1995 Dodge Ram Service Manual

19 9 5
SERVICE
MANUAL
RAM TRUCK
1500 - 3500
ft
2 WHEEL DRIVE
4 WHEEL DRIVE
^CHRYSLER
W CORPORATION
CHRYSLER
CORPORATION
SERVICE MANUAL
1995
RAM TRUCK
1500 - 3500
To order the special service tools used and

illustrated, please refer to the instructions on
inside back cover.
^WCHRYSLiR
w CORPORATION
NO PAET OF THIS PUBLICATION MAY BE

REPRODUCED, STORED IN A RETRIEVAL
SYSTEM, OR TRANSMITTED, IN ANY FORM
OR BY ANY MEANS, ELECTRONIC, ME
CHANICAL, PHOTOCOPYING, RECORDING,
OR OTHERWISE, WITHOUT THE PRIOR
WRITTEN PERMISSION OF CHRYSLER
CORPORATION.
Chrysler Corporation reserves the right to make changes in design or to

make additions to or improvements in Its products without imposing any ob
ligations upon itself to install them on its products previously manufactured.
Litho in U.S.A. Copyright © 1994 Chrysler Corporation 20M0694
Paper Content
50% Recycled
FOREWORD
- The information contained in this service manual has been prepared for the professional automotive tech
nician involved in daily repair operations. This manual does not cover theory of operation, which is addressed
in service training material. Information describing the operation and use of standard and optional equipment
is included in the Owner's Manual provided with the vehicle.
Information in this manual is divided into groups. These groups contain general information, diagnosis,
testing, adjustments, removal, installation, disassembly, and assembly procedures for the components, lb as
sist in locating a group title page, use the Group Tab Locator on the following page. The solid bar after the
group title is aligned to a solid tab on the first page of each group. The first page of the group has a contents
section that lists major topics within the group. If you are not sure which Group contains the information you
need, look up the Component/System in the alphabetical index located in the rear of this manual.
A Service Manual Comment form is included at the rear of this manual. Use the form to provide Chrysler
Corporation with your comments and suggestions.
Tightening torques are provided as a specific value throughout this manual. This value represents the
midpoint of the acceptable engineering torque range for a given fastener application. These torque values are
intended for use in service assembly and installation procedures using the correct OEM fasteners. When re
placing fasteners, always use the same type (part number) fastener as removed.
Chrysler Corporation reserves the right to change testing procedures, specifications, diagnosis, repair
methods, or vehicle wiring at any time without prior notice or incurring obligation.
NOTE: The acronyms, terminology and nomenclature used to identify emissions related components in
this manual may have changed from prior publications. These new terms are in compliance with S.A.E.
recommended practice J1930.
G R O U P TAB LOCATOR
Introduction
0 Lubrication and Maintenance
2 Front Suspension and Axle
3 Rear Suspension and Axles
v ::
5 Brakes j- j # 3
6 Clutch HHHHHHjj
7 Cooling System
8 Electrical vî
9 Engines
11 Exhaust System and Intake Manifold
13 Frame and Bumpers
14 Fuel System
16 Propeller Shafts
19 Steering , v-.--.'\.
21 Transmissions and Transfer Cases
22 Wheels and Tires
23 Body Components
24 Heating and Air Conditioning ., f..- '• 7;.^'
25 Emission Control Systems
Index
Service Manual Comment Forms (Rear of Manual)

BR INTRODUCTION 1
INTRODUCTION
CONTENTS
page page
DESIiNATIONS, LA1ELS/PLATE8/DECALS, l E I S U i E i E N T AND TOFtQUE

COOES ANi DilENSIONS/WEIiHTS 1 SPECIFICATIONS 21
DESIGNATIONS, LABELS/PLATES/DECALS, CODES AND DIMENSIONS/WEIGHTS
INDEX
page page
Body Code Plate 2 Trailer Towing Specifications 19

Engine and Transmission/Transfer Case Vehicle Designation . 1
Identification 2 Vehicle Dimensions . 3
Equipment Identification Label 2 Vehicle Identification Number (VIN) Plate 1
International Vehicle Control and Display Symbols . . 3 Vehicle Safety Certification Label . . . . . . . . . . . . . . . 1
Major Component Identification 2 Vehicle Weights 8
VEHICLE DESIGNATION
The Vehicle Code Designation for Ram Truck vehi m r v B I
CORPORATION XX-XX 04800 LB 2223 KG
cles is B R . The code is used to identify the vehicle in ;
charts, captions and in service procedures. The vehi ' GAWR FRONT WITH TIRES > RIMS AT PSI COLD >
| 2500 LB 1134 KG j P215/75R15 j 15x 7.0 30 |
cle code is different than the Vehicle Identification ; GAWR REAR ' WITH TIRES \ RIMS AT PSI COLD !
Number (V1N) or the wheelbase/model code. j 2700 LB 1225 KG j P215/7SR15 j 15x 7.0 30 j
TNIS VEHKLE CONFORMS TO ALL APPLKAILE FEDERAL MOTOR VEHKLE SAFETY
VEHICLE SAFETY CERTIFICATION LABEL STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE SHOWN ABOVE.
A certification label is attached to the left side B- VIN: xxxxxxxxxxxxxxxxx TYPE: MPV SINGLE X DUAL
pillar (Fig. 1). The label certifies that the vehicle con
forms to Federal Motor Vehicle Safety Standards
(FMVSS). The label also lists the:
• Month and year of vehicle manufacture. MDH: xxxxxx xxx MADE IN U.SJL. 4340503
• Gross Vehicle Weight Rating (GVWR). The gross J95IN-1
front and rear axle weight ratings (GAWR's) are
based on a minimum rim size and maximum cold tire Fig. 1 Vehicle Safety Certification Label—Typical
inflation pressure.
• Vehicle Identification Number (VIN). The Vehicle Identification Number is also im
• Type of vehicle. printed on the:
® Type of rear wheels . • Body Code Plate.
• Bar code. ' Equipment Identification Plate.
• Month, Day and Hour (SlDH) of final assembly. • Vehicle Safety Certification Label.
• Frame rail.
VEHICLE IDENTIFICATION NUMBER (VIN) PLATE To protect the consumer from theft and possible
fraud the manufacturer is required to include a
The Vehicle Identification Number (VIN) plate is
Check Digit at the ninth position of the Vehicle Iden
attached to the top left side of the instrument panel
tification Number. The check digit is used by the
(Fig. 2). The VIN contains 17 characters that provide
manufacturer and government agencies to verify the
data concerning the vehicle. Refer to the decoding
authenticity of the vehicle and official documenta-
chart to determine the identification of a vehicle.
2 INTRODUCTION BR
BODY CODE PLATE

NSTRUMENT
PRIMARY SECONDARY VINYL ROOF
PAINT PAINT
VEHICLE CAR
ORDER - LINE
NUMBER
_± _ r SHELL
(3) XXX X XXXX>K XXX xxxxxx
PAINT - ENGINE
PROCEDURE (2) X X X xxxx xxxx xxxx X X X

XXX X XXXXXXXXXXXXXXXXX •TRIM
-VEHICLE IDENTIFICATION (1)
NUMBER PLATE
VIN J94SN-23 T R A N S M I S S IO
ONN j| VIN
Fig. 2 Vehicle Identification Number (VIN) Location AAARKET

93IN-8
tion. The formula to use the check digit is not re
leased to the general public. Refer to Group 21, Transmissions for all transmis
sion/transfer case identification data.
BODY CODE PLATE
1AJ0R COiPONENT IDENTIFICATION
The Body Code Plate is located on the floor pan un
der the passenger side seat. There are seven lines of Refer to the applicable group for identification
data.
information on the body code plate. Lines 4, 5, 6, and
7 are not used to define service information. Informa E0U1P1ENT IDENTIFICATION LABEL
tion reads from left to right, starting with line 3 in The Equipment Identification Plate (Fig. 3) is lo
the center of the plate to line 1 at the bottom of the cated at the right, front corner of the inner hood
plate. panel. The plate lists information concerning the ve
ENGINE AND TRANSMISSION/TRANSFER CASE hicle as follows:
• The model.
IDENTIFICATION • The wheelbase.
Refer to Group 9, Engines for all engine identifica • The VIN (Vehicle Identification Number).
tion data. • The T.O.N, (order number).
VEHICLE IDENTIFICATION NUMBER (VIN) DECODING
Vehicle Type Line Engine Sequential

4 = Multipurpose C = Ram Chassis C a b / C = 5.9L 6 cyl. Diesel Serial Number
Passenger Ram Pick-up (4 x 2) W= 8.0L 10 cyl. MPI Six Digit Numbers
5 = Bus F = Ram Chassis C a b / X = 3.9L 6 cyl. MPI
6 = Incomplete Ram Pick-up (4 x 4) Y = 5.2L 8 cyl. MPI
7 = Truck Z = 5.9L 8 cyl. MPI-LDC
5 = 5.9L 8 cyl. MPI-HDC
1 B
7 n 100001
z.
Moke
z
GVWR Check Digit Plant Location
B = Dodge H = 6001 -7000 Number or Letter S = Dodge City
J - 7001-8000 G = Saltillo
K = 8001-9000 Lago Alberto Assembly
L = 9001-10,000 Body
M = 10,001-14,000 3 = Club Cab
W = Hydraulic 6 = Conventional Cab
Brakes Chassis Cab
Chassis J95IN-36
BR INTRODUCTION 3
BODY CODE DECODING

Ifrmeum EQUIPMENT IDENTIFICATION wmm'
Line # 1 Digit 1-3 Transmission Sales Code
Digit 4 Open Space MODELS V.I.N. T.O.N.
Digit 5 Market Code - U-C-B-M
Digit 6 Open Space CODE NO. DESCRIPTION CODE N O . DESCRIPTION
Digit 7-23 Vehicle Identification N o .
Line # 2 Digit 1-3 Paint Procedure

Digit 4 Open Space
Digit 5-8 Primary Paint
Digit 9 Open Space
Digit 1 0 - 1 3 Secondary Paint
Digit 14 Open Space J90IN-3>
Digit 1 5 - 1 8 Trim Code
Digit 19 Open Space
Digit 2 0 - 2 2 Engine Sales Code Fig. 3 Equipment Identification Plate
Digit 23 Open Space
INTERNATIONAL VEHICLE CONTROL AND DISPLAY
Line # 3 Digit 1 - 1 2 Vehicle Order Number
Digit 1 3 Open Space
SfiBOLS
Digit 1 4 - 1 6 Vinyl Roof Code (Door Combo The graphic symbols illustrated on the following
Code - Pillette)
Digit 1 7 Open Space
chart are used to identify various instrument con
Digit 1 8 - 2 3 Model trols. The symbols correspond to the controls and dis
" ~ ' " J901N-20 plays that are located on the instrument panel.
• The optional and special equipment installed on VEHICLE DIMENSIONS

the vehicle. The Vehicle Interior and Exterior Dimension charts
Refer to the information listed on the plate when provides the dimensions for each type of Ram truck.
ordering service parts.
INTERNATIONAL VEHICLE CONTROL AND DISPLAY SYMBOLS
10 £0 HEADLIGHTS,
A
PARKING UGHTS, WINDSHIELD
HIGH BEAM FOG LIGHTS PANEL LIGHTS TURN SIGNAL HAZARD WARNING WASHER
%? WINDSCREEN
I S P G P
WINDSHIELD WINDSHIELD WIPER DEMISTING REAR WINDOW REAR WINDOW
WIPER AND WASHER AND DEFROSTING VENTILATING FAN DEFOGGER WIPER
CD
i
REAR WINDOW
WASHER
m
FUEL
i
ENGINE COOLANT
TEMPERATURE
E 3
BATTERY CHARGING
CONDITION ENGINE OIL
*
SEAT BELT
(©) &
REAR HOOD
BRAKE FAILURE PARKING BRAKE FRONT HOOD (TRUNK) HORN LIGHTER
J95IN-23
4 INTRODUCTION BR
VEHICLE INTERIOR DIMENSIONS—STD CAB
A Head Room 40.2

B Hip Room 65.8
C Shoulder Room 66.3
D Seat Width 60.2
E Seat Height 13.2
F Seat Depth 19.0
c§ Seat Adjustment (Fore and aft) 7.5
H Leg Clearance (Seat to steering wheel) 5.9
I Steering Wheel To Seatback (Max) 15.9
J Leg Room 41.0
§c Back Of Seat To Back Of Cab
—Top 3.8
—Bottom 13.2
Seatback Angle (Degrees) 21.0
Door Opening Height 47.1
Door Opening Width 41.8
Note: All dimensions are in inches unless noted.
J94IN-26
VEHICLE INTERIOR DIMENSIONS—CLUB CAB
Front Rear
A Head Room 40.2 39.4
B Hip Room 65.8 66 8
C Shoulder Room 66.3 67.7
D Seat Width 60.2 NA
E Seat Height 13.2 NA
F Seat Depth 19.0 NA
G Seat Adjustment (Fore and aft) 7.5 NA
H Leg Clearance (Seat to steering wheel) 5.9 NA
1 Steering Wheel To Seatback (Max) 15.9 NA
J Leg Room 41.0 33.2
K Back Of Seat To Back Of Cab
—Top 3.8 NA
—Bottom 13.2 NA
Seatback Angle (Degrees) 21.0 16.0
Door Opening Height 47.1 NA
Door Opening Width 41.8 NA
Behind-Seat Storage—Seat Up (cu ft) — NA
Note: All dimensions are in inches unless noted.
J95IN-25
BR INTRODUCTION 5
VEHICLE EXTERIOR DIMENSIONS—STD CAB
1500/ 2500/ 3500/

1500 4 x 4 2500 4 x 4 3500 4 x 4
A Wheelbase 119" 135" 135" 135"
1 Box Length (feet) 6.5 8.0 8.0 8.0
C Ground Clearance {Empty)
—Front 9.7/8.1 10.0/8.1 10.1/8.1 13.1/10.2
—Rear 10.1/9.8 10.1/9.8 10.1/9.8 10.1/9.8
D Overall Length
199.9 220.1 220.1 220.1
-—Without rear bumper
—With rear bumper 204.1 224.3 224.3 224.3
1 Overall Height (Empty) 72.1/75.9 72.1/75.9 73.7/78.0 73.6/75.9
F Overall Width
79.4 79.4 79.4 79.5 1
—At Front Wheel Lip

G Track
' —Front 68.5 68.5 68.6 68.6
—Rear 68.0 68.0 68.0 73.0
H
1
J
Tailgate Load Height
Overhang—Front
Overhang—Rear
31.2/35.6 31.5/35.6
37.9
47.6
37.9
47.6
31.5/35.6
37.9
47.6
31.4/35.6
37 Q
47.6
5u_ KV
—Without Rear lumper
—With Rear lumper 51.7 51.7 51.7 51.7 50.0 C
K Back Of Cab To
Rear Bumper 87.2 107.4 107.4 107.4
L Front Bumper To
Back Of Cab 116.9 116.9 116.9 116.9
M Approach Angle (Degrees) 25.3/29.7 25.3/29.7 25.3/29.7 25.3/29.7
M Breakover Angle (Degrees) 17.8/21.0 17.8/21.0 17.8/21.0 17.8/21.0
30.6/36.2 30.6/36.2 30,6/36.2 30.6/36.2
}
o Departure Angle (Degrees)
93.5 at cargo box.
J94IN-25
INTRODUCTION
VEHICLE EXTERIOR DIMENSIONS—CLUB CAB
1500/ 2500/ 3500/

15004x4 25004x4 35004x4
A Wheelbase 139" 155" 139" 155" 155"
1 Box Length (Feet) 6.5 8.0 8.0 6.5 8.0
C Ground Clearance—(Empty)
—Front 87/8.5 8.6/8.5 9.9/9.0 9.8/9.1 9.8/8.1
—Rear 7.5/7.7 75/7.7 8.6 8.6 8.6
D Overall Length
—Without rear bumper 220.1 240.1 220.1 240.1 240.1
—With rear bumper 224.0 244.0 224.0 244.0 244.0
1 Overall Height (Empty) 71.6/74.6 71.5/74.5 72.9/77.2 72.8/77.1 72.8/77.2
F Overall Width Of Cab 79.4 79.4 79.4 79.4 79.4
G Track
—Front 66.9/68.5 66.9/68.5 68.6/68.9 68.6/68.9 69.8
—Rear 66.9 66.9 68.0 68.0 73.0
H Tailgate Load Height 31.3/33.9 31.3/34.4 34.4/373 33.3/37.2 33.8/37.8
I Overhang—Front 37 9 37.9 37.9 37.9 37.9
J Overhang—Rear
—Without rear bumper 43.5 47.5 47.5 43.5 47.5
—With rear bumper 47.5 51.5 51.5 47.5 51.5
K Back of Cab To Rear Bumper 87.1 107.1 107.1 87.1 107.1
L Front Bumper To Back Of Cab 136.9 136.9 136.9 136.9 136.9
M Approach Angle (Degrees) 25.1/30.6 25.2/30.6 26.7/33.7 26.8/33.8 26.3/33.4
N Breakover Angle (Degrees) 16.7/18.4 15.8/17.1 19.2/23.0 18.1/21.3 18,0/21 4
© Departure Angle (Degrees) 23.8/26.9 21.8/24.7 26.0/31.0 24.1/28.4 24.6/28.9
(1) 93.8 at cargo box with dual-rear wheels.

Note: All dimensions in inches unless otherwise noted.
BR INTRODUCTION 7
VEHICLE EXTERIOR DIMENSIONS—CHASSIS CAB
EXTERIOR
4x2 Models 4x4 Models

28§0 35§t 3500 2500 3500 3500
Model HD DRW DRW PRW
HD DRW
A Wheelbase 135 139 163 135 139 163
B Cab To Axle 55.7 59.7 83.7 55.7 59.7 83.7
C Overall Length 216.7 220.7 244.7 216.7 220.7 244.7
D Overall Height (Empty) 72.4 77.3 77.1 75.9 77.2 77.1
E Overall Width 79.4 94.6 94.6 79.4 94.6 94.6
F Track
68.6 69.8 69.8 68.9 69.8 69.8
—Front
—Rear 68.0 73.0 73.0 68.0 73.0 73.0
6 Rear Track, Inside 58.0 51.4 51.4 58.0 51.4 51 4
H Rear Track, Outside 78.0 94.6 94.6 78.0 94.6 94.6
1 Overhang—Front 37.9 37.9 37.9 37.9 37.9 37.9
J Axle To End Of Frame 44.1 44.1 44.1 44.1 44.1 44.1
K Center Of Front Wheel
To Back Of Cab 79.0 79.0 79.0 79.0 79.0 79.0
L Frame To Top Of Cab 52.9 52.9 52.9 52.9 52.9 52.9
M Top Of Frame To Ground 29.6 34.3 34.1 34.0 34.3 34.2
N Inside Width Between
Frame Rails 31.7 31.7 31.7 31.7 31.7 31.7
o Outside Width Between
Frame Rails 37.6 37.6 37 6 37.6 37.6 37.6
P Front Bumper To Back
116.9 116.9 116.9 116.9 116.9 116.9
Of Cab
Q Front Of Dash To
Back Of Cab NA NA NA NA NA NA
ft Ground Clearance
—Front 10.1 15.2 15.2 8.1 8.6 8.6
—Rear 8.5 9.0 90 8.4 9.0 9.0
NOTE: All dimensions are ininches unless noted,
D R W = Dual-rear wheel.
N A = Not available at time of printing.
J94IN-27
8 INTRODUCTION BR
VEHICLE WEIGHTS • Payload.

The Vehicle Weight charts provides: • Curb weight for each vehicle type/wheelbase.
• Gross vehicle weight rating (GVWR).
BR INTRODUCTION 9
G R O S S VEHICLE WEIGHT RATING—2WD STD CAB
4 x 2 MODELS
1500 W S 1500 MODELS 2500 MODELS 2500 HD MODELS 3500 MODELS
STD STD STD §M STD
6,010 6,400 7,500 8,8©® 10,500 DRW
(ZIA) (ZIB) (Z2A) (Z2B) (Z3B)'
—Front 3,300 3,300 3,300 4,000 4,000

—Rear 3,900 3,900 6,200 6,200 7,500
SPRINGS
—Front 3,300 3,300 3,300 4,000 4,000
—Rear 3,800 3,800 4,670 6,085 7,500
TIRES P225/75R16 P225/75R16XL LT225/75R16 LT245/75R16 LT215/85R16
all-season all-season all-season all-season all-season
(TRW) (TRY) (TWP) (TYD) (TVV)
GAWR
—Front 3,300 3,300 3,300 4,000 4,000
—Rear 3,800 3,800 4,670 6.085 7,460
SHORT BOX p i f " W B )
1
BAYB.OAD
- M A G N U M 3.9L V6 2,000 2,365
- M A G N U M 5.2L V8 2,230 — _ —
- M A G N U M 5.9L V8 2,140 —
CURB WEIGHT
—Front 2,340 2,340 _
—Rear 1,670 1,695 — — —
—Total 4,010 4,035 —

LONG |135" W B )
1
PAYHOAD
- M A G N U M 3.9L V6 1,835 2,200 _
- M A G N U M 5.2L V8 2,065 2,845 — • • —
- M A G N U M 5.9L V8 1,980 2,810 4,100 5,290
CURB WEIGHT
—Front 2,460 2,460 2,800 2,840 2,880
—Rear 1,715 1,740 1,855 1,860 2,330
—Total 4,175 4,200 4,655 4,700 5,210
D R W — Dual-rear wheel.
'Payload allowance must be reduced by weight of passengers and optional equipment.
J95IN-33
10 INTRODUCTION BR
GROSS VEHICLE WEIGHT RATING—4WD STD CAB
4 x 4 MODELS
1500 MODELS 2500 MODELS 2500 HD MODELS 3506 MODELS
STD STD STD STD
6,400 7,500 8,800 10,500 DRW
GVWR ' ' • •• " (Z7A) (Z7B) (Z8A)
(ZiA)
AXLES
—Front 3,500 3,500 4,500 4,500
—Rear 3,900 6,200 6,200 7,500
SPRINGS
—Front 3,500 4,000 4,500 4,500
—Rear 3,600 4,670 6,085 7,500
TIRES LT225/75R16 LT225/75R16 LT245/75R16 LT215/85R16
all-season all-season all-season all-season
(TWA) (TWP) (TYD) (TVV)
GAWR
—Front 3,500 3,500 4,500 4,500
—Rear 3,600 4,670 6,085 7,060
S H O R T BOX {119* W B )
1
PAYLOAD
-MAGNUM 5.2L V8 1,885
- M A G N U M 5.9L V8 1,785 — — —
CURB WEIGHT
—Front 2,730 _
—Rear 1,785 — — —
—Total 4,515 — — —
m
4 Q N O I O X m$ W i J :
1
PAYLOAD
- M A G N U M 5.2LV8 1,720 2,550
- M A G N U M 5.9L V8 1,625 . 2,510 3,450 4,885
CURB WEIGHT
—Front 2,865 3,040 3,250 3,250
—Rear 1,815 1,910 2,000 2,365
—Total 4,680 4,950 5,250 5,615
1
Pay load allowance must be reduced by weight of passengers and optional equipment.
BR INTRODUCTION V
G R O S S VEHICLE WEIGHT RATING—2WD CLUB CAB
4x2 MODELS
1500 MODELS 2500 HD MODELS 3500 MODELS
STD STD STD
GVWi 6,400 8,800 10,500 DIW
(Z1B) (Z21) (Z3A)
AXLES
—Front 3,650 4,500 4,500
—Rear 3,900 6,200 7,500
SPRINGS
—Front 3,650 4,500 4,500
—Rear 3,800 6,085 7,500
TIRES P225/75R16-XL LT245/75R16 LT215/85R16
all-season all-season all-season
(TRY) (TYD) (TW)
GAWR
—Front 3,650 4,500 4,500
—Rear 3,800 6,085 7,500
SHORT BOX (139" WB)
1
PAYLOAD( )
—Magnum 5.2LV8 1,830 —
—Magnum 5.9L V8 1,750 3,920 —
IASE CURB WEIGHT
—Front 2,690 2,900
•—Rear 1,880 1,980 —
—Total 4,570 4,880 —
PAYLOAD(1)
—Magnum 5.2L V8 1,680 — —
—Magnum 5.9L V8 1,600 3,770 4,885
BASE CURB WEIGHT
—Front 2,790 3,000 3,105
—Rear 1,930 2,030 2,510
—Total 4,720 5,030 5,615
DRW — Dual-rear wheel.
(1
) Payload allowance must be reduced by weight of passengers and optional equipment.
J95IN-27
12 INTRODUCTION BR
GROSS VEHICLE WEIGHT RATING—4WD CLUB CAB
4x4 MODELS
1500 MODELS 2500 HD MODELS 350® MODELS
STD STD STD
GVWI 6,400 8,800 M SM MM
F
(Z6A) (Z71) (Z8A|

