P-Code

DRB Scan Tool Display

Brief Description of DTC

P1594

Charging System Voltage Too High

Battery voltage sense input above target charging voltage
during engine operation.

P1595

Speed Control Solenoid Circuits

An open or shorted condition detected in either of the
speed control vacuum or vent solenoid control circuits.

P1595

Speed Control Solenoid Circuits

An open or shorted condition detected in the speed
control vacuum or vent solenoid circuits.

P1596

Speed Control Switch Always High

Speed control switch input above maximum acceptable
voltage.

P1597

Speed Control Switch Always Low

Speed control switch input below minimum acceptable
voltage.

P1597

Speed Control Switch Always Low

Speed control switch input below the minimum acceptable
voltage.

P1598

A/C Pressure Sensor Volts Too High

A/C pressure sensor input above maximum acceptable
voltage.

P1598

A/C Sensor Input Hi

Problem detected in air conditioning electrical circuit.

P1599

A/C Pressure Sensor Volts Too Low

A/C pressure sensor input below minimum acceptable
voltage.

P1599

A/C Sensor Input Lo

Problem detected in air conditioning electrical circuit.

P1680

Clutch Released Switch Circuit

Problem detected in clutch switch electrical circuit.

P1681

No I/P Cluster CCD/J1850
Messages Received

No CCD/J1850 messages received from the cluster
control module.

P1682 (G)

Charging System Voltage Too Low

Battery voltage sense input below target charging voltage
during engine operation and no significant change in
voltage detected during active test of generator output
circuit.

P1682

Charging System Voltage Too Low

Charging system output voltage low.

P1683

SPD CTRL PWR Relay; or S/C 12v
Driver CKT

An open or shorted condition detected in the speed
control servo power control circuit.

P1683

Spd ctrl pwr rly, or s/c 12v driver
circuit

An open or shorted condition detected in the speed
control servo power control circuit.

P1684

Batt Loss in 50 Star

The battery has been disconnected within the last 50
starts

P1685

SKIM Invalid Key

The engine controler has received an invalid key from the
SKIM.

P1686

No SKIM BUS Messages Received

No CCD/J1850 messages received from the Smart Key
Immobilizer Module (SKIM).

P1687

No MIC BUS Message

No CCD/J1850 messages received from the Mechanical
Instrument Cluster (MIC) module.

P1688 (M)

Internal Fuel Injection Pump
Controller Failure

Internal problem within the fuel injection pump. Low
power, engine derated, or engine stops.

P1689 (M)

No Communication Between ECM
and Injection Pump Module

Data link circuit failure between ECM and fuel injection
pump. Low power, engine derated, or engine stops.

P1690 (M)

Fuel Injection Pump CKP Sensor
Does Not Agree With ECM CKP
Sensor

Problem in fuel sync signal. Possible injection pump
timing problem. Low power, engine derated, or engine
stops.

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Generic
Scan Tool
P-Code

DRB Scan Tool Display

Brief Description of DTC

P1691

Fuel Injection Pump Controller
Calibration Error

Internal fuel injection pump failure. Low power, engine
derated, or engine stops.

P1692

DTC Set In ECM

A 9Companion DTC9 was set in both the ECM and PCM.

P1693 (M)

DTC Detected in Companion Module

A fault has been generated in the companion engine
control module.

P1693 (M)

DTC Detected in PCM/ECM or DTC
Detected in ECM

A 9Companion DTC9 was set in both the ECM and PCM.

P1694

Fault In Companion Module

No CCD/J1850 messages received from the powertrain
control module-Aisin transmission

P1694 (M)

No CCD Messages received from
ECM

Bus communication failure to PCM.

P1695

No CCD/J1850 Message From Body
Control Module

No CCD/J1850 messages received from the body control
module.

P1696

PCM Failure EEPROM Write Denied

Unsuccessful attempt to write to an EEPROM location by
the control module.

P1697

PCM Failure SRI Mile Not Stored

Unsuccessful attempt to update Service Reminder
Indicator (SRI or EMR) mileage in the control module
EEPROM.

P1698

No CCD/J1850 Message From TCM

No CCD/J1850 messages received from the electronic
transmission control module (EATX) or the Aisin
transmission controller.

P1698

No CCD Messages received from
PCM

Bus communication failure to PCM. A 9Companion DTC9
was set in both the ECM and PCM.