AXLES
—Front 3,850 4,850 4,850
—Rear 3,900 6,200 7,500
SPRINGS
—Front 3,850 4,850 4,850
—Rear 3,600 6,085 7,500
TIRES LT225/75R16 LT245/75R16 U215/85R16
all-season all-season all-season
(TWA) (TYD) (TW)
GAWR
—Front 3,800 4,850 4,670
•—Rear 3,600 j 6,085 7,500
PAYLOAD! i)
—Magnum 5.2L V8 1,455 —-
—Magnum 5.9L V8 1,365 3,615
BASE CURB WEIGHT
—Front 2,965 3,145 —
—Rear 1,980 2,040 —
—Total 4,945 5,185 —
PAYLOADO)
—Magnum 5.2L V8 1,300 — —
—Magnum 5.9L V8 1,210 3,465 4,995
BASE CURB WEIGHT
—Front 3,080 3,245 3,475
—Rear 2,020 2,090 2,530
—Total 5,100 5,335 6,005
0) Payload allowance must be reduced by weight of passengers and optional equipment.
J95IN-28
BR INTRODUCTION 13
G R O S S VEHICLE WEIGHT RATING—STD CAB 8.0L OR DIESEL
8 . 0 L ¥10 A N D DIESEL ENGINE MODELS

4x2 4x4
2500 H i MODELS 3500 MODELS 2500 HD MODELS 3500 MODELS
STD STD STD STD
8,800 10,500 D R W 8,800 10,500 D R W
®VWR (Z2B) (Z3A) (Z7B) (Z8A)
AXLES
—Front 4,000 4,000 4,500 4,500
—Rear 6,500 7,500 6,500 7,500
SPRINGS
—Front 4,000 4,000 4,500 4,500
—Rear 6,085 7,500 6,085 7,500
(TYD) (TVV) (TYD) (TVV)
GAWR
—Front 4,000 4,000 4,500 4,500
—Rear 6,085 7,500 6,085 7,500
mm® mm. ^m* WB)
1
[PAYLOAD
- M A G N U M 8.0L V10 3,570 4,900 3,315 4,470
—Cummins 5.9L 1-6 3,265 4,595 2,840 4,175
C U R B W E I G H ? — 8.0L ENGINE
—Front 3,165 3,180 3,555 3,555
—Rear 2,065 2,420 2,110 2,475
—Total 5,230 5,600 5,665 6,030
CURB W E I G H T — DIESEL ENGINE
—Front 3,460 3,475 3,845 3,845
—Rear 2,075 2,430 2,115 2,480
—Total 5,535 5,905 5,960 6,325
'Payload allowance must be reduced by weight of passengers and optional equipment.
J95IN-29
14 INTRODUCTION BR
G R O S S VEHICLE WEIGHT RATING—CLUB CAB 8.0L OR DIESEL
8.0L V I 0 AND DIESEL ENGINE MODELS J
4x2 4x4
2500 HD MODELS 3500 MODELS 2500 HD MODELS 3500 MODELS
STD STD STD STD
GVWR 8,800 10,500 DiW 8,800 11,000 DRW

(Z21) (Z3A) (Z71) (Z8B)
AXLES
—front 4,500 4,500 4,850 1,850
—Rear 6,500 7,500 6,500 7,500
SPRINGS
—Front 4,500 4,500 4,850 4,850
—Rear 6,085 7,500 6,085 7,500
(TYD) (TW) (TYD) (TW)
GAWR
•—Front 4,500 4,500 4,850 4,670
—Rear 6,085 7,500 6,085 7,500
PAYLOAD! 1)
—Maqnum 8.0LV10 3,285 4,660 2,860 4,735
—Cummins 5.9L 1-6 Diesel 2,995 4,335 2,540 4,410
BASE CURB WEIGHT — 8.0L ENGINE
—Front 3,295 3,335 3,675 3,740
—Rear 2,220 2,505 2,265 2,525
—Total 5,515 5,840 5,940 6,265
BASE CURB WEIGHT — DIESEL ENGINE
—Front 3,615 3,650 3,985 4,055
—Rear 2,230 2,515 2,275 2,535
—Total 5,845 6,165 6,260 6,590
H) Payload allowance must be reduced by weight of passengers and optional equipment.
J95IN-30
BR INTRODUCTION 15
G R O S S VEHICLE WEIGHT RATING—2WD CHASSIS GAB 5.9L
5.9L M A G N U M V 8 — 4 x 2
2 5 0 0 HD MODELS 3 5 0 0 MODELS
S7D STD STD
8,800 11,000 D R W 11,000 D R W

(Z2B) (Z3B) (Z3B)
. AXLES
—Front 4,000 IFS 4,500* 4500 1
—Rear 6,200 8,000 7,500

SPRINGS
—Front 4,000 IFS 4,670 3,830
—Rear 6,085 8,000 8,000
TIRdS LT245/75R16E LT215/85R16D LT215/85R16D
(TYD) (TVV) (TVV)
GAWR
—Front 4,000 4,500 3,570
—Rear 6,085 8,000 7,060
t r
j m wi ffto* CA)
PAYLOAD 2
4,360 _
CURB W E I G H ?
—Front 2,870
—Rear 1,570
—Total 4,440 _ —
#
ia»* W i p f ' € A ) • •
PAYLOAD 2
— 6,400 —
CURB W E I G H ?
—Front 3,065
—Rear 2,045 —
—Total _ 5,110 —
1*3* W B ( S 4 " C A ) - ; •
PAYLOAD 2
_ _ 5,830
CURB W E I G H ?
—Front 3,120
—Rear _ 2,050
—Total 5,170
D R W = Dual-rear wheel. IFS = Independent Front Suspension. CA = Cab to axle.
^ 5 0 0 4 x 2 models receive the link-coil front suspension with a tubular front axle.
2
Payload allowances must be reduced by weight of passengers end optional equipment.
J95IN-34
GROSS VEHICLE WEIGHT RATING—4WD CHASSIS CAB S.9L
5.9L M A G N U M V 8 — 4 x 4
2 5 0 0 HD MODELS 3 5 0 0 MODELS
S?D S?D STB
" 8,800 SRW 11,000 DRW 11,000 D R W
(Z7B) (Z8B) CZ8H)
—Front 4,500 4,500 4,500

—Rear 6,200 8,000 8,000
SPRINGS
—Front 4,500 4,500 4,500
—Rear 6,085 8,000 8,000
tins LT245/75R16E LT215/85R16D LT215/85R16D
(TYD) (TVV) (TVV)
GAWR
—Front 4,500 4,500 4,500
—Rear 6,085 8,000 8,000
135" W B CA)
3,800 —
CURB W E I G H !
—Front 3,285 _
—Rear 1,715 — —
—Total 5,000 —
l i t * wft'{60» C A |
PAYLOAD 1
— 5,650 —
CURB W E I G H T
—Front
_ 5,350
—Rear 3,275 —
—Iota! _ 2,075 —
1 * 3 * W l ( 8 4 " CA) ' - -
PAYLOAD 1
_ — 5,590
CURB W E I G H ?
—Front 3,335
—Rear — — 2,075
—Total — __ 5,410
DRW—Dual-rear wheel. CA—Cab to axle.
1
Payload allowance must be reduced by weight of passengers and optional equipment.
J95IN-35
BR — INTRODUCTION 17
G R O S S VEHICLE WEIGHT RATING—2WD CHASSIS CAB 8 . 0 L OR DIESEL
8.0L ¥1© AND 5.9L DIESEL — 4x2

2 5 0 0 HD 2 5 0 0 HD 3500 3500
¥10 DIESEL ¥10 DIESEL
8,800 8,800 11,000 DRW 11,000 DRW
GWWft (Z2B) (Z3B)
(Z21) (Z3B)
AXLES
—Front 4,000 4,000 4,500 4,500
—Rear 6,500 6,500 8,000 8,000
SPRINGS
—Front 4,000 4,000 4,500 4,500
—Rear 6,085 6,085 8,000 8,000
TIRES LT245/75R16E LT245/75R16E LT215/85R16D LT215/85R16D
(TYD) (TYD) (TVV) (TVV)
GAWR
—Front 4,000 4,000 4,500 4,500
—Rear 6,085 6,085 8,000 8,000
n
%M W l (54* CA)
1
PAYLOAD 3,825 4,115 — —
CURB WEIGHT
—Front 3,200 3,490 _
—Rear 1,775 1,790 — —
—Total 4,975 5,280 —
139" W i (§0" CA)
PAYLOAD' _ _ 5,500 5,195
CURB WEIGHT
—Front 3,360 3,655
—Rear — 2,140 2,150
—Total 5,500 5,805
1 * 3 * W i ( 8 4 * CA)
PAYLOAD 1
_ 5,440 5,135
CURB WEIGHT
—Front 3,415 3,710
—Rear _ — 2,145 2,155
—Total _ 5,560 5,865
1
Pay load allowance must be reduced by weight of passengers and optional equipment.
J94IN-33
18 INTRODUCTION — — BR
G R O S S VEHICLE WEIGHT RATING—4WD CHASSIS CAB 8.0L OR DIESEL
8.0L ¥10 A N D 5.9L DIESEL — 4 x 4

2 5 0 0 HD 2 5 0 0 HD 3500 3500
¥10 DIESEL ¥10 DIESEL
8,800 8,800 11,000 DRW 11,000 DRW
GVWR (Z7B) (Z7B) (Z8i) (Z8B)
AXLES
— Front 4,500 4,500 4,500 4,500
—Rear 6,500 6,500 8,000 8,000
SPRINGS
— Front 4,500 4,500 4,500 4,500
— Rear 6,085 6,085 8,000 8,000
TIRES LT245/75R16E LT245/75R16E LT215/85R16D LT215/85R16D
(TYD) (TYD) (TVV) (TVV)
GAWR
— Front 4,500 4,500 4,500 4,500
— Rear 6,085 6,085 8,000 8,000
135" W B ( 5 6 " CA)
PAYLOAD 1
3,385 3,090 — —
CURB WEIGHT
— Front 3,590 3,880
—Rear 1,825 1,830 _ —
—Total 5,415 5,710 — —
1 3 9 * W B { 6 0 * CA)
PAYLOAD 1
_ 5,230 4,940
CURB WEIGHT
— Front _ 3,580 3,870
— Rear — — 2,190 2,190
—Total _ — 5,770 6,060
m
163" W B (B4 CA)
PAYLOAD 1
5,170 4,880
CURB WEIGHT
— Front 3,640 3,930
—Rear — — 2,190 2,190
—Total — — 5,830 6,120
!
Payload allowance must be reduced by weight of passengers and optional equipment.
J94IN-34
B R ^^^^ - — INTRODUCTION 19
TRAILER TOWING SPECIFICATIONS • Maximum trailer tongue weight rating.

The Trailer Towing Specification charts provides: • Maximum combined weight of the trailer/load/tow
• Maximum trailer weight rating. ing vehicle.
20 INTRODUCTION
TRAILER TOWING—STD CAB
MAXIMUM
TRUCK MODEL TRAILER
AND M A X I M U M REAR G¥WR WEIGHT MAXIMUM
1
TONGUii WEIGHT AXLE PACKAGE RATING GCWR
(Pounds) ENGINE & TRANSMISSION RATIO (Pounds) (Pounds) (Pounds)
IS©© 4 x 2 3«9L M A G N U M ¥ 6
REGULAR C A I Manual 5-speed O . D . 3.21 6,010/6,400 3,600 7,800
2
6.5' B O X 3.55/3.90 6,010/6,400 3,800 8,000
2
Automatic 4-speed O.D. 3.55/3.90 6,010/6,400 3,400 7,600
5.2L M A G N U M ¥ 8
3.21 6,400 3,500 7,800
Manual 5-speed O . D . 3.55 6,400 5,200 9,500
3.90 6,400 5,700 10,000
Automatic 4-speed O . D . H.D. 3.21 6,400 7,700 12,000
3.55/3.90 6,400 7,700 12,000
5.9L M A G N U M ¥ 8
Tongue Wt. 700 Automatic 4-speed O.D. H.D. 3.21/3.55 6,400 7,700 12,000
3.90 6,400 7,700 12,000
150© 4 x 2 3.9L M A G N U M ¥ 6
REGULAR CAB Manual 5-speed O.D. 3.21 6,010/6,400 3,500 7,800
2
8.0' BOX 3.55/3.90 6,010/6,400 3,700 8,000
2
Automatic 4-speed O.D. 3.55/3.90 6,010/6,400 3,300 7,600
5.2L M A G N U M ¥ 8
Manual 5-speed O.D. 3.21 6,400 3,300 7,800
3.55 6,400 5,000 9,500
3.90 6,400 5,500 10,000
Automatic 4-speed O.D. H.D. 3.21/3.55 6,400 8,000 12,000
3.90 6,400 8,000 12,000
5.9L M A G N U M ¥ 8
Tongue Wt. 700 Automatic 4-speed O.D. H.D. 3.21/3.55 6,400 7,700 12,000
3.90 6,400 7,700 12,000
2500 4 x 2 5.2L M A G N U M ¥ 8
REGULAR CAB Manual 5-speed H.D. 3.54/4.09 7,500 5,200 10,000
8.0' B O X Automatic 4-speed O.D. H.D. 3.55/3.90 7,500 7,700 12,500
5.9L M A G N U M ¥ 8
Manual 5-speed H.D. 3.54/4.09 7,500 9,200 14,000
Tongue W t . 900 Automatic 4-speed O.D. H.D. 3.55/3.90 7,500 9,200 14,000
3.54/4.09 7,500 9,200 14,000
1
Maximum Trailer Weight Ratings include cargo and fluids in the trailer and must be decreased by the weight of optional equipment,
trailer hitch, cargo in the truck, and passengers other than the driver.
2
The 3.90 gear ratio is recommendea when towing with the 3.9L V6 engine.
J94IN-35
BR INTRODUCTION 21
T R A I L E R TOWING—STD CAB
MAXIMUM
mwtK MODEL TRAILER
AND M A X I M U M REAR G¥WR WEIGHT M A X I M U M
1
TONGUE W E I G H T AXLE PACKAGE RATING GCWR
2500 HD 4 x 2 5.9L M A G N U M ¥ S
8.0' l O X Automatic 4-speed O.D. H.D. 3.54/4.09 8,800 9,200 14,000
5.9L 1-6 C u m m i n s Diesel
Manual 5-speed O.D. H.D. 3.54 8,800 8,800 14,500
4.10 8,800 12,300 18,000
Automatic 4-speed O.D. H.D. 3.54 8,800 8,800 14,500
4.10 8,800 12,300 18,000
8.0L M A G N U M ¥ 1 0
Tongue Wt. 900 Manual 5-speed O.D. H.D. 3.54/4.10 8,800 13,600 19,000
3500 4 x 2 5.9L M A G N U M ¥ 8
8.0' B O X Automatic 4-speed O.D. H.D. 3.54/4.10 10,500 9,700 15,000
5o®\L 0=<£> (cummins Diesel
4.10 10,500 12,000 18,000
Dual-Rear W h e e l s 4.10 10,500 12,500 18,000
8.0L M A G N U M ¥ 1 0
Manual 5-speed O.D. H.D. 3.54/4.10 10,500 13,400 19,000
1500 4 x 4 5.2L M A G N U M ¥ 8
REGULAR CAB Manual 5-speed H.D. 3.55 6,400 4,800 9,500
Tongue
6.5' BOWXt . 1,200 3.90 6,400 4,800 10,000
Tongue Wt. 700 5.9L M A G N U M ¥ 8
1500 4 x 4 5.2L M A G N U M ¥ 8
REGULAR CAB Manual 5-speed O.D. 3.55 6,400 4,700 9,500
8.0' B O X 3.90 6,400 4,700 10,000
Tongue Wt. 700 5.9L M A G N U M ¥ 8
'Maximum Trailer Weight Ratinqs include cargo and fluids in the trailer and must be decreased by the weight of optional equipment,
J94IN-36
22 INTRODUCTION BR
TRAILER TOWING—STD CAB
MAXIMUM
TRUCK MODEL TRAILER
AND MAXIMUM. REAR G¥WR WEIGHT M A X I M U M
TONGUE WEIGHT AXLE PACKAGE RATING GCWR 1

2500 4 x 4 5.2L M A G N U M ¥ 8
8.0' BOX Automatic 4-speed O.D. H.D. 3.55/3.90 7,500 7,400 12,500
5.9L M A G N U M ¥ 8
Manual 5-speed H.D. 3.54/4.09 7,500 8,900 14,000
Tongue W t . 900 Automatic 4-speed O.D. H.D. 3.55/3.90 7,500 8,900 14,000
4.09 7,500 8,900 14,000
2500 HD 4 x 4 5.9L M A G N U M ¥ 8
8.0' B O X 3.54/4.09 8,800 8,600 14,000
5.9 1-6 C u m m i n s Diesel
4.10 8,800 11,700 18,000
4.10 8,800 11,700 18,000
8.0L M A G N U M ¥ 1 0
Tongue W t . 900 Manual 5-speed O.D. H.D. 3.54/4.10 8,800 13,200 19,000
3500 4 x 4 5.9L M A G N U M ¥ 8
REGULAR CAB Manual 5-speed O.D. H.D. 3.54/4.09 10,500 9,400 15,000
8.0' BOX Automatic 4-speed O.D. H.D. 3.54/4.09 10,500 9,400 15,100
Dual-Rear Wheels 5.9L 1-6 C u m m i n s Diesel
4.10 10,500 11,500 18,000
4.10 10,500 11,500 18,000
8.0L M A G N U M ¥ 1 0
Tongue W t . 1,200 Manual 5-speed O.D. H.D. 3.54/4.10 10,500 13,000 19,000
1
J94IN-37
BR INTRODUCTION 23
T R A I L E R TOWING—CLUB CAB 4X2
MAXIMUM
TRUCK MODEL TRAILER
AND MAXIMUM REAR GVWR WEIGHT MAXIMUM
TONGUE WEIGHT AXLE PACKAGE RATINGS) m m
(Pounds) ENGINE AND TRANSMISSION RATIO (Pounds) (Pounds) (Pounds)
15004x2 5.2L Magnum V8
CLUB CAB Manual 5-speed OD 3.21(2) 6,400 3,500 7,800
3.55 6,400 5,200 9,500
3.92 6,400 5,700 10,000
Automatic 4-speed OD HD 3.21(2) 6,400 8,100 12,500
3.55/3.92 6,400 8,100 12,500
5.9L Magnum V8
Tongue Wt 700 Automatic 4-speed OD HD 3.21(2)/3.55 6,400 8,100 12,500
3.92 6,400 8,100 12,500
2500 HD 4x2 5.9L Magnum V8
CLUB CAB Manual 5-speed HD 3.54/4.09 8,800 9,100 14,000
Automatic 4-speed OD HD 3.54/4.09 8,800 9,100 14,000
5.9L 1-6 Cummins Diesel
Manual 5-speed OD HD 3.54 8,800 10,500(3) 16,000
4.10 8,800 12,300(3) 18,000
Automatic 4-speed OD HD 3.54 8,800 10,500(3) 16,000
4.10 8,800 12,300(3) 18,000
8.0L Magnum V10
Tongue W t 900 Manual 5-speed OD HD 3.54/4.10 8,800 13,600(3) 19,000
Automatic 4-speed OD HD 3.54/4.10 8,800 13,600(3) 19,000
3500 4x2 5.9L Magnum V8
Dual-Rear Wheels Automatic 4-speed OD HD 3.54/4.10 10,500 9,600 15,000
4.10 10,500 11,900(3) 18,000
4.10 10,500 11,900(3) 18,000
8.0L Magnum VI0
Tongue W t 1,200 Manual 5-speed OD HD 3.54/4.10 10,500 13,200(3) 19,000
H) Maximum Trailer Weight Ratings include cargo and fluids in the trailer and must be decreased by the weight of optional
equipment, trailer hitch, cargo in trie truck, and passengers other than the driver. (2) Trailer towing is not recommended with the 3.21
gear ratio. (3) Chrysler Corporation requires that vehicles with maximum trailer weight ratings of 10,000 pounds or greater be
equipped with a fifth-wheel hitch.
J95IN-32
24 INTRODUCTION
T R A I L E R TOWING—CLUB CAB 4X4
MAXIMUM
TRUCK MODEL TRAILER
AND MAXIMUM REAR GVWR WEIGHT MAXIMUM
TONGUE WEIGHT AXLE PACKAGE RATINGS) GCWft
(Pounds) ENGINE AND TRANSMISSION RATIO (Pounds) (Pounds) (Pounds)
1500 4x4 5.2L Magnum V8
CLUi CAB Manual 5-speed OD 3.55 6,400 4,800 9,500
3.92 6,400 5,300 10,000
Tongue W t 700 5.9 Magnum V8
2500 HD 4x4 5.9L Magnum V8
Automatic 4-speed OD HD 3.54/4.09 8,800 8,600 14,0)0
4.10 8,800 11,900(2) 18,000
4.10 8,800 11,900(2) 18,000
8.0L Magnum V I 0
Tongue W t 900 Manual 5-speed OD HD 3.54/4.10 8,800 13,200(2) 19,000
3500 4x4 5.9L Magnum V8
CLUB CAB Manual 5-speed OD HD 3.54/4.09 10,500 9,200 15,000
Dual-Rear Wheels Automatic 4-speed OD HD 3.54/4.09 10,500 9,200 15,000
Manual 5-speed OD HD 3.54 10,500 9,700 16,000
4.10 10,500 11,500(2) 18,000
. 4.10 10,500 11,500(2) 18,000
8.0L Magnum V10
Tongue Wt 1,200 Manual 5-speed OD HD 3.54/4.10 10,500 12,800(2) 19,000
]
( ) Maximum Trailer Weight Ratings include cargo and fluids in the trailer and must be decreased by the weight of optional equipment,
trailer hitch, cargo in the truck, and passengers other than the driver. (2) Chrysler Corporation requires that vehicles with maximum
trailer weight ratings of 10,000 pounds or greater be equipped with a fifth-wheel hitch.
J95IN-31
BR INTRODUCTION 25
T R A I L E R TOWING—CHASSIS CAB
MAXIMUM
TRUCK MODEL TRAILER
A N D MAXIMUM REAR GVWR WEIGHT M A X I M U M
TONGUE WEIGHT AXLE PACKAGE RATING 1
6CWR
(Pounds) E N G I N E & TRANSMISSION RATIO (Pounds) (Pounds) (Pounds)
2500 H D 5.9L M A G N U M ¥ 8 LDC
4x2 Manual 5-speed O.D. M.D. 3.54 8,800 14,000
4.09 8,800 2 14,000
Automatic 4-speed O.D. H.D. 3.54 8,800 14,000
4.09 8,800 14,000
5.9L 1-6 C U M M I N S Diesel
Manual 5-speed O.D. M.D. 3.54 8,800 14,500
4.10 8,800 2 18,000
4.10 8,800 18,000
8.0L M A G N U M V I 0
Manual 5-speed O.D. H.D. 3.54 8,800 19,000
4.10 8,800 2 19,000
Tongue W t 900 Automatic 4-speed O.D. H.D. 3.54 8,800 19,000
4.10 8,800 19,000
3500 5.9L M A G N U M V 8 HDC
4x2 4.10 11,000 2 15,000
4.10 11,000 15,000
4.10 11,000 2 18,000
4.10 11,000 18,000
4.10 11,000 2 19,000
Tongue W t 1,200 Automatic 4-speed O.D. H.D. 3.54 11,000 19,000
4.10 11,000 19,000
2500 HD 5.9L M A G N U M V 8 HDC
4x4 4.09 8,800 2 15,000
4.09 8,800 15,000
4.10 8,800 2 18,000
4.10 8,800 18,000
4.10 8,800 2 19,000
Tongue W t 900 Automatic 4-speed O.D. H.D. 3.54 8,800 19,000
4.10 8,800 19,000
3500 5.9L M A G N U M V 8 HDC
4x4 Manual 5-speed O.D. M.D. 3.54 11,000 15,000
4.10 11,000 2 15,000
4.10 11,000 15,000
4.10 11,000 2 18,000
4.10 11,000 18,000
8.0L M A G N U M V I ©
4.10 11,000 2 19,000
Tongue W t 1,200 Automatic 4-speed O.D. H.D. 3.54 11,000 19,000
4.10 11,000 19,000
1
2
Due to large variations in the weight of body equipment installed on Chassis Cab models, no maximum trailer weights are shown.
To determine allowable trailer weight, subtract actual truck weight, passenger and cargo weight from the Gross Combination
Weight Rating. J941N-38
26 INTRODUCTION
MEASUREMENT AND T O R Q U E SPECIFICATIONS
INDEX
page page
Metric and English/SAE Conversion 26 Torque Specifications 26

Specification Notations 26
SPECIFICATION NOTATIONS Torque Specifications chart to determine torque val

ues not listed in the group.
W A R N I N G : THE U S E OF INCORRECT ATTACHING It is important to be aware that the torque values
H A R D W A R E CAN R E S U L T IN COMPONENT DAM listed in the chart are based on clean and dry bolt
A G E AND/OR P E R S O N A L INJURY. threads. Reduce the torque value by 10 percent when
the bolt threads are lubricated and by 20 percent if
It is important to retain the original attaching new.
hardware for assembly of the components. If the at
taching hardware is not reusable, hardware with BOLT THREAD AND GRADE/CLASS
equivalent specifications must be used. IDENTIFICATION
METRIC AND ENGLISH/SAE CONVERSION THREAD IDENTIFICATION

The following chart will assist in converting metric SAE and metric bolt/nut threads are not the same.
units to equivalent English and SAE units, or vise The difference is described in the Thread Notation
versa. chart.
TORQUE SPECIFICATIONS
TORQUE CHARTS
A torque chait for fasteners is provided at the end
of each group (of service information). Refer to the
CONVERSION FORMULAS AND EQUIVALENT VALUES
multiply By T® Get MuMply ly To Get

in-lbs x 0.11298 Newton-Meters (N°m) x 8.851 = in-lbs
ft-lbs x 1.3558 Newton-Meters (N*m) N*m x 0.7376 = ft-lbs
Inches Hg (60°F)
F>si
x 3.377
x 6.895
- Kilopascals (kPa)
Kilopascals (kPa)
kPa
kPa
x 0.2961
x 0.145
= Inches Hg
= psi
Inches x 25.4 Millimeters (mm) mm x 0.03937 = Inches
Feet x 0.3048 = Meters (M) M x 3.281 = Feet
Yards x 0.9144 Meters (M) M x 1.0936 = Yards
Miles x 1.6093 SB Kilometers (Km) Km x 0.6214 = Miles
mph x 1.6093 SB Kilometers/Hr. (Km/h) Km/h x 0.6214 = mph

Feet/Sec. x 0.3048 ss Meters/Sec. (M/S) M/S x 3.281 = Feet/Sec.
Kilometers/Hr. x 0.27778 SB Meters/Sec. (M/S) M/S x 3.600 = Kilometers/Hr.
mph x 0.4470 = Meters/Sec. (M/S) M/S x 2.237 = mph
COMMON METRIC EQUIVALENTS
1 Inch = 25 Millimeters 1 Cubic Inch = 16 Cubic Centimeters

1 Foot = 0.3 Meter 1 Cubic Foot = 0.03 Cubic Meter
1 Yard = 0.9 Meter 1 Cubic Yard = 0.8 Cubic Meter
1 Mile =1.6 Kilometers
J91IN-1
BR INTRODUCTION 27
SPECIFIED TORQUE FOR STANDARD BOLTS
Specified torque
Class Diameter Pitch Hexagon head bolt Hexagon flange bob
mm mm N«m kgf-cm ft-lbf N»m kgf-cm ft-lbf
6 1 5 55 48 in.-lbf 6 60 5 2 in.-lbf
8 1.25 12.5 130 9 14 145 10
4T 10 1.25 26 260 19 29 290 21
12 1.25 47 480 35 53 540 39
14 1.5 74 760 55 84 850 61
16 1.5 115 1,150 83 — — —
6 1 6.5 65 5 6 in.-lbf 7.5 75 65 in.-lbf
8 1.25 15.5 160 12 17.5 175 13
5T 10 1.25 32 330 24 36 360 26
12 1.25 59 600 43 65 670 48
14 1.5 91 930 67 100 1,050 76
16 1.5 140 1,400 101 — — —
6 1 8 80 69 in.-lbf 9 90 78 in.-lbf
8 1.25 19 195 14 21 210 15
6T 10 1.25 39 400 29 44 440 32
12 1.25 71 730 53 80 810 59
14 1.5 110 1,100 80 125 1,250 90
16 1.5 170 1,750 127 — — —
6 1 10.5 110 8 12 120 9
8 1.25 25 260 19 28 290 21
71 10 1.25 52 530 38 58 590 43
12 1.25 95 970 70 105 1,050 76
14 1.5 145 1,500 108 165 1,700 123
16 j 1.5 230 2,300 166 — — —
8 1.25 29 300 22 33 330 24

8T 10 1 25 61 620 45 68 690 50
12 1 25 110 1,100 80 120 1,250 90
8 1.25 34 340 25 37 380 27

9T 10 1.25 70 710 51 78 790 57
12 1.25 125 1,300 94 140 1,450 105
8 \.1 38 390 28 42 430 31

10T 10 1.25 ! 78 800 58 88 890 64
12 1.25 140 1,450 105 155 1,600 116
8 1.25 42 430 31 47 480 35

1 IT 10 1.25 87 890 64 97 990 72
12 1.25 155 1,600 116 175 1,800 130
28 INTRODUCTION BR
THREAD NOTATION—SAE AND METRIC line marks on the top of each bolt head. The actual
bolt strength grade corresponds to the number of line
INCH METRIC marks plus 2. The most commonly used metric bolt
strength classes are 9.8 and 12.9. The metric
5/16-18 M8 X 1.25
strength class identification number is imprinted on
THREAD NUMBER THREAD DISTANCE
MAJOR OF MAJOR BETWEEN the head of the bolt. The higher the class number,
DIAMETER THREADS DIAMETER IN THREADS IN the greater the bolt strength. Some metric nuts are
IN INCHES PER INCH MILLIMETERS MILLIMETERS imprinted with a single-digit strength class on the
nut face. Refer to the bolt identification and bolt
PR606B strength chart.
HAiE/CLASS IDENTIFICATION METRIC CONVERSION

The SAE bolt strength grades range from grade 2 Refer to the chart to convert torque values listed in
to grade 8. The higher the grade number, the greater metric Newton-meters (N-m). Also, use the chart to
the bolt strength. Identification is determined by the convert between millimeters (mm) and inches (in.)
BR INTRODUCTION 2S
BOLT IDENTIFICATION
Bolt Markings and Torque - Metric

Commercial Steel Class
8.8 10.9 12.9
Body
Size Torque _ _ _ Torque Torque
Diam. Cast Iron Aluminum Cast Iron Aluminum Cast Iron Aluminum
mm ft-Ib N*m Mb N®m ft-lh ft-Ib Mb N*m ft-Ib
6 9 5 7 4 14 9 11 7 14 9 11 7
7 14 9 11 7 18 14 14 11 23 18 18 14
8 25 18 18 14 32 23 25 18 36 27 28 21
10 40 30 30 25 60 45 45 35 70 50 55 40
12 70 55 55 40 105 75 80 60 125 95 100 75
14 115 85 90 65 160 120 125 95 195 145 150 110
16 180 130 140 100 240 175 190 135 290 210 220 165
18 230 170 180 135 320 240 250 185 400 290 310 230
Bolt Markings and Torque Values - U.S. Customary

SAE Grade Number 5 8
Bolt Head Markings

These are all SAE Grade 5 (3) line
Bolt Torque - Grade 5 Bolt Bolt Torque - Grade 8 Bolt

Body Size Cast Iron Aluminum Cast Iron Aluminum
Mb N»m Mb N*m Mb N«m Mb
1/4 -20 9 7 8 6 15 11 12 9
-28 12 9 9 7 18 13 14 10
5/16 - 18 20 15 16 12 30 22 24 18
-24 23 17 19 14 33 24 25 19
3/8 - 16 40 30 25 20 55 40 40 30
-24 40 30 35 25 60 45 45 35
7/16 - 14 60 45 45 35 90 65 65 50
-20 65 50 55 40 95 70 75 55
1/2 - 13 95 70 75 55 130 95 100 75
-20 100 75 80 60 150 no 120 90
9/16 - 12 135 100 no 80 190 140 150 110
- 18 150 110 115 85 210 155 170 125
5/8-11 180 135 150 110 255 190 205 150
- 18 210 155 160 120 290 215 230 170
3/4 - 10 325 240 255 190 460 340 365 270
- 16 365 270 285 210 515 380 410 300
7/8 - 9 490 360 380 280 745 550 600 440
- 14 530 390 420 310 825 610 660 490
1 -8 720 530 570 420 1100 820 890 660
- 14 800 590 650 480 1200 890 960 710
95IN-6
30 INTRODUCTION BR
BOLT STRENGTH
HOW TO DETERMINE BOLT STRENGTH
Hexagon
Mark
4—
Class
4T
^^-^
Stud bolt
Mark Class
head bolt 5— 51
^-s. Bolt 6— 61
j f ^ ^ ^ head No. 7 - 71 No mark
81
91 4T
10 — 10T
11 — 1 IT
[^^] No mark 4T
(J^^J)
Hexagon
flange bolt
No mark 4T Grooved
w / washer
hexagon bolt
j 61
Hexagon
head bolt Two 51
f| ^ || protruding
% ^ lines
Hexagon
flange bolt
T W
° j - Welded bolt
protrudinq 61
w / washer
hexagon bolt Ls
Hexagon
Three
head bolt tffS 71
IL? ^ 1 protruding
41
% ^ lines
Hexagon
head bolt ^^>n. Four
|L J
n protruding 81
lines
95IN-4
iiTRODUCTiOi 31
METRIC CONVERSE
in-lbs to N*m N®m to in-lbs
in- lb N « m in-lb N®m in-lb -lb N®m in-lb N®m in-lb .-lb N*m in-lb in-lb
tst»m
2 2260 42 4.7453 82 9.2646 122 13.7839 162 18.3032 .2 1.7702 4.2 37.1747 8.2 72.5792 12.2 107.9837 16.2
4 4519 44 4.9713 84 9.4906 124 14.0099 164 18.5292 .4 3.5404 4.4 38.9449 8.4 74.3494 12.4 109.7539 16.4
6 46
6779 5.1972 86 9.7165 126 14.2359 166 18.7552 .6 5.3107 4.6 40.7152 8.6 76.1197 12.6 111.5242 16.6
8 9039 48 5.4232 88 9.9425 128 14.4618 168 18.9811 .8 7.0809 4.8 42.4854 8.8 77.8899 12.8 113.2944 16.8
10 1298 50 5,6492 90 10.1685 130 14.6878 170 19.2071 1 8.8511 5 44.2556 9 MM)} 13 115.0646 17
12 .3558 52 5.8751 92 10.3944 132 14.9138 172 19.4331 1.2 10.6213 5.2 46.0258 9.2
81.4303
13.2 116.8348 17.2
14 5818 54 6.1011 94 10.6204 134 15.1397 174 19.6590 1.4 12.3916 5.4 47.7961 9.4 13.4 118.6051 17.4
1.6 14.1618 5.6 49.5663 9.6 83.2006 13.6 120.3753 17.6
16 MU 56 6.3270 96 10.8464 136 15.3657 176 19.8850 84.9708
18 58 6.5530 98 11.0723 138 15.5917 178 20.1110 1.8 15.9320 5.8 51.3365 9.8 13.8 122.1455 17.8
0337 17.7022 6 10 86.7410 123.9157 18
20 60 6.7790 100 11.2983 140 15.8176 180 20.3369 2 53.1067 14
2597 19.4725 10.2 88.5112 125.6860 18.5
22 62 7.0049 102 11.5243 142 16.0436 182 20.5629 2.2 6.2 54.8770 14.2
4856 21.2427 10.4 90.2815 127.4562 19
24 64 7.2309 104 11.7502 144 16.2696 184 20.7889 2.4 6.4 56.6472 14.4
7116 23.0129 10.6 92,0517 129.2264 19.5
26 66 7.4569 106 11.9762 146 16.4955 186 21.0148 2.6 6.6 58.4174 14.6
93.8219
28 9376
68 7.6828 108 12.2022 148 16.7215 188 21.2408 2.8 24.7831 6.8 60.1876 10.8
95.5921
14.8 130.9966 20
30 1635
3895
70 7.9088 110 12.4281 150 16.9475 190 21.4668 3 26.5534
28.3236
7
7.2
61.9579
63.7281
11
11.2
97.3624
15 132.7669 20.5
134.5371 21
32 72 8.1348 112 12.6541 152 17.1734 192 21.6927 3.2 15.2
6155 30.0938 99.1326 136.3073 22
34 74 8.3607 114 12.8801 154 17.3994 194 21.9187 3.4 7.4 65.4983 11.4 15.4
8414 31.8640 100.9028 138.0775 23
36 76 8.5867 116 13.1060 156 17.6253 196 22.1447 3.6 7.6 67.2685 11.6 15.6
0674 33.6342 102.6730 139.8478 24
38 78 8.8127 118 13.3320 158 17.8513 198 22.3706 3.8 7.8 69.0388 11.8 15.8
2934 35.4045 104.4433 141.6180 25
40 80 9.0386 120 13.5580 160 18.0773 200 22.5966 4 8 70.8090 12 16
5193 106.2135
ft-lbs to N®m N®m to ft-lbs

ft-Ib N®m ft-Ib N®m ft-Ib N®m ft-Ib N©m ft-Ib N»m N«m ft-Ib N®m ft-Ib N»m ft-Ib N©m ft-Ib N®m ft-Ib
1 1.3558 21 28.4722 41 55.5885 61 82.7049 81 109.8212 1 .7376 21 15.9m 41 30.2400 61 44.9913 81 59.7425
2 2.7116 22 29.8280 42 56.9444 62 84.0607 82 111.1770 2 1.4751 22 16.2264 42 30.9776 62 45.7289 82 60.4801
3 23 31.1838 43 58.3002 63 85.4165 83 112.5328 3 2.2127 23 16.9639 43 31.7152 63 83 61.2177
4 4.0675
5.4233 24 32.5396 44 59.6560 64 86.7723 84 113.8888 4 2.9502 24 17.7015 44 32.4527 64 46.4664
47.2040 84 61.9552
5 6.7791 25 33.8954 45 61.0118 65 88.1281 85 115.2446 5 3.6878 25 18.4391 45 33.1903 65 47.9415 85 62.6928
6 8.1349 26 35.2513 62.3676 66 89.4840 86 116.6004 6 4.4254 26 19.1766 33.9279 86 63.4303
7 27 36.6071 46
47 63.7234 67 87 117.9562 7 5.1629 27 19.9142 46
47 34.6654 66 4
67 8.6791
49.4167 87 64.1679
8 9.4907
10.8465 28 37.9629 48 65.0793 68 90.8398
92.1956 88 119.3120 8 5.9005 28 20.6517 48 35.4030 68 50.1542 88 64.9545
9 12.2024 29 39.3187 49 66.4351 69 93.5514 89 120.6678 9 6.6381 29 21.3893 49 36.1405 69 50.8918 89 65.6430
10 13.5582 30 40.6745 50 67.7909 70 94.9073 90 122.0236 10 7.3756 30 22.1269 50 36.8781 70 51.6293 90
11 14.9140 31 42.0304 51 69.1467 71 96.2631 91 123.3794 11 8.1132 31 22.8644 51 37.6157 71 52.3669 91 66.3806
67.1181
12 16.2698 32 43.3862 52 70.5025 72 97.6189 92 124.7352 12 8.8507 32 23.6020 52 38.3532 72 53.1045
13 17.6256 33 44.7420 53 71.8583 73 98.9747 93 126.0910 .13 33 24.3395 53 39.0908 73 53.8420 92
93 67.8557
68.5933
14 18.9815 34 46.0978 54 73.2142 74 100.3316 94 127.4468 14 9.5883
10.3259 34 25.0771 54 39.8284 74 54.5720 94 69.3308
15 20.3373 35 47.4536 55 74.5700 75 101.6862 95 128.8026 15 11.0634 35 25.8147 55 40.5659 75 55.3172 95 70.0684
16 21.6931 36 48.8094 56 75.9258 76 103.0422 96 130.1586 16 11.8010 36 26.5522 56 41.3035 76 56.0547 96 70.8060
17 23.0489 37 50.1653 57 77.2816 77 104.3980 97 131.5144 17 12.5386 37 27.2898 57 42.0410 77 97 71.5435
18 24.4047 38 51.5211 58 78.6374 78 98 132.8702 18 13.2761 38 28.0274 58 78 56.7923
57.5298 98 72.2811
19 25.7605 39 52.8769 59 79.9933 79 105.7538
107.1196 99 134.2260 19 14.0137 39 28.7649 59 42.77%
43.5162 79 58.2674 73.0187
20 27.1164 40 54.2327 81.3491 80 108.4654 135.5820 20 14.7512 40 29.5025 60 44.2537 80 59.0050 100 99 73.7562
60 100
in. to mm mm to in.
in. mm in. mm in. mm in. mm in. mm mm in. mm in. mm in. mm in. mm in.
.01 .254 .21 5.334 .41 10.414 .61 15.494 .81 20.574 .01 .00039 .21 .00827 .41 .01614 .61 .02402 .81 .03189
.02 .508 .22 5.588 .42 10.668 .62 15.748 .82 20.828 .02 .00079 .22 .00866 .42 .01654 .62 .02441 .82 .03228
.03 .762 .23 5.842 .43 10.922 .63 16.002 .83 21.082 .03 .00118 .23 .00906 .43 .01693 .63 .02480 .83 .03268
.04 1.016 .24 6.096 .44 11.176 .64 16.256 .84 21.336 .04 .00157 .24 .00945 .44 .01732 .64 .02520 .84 .03307
.05 1.270 .25 6.350 .45 11.430 .65 16.510 .85 21.590 .05 .00197 .25 .00984 .45 .01772 .65 .02559 .85 .03346
.06 1.524 .26 6.604 .46 11.684 .66 16.764 .86 21.844 .06 .00236 .26 .01024 .46 .01811 66 .025% .86 .03386
.07 1.778 .27 6.858 .47 11.938 .67 17.018 .87 .07 .00276 .27 .01063 .47 .01850 .67 .02638 .87 .03425
.08 2.032 .28 7.112 .48 12.192 .68 17.272 .88 22.0%
22.352 .08 .00315 .28 .01102 .48 .01890 .68 .02677 .88 .03465
.09 2.286 .29 7.366 .49 12.446 .69 17.526 .89 22.606 .09 .00354 .29 .01142 .49 .01929 .69 .02717 .89 .03504
.10 2.540 .30 7.620 .50 12.700 .70 17.780 .90 22.860 .10 .00394 .30 .01181 .50 .01969 .70 .02756 .90 .03543
.11 2.794 .31 7.874 .51 12.954 .71 18.034 .91 23.114 .11 .00433 .31 .01220 .51 .02008 .71 .02795 .91 .03583
.12 3.048 .32 8.128 .52 13.208 .72 18.288 .92 23.368 .12 .00472 .32 .01260 .52 .02047 .72 .02835 .92 .03622
.13 3.302 .33 8.382 .53 13.462 .73 18.542 .93 • 23.622 .13 .00512 .33 .01299 .53 .02087 .73 .02874 .93 .03661
.14 3.556 .34 8.636 .54 13.716 .74 18.796 .94 23.876 .14 .00551 .34 .01339 .54 .02126 .74 .02913 .94 .03701
.15 3.810 .35 8.890 .55 13.970 .75 19.050 .95 24.130 .15 .00591 .35 .01378 .55 .02165 .75 .02953 .95 .0374)
.16 4.064 .36 9.144 .56 14.224 .76 19.304 .96 24.384 .16 .00630 .36 .01417 .56 .02205 .76 .02992 .96 .03780
.17 3.318 .37 9.398 .57 14.478 .77 19.558 .97 24.638 .17 .37 .01457 .57 .02244 .77 .03032 .97 .03819
.18 4.572 .38 9.652 .58 14.732 .78 19.812 24.892 .18 .00669
.00709 .38 .01496 .58 .02283 .78 .03071 .98 .03858
.19 4.826 .39 9.906 .59 14.986 .79 20.066 .98
.99 25.146 .19 .00748 .39 .01535 .59 .02323 .79 .03110 .99 .03898
.20 5.080 .40 10.160 .60 15.240 .80 20.320 1.00 25.400 .20 .00787 .40 .01575 .60 .02362 .80 .03150 1.00 .03937
J901N-10
BR LUBRICATION AND MAINTENANCE 0 1
LUBRICATION A N D MAINTENANCE
CONTENTS
page page
CHASSIS AND BODY 35 MAINTENANCE SCHEDULES—DIESEL ENGINE

DIESEL ENGINE 26 VEHICLE 13
DRIVETRAIN 30 MAINTENANCE SCHEDULES—HEAVY DUTY . . . 8
ENGINE MAINTENANCE-GASOLINE 20 MAINTENANCE SCHEDULES—LIGHT DUTY
GENERAL INFORMATION 1 VEHICLES 4
JUMP STARTING, TOWING AND HOISTING . . . 17
GENERAL INFORMATION
INDEX
page page
Classification of Lubricants 2 International Symbols 1

Components Requiring No Lubrication 3 Introduction ., 1
Fluid Capacities 3 Lubrieation and Replacement Parts
Fuel Requirements 1 Recommendation 2
INTRODUCTION
Lubrication and maintenance is divided into re W CHRYSLER CORPORATION
quired and recommended service tasks. The required
service tasks must be completed to verify the emis
sion controls function correctly. The recommended
service tasks should be completed to maintain safety
ENGINE OIL
o BRAKE FLUID
and durability.
This information will assist the service personnel
in providing maximum protection for each owner's
vehicle.
Conditions can vary with individual driving habits.
o AUTOMATIC
TRANSMISSION
FLUID 0
POWER
STEERING
FLUID
It is necessary to schedule maintenance as a time in ENGINE WINDSHIELD