P1719

Skip Shift Solenoid Circuit

An open or shorted condition detected in the transmission
2-3 gear lock-out solenoid control circuit.

P1740

TCC or OD Sol Perf

A rationality error has been detected in either the TCC
solenoid or overdrive solenoid systems.

P1740 (M)

TCC OR O/D Solenoid Performance

Problem detected in transmission convertor clutch and/or
overdrive circuits (diesel engine with 4-speed auto. trans.
only).

P1756 (M)

GOV Press Not Equal to Target @
15-20 PSI

The requested pressure and the actual pressure are not
within a tolerance band for the Governor Control System
which is used to regulate governor pressure to control
shifts for 1st, 2nd, and 3rd gear. (Mid Pressure
Malfunction)

P1756 (M)

Governor Pressure Not Equal to
Target @ 15-20 PSI

Governor sensor input not between 10 and 25 psi when
requested (4-speed auto. trans. only).

P1757

GOV Press Not Equal to Target @
15-20 PSI

The requested pressure and the actual pressure are not
within a tolerance band for the Governor Control System
which is used to regulate governor pressure to control
shifts for 1st, 2nd, and 3rd gear (Zero Pressure
Malfunction)

P1757 (M)

Governor Pressure Above 3 PSI In
Gear With 0 MPH

Governor pressure greater than 3 psi when requested to
be 0 psi (4-speed auto. trans. only).

P1762 (M)

Gov Press Sen Offset Volts Too Lo
or High

The Governor Pressure Sensor input is greater than a
calibration limit or is less than a calibration limit for 3
consecutive park/neutral calibrations.

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P-Code

DRB Scan Tool Display

Brief Description of DTC

P1762 (M)

Governor Press Sen Offset Volts Too
Low or High

Sensor input greater or less than calibration for 3
consecutive Neutral/Park occurrences (4-speed auto.
trans. only).

P1763

Governor Pressure Sensor Volts Too
Hi

The Governor Pressure Sensor input is above an
acceptable voltage level.

P1763 (M)

Governor Pressure Sensor Volts Too
HI

Voltage greater than 4.89 volts (4-speed auto. trans.
only).

P1764 (M)

Governor Pressure Sensor Volts Too
Low

The Governor Pressure Sensor input is below an
acceptable voltage level.

P1764 (M)

Governor Pressure Sensor Volts Too
Low

Voltage less than .10 volts (4-speed auto. trans. only).

P1765 (M)

Trans 12 Volt Supply Relay CTRL
Circuit

An open or shorted condition is detected in the
Transmission Relay control circuit. This relay supplies
power to the TCC

P1765 (M)

Trans 12 Volt Supply Relay Ctrl
Circuit

Current state of solenoid output port is different than
expected (4-speed auto. trans. only).

P1899 (M)

P/N Switch Stuck in Park or in Gear

Incorrect input state detected for the Park/Neutral switch.

P1899 (M)

P/N Switch Stuck in Park or in Gear

Incorrect input state detected for the Park/Neutral switch
(3 or 4-speed auto. trans. only).

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All Engines

2% to 8% of
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Maximum Load

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EVAPORATIVE EMISSION CONTROLS
×ØÙÚBÛ
page
DESCRIPTION AND OPERATION
CRANKCASE VENTILATION SYSTEM . . . . . . .
DUTY CYCLE EVAP CANISTER PURGE
SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . .
EVAP CANISTER . . . . . . . . . . . . . . . . . . . . . . .
EVAPORATION CONTROL SYSTEM . . . . . . . .
LEAK DETECTION PUMP (LDP) . . . . . . . . . . . .
ROLLOVER VALVE . . . . . . . . . . . . . . . . . . . . . .
VEHICLE EMISSION CONTROL INFORMATION
(VECI) LABEL . . . . . . . . . . . . . . . . . . . . . . . .

. 21
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21
20
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20

. 23

page
DIAGNOSIS AND TESTING
LEAK DETECTION PUMP (LDP) . . . . .
VACUUM SCHEMATICS . . . . . . . . . . .
REMOVAL AND INSTALLATION
EVAP CANISTER . . . . . . . . . . . . . . . .
EVAP CANISTER PURGE SOLENOID
LEAK DETECTION PUMP (LDP) . . . . .
ROLLOVER VALVE . . . . . . . . . . . . . . .
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . .

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