COOLANT WASHER FLUID^
terval as well as a distance interval.
It is the owner's responsibility to determine the ap 9500-1
plicable driving condition. Also to have the vehicle
serviced according to the maintenance schedule, and Fig. 11nternational Symbols
to pay for the necessary parts and labor.
FUEL REQUIREMENTS
Additional maintenance and lubrication informa
tion is listed in the Owner's Manual. GASOLINE ENGINES
Chrysler Corporation gasoline engines require the
UTEilATlOlAL SfiBOLS
use of unleaded gasoline to reduce the potentially
Chrysler Corporation uses international symbols to harmful effects of lead to the environment. Also un
identify engine compartment lubricant and fluid in leaded fuel is necessary to prevent damage to the
spection and fill locations (Fig. 1). catalytic converter/02 sensor. The fuel must have a
minimum octane rating of 87 based on the (R + M)/2
calculation method.
I -2 LUBRICATION AND MAINTENANCE
CAPTION: UNLEADED FUEL ONLY must be used in

vehicles equipped with a catalyst emission control
system. All vehicles have reminders printed on the
instrument panel below the fuel gauge and on the
fuel filler door. The vehicles also have fuel filler
tubes that are specially designed to accept only the
small-diameter dispensing nozzles. It is illegal to
bypass the design of an unleaded fuel filler tube
and contaminate the fuel system.
9400-9
DIESEL ENGINES
Fig. 2 The API Engine Oil Certification Mark
The Cummins Diesel engine and its fuel system are
compatible with, and have been designed to operate API SERVICE GRADE CERTIFIED
with low sulfur diesel fuels. The use of diesel fuel The API Service Grade specifies the type of perfor
additive to increase fuel lubricity is not re mance the engine oil is intended to provide. The API
quired or recommended. Diesel fuel lubricity addi Service Grade specifications also apply to energy con
tives will not damage the 5.9L engine, but will add serving engine oils.
unnecessary expense to the operation of the vehicle. Use an engine oil that is API Service Grade Certi
Cummins Turbo Diesel engines require number 2 fied or an oil that conforms to the API Service Grade
diesel fuel for operation in most climates. Refer to SH or SH/CD. MOPAR provides engine oils that con
Group 14, Fuel Systems for fuel recommendations. form to all of these service grades.
CLASSIFICATION OF LUBRICANTS GEAR LUBRICANTS
Lubricating fluids and chassis lubricants are clas A dual grade is also used to specify the viscosity of
multi-purpose gear lubricants.
sified according to standards recommended by the:
The API grade designation identifies gear lubri
® Society of Automotive Engineers (SAE).
cants in terms of recommended usage.
• American Petroleum Institute (API).
• National Lubricating Grease Institute (NLGI). CHASSIS AND WHEEL BEARING LUBRICANTS
The chassis and wheel bearing lubricants that are
ENGINE OIL recommended are identified by the NLGI Certifica
tion Symbol. The symbol contains a coded designa
API CERTIFICATION MARK
tion. This identifies the usage and quality of the
For maximum engine protection during all driving lubricant.
conditions, install an engine oil that contains the API The letter G within the symbol designates wheel
Certification Mark (Fig. 2). The API Certification bearing lubricant. The letter L designates chassis lu
Mark indicates that the oil is certified to meet the bricant. When the letters are combined, the lubricant
most critical requirements established by the manu can be used for dual applications. Use only lubricants
facturer. that display the NLGI Certification Symbol (Fig. 3).
Conformance to API specifications is determined by
NATIONAL LUBRICATING NATIONAL LUBRICATING NATIONAL LUBRICATING
tests that measure the ability of an oil to control: GREASE INSTITUTE GREASE INSTITUTE GREASE INSTITUTE
• Engine wear. NLGI NLQI NLQI

• Bearing corrosion. AUTOMOTIVE
WHEEL BEARING & CHASSIS
AUTOMOTIVE
AUTOMOTIVE
• Sludge. LUBRICANT LUBRICANT LUBRICANT
• Varnish. GC LB QC-LB
• Oil thickening.
WHEEL CHASSIS CHASSIS AND
• Rust. BEARINGS LUBRICATION WHEEL BEARINGS
• Piston deposits. 9200-7
SAE VISCOSITY GRADE Fig. 3 NLGI Lubricant Container Certification/

An SAE viscosity grade is used to specify the vis Identification Symbol
cosity of engine oil. SAE 30 specifies a single viscos LUBRICATION AND REPLACEMENT PARTS
ity engine oil. Engine oils also have multiple
viscosities. These are specified with a dual SAE vis RECOMMENDATION
cosity grade which indicates the cold-to-hot tempera Chrysler Corporation vehicles are engineered to
ture viscosity range. provide many years of dependable operation. How
ever,' lubrication service and maintenance are re-
BR LUBRICATION AND MAINTENANCE 0-3
quired for each vehicle. When necessary, MOPAR® 5.2 L 19 L (20.0 qts.)
brand lubricants and genuine replacement parts are 5.9 L Gas 19 L (20.0 qts.)
highly recommended. Each MOPAR brand lubricant 5.9 L Diesel 24.5 L (26.0 qts.)
and replacement part is designed and to provide de 8.0 L 22.7 L (24.0 qts.)
pendability and long service life. Automatic Transmission
Dry fill capacity*
COMPONENTS REQUIRING NO LUBRICATION 42RH 8.0-10.4 L (17-22 pts.)
There are many components that should not be lu 46RH 8.2-12.3 L (17.5-26 pts.)
bricated. The components that should not be lubri 47RH 8.2-15.6 L (17.5-33 pts.)
cated are: •Depending on type and size of internal cooler,
® Air pumps. length and inside diameter of cooler lines, or use of
• Generator bearings. an auxiliary cooler, these figures may vary. Refer to
• Brake booster cylinder. Group 21, Transmission for proper fluid fill proce
• Clutch release bearings. dure.
• Distributors. Manual Transmission
• Drive belts. NV4500 3.8 L (8.0 pts.)
• Drive belt idler pulleys. NV3500 2.0 L (4.2 pts.)
• Drive shaft center bearings. Transfer Case
• Idler arms. NP231 1.2 L (2.5 pts.)
• Rubber bushings. NP231HD 1.2 L (2.5 pts.)
• Starter motor bearings. NP241 .2.2 L (4.7 pts.)
• Suspension strut bearings. NP241HD 3.1 L (6.5 pts.)
• Rear spring shackle bolts. Fill to bottom of fill hole.
• Throttle control cables. Front Axle
• Throttle linkage ball joints. Dana 44 2.7 L (5.6 pts.)
© Water pump bearings. Dana 60 3.0 L (6.3 pts.)
Rear Axle
FLUID CAPACITIES 9-1/4 in 2.3 L (4.8 pts.)
Fuel Tank Dana 60 (2WD) 3.0 L (6.3 pts.)
118 inch wheel base 98 L (26 gal.) Dana 60 (4WD) 3.4 L (7.3 pts.)
138 inch wheel base 98 L (26 gal.) Dana 70 (2WD) 3.3 L (7.0 pts.)
All Others 132 L (35 gal.) Dana 70 (4WD) 3.6 L (7.8 pts.)
Engine Oil W/Filter change Dana 80 (2WD) 3.2 L (6.8 pts.)
3.9 L 3.8 L (4.0 qts.) Dana 80 (4WD) 4.8 L (10.1 pts.)
5.2 L 4.7 L (5.0 qts.) Rear Axle—Limited Slip Differential
5.9 L Gas 4.7 L (5.0 qts.) Dana 60 (2WD) 2.8 L (5.9 pts.*)
5.9 L Diesel 10.4 L (11.0 qts.) Dana 60 (4WD) 3.2 L (6.9 pts.*)
8.0 L 6.6 L (7.0 qts.) Dana 70 (2WD) 3.1 L (6.6 pts.*)
Engine Oil W/O Filter change Dana 70 (4WD) 3.4 L (7.4 pts.*)
3.9 L 3.3 L (3.5 qts.) Dana 80 (2WD) 3.0 L (6.4 pts.*)
5.2 L 4.3 L (4.5 qts.) Dana 80 (4WD) 4.5 L (9.6 pts.**)
5.9 L Gas 4.3 L (4.5 qts.) * Include 0.2 L (0.4 pts.) friction modifier.
5.9 L Diesel* ** Include 0.3 L (0.6 pts.) friction modifier.
8.0 L* Power Take Off Adapter
* Oil filter must be changed with every oil change. NV-021 2.1 L (4.6 pts.)
Cooling System Power Steering
3.9 L 19 L (20.0 qts.) All 1.3 L (2.7 pts.)
0-4 LUBRICATION AND MAINTENANCE
MAINTENANCE SCHEDULES—LIGHT DUTY VEHICLES
INTRODUCTION • Inspect battery and clean and tighten terminals as

There are two maintenance schedules that show required.
proper service intervals for Dodge Ram vehicles. Use • Check rubber seals on each side of the radiator for
the schedule that best describes the conditions the proper fit.
vehicle is operated under. When mileage and time is AT EACH OIL CHANGE
listed, follow the interval that occurs first. • Inspect exhaust system.
Schedule—A lists all the scheduled maintenance • Inspect brake hoses.
to be performed under normal operating conditions. • Rotate the tires at each oil change interval shown
Schedule—B is a schedule for vehicles that are on Schedule—A: (7,500 Miles) or every other interval
usually operated under one or more of the following shown on Schedule-B: (6,000 Miles).
conditions. • Check engine coolant level, hoses, and clamps.
• Frequent short trip driving less than 5 miles (8 • Lubricate steering linkage.
km). • If your mileage is less than 7,500 miles (12 000
• Frequent driving in dusty conditions. km) yearly, replace the engine oil filter at each oil
• Trailer towing or heavy load hauling. change.
• Frequent long periods of engine idling. • Lubricate propeller shaft universal joints and slip
• Sustained high speed operation. spline, if equipped.
• Desert operation. After completion of off-road (4WD) operation, the
9 Frequent starting and stopping. underside of the vehicle should be thoroughly in
® Cold climate operation. spected. Examine threaded fasteners for looseness.
• Off road driving.
• Commercial service. SCHEDULE—A
• Snow plow operation.
• More than half of vehicle operation occurs in 7,500 MILES (12 OOOKM) OR AT 6 MONTHS
heavy city traffic during hot weather (above 90° F). • Change engine oil.
EMISSION CONTROL SYSTEM MAINTENANCE 15,000 MILES (24 OOOKM) OR AT 12 MONTHS
The schedule emission maintenance listed in bold • Change engine oil.
type on the following schedules, must be done at the • Replace engine oil filter.
mileage specified to assure the continued proper
functioning of the emission control system. These, 22,500 MILES (36 OOOKM) OR AT 18 MONTHS
and all other maintenance services included in this • Change engine oil.
manual, should be done to provide the best vehicle • Inspect front wheel bearings. Clean and repack, if
performance and reliability. More frequent mainte required (4x2).
nance may be needed for vehicles in severe operating • Inspect brake linings.
conditions such as dusty areas and very short trip
driving. 30,000 MILES (48 OOOKM) OR AT 24 MONTHS
• Change engine oil.
SERVICE INTERVALS FOR 1500 AND 2500 LIGHT • Change engine oil filter.
DUTY VEHICLES • Replace engine air cleaner element.
• Replace spark plugs.
AT EACH STOP FOB GASOLINE
• Check engine oil level and add as required. 37,500 MILES (60 OOOKM) OR AT 30 MONTHS
• Check windshield washer solvent and add as re • Change engine oil.
quired. • Drain and refill automatic transmission fluid. Re
place filter and adjust bands.
ONCE A MONTH • Drain and refill transfer case fluid.
• Check tire pressure and look for unusual tire wear
or damage. 45,000 MILES (72 OOOKM) OR AT 36 MONTHS
• Check fluid levels of coolant reservoir, brake mas • Change engine oil.
ter cylinder, power steering and transmission. Add • Replace engine oil filter.
fluid as required. • Inspect front wheel bearings. Clean and repack, if
• Check all lights and other electrical items for cor required (4x2).
rect operation. • Inspect brake linings.
BR LUBRICATION AND MAINTENANCE 0- 5
• Flush and replace engine coolant at 36 months re 105,000 MILES (168 OOOKM) OR AT 84
gardless of mileage. MONTHS
© Change engine oil.
52,500 MILES (84 OOOKM) ©ft AT 42 MONTHS • Replace engine oil filter.
• Change engine oil. • Flush and replace engine coolant if it has been
• Flush and replace engine coolant, if not done at 36 30,000 miles (48 000km) or 24 months since last
months. change.
60,000 MILES 196 OOOKM) O R AT 48 MONTHS 112,500 MILES (180 OOOKM) OR AT 90
• Change engine oil. MONTHS
• Replace engine oil filter. • Change engine oil.
• Replace engine air cleaner element. • Inspect front wheel bearings. Clean and repack, if
• Replace distributor cap and rotor. required (4x2).
• Replace ignition cables. © Drain and refill automatic transmission fluid. Re
• Check PCV valve and replace as necessary.* place filter and adjust bands.
• Replace spark plugs. ® Drain and refill transfer case fluid.
• Clean and relubricate crankcase inlet air cleaner. • Inspect brake linings.
• Flush and replace engine coolant if it has been
67,500 MILES (108 OOOKM) OR AT 54
30,000 miles (48 000km) or 24 months since last
MONTHS
change.
• Inspect front wheel bearings. Clean and repack, if 120,000 MILES (192 OOOKM) OR AT 96
required (4x2). i MONTHS
• Inspect brake linings. > Change engine oil.
> Replace engine oil filter.
• Replace engine air cleaner element.
MONTHS
> Replace distributor cap and rotor.
• Change engine oil. • Replace ignition cables.
• Replace engine oil filter. • Check PCV valve and replace as necessary.*
® Drain and refill automatic transmission fluid. Re • Replace spark plugs.
place filter and adjust bands. • Clean and relubricate crankcase inlet air cleaner.
• Drain and refill transfer case fluid. *This maintenance is recommended by Chrysler to
® Flush and replace engine coolant if it has been the customer but it is not required to maintain war
30,000 miles (48 000km) or 24 months since last ranty on the PCV valve.
change.
SCHEDULE—B
MONTHS 3,000 MILES (5 OOOKM)
® Change engine oil. • Change engine oil.
® Flush and replace engine coolant if it has been
30,000 miles (48 000km) or 24 months since last 6,000 MILES (10 OOOKM)
change. • Change engine oil.
• Replace engine oil filter.
90,000 MILES (144 OOOKM) OR AT 72-
9,000 MILES (14 OOOKM)
MONTHS
• Change engine oil. • Change engine oil.
• Replace engine oil filter. 12,000 MILES (19 OOOKM)
• Replace engine air cleaner element. • Change engine oil.
• Replace spark plugs. ® Replace engine oil filter.
• Inspect front wheel bearings. Clean and repack, if • Drain and refill automatic transmission fluid. Re
required (4x2). place filter and adjust bands.**
• Inspect brake linings. • Change rear axle fluid.
• Change front axle fluid (4x4).
97,500 MILES (156 OOOKM) OR AT 78 • Inspect brake linings.
MONTHS
• Change engine oil. 15,000 MILES (24 OOOKM)
• Inspect engine air cleaner element, replace as nec 48,000 MILES (77 OOOKM)
essary. • Change engine oil.
@ Replace engine oil filter.
18,000 MILES (29 OOOKM) • Drain and refill automatic transmission fluid. Re
• Change engine oil. place filter and adjust bands.**
• Replace engine oil filter. • Change rear axle fluid.
21,000 MILES (34 OOOKM) • Inspect brake linings.
• Inspect front wheel bearings. Clean and repack, if 51,000 MILES (82 OOOKM)
required (4x2). • Change engine oil.
• Flush and replace engine coolant.
• Drain and refill automatic transmission fluid. Re • Replace engine oil filter.
• Change rear axle fluid. 57,000 MILES (91 OOOKM)
• Change front axle fluid (4x4). • Change engine oil.
• Inspect brake linings.
27,000 MILES (43 OOOKM) • Change engine oil.
• Change engine oil. • Replace engine air cleaner element.
30,000 MILES (48 OOOKM) • Replace distributor cap and rotor.
o Change engine oil. • Replace ignition cables.
• Replace engine oil filter. • Inspect PCV valve and replace as necessary.*
• Replace engine air cleaner element. • Replace spark plugs.
• Inspect PCV valve, replace as necessary.* • Clean and relubricate crankcase inlet air cleaner.
• Replace spark plugs. • Drain and refill automatic transmission fluid. Re
place filter and adjust.**
33,000 MILS (S3 OOOKM) • Change rear axle fluid.
• Inspect front wheel bearings, Clean and repack, if
• Drain and refill automatic transmission fluid. Re required (4x2).
• Drain and refill transfer case fluid. 66,000 MILES (106 OOOKM)
• Change rear axle fluid. • Change engine oil.
• Change front axle fluid (4x4). • Replace engine oil filter.
• Change engine oil. ® Replace engine oil filter.
9 Replace engine oil filter. • Drain and refill automatic transmission fluid, Re-
• Inspect front wheel bearings. Clean and repack, if place filter and adjust bands.
required (4x2). < Drain and refill transfer case fluid.
• Change rear axle fluid.
45,000 MILES (72 OOOKM) • Change front axle fluid (4x4).
• Change engine oil. o Inspect brake linings.
• Inspect engine air cleaner element, replace
as necessary. 75 000
9 MILES (120 OOOKM)
® Change engine oil.
BR LUBRICATION AND MAINTENANCE 0 -7
• Inspect engine air, cleaner element, replace as nec • Inspect engine air cleaner element, replace
essary. as necessary.
® Inspect front wheel bearings. Clean and repack if
78,000 MILES (12S OOOKM)
required (4x2).
• Change engine oil
• Change engine oil. ® Drain and refill automatic transmission fluid. Re
84,000 MILES (134 OOOKM) • Drain and refill transfer case fluid.
• Change engine oil. • Change rear axle fluid.
© Replace engine oil filter. • Change front axle fluid (4x4).
® Drain and refill automatic transmission fluid. Re • Inspect brake linings.
place filter and adjust bands.**
• Change rear axle fluid. 111,000 MILES (178 OOOKM)
© Change front axle fluid (4x4). • Change engine oil.
• Inspect front wheel bearings. Clean and repack if ® Flush and replace engine coolant.
required (4x2).
© Inspect brake linings. 114,000 MILES (182 OOOKM)
87,000 MILES (139 OOOKM) • Replace engine oil filter.
© Replace engine oil filter. 120,000 MILES (192 OOOKM)
• Replace engine air cleaner element. • Change engine oil.
• Inspect PCV valve, replace as necessary.* • Replace engine oil filter.
• Replace spark plugs. © Replace engine air cleaner element.
• Replace distributor cap and rotor.
93,000 MILES (149 OOOKM) • Replace ignitions cables.
© Change engine oil. • Check PCV valve and replace as necessary.*
• Change engine oil. • Clean and relubricate crankcase inlet air cleaner.
• Replace engine oil filter. • Drain and refill automatic transmission fluid. Re
@ Drain and refill automatic transmission fluid. Re place filter and adjust bands.**
place filter and adjust bands.** • Change rear axle fluid.
• Change rear axle fluid. © Change front axle fluid (4x4).
• Change front axle fluid (4x4). ® Inspect brake linings.
• Inspect brake linings. *This maintenance is recommended by Chrysler to
the customer but it is not required to maintain war
99,000 MILES (158 OOOKM) ranty on the PCV valve.
• Change engine oil. * * Off-the-highway operation, trailer towing, snow
plowing, or prolonged operation with heavy loading,
102,000 MILES (163 OOOKM) especially in hot weather require the more frequent
• Change engine oil. transmission service indicated with ** in Sched
• Replace engine oil filter. ule—B. Perform these services if you usually operate
105,000 MILES (168 OOOKM) your Ram Truck under these conditions.
MAINTENANCE SCHEDULES—HEAVY DUTY
INTRODUCTION • Inspect battery and clean and tighten terminals as

There are two maintenance schedules that show required.
proper service intervals for Heavy Duty Dodge Earn AT EACH OIL CHANGE
vehicles. Use the schedule that best describes the
® Inspect exhaust system.
conditions the vehicle is operated under. When mile
• Inspect brake hoses.
age and time is listed, follow the interval that occurs
first. ® Rotate the tires at each oil change interval shown
Schedule—A lists all the scheduled maintenance on Schedule—A (6,000 Miles) or every other interval
to be performed under normal operating conditions. shown on Schedule-B (6,000 Miles).
Schedule—B is a schedule for vehicles that are • Check engine coolant level,hoses, and clamps.
usually operated under one or more of the following • If your mileage is less than 6,000 miles (9 600km)
. conditions. yearly, replace the engine oil filter at each oil change.
• Frequent short trip driving less than 5 miles (8 • Lubricate steering linkage.
km). • Replace engine oil filter at every oil change (8.0L
• Frequent driving in dusty conditions. only).
• Trailer towing or heavy load hauling.
• Frequent long periods of engine idling. SCHEDULE—A
• Sustained high speed operation.
• Desert operation. 6,000 MILES (10 OOOKM) OR AT 6 MONTHS
® Frequent starting and stopping. • Change engine oil.
® Cold climate operation. • Replace engine oil filter (8.0L only).
• Off road driving.
• Commercial service. 12,000 MILES (19 OOOKM) OR AT 12 MONTHS
• Snow plow operation. • Change engine oil.
o More than half of vehicle operation occurs in • Replace engine oil filter.
heavy city traffic during hot weather (above 90° F).
18,000 MILES (29 OOOKM) OR AT 18 MONTHS
EMISSION CONTROL SYSTEM MAINTENANCE • Change engine oil.
The schedule emission maintenance listed in bold • Replace engine oil filter (8.0L only).
type on the following schedules, must be done at the • Inspect brake linings.
mileage specified to assure the continued proper
functioning of the emission control system. These, 24,000 MILES (38 OOOKM) OR AT 24 MONTHS
and all other maintenance services included in this ® Change engine oil.
manual, should be done to provide the best vehicle • Replace engine oil filter.
performance and reliability. More frequent mainte • Replace engine air cleaner and air pump ele
nance may be needed for vehicles in severe operating ments.
conditions such as dusty areas and very short trip • Clean and relubricate crankcase inlet air filter
driving. (5.9L).
• Drain and refill automatic transmission fluid. Re
SERVICE INTERVALS FOR 2500 AND 3500 HEAVY place filter and adjust bands.
DUTY VEHICLES • Inspect front wheel bearings. Clean and repack, if
required (4x2).
AT EACH STOP FOR GASOLINE
• Check engine oil level and add as required. 30,000 MILES (48 OOOKM) OR AT 30 MONTHS
• Check windshield washer solvent and add as re • Change engine oil.
quired. • Replace engine oil filter (8.0L only).
ONCE A MONTH
• Check tire pressure and look for unusual tire wear 36,000 MILES (58 OOOKM) OR AT 36 MONTHS
or damage. © Change engine oil.
® Check fluid levels of coolant reservoir, brake mas © Replace engine oil filter.
ter cylinder, power steering and transmission. Add © Drain and refill transfer case fluid.
fluid as required. o Inspect brake linings.
• Check all lights and other electrical items for cor © Flush and replace engine coolant at 36 months, re
rect operation. gardless of mileage..
BR LUBRICATION AND 1AINTENANCE 0 -1
42,000 MILES (67 OOOKM) OR AT 42 MONTHS 78,000 MILES (125 OOOKM) OR AT 78

• Replace engine oil filter (8.0L only). • Change engine oil.
• Replace engine oil filter (8.0L only).
48,000 MILES (77 OOOKM) OR AT 48 MONTHS © Flush and replace engine coolant if it has been
• Change engine oil. 30,000 miles (48 000km) or 24 months since last
• Replace engine oil filter. change.
• Replace engine air cleaner and air pump ele
ments. 82,500 MILES (132 OOOKM) OR AT 82
• Clean and relubricate crankcase inlet air filter MONTHS
(5.9L). • Replace oxygen sensor (5.9L only).***
• Drain and refill automatic transmission fluid. Re
place filter and adjust bands. 84,000 MILES (184 OOOKM) OR AT 84
• Inspect front wheel bearings. Clean and repack, if MONTHS
required (4x2). • Change engine oil.
• Flush and replace engine coolant if not done at 36 • Replace engine oil filter.
months. • Flush and replace engine coolant if it has been
30,000 miles (48 000km) or 24 months since last
54,000 MILES (86 OOOKM) OR AT 54 MONTHS change.
• Replace engine oil filter (8.0L only). 90,000 MILES (144 OOOKM) OR AT 90
• Inspect brake linings. MONTHS
» Change engine oil.
60,000 MILES (96 OOOKM) OR AT 60 MONTHS • Replace engine oil filter (8.0L only).
• Change engine oil. • Replace spark plugs.
• Replace engine oil filter. • Inspect brake linings.
• Replace ignition cables.
• Replace PCV valve (5.9L).*** 96,000 WILES (154 OOOKM) OR AT 96
• Replace distributor cap and rotor (5.9L only). MONTHS
• Replace spark plugs. • Change engine oil.
• Clean EGR air passages.*** • Replace engine oil filter.
• Replace EGR valve.*** Replace engine air cleaner and air pump ele
• Replace battery. ments.
• Lubricate front suspension ball joints. • Clean and relubricate crankcase inlet air filter
• Flush and replace engine coolant if it has been 5.9L).
30,000 miles (48 000km) or 24 months since last • Drain and refill automatic transmission fluid. Re
change. place filter and adjust bands.
• Inspect front wheel bearings. Clean and repack, if
66,000 MILES (106 OOOKM) OR AT 66 required (4x2).
MONTHS
• Change engine oil. 102,000 MILES (163 OOOKM) OR AT 102
• Replace engine oil filter (8.0L only). MONTHS
72,000 MILES (115 OOOKM) OR AT 72 Replace engine oil filter (8.0L only).
MONTHS
• Change engine oil. 108,000 MILES (173 OOOKM) OR AT 108
• Replace engine oil filter. MONTHS
• Replace engine air cleaner and air pump ele • Change engine oil.
ments. • Replace engine oil filter.
• Clean and relubricate crankcase inlet air filter • Drain and refill transfer case fluid.
(5.9L). © Inspect brake linings.
• Drain and refill automatic transmission fluid. Re • Flush and replace engine coolant if it has been
place filter and adjust bands. 30,000 miles (48 000km) or 24 months since last
© Drain and refill transfer case fluid. change.
• Inspect front wheel bearings. Clean and repack, if ***Requires Service Reminder Indicator Light, if so
required (4x2). equipped, these parts are to be replaced at the indi
• Inspect brake linings. cated mileage or when emissions Service Reminder
I -II LUiliClTiOi l i i MAINTENANCE BR
Indicator Light remains on continuously with the key 27,000 MILES (43 OOOKM)
in the ON position, whichever occurs first. • Change engine oil.
SCHEDULE—B
3,&0@ MILES fS OOOKM) • Change engine oil.
• Change engine oil. • Replace engine oil filter.
© Replace engine oil filter (8.0L only). • Inspect PCV valve, replace as necessary
(5.9L).
6,000 MILES 11© OOOKM) • Replace spark plugs.
9,000 MILES (14 &OOKM) • Replace engine oil filter (8.0L only).
9 Replace engine oil filter (8.0L only). 36,000 MILES (58 OOOKM)
12,000 MILES (19 OOOKM) ® Replace engine oil filter.
• Change engine oil. • Inspect engine air cleaner and air pump ele
• Replace engine oil filter. ments, replace as necessary.
• Inspect engine air cleaner and air pump ele • Clean and relubricate crankcase inlet air filter
ments, replace as necessary. (5.9L).
• Clean and relubricate crankcase inlet air filter • Drain and refill automatic transmission fluid. Re
(5.9L). place filter and Adjust bands.**
• Drain and refill automatic transmission fluid. Re • Drain and refill transfer case.
place filter and adjust bands.** • Change rear axle fluid.
© Change front axle fluid (4x4).
• Inspect brake linings. 39,000 MILES (62 OOOKM)
24 000 MILES
9 (38 OOOKM) • Replace engine air cleaner and air pump ele
• Change engine oil. ments.
© Replace engine oil filter. © Clean and relubricate crankcase inlet air filter
• Replace engine air cleaner and air pump ele (5.9L).
ments. • Drain and refill automatic transmission fluid. Re
• Clean and relubricate crankcase inlet air filter place filter and adjust bands.
(5.9L). • Change rear axle fluid.
• Drain and refill automatic transmission fluid. Re • Change front axle fluid (4x4).
place filter and adjust bands. • Inspect front wheel bearings. Clean and repack, if
• Change rear axle fluid. required (4x2).
• Change front axle fluid (4x4). • Inspect brake linings.
• Inspect front wheel bearings. Clean and repack, if • Flush and replace engine coolant.
required (4x2). S1 000
9 MILES (82 OOOKM)
® Inspect brake linings. • Change engine oil.
54,00© MILES (88 OOOKM) 75,000 MILES (120 OOOKM) '

• Replace engine oil filter. • Replace engine oil filter (8.0L only).
57,000 MILES (91 000KM)
9 78,000 MILES (125 OOOKM)
9 Change engine oil. • Change engine oil.
• Replace engine oil filter (8.0L only). © Replace engine oil filter.
® Replace engine oil filter. • Change engine oil.
• Inspect engine air cleaner and, air pump ele • Replace engine oil filter (8.0L only).
ments, replace as necessary.
82 S00 MILES (132 OOOKM)
® Inspect PCV valve, replace as necessary 9
(5.9L). " • Replace oxygen sensor (5.9L).***

• Replace distributor cap and rotor (5.9L). 84,000 MILES (134 OOOKM)
• Replace ignition cables. • Change engine oil.
• Replace spark plugs. • Replace engine oil filter.
• Clean and relubricate crankcase inlet air filter • Inspect engine air cleaner a n d air pump ele
(5.9L). ments, replace as necessary.
• Clean EGR passages.*** • Clean and relubricate crankcase inlet air filter
• Replace EGR valve.*** (5.9L).
© Replace battery. • Replace oxygen sensor.***
• Drain and refill automatic transmission fluid. Re • Drain and refill automatic transmission fluid. Re
place filter and adjust bands.** place filter and adjust bands.**
• Change rear axle fluid. • Change rear axle fluid.
• Change front axle fluid (4x4). • Change front axle fluid (4x4).
© Inspect brake linings. © Inspect brake linings.
63,000 MILES (101 OOOKM) 87,000 MILES (139 OOOKM)

• Replace engine oil filter (8.0L only). • Replace engine oil filter (8.0L only).
66 00O MILES (106 OOOKM) 90,000 MILES (144 OOOKM)

9

© Replace engine oil filter. ® Replace engine oil filter.
• Inspect PCV valve, replace as necessary
69,000 MILES (110 OOOKM) (5.9L).
• Change engine oil. • Replace spark plugs.
• Change engine oil. • Replace engine oil filter (8.0L only).
• Replace engine air cleaner a n d air pump ele • Change engine oil.
ments. • Replace engine oil filter.
• Clean and relubricate crankcase inlet air filter • Replace engine air cleaner and air pump ele
(5.9L). ments.
• Drain and refill automatic transmission fluid. Re • Clean and relubricate crankcase inlet air filter
place filter and adjust bands. (5.9L).
• Drain and refill transfer case fluid. • Drain and refill automatic transmission fluid. Re
• Change rear axle fluid. place filter and adjust bands.
• Change front axle fluid (4x4). • Change rear axle fluid.
© Inspect front wheel bearings. Clean and repack, if • Change front axle fluid (4x4).
required (4x2). • Inspect front wheel bearings. Clean and repack, if
© Inspect brake linings. required (4x2).
0-12 LUBRICATION AND MAINTENANCE BR
99,000 MILES (158 OOOKM) • Drain and refill automatic transmission fluid. Re
• Change engine oil place filter and adjust bands.**
• Replace engine oil filter (8.0L only). • Drain and refill transfer case fluid.
102,000 MILES (163 OOOKM) • Change front axle fluid (4x4).
• Change engine oil. • Inspect brake linings.
@ Replace engine oil filter. • Flush and replace engine coolant.
* * Off-the-highway operation, trailer towing, snow
• Change engine oil. plowing, prolonged operation with heavy loading, es
• Replace engine oil filter (8.0L only). pecially in hot weather require the more frequent
transmission service indicated with ** in Sched
108,000 MILES (172 800KM) ule—B. Perform these services if you usually operate
• Change engine oil. your Ram Truck under these conditions.
• Replace engine oil filter. ***Requires Service Reminder Indicator Light. If so
• Inspect engine air cleaner and air pump ele equipped, these parts are to be replaced at the indi
ments, replace as necessary. cated mileage or when the service reminder indicator
• Clean and relubricate crankcase inlet air filter light remains on continuously with the key in the ON
(5.9L). position, whichever occurs first.
BR LUBRICATION AND MAINTENANCE 0 -13
M A I N T E N A N C E SCHEDULES—DIESEL E N G I N E VEHICLE
INTRODUCTION 6,000 MILES (9 800KM) OR AT 6 MONTHS

There are two maintenance schedules that show • Change engine oil.
proper service intervals for Diesel Engine equipped • Replace engine oil filter.
Dodge Ram vehicles. Use the schedule that best de 12,000 MILES (19 200KM) ©ft AT 12 MONTHS
scribes the conditions the vehicle is operated under. • Change engine oil.
When mileage and time is listed, follow the interval • Replace engine oil filter.
that occurs first. © Inspect water pump weep hole for blockage.
Schedule—A lists all the scheduled maintenance • Replace fuel filter.
to be performed under normal operating conditions. • Inspect charge air cooler connections for leaks.
Schedule—B is a schedule for vehicles that are
usually operated under one or more of the following 18,000 MILES (28 800KM) OR AT 18 MONTHS
conditions. • Change engine oil.
• Frequent short trip driving less than 5 miles (8 km). • Replace engine oil filter.
• Frequent driving in dusty conditions. • Inspect drive belt, replace as necessary.
• Trailer towing or heavy load hauling.
• Frequent long periods of engine idling. 24,000 MILES (38 400KM) OR AT 24 MONTHS
• Sustained high speed operation. • Change engine oil.
• Desert operation. • Replace engine oil filter.
• Frequent starting and stopping. • Adjust valve lash clearance.
• Cold climate operation. • Inspect fan hub.
• Off road driving. • Inspect damper.
• Commercial service. • Inspect water pump weep hole for blockage.
• Snow plow operation. @ Drain and refill automatic transmission fluid. Re
• More than half of vehicle operation occurs in place filter and adjust band.
heavy city traffic during hot weather (above 90° F). • Inspect front wheel bearings. Clean and repack, if
required (4x2).
SERWiCE INTERVALS FOR DIESEL ENGINE • Inspect brake linings.
• Inspect charge air cooler connections for leaks.
VEHICLE
30,000 MILES (48 OOOKM) OR AT 30 M@MTHS
AT EACH STOP FOR FUEL • Change engine oil.
• Check engine oil level and add as required. © Replace engine oil filter.
• Check windshield washer solvent and add as required.
36,000 MILES (57 600KM) OR AT 36 MONTHS
ONCE A MONTH • Change engine oil.
• Check tire pressure and look for unusual tire wear • Replace engine oil filter.
or damage. • Inspect drive belt, replace as necessary.
• Inspect battery and clean an tighten terminals as re • Inspect water pump weep hole for blockage.
quired. • Drain and refill transfer case fluid.
• Check fluid levels of coolant reservoir, brake mas • Inspect water pump weep hole for blockage.
ter cylinder, power steering and transmission. Add • Inspect brake linings.
fluid as required. ' • Flush and replace engine coolant at 36 months, re
• Check all lights and all other electrical items for gardless of mileage.
correct operation. • Inspect charge air cooler connections for leaks.
• Drain water from fuel filter.
• Check Filter Minder, replace filter if necessary. 42,000 MILES (67 200KM) OR AT 42 MONTHS
AT EACH OIL CHANGE • Replace engine oil filter.
• Inspect exhaust system.
• Inspect brake hoses. 48,000 MILES (76 800KM) OR AT 48 MONTHS
• Rotate the tires at each oil change interval shown, © Change engine oil.
6,000 miles (9 600 km) on Schedule-A or every • Replace engine oil filter.
other interval shown on Schedule—B. • Drain and refill automatic transmission fluid. Re
• Check engine coolant level, hoses, and clamps. place filter and adjust bands.
• Lubricate steering linkage. • Adjust valve lash clearance.
0 -14 LUBRICATION AND MAINTENANCE — —__________ BR
o Inspect fan hub. • Flush and replace engine coolant if it has been 30,000
© Inspect damper. miles (48 000 km) or 24 months since last change.
© Inspect front wheel bearings. Clean and repack, if • Inspect charge air cooler connections for leaks.
required (4x2).
© Inspect water pump weep hole for blockage. 90,000 MILES (144 OOOKM) OR AT 90
© Flush and replace engine coolant if not done at 36 MONTHS
months. o Change engine oil.
• Inspect charge air cooler connections for leaks. » Replace engine oil filter.
• Inspect drive belt, replace as necessary.
54,000 MILES (86 400KM) OM AT 5 4 If ©If fffS • Inspect brake linings.
• Replace engine oil filter. 96,000 MILES (153 600KM) OR AT 96
MONTHS
• Inspect drive belt, replace as necessary.
© Inspect brake linings. • Change engine oil.
60,000 MILES (96 OOOKM) OR AT 60 I C I f H S • Drain and refill automatic transmission fluid. Re
© Change engine oil. place filter and adjust bands.
@ Replace engine oil filter. • Adjust valve lash clearance.
© Inspect water pump weep hole for blockage. • Inspect fan hub.
• Inspect damper.
o Flush and replace engine coolant if it has been
• Inspect front wheel bearings. Clean and repack, if
30,000 miles (48 000 km) or 24 months since last required (4x2).
change. • Inspect water pump weep hole for blockage.
© Inspect charge air cooler connections for leaks. • Inspect charge air cooler connections for leaks.
66,000 MILfES (1&5 6O0KM) OR AT 66 MONTHS 102,000 MILES (163 200KM) OR AT 102
© Replace engine oil filter. © Change engine oil.
72,000 MILES (115 200KM) OR AT 72
MONTHS 108,000 MILES (172 800KM) OR AT 108
® Change engine oil. MONTHS
© Replace engine oil filter. • Change engine oil.
• Inspect drive belt, replace as required. • Replace engine oil filter.
® Drain and refill automatic transmission fluid. Re • Inspect water pump weep hole for blockage.
place filter and adjust bands. • Inspect drive belt, replace as necessary.
® Drain and refill transfer case fluid. • Drain and refill transfer case fluid.
© Adjust valve lash clearance. • Inspect brake linings.
© Inspect fan hub. • Flush and replace engine coolant if it has been 30,000
© Inspect damper. miles (48 000 km) or 24 months since last change.
o Inspect water pump weep hole for blockage. © Inspect charge air cooler connections for leaks.
® Inspect front wheel bearings. Clean and repack, if
required (4x2). SCHEDULE—B
© Inspect brake linings.
• Inspect charge air cooler connections for leaks. 3,000 MILES (4 800KM)
@ Change engine oil.
7B,@m MILES (124 800KM) OR AT 78 • Replace engine oil filter.
© Change engine oil. 6,000 MILES (9 600KM)
• Replace engine oil filter. © Change engine oil.
® Flush and replace engine coolant if it has been 30,000 © Replace engine oil filter.
miles (48 000 km) or 24 months since last change.
9,000 MILES (14 400KM)
84,000 MILES (134 400KM) OR AT 84 • Change engine oil.
MONTHS © Replace engine oil filter.
© Replace engine oil filter. 12,000 MILES (19 200KM)
© Replace fuel filter. • Change engine oil.
• Inspect water pump weep hole for blockage. • Replace engine oil filter.
• Inspect water pump weep hole for blockage. • Change rear axle fluid.
© Drain and refill automatic transmission fluid. Re • Change front axle fluid (4x4).
place filter and adjust bands. • Inspect brake linings.
© Change rear axle fluid. • Inspect charge air cooler connections for leaks or
• Change front axle fluid (4x4). at 12 month intervals.
• Inspect charge air cooler connections for leaks or 39,000 MILES (62 OOOKM)
at 12 month intervals. • Change engine oil.
• Replace engine oil filter. • Change engine oil. -
18,000 MILES im OOOKM)
• Replace engine oil filter. ® Change engine oil.
© Inspect drive belt, replace as necessary. • Replace engine oil filter.
o Change engine oil. • Change engine oil.
© Replace engine oil filter. • Replace engine oil filter.
• Adjust valve lash clearance.
• Change engine oil. • Inspect fan hub.
• Replace engine oil filter. • Inspect damper.
• Adjust valve lash clearance. • Inspect water pump weep hole for blockage.
© Inspect fan hub. • Drain and refill automatic transmission fluid. Re
• Inspect damper. place filter and adjust bands.
• Inspect water pump weep hole for blockage. ® Change rear axle fluid.
• Drain and refill automatic transmission fluid. Re o Change front axle fluid (4x4).
place filter and adjust bands. o Inspect front wheel bearings. Clean and repack if
• Change rear axle fluid. required (4x2).
© Change front axle fluid (4x4). • Inspect brake linings.
• Inspect front wheel bearings. Clean and repack if • Flush and replace engine coolant.
required (4x2). • Inspect charge air cooler connections for leaks or
• Inspect brake linings. at 12 month intervals.
• Inspect charge air cooler connections for leaks or
at 12 month intervals. 51,000 MILES (82 OOOKM)
27,000 MILES (43 200 KM) • Replace engine oil filter.
• Replace engine oil filter. 54,000 MILES (86 400KM)
® Change engine oil. • Inspect drive belt, replace as necessary.
33,000 MILES (53 OOOKM) ® Change engine oil.
• Replace engine oil filter. © Inspect water pump weep hole for blockage.
• Inspect drive belt, replace as necessary. • Drain and refill automatic transmission fluid. Re
• Inspect water pump weep hole for blockage. place filter and adjust bands.
• Drain and refill automatic transmission fluid. Re • Change rear axle fluid.
place filter and adjust bands. • Change front axle fluid (4x4).
• Drain and refill transfer case fluid. © Inspect brake linings.
0 -16 LUBRICATION AND MAINTENANCE BR
• Inspect charge air cooler connections for leaks or 87,000 MILES (140 OOOKM)
at 12 month intervals. • Change engine oil.
66,000 MILES (102 OOOKM) • Inspect drive belt, replace as necessary.
72,000 MILES (115 200KM) • Replace engine oil filter.
• Change engine oil. • Adjust valve lash clearance.
• Replace engine oil filter. • Inspect fan hub.
• Inspect drive belt, replace as necessary. • Inspect damper.
® Adjust valve lash clearance. • Inspect water pump weep hole for blockage.
• Inspect fan hub. • Drain and refill automatic transmission fluid. Re
• Inspect damper. place filter and adjust bands.
• Drain and refill automatic transmission fluid. Re • Change front axle fluid (4x4).
place filter and adjust bands. • Inspect front wheel bearings. Clean and repack if
• Drain and refill transfer case fluid. required (4x2).
• Change rear axle fluid. • Inspect brake linings.
• Change front axle fluid (4x4). • Inspect charge air cooler connections for leaks or
• Inspect front wheel bearings. Clean and repack if at 12 month intervals.
required (4x2).
© Inspect brake linings. 99,000 MILES (158 400KM)
® Inspect charge air cooler connections for leaks or • Change engine oil.
at 12 month intervals. • Replace engine oil filter.

® Replace engine oil filter. • Replace engine oil filter.
78,000 MILES (125 OOOKM) 105,000 MILES (168 OQOKM)

© Change engine oil. • Change engine oil.
• Replace engine oil filter. • Replace engine oil filter.
108,000 MILES (172 800KM)
• Replace engine oil filter. • Inspect drive belt, replace as necessary.
• Inspect water pump weep hole for blockage.
84,000 MILES (134 400KM) • Drain and refill automatic transmission fluid. Re
• Change engine oil. place filter and adjust bands.
® Replace engine oil filter. • Drain and refill transfer case fluid.
© Drain and refill automatic transmission fluid. Re • Change front axle fluid (4x4).
place filter and adjust bands. • Inspect brake linings.
• Change rear axle fluid. • Flush and replace engine coolant.
• Change front axle fluid (4x4). • Inspect charge air cooler connections for leaks or
• Inspect brake linings. at 12 month intervals.
• Inspect charge air cooler connections for leaks or Inspection and service should also be performed
at 12 month intervals. anytime a malfunction is observed or suspected.
LUBRICATION AND MAINTENANCE 0-17
J U M P S T A R T I N G , TOWING AND H O I S T I N G
INDE1
page page
Four-Wheel-Drive Vehicle Towing . . . . . . . . . . . . . . 19 Towing Recommendations . . . . . . . . . . . . . . . . . . . 18

Ground Clearance and Ramp Angle . . . . . . . . . . . 19 Towing When Keys Are Not Available 19
Hoisting Recommendations . . . . . . . . . . . . . . . . . . 18 Two-Wheel-Drive Vehicle Towing 19
Jump Starting 17
JUMP STARTING (2) When using another vehicle as a booster

source, turn off all accessories, place gear selector in
WARNING: R E V I E W A L L S A F E T Y PRECAUTIONS park or neutral, set park brake and operate engine at
AND WARNINGS IN GROUP 8A, BATTERY/START 1200 rpm.
ING/CHARGING S Y S T E M S DIAGNOSTICS. (3) On disabled vehicle, place gear selector in park
DO NOT J U M P START A FROZEN BATTERY, P E R or neutral and set park brake. Turn off all accesso
SONAL INJURY CAN RESULT. ries.
DO NOT J U M P , START W H E N MAINTENANCE (4) Connect jumper cables to booster battery. RED
F R E E BATTERY INDICATOR DOT IS Y E L L O W OR clamp to positive terminal (+). BLACK clamp to neg
BRIGHT COLOR. ative terminal (-). DO NOT allow clamps at opposite
DO NOT J U M P START A VEHICLE W H E N THE
end of cables to touch, electrical arc will result. Re
BATTERY FLUID IS B E L O W THE TOP OF LEAD view all warnings in this procedure.
PLATES.
(5) On disabled vehicle, connect RED jumper cable
clamp to positive (+) terminal. Connect BLACK
DO NOT A L L O W J U M P E R C A B L E C L A M P S TO
jumper cable clamp to engine ground as close to the
TOUCH EACH OTHER WHEN CONNECTED TO A
ground cable attaching point as possible (Fig. 1 and
BOOSTER SOURCE.
2).
DO NOT U S E O P E N FLAME NEAR BATTERY.
REMOVE METALLIC J E W E L R Y W O R N ON HANDS - NEGATIVE O R zz ^—:
:
G R O U N D CABLE ~ POSITIVE -
OR W R I S T S TO AVOID INJURY B Y ACCIDENTAL CONNECTION CABLE
ARCING O F BATTERY CURRENT. CONNECTION^
W H E N USING A HIGH OUTPUT BOOSTING DE

VICE, DO NOT A L L O W BATTERY VOLTAGE TO E X
C E E D 16 VOLTS. R E F E R TO INSTRUCTIONS
PROVIDED WITH DEVICE BEING U S E D .
CAUTION: When using another vehicle as a

booster, do not allow vehicles to touch. Electrical
systems can be damaged on either vehicle.
BATTERY J9500-26
TO JUMP START A DISABLED VEHICLE** N
(1) Raise hood on disabled vehicle and visually in

spect engine compartment for: Fig. 1 Jumper Cable Clamp Connections—Gas
• Battery cable clamp condition, clean if necessary. Engine
• Frozen battery. CAUTION: Do not crank starter motor on disabled
• Yellow or bright color test indicator, if equipped. vehicle for more than 15 seconds, starter will over
• Low battery fluid level. heat and could fail.
• Generator drive belt condition and tension.
• Fuel fumes or leakage, correct if necessary. (6) Allow battery in disabled vehicle to charge to at
least 12.4 volts (75% charge) before attempting to
CAUTION: If the cause of starting problem on dis start engine. If engine does not start within 15 sec
abled vehicle is severe, damage to booster vehicle onds, stop cranking engine and allow starter to cool
charging system can result. (15 min.), before cranking again.
0-18 LUBRICATION AMD MAINTENANCE IBIIlPfl
Pig. 2 Jumper Cahie damp Connections—Diesei

Engine
ilSCillECT CABLE CHIPS I S FOLLOWS:
• Disconnect BLACK cable clamp from engine
ground on disabled vehicle.
• When using a Booster vehicle, disconnect BLACK
cable clamp from battery negative terminal. Discon
nect RED cable clamp from battery positive terminal. ' FRAME CONTACT HOIST g FLOOR JACK
• Disconnect RED cable clamp from battery positive
terminal on disabled vehicle. J9500-5
PORTABLE STARTING UNIT Fig. 3 Vehicle Lifting Locations

There are many types of portable starting units HOIST
available for starting engines. Follow the manufac A vehicle can be lifted with:
turer's instructions and observe the listed precau • A single-post, frame-contact hoist.
tions when involved in any engine starting • A twin-post, chassis hoist.
procedure. • A ramp-type, drive-on hoist.
When a frame-contact type hoist is used, ver
HOISTING RECOMMENDATIONS
ify that the lifting pads are positioned properly
Refer to the Owner's Manual for emergency vehicle (Fig. 3 ) .
lifting procedures.
WARNING: THE HOISTING AND J A C K LIFTING
FLOOR JACK
POINTS PROVIDED A R E FOR A C O M P L E T E VEHI
When properly positioned, a floor jack can be used
C L E . W H E N A C H A S S I S OR DRIVETRAIN COMPO
to lift a vehicle (Fig. 3). Support the vehicle in the
NENT IS REMOVED FROM A VEHICLE, T H E
raised position with jack stands at the front and rear
CENTER O F GRAVITY I S ALTERED MAKING S O M E
ends of the frame rails.
HOISTING CONDITIONS UNSTABLE. P R O P E R L Y
CAUTION: Do not lift vehicle with a floor jack posi S U P P O R T OR S E C U R E VEHICLE TO HOISTING DE
tioned under: VICE WHEN T H E S E CONDITIONS EXIST.
• An axle tube.
• A body side sill. TOWING RECOMMENDATIONS
• A steering linkage component. A vehicle equipped with SAE approved sling-type
© A drive shaft. towing equipment can be used to tow all vehicles.
• The engine or transmission oil pan. When towing a 4WD vehicle using a wheel-lift towing
• The fuel tank. device, use a tow dolly under the opposite end of the
• A front suspension arm. vehicle. A vehicle with flat-bed device can also be
Use the correct frame rail lifting locations used to transport a disabled vehicle (Fig. 4).
only (Fig, 8).
BR - — - LUBRICATION AND MAINTENANCE 0 -19
A towed vehicle should be raised until lifted wheels

are a minimum 100 mm (4 in) from the ground. Be
sure there is adequate ground clearance at the oppo
site end of the vehicle, especially when towing over
rough terrain or steep rises in the road. If necessary,
remove the wheels from the lifted end of the vehicle
and lower the vehicle closer to the ground, to in
crease the ground clearance at the opposite end of
the vehicle. Install lug nuts on wheel attaching studs
to retain brake drums or rotors.
FLAT-BED TOWING RAMP ANGLE
If a vehicle with flat-bed towing equipment is used,
the approach ramp angle should not exceed 15 de
grees.
TWO-WHEEL-DRIVE VEHICLE TOWING

Chrysler Corporation recommends that a vehicle be
FLAT BED towed with the rear end lifted, whenever possible.
J9500-6
TOWING-REAR END LIFTED
Fig. 4 Tow Vehicles With Approved Equipment CAUTION: Do not use steering column lock to se
A wooden crossbeam may be required for proper cure steering wheel during towing operation.
connection when using the sling-type, front-end tow
ing method. © Unlock steering column and secure steering wheel
in straight ahead position with a clamp device de
SAFETY PRECAUTIONS signed for towing.
The following safety precautions must be ob © Verify that steering components are in good condi
served when towing a vehicle. tion.
© Secure loose and protruding parts.
• Always use a safety chain system that is indepen TOWING-FRONT END LIFTED
dent of the lifting and towing equipment. If a two-wheel-drive vehicle cannot be towed with
• Do not allow towing equipment to contact the dis the rear wheels lifted, it can be towed with the front
abled vehicle's fuel tank. wheels lifted with the transmission in the neutral po
• Do not allow anyone under the disabled vehicle sition.
while it is lifted by the towing device.
9 Do not allow passengers to ride in a vehicle being FOUR-WHEEL-DRIVE VEHICLE TOWING
towed. Chrysler Corporation recommends that a vehicle be
• Always observe state and local laws regarding tow transported on a flat-bed device. A Wheel-lift or
ing regulations. Sling-type device can be used provided all the wheels
• Do not tow a vehicle in a manner that could jeop are lifted off the ground using tow dollies.
ardize the safety of the operator, pedestrians or other
motorists. TOWING WHEN KEYS ARE NOT AVAILABLE
• Do not attach tow chains, T-hooks, J-hooks, or a
tow sling to a bumper, steering linkage, drive shafts When the vehicle is locked and keys are not avail
or a non-reinforced frame hole. able, use a flat bed hauler. A Wheel-lift or Sling-type
• Do not tow a heavily loaded vehicle. Damage to device can be used provided all the wheels are lifted
the cab, cargo box or frame may result. Use a flatbed off the ground using tow dollies.
device to transport a loaded vehicle.
GROUND CLEARANCE AND RAMP ANGLE
GROUND CLEARANCE
CAUTION: If vehicle is towed with wheels removed,

install lug nuts to retain brake drums or rotors.
I - 21 LUBRICATION AND MAINTENANCE BR
ENGINE MAINTENANCE-GASOLINE
INDEX
page page
Accessory Drive Belts 25 Engine Oil 20

Air-Conditioner Compressor 25 Engine Oil Filter 21
Battery . . . . . . . . . . . . . . . . . . . . ... . . 25 Exhaust System—Gasoline 25
Break-In Period 20 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Crankcase Ventilation System 23 Fuel System 24
Emission Control System . . 25 Ignition Cables, Distributor Cap, and Rotor ...... 24
Engine Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . 23 Rubber and Plastic Component Inspection . . . . . . . 25
Engine Cooling System . . . . . . . . . . . . . . . . . . . . . 22 Spark Plugs 24
BREAK-IN PERIOD ENGINE OIL SPECIFICATION
C A U T I O N ; W i d e o p e n throttle operation in l o w CAUTION: Do not use non-detergent or straight

g e a r s , before e n g i n e break-in period i s c o m p l e t e , mineral oil when adding or changing crankcase lu
can damage engine. bricant. Engine failure can result.
After first starting a n e w engine, allow it to idle for

API SERVICE GRADE CERTIFIED
15 seconds before shifting into a drive gear. Also:
• D r i v e t h e vehicle at v a r y i n g speeds less t h a n 88 U s e a n engine oil t h a t is A P I Service G r a d e C e r t i
k m / h (55 m p h ) for t h e first 100 k m (60 miles). fied or a n oil t h a t conforms to the A P I Service G r a d e
• Avoid fast acceleration a n d sudden stops. S H or S H / C D . M O P A R provides engine oils t h a t con
• Do not drive a t full-throttle for extended periods of form to a l l of these service grades.
time.
SAE VISCOSITY
• Do not drive a t constant speeds.
A n S A E viscosity grade is used to specify t h e vis
• Do not idle t h e engine excessively.
cosity of engine oil. S A E 30 specifies a single viscos
A special break-in engine oil is not required. T h e
ity engine oil. E n g i n e oils also h a v e multiple
original engine oil installed is a h i g h quality, energy
viscosities. These a r e specified w i t h a d u a l S A E vis
conserving lubricant. S p e c i a l b r e a k - i n oils a r e not
cosity grade w h i c h indicates t h e cold-to-hot tempera
recommended. These oils could interfere w i t h t h e
ture viscosity range. Select a n engine oil t h a t is best
n o r m a l piston r i n g seating process.
suited to your particular temperature range a n d v a r i
N e w engines tend to consume more fuel a n d oil u n
ation ( F i g . 1).
t i l after t h e break-in period h a s ended.
ENIINE OIL
WARNING: NEW OR USED ENGINE O I L CAN BE IR
5W-30
10W-30
>
RITATING TO THE SKIN* AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
< 1 I 1
F -20 0 10 20 32 60 80 100
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO C -29 -18 -12 -7 0 16 27 38
YOUR HEALTH. THOROUGHLY WASH EXPOSED ANTICIPATED TEMPERATURE RANGE
BEFORE NEXT OIL CHANGE J9000-39
SKIN WITH SOAP AND WATER.
DO NOT WASH SKIN WITH GASOLINE, DIESEL
Fig. 1 Temperature/Engine Oil Viscosity
FUEL, THINNER, OR SOLVENTS, HEALTH PROB
LEMS CAN RESULT. ENERGY CONSERVING OIL
DO NOT POLLUTE, DISPOSE OF USED ENGINE An Energy Conserving type oil is recommended for
OIL PROPERLY. CONTACT YOUR DEALER OR GOV gasoline engines. They are designated as either EN
ERNMENT AGENCY FOR LOCATION OF COLLEC ERGY CONSERVING or ENERGY CONSERVING
TION CENTER IN YOUR AREA.. II.
BR LUBRICATION AND MAINTENANCE 0 - 21
CONTAINER IDENTiFiCATIOi
Standard engine oil identification notations have
been adopted to aid in the proper selection of engine
oil The identifying notations are located on the label
of engine oil plastic bottles and the top of engine oil
cans (Fig. 2).
Fig. 3 Oil Level indicator (Dipstick)
(2) Hoist and support vehicle on safety stands. Re

fer to Hoisting and Jacking Recommendations in this
group.
9400-9 (3) Remove oilfillcap.
(4) Place a suitable drain pan under crankcase
Fig. 2 Engine Oil Container Standard Notations drain.
(5) Remove drain plug from crankcase and allow
ENGINE OIL ADDITIVES
oil to drain into pan. Inspect drain plug threads for
In some instances, such as infrequent operation,
stretching or other damage. Replace drain plug and
short trip driving, and during break-in after a major
gasket if damaged. ,
overhaul, addition of special materials containing an
(6) Install drain plug in crankcase.
ti-rust and anti-scuff additives are beneficial. A suit
(7) Lower vehicle and fill crankcase with specified
able product for this purpose is MOPAR Engine Oil
type and amount of engine oil described in this sec
Supplement.
tion.
CRANKCASE OIL LEVEL INSPECTION (8) Install oilfillcap.
(9) Start engine and inspect for leaks.
CAUTION: Do not overfill crankcase with engine oil, (10) Stop engine and inspect oil level.
oil foaming and oil pressure loss can result.
ENGINE OIL FILTER
Inspect engine oil level approximately every 800 ki
OIL FILTER SPECIFICATION
lometers (500 miles). Unless the engine has exhibited
loss of oil pressure, run the engine for about five Chrysler Corporation recommends a Mopar or
minutes before checking oil level. Checking engine oil equivalent oil filter be used when replacement is re
quired. A replacement filter must be designed to
level on a cold engine is not accurate.
withstand 1756 kPa (256 psi) of internal pressure.
(1) Position vehicle on level surface.
(2) With engine OFF, allow approximately ten min OIL FILTER REMOVAL
utes for oil to settle to bottom of crankcase, remove (1) Position a drain pan under the oil filter.
engine oil dipstick. (2) Using a suitable oil filter wrench (Fig. 4) loosen
(3) Wipe dipstick clean. filter by turning counterclockwise.
(4) Install dipstick and verify it is seated in the (3) When filter separates from adapter nipple, tip
tube. gasket end upward to minimize oil spill. Remove fil
(5) Remove dipstick, with handle held above the ter from vehicle.
tip, take oil level reading (Fig. 3). (4) With a wiping cloth, clean the gasket sealing
(6) Add oil only if level is below the ADD mark on surface (Fig. 5) of oil and grime.
dipstick.
OIL FILTER INSTALLATION
ENGINE OIL CHANGE (1) Lightly lubricate oil filter gasket with engine
Change engine oil at mileage and time intervals oil or chassis grease.
described in Maintenance Schedules. (2) Thread filter in a clockwise motion onto
adapter nipple. When gasket makes contact with
TO CHANiE ENGINE OIL sealing surface, hand tighten filter one full turn, do
Run engine until achieving normal operating tem not over tighten.
perature. (3) Add oil, verify crankcase oil level and start en
(1) Position the vehicle on a level surface. gine. Inspect for oil leaks.
0 - 22 LUBRICATION AND MAINTENANCE BR
CAUTION: Do not use straight antifreeze as engine

coolant, inadequate engine running temperatures
can result.
Do not operate vehicle without proper concentra
tion of recommended ethylene glycol coolant, high
running temperatures and cooling system corrosion
can result.
The engine cooling system will develop internal

pressure of 97 to 123 kPa (14 to 18 psi) at normal op
erating temperature. Allow the vehicle approximately
one half hour to cool off before opening the cooling
Fig. 4 Remove Oil Filter—Typical system. As an indicator of pressure, squeeze the up
per radiator hose between index finger and thumb. If
it collapses with little effort the system would have
low internal pressure and should be safe to open to
the first safety notch of the radiator cap. Refer to
Group 7, Cooling System.
COOLING SYSTEM INSPECTION

Coolant level should be inspected when other en
gine compartment service is performed or when cool
ant leak is suspected. Coolant recovery tank level
should read between the ADD and FULL marks, lo
Fig. 5 Install Oil Filter—Typical
cated on the side of recovery tank, when the engine
is at normal operating temperature. Normal coolant
used e n g i n e OIL d i s p o s a l
level maintenance does not require the removal of ra
Care should be exercised when disposing used en diator cap.
gine oil after it has been drained from a vehicle en • Cooling system freeze protection should be tested
gine. • at the onset of the winter season or every 12 months.
Service is required if coolant is low, contaminated,
ENGINE COOLING SYSTEM rusty or freeze protection is inadequate. To properly
WARNINGS AND PRECAUTIONS
test cooling system, see Group 7, Cooling System.
The cooling system factory fill is a mixture of 50%
WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL Ethylene Glycol based antifreeze and 50% water. Us
B A S E COOLANT AND I S HARMFUL IF S W A L ing a suitable hydrometer, measure antifreeze con
L O W E D OR INHALED. IF S W A L L O W E D , DRINK centration in the radiator when the engine is cool. If
TWO G L A S S E S O F WATER AND INDUCE VOMIT the cooling system has recently been serviced, allow
ING. IF INHALED, MOVE TO F R E S H AIR A R E A . coolant to circulate for at least 20 minutes before
S E E K MEDICAL ATTENTION IMMEDIATELY. DO NOT taking hydrometer reading. Properly mixed coolant
S T O R E IN O P E N OR UNMARKED CONTAINERS. will protect the cooling system to -37°C (-35°F). If the
W A S H SKIN AND CLOTHING THOROUGHLY A F T E R freeze protection is above -28°C (-20°F), drain enough
COMING IN CONTACT WITH ETHYLENE GLYCOL. coolant from the cooling system to allow room to add
K E E P OUT O F R E A C H O F CHILDREN. antifreeze to achieve adequate protection. A mix table
D I S P O S E O F GLYCOL B A S E COOLANT P R O P on the coolant container indicates the amount of an
ERLY, CONTACT YOUR D E A L E R OR GOVERNMENT tifreeze required to winterize the cooling system
A G E N C Y FOR LOCATION O F COLLECTION C E N T E R based on the capacity, see Capacity Chart in General
IN YOUR A R E A . Information section of this group.
DO NOT O P E N A COOLING S Y S T E M W H E N T H E ANTIFREEZE SPECIFICATION
ENGINE IS AT RUNNING T E M P E R A T U R E , P E R Chrysler Corporation recommends Mopar Anti
SONAL I N J U R Y CAN RESULT. freeze/Coolant or a high quality, ethylene glycol base
AVOID RADIATOR COOLING FAN W H E N ENGINE antifreeze/coolant, with a silicate inhibitor.
COMPARTMENT RELATED S E R V I C E IS P E R
FORMED, P E R S O N A L INJURY CAN R E S U L T RADIATOR CAP
The radiator cap must be secure to provide proper
pressure
release and coolant recovery. Inspect and test radi AIR INLET
ator cap when cooling system service is performed or
when problem is suspected.
COOLING SYSTEM SERVICE
The cooling system should be drained, flushed and
filled with the proper coolant mixture at the inter
vals described in the Lubrication and Maintenance
Schedules. Refer to General Information section of
this group. For proper service instructions see Group
7, Cooling System.
ENGINE AIR CLEANER

The engine air cleaner should be serviced at the in
tervals described in the Lubrication and Maintenance
Schedules sections of this group. Additional informa
tion can be found in Group 14, Fuel System and
Group 25, Emission System. Inspect all air cleaner
hoses or tubes for damage or leaks when other en
gine compartment service is performed. Replace
faulty components.
AIR CLEANER SBMWiGB
CAUTION: The air cleaner cover must be Installed

properly for the emissions system and engine con
troller to function correctly.
Do not immerse paper air element in cleaning sol
vents, damage can result- Fig, 6 Mir Cleaner—3.9 L, 5.2 L or 5.9 L Engines
HOUSING
10 SERVICE l i i CLEANER ASSEMBLY
(1) Raise hood of vehicle and inspect all air cleaner
components for damage or improper attachment.
(2) Remove air cleaner cover (Fig. 6 or 7).
(3) Remove paper air filter element from air
cleaner body. Hold a shop light on throttle body side
of element. Inspect air intake side of element. If ele
ment is saturated with oil or light is not visible, re
place filter. If element is saturated with oil, perform
crankcase ventilation system tests.
(4) Clean inside of air cleaner cover and body with
vacuum or compressed air. If oily, wipe out with shop
towel,
(5) Install the air cleaner filter element and attach
the cover to the body/housing.
CRANKCASE VENTILATION SYSTEM

Engine crankcase pressure and emissions are
vented into combustion chambers through the posi
tive crankcase ventilation (PCV) system. The crank
case ventilation system should have enough volume
to overcome crankcase pressure created by' piston Fig. 7 Air Cleaner—8.0 L Engine
backwash. If a crankcase ventilation system-becomes valve, crankcase filter or a collapsed hose. Refer to
plugged, the crankcase pressure will increase and Group 25, Emission Control Systems for proper ser
force engine oil past the piston rings creating oil con vice information.
sumption. Blockage of crankcase ventilation system
can occur at the vacuum source coupling, ventilation
0 - 24 LUBRICATION AND MAINTENANCE BR
FUEL SYSTEM line. You may encounter fuels containing 3 percent or

more methanol along with other alcohols called cosol-
INSPECTION vents.
It is recommended that the fuel system filler cap, Problems that are the result of using methanol/gas
nozzle, tubes, hoses, and connections be inspected pe oline blends are not the responsibility of Chrysler
riodically. Corporation. They may not be covered by the vehicle
warranty.
FUEL FILTER
The fuel filter requires service only when a fuel MTBE/ETBE
contamination problem is suspected. For proper diag Gasoline and MTBE (Methyl Tertiary Butyl Ether)
nostic and service procedures refer to Group 14, Fuel blends are a mixture of unleaded gasoline and up to
System, 15 percent MTBE. Gasoline and ETBE (Ethyl Ter
tiary Butyl Ether) are blends of gasoline and up to
FUEL USAGE SWATEmEmW—GMB@LimE 17 percent ETBE. Gasoline blended with MTBE or
ENGINES ETBE may be used.
Dodge vehicles are designed to meet all emission
regulations and provide excellent fuel economy using CLEAN AIR IAS0LINE
high quality unleaded gasoline. Only use unleaded Many gasolines are now being blended that con
gasolines having a minimum posted octane of 87. tribute to cleaner air, especially in those areas of the
If the vehicle develops occasional light spark knock country where air pollution levels are high. These
(ping) at low engine speeds, this is not harmful. How new blends provide a cleaner burning fuel and some
ever, continued heavy knock at high speeds can are referred to as Reformulated Gasoline.
cause damage and should be checked immedi In areas of the country where carbon monoxide lev
ately. els are high, gasolines are being treated with oxygen
In addition to using unleaded gasoline with the ated materials such as MTBE, ETBE and ethanol.
proper octane rating, those that contain deter Chrysler Corporation supports these efforts toward
gents, corrosion and stability additives are rec cleaner air and recommends the use of these gaso
ommended. Using gasolines that have these lines as they become available.
additives will help improve fuel economy, reduce
emissions and maintain vehicle performance. IGNITION CABLES, DISTRIBUTOR CAP, AND
Poor quality gasoline can cause problems such
as hard starting, stalling and stumble. If these prob ROTOR
lems occur, use another brand of gasoline before con Inspect and test ignition cables, distributor cap and
sidering servicing the vehicle. rotor when the spark plugs are replaced. Oil and
grime should be cleaned from the ignition cables and
GASOLINE/OXYGENATE SLEMPS distributor cap to avoid possible spark plug fouling.
Some fuel suppliers blend unleaded gasoline with Mopar Foamy Engine Degreaser or equivalent is rec
materials that contain oxygen such as alcohol, MTBE ommended for cleaning the engine compartment. For
and ETBE. The type and amount of oxygenate used proper service and diagnostic procedures refer to
in the blend is important. The following are generally Group 8D, Ignition System.
used in gasoline blends:
SPARKPLUGS
ETHANOL
Ethanol (Ethyl or Grain Alcohol) properly blended, Ignition spark plugs should be replaced at the
is used as a mixture of 10 percent ethanol and 90 mileage interval described in the Lubrication and
percent gasoline. Gasoline with ethanol may be Maintenance Schedules. Refer to the General Infor
used in your vehicle. mation section of this group. For proper service pro
cedures refer to Group 8D, Ignition Systems.
1EIHAN0L
CAUTION: Do not use gasolines containing metha

nol. Use of methanol/gasoline blends may result in
starting and driveability problems. In addition, dam
age may be done to critical fuel system compo
nents.
Methanol (Methyl or Wood Alcohol) is used in a va

riety of concentrations blended with unleaded gaso
BATTERY EMISSION CONTROL SYSTEM

Inspect all emission control components and hoses
WARNING: W E A R S A F E T Y G L A S S E S , R U B B E R
G L O V E S AND PROTECTIVE CLOTHING W H E N HAN
when other under hood service is performed. Refer to
DLING/SERVICING A BATTERY. THE BATTERY
emission system Vacuum Hose Label located on the
ELECTROLYTE CONTAINS S U L F U R I C ACID AND inside of the hood in the engine compartment and
WILL C A U S E HARM IF IT CONTACTS SKIN, E Y E S Group 25, Emission Control Systems for proper ser
OR CLOTHING. IT W I L L A L S O DAMAGE PAINTED vice procedures.
(AS W E L L A S UN-PAINTED) S U R F A C E S OF A VEHI
ACCESSORY DRIVE BELTS
C L E . IF S U L F U R I C ACID CONTACTS ANY OF
THESE, FLUSH IMMEDIATELY WITH LARGE Inspect and adjust drive belts at the interval de
AMOUNTS OF WATER. IF S U L F U R I C ACID CON scribed in the Lubrication and Maintenance Sched
TACTS SKIN OR E Y E S , G E T IMMEDIATE MEDICAL ules. Refer to General Information section of this
ATTENTION. DO NOT S M O K E IN THE VICINITY OF A group. For proper inspection and adjustment proce
BATTERY. K E E P O P E N F L A M E S AND S P A R K S dures, see Group 7, Cooling System.
AWAY FROM BATTERY F I L L E R C A P S B E C A U S E
E X P L O S I V E G A S IS ALWAYS P R E S E N T EXHAUST SYSTEM—GASOLINE
The exhaust system should be inspected when un
Inspect battery tray, hold down and terminal con der vehicle service is performed or as specified in the
nections when other under hood service is performed. Lubrication and Maintenance Schedules.
For proper diagnostic procedures refer to Group 8A,
Battery/Starting/Charging System Diagnostics. For INSPECTION
service and cleaning procedures refer to Group 8B, When inspecting an exhaust system, inspect for
Battery/Starter Service. cracked or loose joints, stripped screw/bolt threads,
Care should be taken when disposing a bat corrosion damage, and worn or broken hangers.(S-
tery a f t e r removal from a vehicle. Lead-acid light cracking in rubber isolator or hanger is accept
batteries are highly poisonous and, when indis able). Replace all components that are corroded or
criminately disposed, could create a problem damaged. Do not attempt repair. Also, inspect for the
for the environment. Contact the applicable lo following obvious conditions and correct as necessary:
cal city or county government agency to deter • Exhaust system leaks, damage, misalignment.
mine where automobile (lead-acid) batteries • Contact with body panels metal or the frame.
can be properly disposed in the local area. • Catalytic converter bulging or excessive heat dam
age.
RUBBER A M PLASTIC COMPONENT INSPECTION
CAUTION: A catalytic converter will become con
CAUTION: Plastic hoses or wire harness covers will
taminated if leaded gasoline is burned in the en
melt or deform when exposed to heat from exhaust
gine. If this occurs, the complete converter must be
system or engine manifolds.
replaced.
Position plastic or rubber components away from
moving parts in engine compartment or under vehi For proper service procedures see Group 11, Ex
cle, or damage will result.
haust System and Intake Manifold.
Do not allow rubber engine mounts or other com
ponents to become oil contaminated, repair cause
AIR-CONDITIONER COMPRESSOR
of oil contamination and clean area.
LUBRICANT AND REFRIGERANT
All rubber and plastic components should be in
spected when engine compartment or under vehicle The lubricant level in the air-conditioner compres
service is performed. When evidence of deterioration sor should be checked if there are indications that oil
exists, replacement is required. To reduce deteriora was lost. Loss of lubricating oil usually accompanies
tion of rubber components, Chrysler Corporation rec a loss of refrigerant.
ommends Mopar Foamy Engine Degreaser or For additional information involving the A/C sys
equivalent be used to clean engine compartment of tem, refer to Group 24, Heater And Air Conditioning.
oil and road grime.
0 - 26 LUBRICATION AND MAINTENANCE
DIESEL ENGINE
INDEX
page page
Air-Conditioner Compressor 29 Engine Oil 26

Battery 28 Engine Oil Filter 27
Break-In Period 26 Exhaust System—Diesel 29
Engine Air Cleaner 28 Rubber and Plastic Component Inspection . . . . . . . 29
Engine Cooling System 28
ENGINE OIL The factory fill engine oil is a high quality, energy
conserving, crankcase lubricant. The Recommended
WARNING: N E W OR U S E D ENGINE OIL CAN B E IR SAE Viscosity Grades chart defines the viscosity
RITATING TO THE SKIN. AVOID P R O L O N G E D OR grades that must be used based on temperature in
R E P E A T E D SKIN CONTACT WITH ENGINE OIL. the region where vehicle is operated (Fig. 1). .
CONTAMINANTS IN U S E D ENGINE OIL, C A U S E D B Y
INTERNAL COMBUSTION, CAN B E HAZARDOUS TO
YOUR HEALTH. THOROUGHLY W A S H E X P O S E D 15W40
SKIN WITH S O A P AND WATER.
DO NOT W A S H SKIN WITH GASOLINE, D I E S E L
F U E L , THINNER, OR S O L V E N T S , HEALTH P R O B
L E M S CAN RESULT.
DO NOT POLLUTE, D I S P O S E OF U S E D ENGINE
OIL P R O P E R L Y . CONTACT YOUR D E A L E R OR GOV
ERNMENT A G E N C Y FOR LOCATION OF C O L L E C J9500-24
TION C E N T E R IN YOUR A R E A . .
Fig. 1 Temperature/Engine Oil Viscosity
Use only oils conforming to API Quality CF-4 or
BREAK-IN PERIOD CE. These heavy duty diesel categories may be used
Cummins diesel engines do not require a break-in with other API non-diesel categories, such as SH or
period due to its heavy duty construction. Normal op SG. A sulfated ash limit is specified for lubrication oil
eration is allowed, provided the following recommen used in Cummins engines. Oils with a high ash con
dations are followed: tent may produce deposits on valves that can
• After first starting a new engine, allow it to idle progress to guttering and valve burning. A maximum
for 15 seconds before shifting into a drive gear. sulfated ash content of 1.85 mass % is recommended
• Drive the vehicle at varying speeds less than 88 for all oil used in the engine.
km/h (55 mph) for the first 100 km (60 miles).
9 Avoid fast acceleration and sudden stops. CRANKCASE OIL LEVEL INSPECTION
• Do not drive at constant speeds.
CAUTION: Do not overfill crankcase with engine oil,
© Do not idle the engine excessively.
© Allow the engine to reach normal operating tem oil foaming and oil pressure loss can result.
perature before applying full load. Inspect engine oil level at every fuel fill. The oil
A special break-in engine oil is not required. The level should be in the safe range after the engine has
original engine oil installed is a high quality, energy been shut off for 15 minutes. The oil is most accu
conserving lubricant. Special break-in oils are not rately checked on a cold engine.
recommended. These oils could interfere with the
(1) Position vehicle on level surface.
normal piston ring seating process.
(2) With engine OFF, allow approximately 15 min
New engines tend to consume more fuel and oil un
utes for oil to settle to bottom of crankcase, remove
til after the break-in period has ended.
engine oil dipstick (Fig. 2).
ENGINE OIL SPECIFICATION (3) Wipe dipstick clean.
(4) Install dipstick and verify it is seated in the
CAUTION: Do not use non-detergent or straight tube.
mineral oil when adding or changing crankcase lu (5) Remove dipstick, with handle held above the
bricant. Engine failure can result. tip, take oil level reading (Fig. 3).
ENGINE OIL FILTER

OIL FILTER SPECIFICATION
The quality of replacement filter cartridges varies
considerably. Only a high quality filter cartridge
should be used to assure most efficient service. MO
PAR oil filter cartridge is a cartridge of this type and
is recommended.
OIL FILTER REMOVAL
(1) Position a drain pan under the oil filter.
(2) Using a suitable oil filter wrench loosen filter
by turning counterclockwise (Fig. 4).
Fig. 2 Dipstick Location

(6) Add oil only if level is below the ADD mark on
dipstick.
Fig. 4 Oil Filter Removal

(3) When filter separates from adapter nipple, tip
Fig. 3 Oil Level Indicator Dipstick
gasket end upward to minimize oil spill. Remove fil
ENGINE OIL CHANGE ter from vehicle.
Change engine oil at mileage and time intervals (4) With a wiping cloth, clean the gasket sealing
described in the Maintenance Schedule. surface (Fig. 5) of oil and grime.
TO CHANGE ENI1NE OIL
Run engine until achieving normal operating tem
perature.
(1) Position the vehicle on a level surface.
(2) Hoist and support vehicle on safety stands. Re
fer to Hoisting and Jacking Recommendations in this
group.
(3) Remove oil fill cap.
(4) Place a suitable drain pan under crankcase
drain.
(5) Remove drain plug from crankcase and allow
oil to drain into pan. Inspect drain plug threads for Fig. 5 Oil Filter Sealing Surface—Typical
stretching or other damage. Replace drain plug and
gasket if damaged. £ML FILTER INSTALLATION
(6) Install drain plug in crankcase. (1) Lightly lubricate oil filter gasket with engine
(7) Lower vehicle and fill crankcase with specified oil or chassis grease.
type and amount of engine oil described in this sec (2) Thread filter in a clockwise motion onto
tion. adapter nipple. When gasket makes contact with
(8) Install oilfillcap. sealing surface, hand tighten filter one full turn, do
(9) Start engine and inspect for leaks. not over tighten.
(10) Stop engine and inspect oil level.
0 - 28 LUBRICATION AND MAINTENANCE — ^ — ^ - BR
(3) Add oil, verify crankcase oil level and start en 12 months. Service is required if coolant is low, con
gine. Inspect for oil leaks. taminated, rusty or freeze protection is inadequate.
To properly test cooling system, see Group 7, Cooling
ENGINE COOLING SYSTEM System.
The cooling system factory fill is a mixture of 50%
WARNINGS JIMP PRECAUTIONS Ethylene Glycol based antifreeze and 50% water. Us
ing a suitable hydrometer, measure antifreeze con
WARNING: A N T I F R E E Z E IS AH ETHYLENE GLYCOL
centration in the radiator when the engine is cool. If
BASE COOLANT AND I S HARMFUL IF S W A L
the cooling system has recently been serviced, allow
L O W E D OR INHALED. IF S W A L L O W E D , DRINK
coolant to circulate for at least 20 minutes before
TWO G L A S S E S O F WATER AND INDUCE VOMIT
taking hydrometer reading. Properly mixed coolant
ING. IF INHALED, MOVE TO FRESH AIR A R E A .
will protect the cooling system to -37°C (-35°F). If the
S E E K MEDICAL ATTENTION IMMEDIATELY. DO NOT
freeze protection is above -28°C (-20°F), drain enough
STORE IN O P E N OR UNMARKED CONTAINERS.
coolant from the cooling system to allow room to add
WASH SKIN AND CLOTHING THOROUGHLY A F T E R
antifreeze to achieve adequate protection. A mix table
COMING IN CONTACT WITH ETHYLENE GLYCOL.
on the coolant container indicates the amount of an
K E E P OUT O F REACH O F CHILDREN.
tifreeze required to winterize the cooling system
D I S P O S E O F GLYCOL B A S E COOLANT P R O P
based on the capacity, see Capacity Chart in General
ERLY, CONTACT YOUR D E A L E R OR GOVERNMENT
Information section of this group.
AGENCY FOR LOCATION OF COLLECTION CENTER
IN YOUR A R E A . ANTIFREEZE SPECIFICATION
DO NOT O P E N A COOLING S Y S T E M W H E N THE Chrysler Corporation recommends Mopar Anti
ENGINE IS AT RUNNING T E M P E R A T U R E , P E R freeze/Coolant or a high quality, ethylene glycol base
SONAL INJURY CAN RESULT. antifreeze/coolant, with a silicate inhibitor.
AVOID RADIATOR COOLING FAN W H E N ENGINE
COMPARTMENT RELATED S E R V I C E I S P E R RADIATOR CAP
FORMED, P E R S O N A L INJURY CAN RESULT. The radiator cap must be secure to provide proper
pressure release and coolant recovery. Inspect and
CAUTION: Do not use straight antifreeze a s engine
test radiator cap when cooling system service is per
coolant, inadequate engine running temperatures
formed or when problem is suspected.
can result.
COOLING SYSTEM SERVICE
Do not operate vehicle without proper concentra
The cooling system should be drained, flushed and
tion of recommended ethylene glycol coolant, high
running temperatures and cooling system corrosion
filled with the proper coolant mixture at the inter
can result.
vals described in the Lubrication and Maintenance
Schedules. Refer to General Information section of
The engine cooling system will develop internal this group. For proper service instructions see Group
pressure of 97 to 123 kPa (14 to 18 psi) at normal op 7, Cooling System.
erating temperature. Allow the vehicle approximately
one half hour to cool off before opening the cooling ENGINE AIR CLEANER
system. As an indicator of pressure, squeeze the up The engine air filter should be serviced only when
per radiator hose between index finger and thumb. If the Filter Minder™ on the air cleaner lid (Fig. 6) in
it collapses with little effort the system would have dicates restricted air flow (Fig. 7). Refer to Group 25,
low internal pressure and should be safe to open to Emission Control Systems for proper service proce
the first safety notch of the radiator cap. Refer to dures.
Group 7, Cooling System.
BATTERY
COOLING SYSTEM INSPECTION Inspect battery trays, hold down and terminal con
Coolant level should be inspected when other en nections when other under hood service is performed.
gine compartment service is performed or when cool
For proper diagnostic procedures refer to Group 8A,
ant leak is suspected. Coolant recovery tank level
should read between the ADD and FULL marks, lo Battery/Starting/Charging System Diagnostics. For
cated on the side of recovery tank, when the engine service and cleaning procedures refer to Group 8B,
is at normal operating temperature. Normal coolant Battery/Starter Service.
level maintenance does not require the removal of ra
diator cap. Cooling system freeze protection should
be tested at the onset of the winter season or every
B R LUBRICATION A N i MAINTENANCE 0 - 29-
Position plastic o r r u b b e r ' components away from

mowing parts i n engine compartment o r under vehi
c l e , o r d a m a g e w i l l result.
Do n o t a l l o w rubber e n g i n e m o u n t s o r o t h e r com
ponents to b e c o m e oil c o n t a m i n a t e d , repair c a u s e
of oil contamination and clean area-
All rubber and plastic components should be in
spected when engine compartment or under vehicle
service is performed. When evidence of deterioration
exists, replacement is required. To reduce deteriora
tion of rubber components, Chrysler Corporation rec
ommends Mopar Foamy Engine Degreaser or
equivalent be used to clean engine compartment of
oil and road grime.
Fig. 6 Filter Minder™ Location EXHAUST SYSTEM—DIESEL
PRESS BUTTON
The exhaust system should be inspected when un
TO RESET der vehicle service is performed or as specified in the
Lubrication and Maintenance Schedules.
fifSPECTfOM
When inspecting an exhaust system, inspect for
cracked or loose joints, stripped screw/bolt threads,
corrosion damage, and worn or broken hangers.
(Slight cracking in rubber isolator or hanger is ac
ceptable). Replace all components that are corroded
or damaged. Do not attempt repair. Also, inspect for
the following obvious conditions and correct as neces
sary:
• Exhaust system leaks, damage, misalignment.
• Contact with body panels metal or the frame.
For proper service procedures see Group 11, Ex
haust System and Intake Manifold.
TO AIR
FILTER HOUSING AIR-CONDITIONER COMPRESSOR
J9425-4 LUBRICANT AND REFRIGERANT
The lubricant level in the air-conditioner compres
Flg 7 Filter
B Minder™
sor should be checked if there are indications that oil
RU1BER ANi PLASTIC COMPONENT INSPECTION was lost. Loss of lubricating oil usually accompanies
a loss of refrigerant.
CAUTION: Plastic hoses or wire harness cowers w i l l For additional information involving the A/C sys
m e l t or deform w h e n exposed t o h e a t from exhaust tem, refer to Group 24, Heater And Air Conditioning.
s y s t e m or engine manifolds.
I - 31 LUBRICATION AND MAINTENANCE BR
DRIVETRAIN
•- INDE1
page page
Automatic Transmission . 31 Front Axle U-Joint and Pivot Bearings . . . . . . . . . . 33

Clutch and Brake Pedal Bushings . . . . . . . . . . . . . 30 Manual Transmissions . 31
Clutch Master Cylinder 30 Rear Axle 33
Drive Shafts 34 Rubber and Plastic Hoses/Tubing . . . . . . . . . . . . . 34
Front Axie (4WD) . . . . . . . . . . . . ......... 32 Transfer Case ( 4 W D Vehicles) 32
CLUTCH AND BRA1E PEDAL BUSHINGS CLUTCH MASTER CYLINDER

If the clutch and brake pedal mechanism squeaks,
the pivot bushings (Fig. 1 and 2) should be lubri LEVEL INSPECTION
cated. Use Mopar Multi-Purpose Lubricant, or an
WARMING: DO NOT A L L O W P E T R O L E U M OR WA
equivalent.
T E R B A S E LIQUIDS TO CONTAMINATE CLUTCH
PEDAL SHAFT FLUID, S E A L DAMAGE AND CLUTCH FAILURE CAN
RESULT.
The clutch reservoir level (Fig. 3) should be in

spected when other under hood service is performed.
FLUID SPECIFICATION
RING
J9106-11
Fig. 3 Clutch Master Cylinder

Use Mopar, Brake And Hydraulic Clutch Fluid or
equivalent. Use only brake fluid conforming to DOT
3, Federal, Department of Transportation specifica
tion. To avoid fluid contamination, use fluid from a
properly sealed container.
CAUTION: Never use reclaimed brake fluid or fluid
from an unsealed container. In addition, do not use
fluid from a container that has been opened and al
lowed to stand for an extended length of time.
Moisture in the air can be absorbed by the fluid,
which causes dilution with loss of effectiveness.
Fig. 2 Clutch Pedal Bushings

LUBRICATION AND MAINTENANCE 0 - 31
MANUAL TRANSMISSIONS CAUTION: To minimize fluid contamination, verify

The manual transmission should be inspected for that dipstick i s seated in the fill tube after fluid level
oil leaks and proper oil level when other under vehi reading is taken.
cle service is performed. To inspect the transmission
oil level, position the vehicle on a level surface. Re TO INSPECT THE TRANSMISSION FLUID
move fill plug from the transmission (Fig. 4). The oil LEVEL
level should not be below 6 mm (1/4 in) from the bot
tom of the oil fill hole. Refer to Group 21, Transmis WARNING; U S E E X T R E M E CAUTION W H E N THE
sion proper service procedures. ENGINE IS OPERATING. DO NOT PUT YOUR
HANDS NEAR THE DRIVE BELT, P U L L E Y S OR FAN
B L A D E . DO NOT STAND IN A DIRECT LINE WITH
THE FAN B L A D E .
(1) Position the vehicle on a level surface.

(2) Start engine and allow to idle in PARK for at
least 60 seconds. The warmer the transmission fluid,
the more accurate the reading.
(3) While sitting in driver seat, apply brakes and
place gear selector in each position. Return gear se
lector to park.
(4) Raise hood and remove transmission fluid level
Fig. 4 Fill Plug Location—Typical (NV4500) indicator (dipstick) and wipe clean with a wiping
cloth.
NV-3500 or NV-4500 MANUAL TRANSMISSION
(5) Install dipstick and verify it is seated in fill
NV-3500 and NV-4500 manual transmissions does hole or tube.
not require periodic maintenance. The oil should be (6) Remove dipstick, with handle above tip, take
changed only when water contamination is sus fluid level reading. If the vehicle has been driven for
pected. If oil has a foamy or milky appearance it at least 15 minutes before inspecting fluid level,
probably is contaminated. For proper diagnostic and transmission can be considered hot and reading
service procedures, refer to Group 21, Manual Trans should be in the OK area. If vehicle has run for less
mission. than 15 minutes and more than 60 seconds transmis
sion can be considered warm and reading should be
MANUAL TRANSMISSION OIL SPECIFICATION above ADD mark. Add fluid only if level is below
MIN mark (Fig. 5) on dipstick when transmission is
NV-3500 MANUAL TRANSMISSION warm.
Chrysler Corporation recommends Mopar Manual
Transmission Fluid (P/N MS9224), be used to fill an DIPSTICK
NV-3500 manual transmission.
NV-4500 MANUAL TRANSMISSION
Chrysler Corporation recommends API/GL-4 SAE
/
75w-90, Mopar Synthetic Manual Transmission Fluid MINIMUM I ^ MAXIMUM
(P/N 4637579) be used to fill an NV-4500 manual LEVEL DOT ACCEPTABLE CORRECT
MARK FLUID FLUID
transmission. (ADD FLUID) LEVEL LEVEL J9321-96
Mopar synthetic manual transmission oil is
the ONLY lubricant recommended for use in Fig. 5 Dipstick & ATF Level
the NV-4500 transmission. CAUTION: Do not overfill automatic transmission,
leakage or damage can result.
AUTOMATIC TRANSMISSION
The automatic transmission fluid should be
changed and bands adjusted at the intervals de AUTOMATIC TRANSMISSION FLUID
scribed in the Maintenance Schedules section of this SPECIFICATION
Group. The automatic transmission should be in Chrysler Corporation recommends Mopar ATF Plus
spected for fluid leaks and proper fluid level when (automatic transmission fluid type 7176) be used to
other under hood service is performed. Refer to add to or replace automatic transmission fluid. If
Group 21, Transmission for proper service proce ATF Plus is not available use Mopar Dexron II Auto
dures. matic Transmission Fluid or equivalent.
I - 32 LUBRICATION AND MAINTENANCE — — B U
SPECIAL AiiillWES LUBRICANT SPECIFICATION

Chrysler Corporation does not recommend the use Chrysler Corporation recommends Mopar ATF Plus
of special-type fluid additives. (automatic transmission fluid type 7176) be used to
fill the transfer case. If ATF Plus is not available use
FLUID AND FILTER CHANGE Mopar Dexron II Automatic Transmission Fluid or
The automatic transmission fluid and filter should equivalent.
be changed at the intervals described in the Mainte
nance Schedules section of this Group. Refer to FRONT AXLE (4WD)
Group 21, Transmission for proper service proce The front axle does not require periodic mainte
dures. nance. Inspect the axle for oil leaks or damage and
proper oil level when other under vehicle service is
TRANSFER CASE (4WD VEHICLES) performed. Oil leaks should be repaired before re
The transfer case should be inspected for fluid turning vehicle to service. If the oil appears milky or
leaks and proper fluid level when other under vehicle foamy it is probably water contaminated. If contami
service is performed. nation is evident, change the axle lubricant. Refer to
Group 2, Front Suspension and Axle for proper ser
[FLUID LEVEL
The transfer case fill hole plug is located at the vice procedures.
rear of the housing (Fig. 6). LUBRICANT LEVEL
Dana 44—approximately 6 mm (0.25 in.) below the
bottom of the fill hole in the differential cover (Fig.
7).
DIFFERENTIAL
COVER
Fig. 6 NP 241 Transfer Case

Determine the transfer case fluid level according to
the following procedure.
(1) Raise and support the vehicle.
(2) Remove the fill hole plug from the transfer
case. The fluid level should be at the bottom edge of
the fill hole. The level can be slightly below the bot IDENTIFICATION
tom edge of the fill hole if the fluid is cold. TAG J9202-23
If the transfer case fluid is warm, it is accept
able for the fluid to drip out of the fill hole. If Fig. 7 Model 44 Differential Cover
the fluid gushes out of the fill hole, the level is Dana 60—approximately 12 mm (0.5 in.) below the
too high. bottom of the fill hole in the differential cover (Fig.
(3) If the level is low, add fluid to the bottom edge 8).
of the fill hole. The vehicle must be positioned on a level surface
(4) Install the fill hole plug. Tighten the plug to before inspecting oil level.
41-54 N-m (30-40 ft. lbs.) torque.
(5) Remove the support and lower the vehicle. LUBRICANT SPECIFICATION
The transfer case requires periodic maintenance at Use API/GL-5 SAE 80W-90, Mopar Multipurpose
the intervals described in the Maintenance Schedules Gear Lubricant or equivalent to fill the front axle.
sections of this Group. For proper diagnostic and ser
vice procedures, refer to Group 21, Transmission and
Transfer Case.
BR LUBRICATION AID MAINTENANCE 0 - 33
DIFFERENTIAL FILL PLUG IDENTIFICATION

COVER
TAG
DIFFERENTIAL
COVER
MODEL
NUMBER PUSH-I
FILL PLUG
J9202-97
Fig. 8 Model 60 Differential Cower

J9203-32
REAR AXLE
The rear axle does not require periodic mainte Fig. 9 Differential Cover—9 1/4 Axle
nance. Inspect the axle for oil leaks or damage and DIFFERENTIAL
proper oil level when other under vehicle service is COVER FILL PLUG
performed. Oil leaks should be repaired before re
turning vehicle to service. If the oil appears milky or
foamy it is probably water contaminated. If contami
nation is evident, change the axle lubricant. Refer to
Group 3, Rear Suspension and Axle for proper service
procedures.
LUBRICANT LEVEL
9-1/4 Inch Axle—approximately 15 mm (0.625 in.)
below the bottom of the fill hole in the differential
cover (Fig. 9).
Dana 60, 70 or 80—approximately 17 mm (0.75
in.) below the bottom of the fill hole in the differen
tial cover (Fig. 10).
The vehicle must be positioned on a level surface
before inspecting oil level.
LUBRICANT SPECIFICATION IDENTIFICATION
Use API/GL-5 SAE 80w-90, Mopar Multipurpose TAG J9403-54
Gear Lubricant or equivalent to fill the rear axle.
Fig. 10 Model 70 and 80 Differential Cover
FRONT AXLE U-J0INT AND PIVOT BEARINGS Do not use high pressure to lubricate the
front axle universal joints.
B R 3500 WITH DANA m FRONT AXLE
Lubricate Universal Joints if equipped, at the in B R 1500 AND 2500 FRONT AXLE
tervals described in the Maintenance Schedules sec The front axle universal joint and pivot bearings
tion of this Group. Refer to Group 2, Front are permanently lubricated and do not require ser
Suspension and Axles and Group 16, Propeller Shafts vice.
for proper service procedures.
LUBRICANT SPECIFICATION
Use Mopar, Multi-purpose Grease or any lubricate
that is identified as NLGI GC-LB lubricant.
I - 34 LUBRICATION AND MAINTENANCE mm
DRIVE SHAFTS • The extent and quality of vehicle maintenance.
• The geographic area of vehicle operation.
SUP-YOKE LUBRICATION • The length of exposure time to excess heat and
When equipped with lube fittings, it is recom chemical contaminants.
mended that the slip-yoke splines be lubricated at (1) Inspect all hose and tubing fittings for loose
the intervals described in the Maintenance Schedules ness and corrosion. Inspect the rubber hoses for brit-
section of this Group. Refer to Group 16, Propeller tleness and cracks. Thoroughly inspect the hose ends
Shafts for proper service procedures. (those that are slipped over nipple connectors) for
splits.
LUBRICANT SPECIFICATION
(2) Inspect the surface of hoses and tubing for heat
Use Mopar, Multi-purpose Grease or any lubricate
that is identified as NLGI GC-LB lubricant. and mechanical damage. Hose and tubing located
close to an exhaust pipe should be given special at
RUBBER AND PLASTIC HOSES/TUBING tention.
(3) Inspect the rubber hose routing to ensure that
The condition of underbody rubber hose and plastic
tubing should be inspected whenever underbody ser the hoses do not contact any heat source, moving
vice is performed. component, etc., that would potentially cause heat or
Rubber hoses and plastic tubing should be re mechanical damage.
placed immediately if there is any evidence of (4) Inspect all the hose connections to ensure that
failure. they are secure and there is no fluid leakage. Actual
dripping of hot fluid should be noted and the clamps
HOSE/TUBING INSPECTION tightened in an attempt to stop the leakage before re
Vehicle operating conditions determine the useable placing the hose.
life of underbody hoses and tubing. These conditions
include:
C H A S S I S AND BODY
INDEX
page page
Body Component Mechanisms . . 39 Parking Brake .... 38

Brakes 37 Power Steering System . . . . . . . . . . . . . . . . . . . . . . . . 35
Chassis Component and Wheel Bearing Rear Wheel Bearings 37
Lubricants 35 Speedometer Cable 39
Front Wheel Bearings 36 Steering Linkage 35
Headlamps 39 Tires 38
Manual Steering Gear . . . .- 35
CHASSIS COMPONENT AND WHEEL BEARING INSPECTION

LUBRICANTS (1) Inspect the steering linkage. Examine the tie
The chassis component and wheel bearing lubri rods and the drag link for bending, and the ball
cants that are recommended for Chrysler Corporation studs for looseness and excessive wear.
vehicles are identified by the NLGI Certification (2) Replace, as necessary, all torn/ruptured ball-
Symbol (Fig. 1). The symbol contains a coded desig stud seals and damaged/defective steering linkage
nation that identifies the usage and quality of the lu components.
bricant.
CAUTION: Use care to prevent lubricant from con
NATIONAL LUBRICATING
GREASE INSTITUTE
^ tacting the brake rotors.
1LGI NLQI NLGI

AUTOMOTIVE
AUTOMOTIVE
LUBRICANT
AUTOMOTIVE
LUBRICANT
LUBRICANT
MANUAL STEERING GEAR
GC-LB
The manual steering gear is permanently lubri
GC LB
cated. Periodic lubrication is not necessary.
WHEEL CHASSIS CHASSIS AND
BEARINGS LUBRICATION WHEEL BEARINGS POWER STEERING SYSTEM
9200-7 The power steering fluid level should be inspected
when other under hood service is performed. If the
Fig. 1 NLGI Lubricant Container Certification/
fluid level is low and system is not leaking, use Mo
. Identification Symbol
par, Power Steering Fluid or equivalent. The power
The letter G designates wheel bearing lubricant. steering system should be inspected for leaks when
Letter L designates chassis lubricant. When the let other under vehicle service is performed. For proper
ters are combined the lubricant can be used for dual service procedures, refer to Group 19, Steering.
applications. The suffix letters C and B designate the The power steering pump drive belt should be in
level of the lubricant for the application. The letter C spected at the time and distance interval described in
represents level available for wheel bearing lubricant the Lubrication and Maintenance Schedules. Refer to
(G) and the letter B represents level available for the General Information section of this group.
chassis lubricant (L).
POWER STEERING FLUID INSPECTION
STEERING LINKAGE WARNING: ENGINE MUST NOT B E RUNNING W H E N
The steering linkage should be lubricated and in INSPECTING P O W E R S T E E R I N G FLUID L E V E L ,
spected at the intervals described in the Maintenance P E R S O N A L I N J U R Y CAN RESULT.
Schedules section of this Group. Refer to Group 2,
Front Suspension and Axles for proper service proce
dures. CAUTION: Do not over fill power steering reservoir
when adding fluid, seal damage and leakage can re
LUBRICANT SPECIFICATION sult.
Use Mopar, Multi-purpose Grease or NLGI GC-LB
lubricant equivalent to lubricate the steering linkage.
TO INSPECT FLUID LEVEL:
(1) Position vehicle on a level surface with engine
at normal running temperature.
0 - 36 LUBRICATION AND MAINTENANCE
(2) Turn OFF engine and remove ignition key. hose unless the caliper must also be removed
(3) Using a wiping cloth, clean oil and dirt residue for maintenance. Support the caliper with a
from around power steering reservoir cap. hanger to prevent brake fluid hose damage.
(4) Remove reservoir cap or dipstick and wipe off (2) Remove the dust cap, the cotter pin, the nut re
fluid. tainer, the adjustment nut, and the thrust washer
(5) Install cap or dipstick. from the spindle. Discard the cotter pin.
(6) Remove cap or dipstick. Holding handle or cap (3) Remove the wheel outer bearing from the hub.
above tip of dipstick, read fluid level (Fig. 2). Add (4) Remove the wheel hub/disc brake rotor from
fluid if reading is below cold level mark on dipstick. the spindle.
(5) Remove the seal and the inner wheel bearing
from the hub cavity.
(6) Clean the original lubricant from the bearings
and from the hub cavity (Fig. 3).
J8900-27
Fig. 2 Power Steering Reservoir & Cap—Typical

FRONT WHEEL BEARINGS
WHEEL BEARINGS—2WO
It is recommended that front wheel bearings be in
Fig. 3 Front Wheel Bearing—2 WD Vehicles
spected for proper lubrication whenever the brake ro
tors are removed or at least at the. intervals (7) Inspect the bearing rollers for indications of
described in the Maintenance Schedules section of pitting. Light bearing roller discoloration is consid
this Group. ered normal. A wheel bearing must be replaced if any
serious damage exists.
WHEEL BEARINGS—4WD (8) Re-pack the bearings with a multi-purpose
The front wheel bearings are sealed and perma NLGI GC-LB lubricant. The use of a bearing packer
nently lubricated. is recommended.
(9) Wipe the spindle clean and apply a small
LUBRICANT SPECIFICATION amount of chassis/wheel bearing lubricant (NLGI
Wheel bearings should be lubricated with a lubri GC-LB lubricant) to prevent rust. Wipe the wheel
cant that is identified as NLGI GC-LB lubricant. hub cavity clean.
(10) Add a small amount of fresh lubricant to the
CAUTION; Do not add lubricant to the wheel bear hub cavity.
ings. Re-pack completely. Mixing of different types
of lubricants in wheel bearings should be avoided. CAUTION: Do not over fill the wheel hub cavity with
This could possibly result in excessive thinning and lubricant. Excessive lubricant can cause overheat
leakage of the lubricant. ing and bearing damage. Also, excessive lubricant
can be forced out of the wheel hub cavity and con
taminate the brake rotor/pads.
INSPECTIOH/LUBRICATION
(1) Remove the wheel/tire and the disc brake cali (11) Install the wheel inner bearing in the wheel
per. Do not disconnect the caliper brake fluid hub and install a replacement seal.
(12) Clean the disc brake rotor contact surfaces, if INDICATOR

necessary. WINDOW
(13) Install the wheel hub/disc brake rotor on the
spindle.
(14) Install the wheel outer bearing, the thrust
washer, and the spindle nut.
(15) Tighten wheel bearing nut to 27-34 N-m (240-
300 in. lbs.) torque while rotating hub/rotor. This will
seat the bearings.
(16) Loosen the nut 1/4 of-a-turn (90°), then
tighten it finger tight.
(17) Position nut lock on the nut with one pair of
slots aligned with the cotter pin hole. Install the cot
ter pin.
(18) Clean the dust cap and apply wheel bearing
lubricant to the inside surface. Do not fill the dust
cap with lubricant.
(19) Install the dust cap.
(20) Install the disc brake caliper.
(21) Install the wheel/tire. Tighten the wheel lug
J94Q5-22
nuts to 115 N-m (85 ft. lbs.) torque. Install the wheel
cover. Fig. 4 Reservoir And Fluid Level indicator (1500
Series)
REAR WHEEL BEARINGS
The rear wheel bearings for vehicles equipped with INDICATOR
WINDOW
a Dana 60, 70 or 80 axle should be cleaned and re
packed whenever the rear brakes are serviced. Refer
to Group 3, Rear Axles for the service procedure.
BRAKES
The brake fluid level should be inspected when
other underhood service is done (Fig. 4, 5 and 6). If
necessary, add fluid to raise the level to the top of
the indicator window. With disc-brakes, the fluid
level can be expected to fall as the brake pads wear.
However, a low fluid level can also be caused by a
leak, and repair will then be necessary, refer to
Group 5, Brakes for proper service procedures.
FLUID SPECIFICATION
Power brake systems require Mopar Heavy-Duty
Brake Fluid, or an equivalent product identified with
FMVSS No. 116, DOT-3 and SAE J-1703 Standard
designations. J9405-23
Use brake fluid properly sealed container when
adding fluid to the reservoir. Never use reclaimed Fig. 5 Reservoir And Fluid Level indicator (2500
fluid or fluid that does not conform to the DOT/SAE Series)
Standards. BRAKE SYSTEM INSPECTION
(1) Inspect the brake pads and linings for excessive
CAUTION: Use of a brake fluid that has a lower ini wear, cracks and broken rivets.
tial boiling point then specified by F M V S S No. 116 (2) Inspect brake pads and linings for contamina
or DOT 3 and S A E J1703 could result in sudden tion with brake fluid, axle lubricant and/or other flu
brake failure during hard, prolonged braking. ids.
Do not allow petroleum base fluids to contami (3) Replace the front brake pads and the rear
nate the brake fluid. Seal damage will result. brake linings if they are worn to within 0.78 mm
(0.031 in) of a rivet head.
I - 31 LUBRICATION ANO MAINTENANCE BR
pinched, kinked, or corroded, it should be repaired.

For proper service procedures, refer to Group 5,
CORRECT
Brakes.
FLUID
PARKING BRAKE
The sliding contact areas of the parking brake cable
should be lubricated (Fig. 7). Apply Mopar Spray White
Lube or equivalent to the sliding contact areas.
J94Q5-24
Fig. 6 Reservoir And Fluid Level indicator (3500

Series)
(4) Operate the rear brake self-adjuster lever and
pivot. Test the operation of the self-adjuster screw for CABLE
TENSIONER
ease of movement.
(5) Inspect the self-adjuster components for frayed J9405-173
cables, loose or overheated springs, and a binding
condition. Fig. 7 Parking Brake Cable Lubrication
(6) Inspect the caliper dust boots for damage/tears and
PARKING BRAKE FUNCTIONAL TEST AND
indications of brake fluid leakage. Inspect the bushings
INSPECTION
and pins for corrosion, tears and a binding condition.
(1) Engage the parking brake pedal and then re
(7) Inspect the rear wheel cylinder dust boots for
lease it.
fluid leaks. Inspect the pistons and cylinder bores for
(2) Test it for smooth operation and vehicle-holding
proper appearance.
capability.
(8) Inspect the brake differential warning valve
(3) Inspect the parking brake cables for kinks,
and housing for Indications of leakage, kinked hoses
fraying and a binding condition.
and loose fittings.
(4) With the parking brake released, the rear
B R A K E HOSE INSPECTION wheels should rotate without restriction. Adjust the
parking brake cable tension, if necessary.
WARNING: IF FRONT W H E E L OR R E A R A X L E (5) Repair any parking brake malfunctions.
B R A K E HOSE OUTER C O V E R IS C R A C K E D ,
CHAFED, OR B U L G E D , R E P L A C E H O S E IMMEDI TIRES
ATELY. B R A K E FAILURE CAN RESULT. The condition of the tires should be inspected. The
inflation pressures tested/corrected at least once a
The front wheel and rear axle brake hoses should month.
be inspected at time and distance intervals described Check more often if subject to a wide range of out
in the Lubrication and Maintenance Schedules. Refer door temperatures, as tire pressures vary with tem
to the General Information section of this group. A perature changes.
hose must be replaced if it has signs of cracking, The tires/wheels should be rotated at the intervals
chafing, fatigue or bulging. For proper service proce described in the Maintenance Schedules section of
dures, refer to Group 5, Brakes. this Group.
BRAKE LINE INSPECTION INSPECTION
The metal brake lines should be inspected when Inspect the tires for excessive wear, damage. Test
other under vehicle service is preformed. If a line is the tires for the recommended inflation pressure and
COMPONENT SERVICE INTERVAL LUBRICANT

Door Hinges As Required Engine Oil
Door Latches As Required Multi-Purpose Grease NLGI GC-LB
(Water Resistant) (1)
Hood Latch Release Mechanism & Safety Latch As Required Multi-Purpose Grease NLGI GC-LB 2 EP (2)
(When Performing
Other Underhood
Services)
Hood Hinges As Required Engine Oil
Seat Regulator & 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)
Tailgate Support Arms As Required Engine Oil
Tailgate Latches As Required White Spray Lubricant (3)
Tailgate Release Handle (Pivot & Slide Contact Surfaces) As Required Multi-Purpose Grease NLGI GC-LB 2 EP (2)
Window System Components (Regulators, Tracks, Rods As Required White Spray Lubricant (3)
& Channel Areas — Except Glass Run Weatherstrips
and Felt Lubricator, if Equipped)
Lock Cylinders Twice/Year Lock Cylinder Lubricant (4)
Parking Brake Mechanism As Required Multi-Purpose Grease NLGI GC-LB (1)
1. Mopar Wheel Bearing Grease (High Temperature)
2. Mopar Multi-Mileage Lubricant
3. Mopar Spray White Lube
4. Mopar Lock Cylinder Lubricant
J9200-58
Fig. 8 Body Lubrication Specifications

adjust the pressure accordingly. Refer to the tire in © Inspected.
flation pressure decal located on the left door face. ® Cleaned.
Also to Group 22, Tires And Wheels for tire pressure © All the pivoting/sliding contact areas on the mech
charts, tire replacement, and tread wear indicators. anisms should then be lubricated.
Mopar Multi-Mileage Lubricant or an equivalent,
ROTATION
should be used to lubricate the mechanisms. The
Tires/wheels should be rotated according to the rec door weatherstrip seals should be lubricated with sil
ommended interval. The first tire/wheel rotation is
icone lubricant spray (Fig. 8).
the most important for establishing the prevention of
uneven tread wear. After rotation, adjust the tire in
HEADLAMPS
flation pressure to the air pressure recommended on
the decal located on the left door face. MAINTENANCE SCHEDULE
Refer to Group 22, Tires And Wheels for the recom Every six months check the headlamp beams to en
mended method of tire/wheel rotation.
sure that the headlamp beams are correctly posi
BODY COMPONENT MECHANISMS tioned.
AIM ADJUSTMENT
LUBRICATION REQUIREMENTS
All operating mechanisms and linkages should be Refer to Group 8L, Lamps for headlamp aim ad
lubricated when necessary. This will maintain ease of justment procedures.
operation and provide protection against rust and ex
cessive wear. The door weatherstrip seals should be SPEEDOMETER CABLE
lubricated to prolong their life as well as to continue
SERVICE INFORMATION
proper sealing.
Speedometer cable lubrication is not necessary. For
LUBRICANT SPECIFICATIONS service information involving noisy cables, refer to
All applicable exterior and interior vehicle operat Group 8E, Instrument Panel and Gauges.
ing mechanisms should be:
BR FRONT SUSPENSION AND AXLE 2•1
FRONT SUSPENSION AND AXLE
CONTENTS
page page
ALIGNMENT SPECIFICATIONS . . . . . 8 GENERAL INFORMATION 1

AXLE NOISE/VIBRATION DIAGNOSIS 17 INDEPENDENT FRONT SUSPENSION (IFS) ...12
AXLE SERVICE PROCEDURES . . . . 21 LINK/COIL SUSPENSION 9
AXLE SPECIFICATIONS 44 TORQUE SPECIFICATIONS 45
FRONT WHEEL ALIGNMENT . . . . . . . 4
GENERAL INFORMATION
FRONT SUSPENSION serviceable and is replaced. as a unit only. Steering

The Ram Truck uses two suspension designs, link/ knuckles pivot on replaceable ball studs attached to
the axle tube yokes.
coil and independent front suspension (IFS). Both de
Drive axle (4WD) is a Model 44 or 60. It has a cast
signs use coil springs. IFS uses upper and lower iron differential case with axle shaft tubes extending
suspension arms attached to the frame and steering from either side.
knuckles. Link/coil design uses upper and lower sus They are equipped with a vacuum disconnect to ac
pension arms attached to the frame and drive axle tivate the 4WD.
(4WD), tube axle (2WD). Tube axle (2WD) is a one-piece tube. This axle
UNK/GOIL SUSPENSION fFI® B fJ mounts to the same bracketry as the four-wheel drive
axle. The ^ steering knuckles are the same as the
STABILIZER SHOCK A 1 S O R I E R Model 60 drive axle.
BAR The upper and lower suspension arms use bushings
COIL SPRING
to isolate road noise. The suspension arms are bolted
UPPER to the frame and axle through the rubber bushings.
SUSPENSION
ARM
The lower suspension arm uses cam bolts at the axle
to allow for caster and pinion angle adjustment. The
suspension arm travel (jounce or rebound) is limited
through the use of urethane bumpers.
Suspension components which use rubber bushings
should be tightened at vehicle ride height. This will
prevent premature failure of the bushing and main
tain ride comfort. Bushings must never be lubricated.
LOWER i The coil springs control ride quality and maintain
TRACK
BAR SUSPENSION proper ride height. The springs use a rubber isolators
ARM J9402-54 between the frame bracket and spring. The isolators
help prevent road noise. The bottom of the spring sits
Fig. 1 Link/Coil Suspension on a seat mounted to the axle.
© Drive axle (4WD),tube axle (2WD) Shock absorbers dampen the jounce and rebound of
9 Upper and lower suspension arms the vehicle over various road conditions. Shocks are
® Coil springs mounted inside the springs and attached at the top
© Shock absorbers to brackets with grommets. These brackets are bolted
® Track bar on the frame with three studs on a ring. The shock is
o Stabilizer bar mounted at the bottom of the axle below the spring
Link/coil suspension allows each wheel to adapt to seat. -
different road surfaces. Wheels are mounted to The track bar is used to minimize front axle side-
to-side movement. The bar is attached to a frame rail
knuckles with a hub/bearing. The hub/bearing is not
bracket with a ball stud and is isolated with a bush
ing at the axle bracket.
2 -2 FRONT SUSPENSION AND AXLE llfl
The stabilizer bar is used to minimize vehicle front adjusted for caster and camber. The suspension arm
sway during turns. The spring steel bar helps to con travel (jounce or rebound) is limited through the use
trol the vehicle body in relationship to the suspen of urethane bumpers.
sion. The bar extends across the front underside of The coil springs control ride quality and maintain
the chassis and connects to the frame rails. Links are proper ride height. The springs mount between the
connected from the bar to the axle brackets. Stabi lower suspension arm and the front cross member
lizer bar mounts are isolated by teflon lined rubber spring seat. A rubber isolator seats on top off the
bushings. spring to help prevent noise.
The shock absorbers dampen jounce and rebound of
INDEPENDENT FRONT SUSPENSION (IFS) the vehicle over various road conditions. Shocks are
(FIG 2,3) mounted on the bottom to the lower suspension
arms. The top of the shock mounts on frame brackets
using grommets.
The stabilizer bar is used to minimize vehicle front
sway during turns. The spring steel bar helps to con
trol the vehicle body in relationship to the suspen
sion. The bar extends across the front underside of
the chassis and mounts on the frame rails. Links
connected the bar to the lower suspension arms. Sta
bilizer bar mounts are isolated by rubber bushings.
Links are isolated with rubber grommet.
FRONT DRIVE AXLE

The integral type housing, has the centerline of the
pinion set below the centerline of the ring gear.
The axles are equipped with optional A.B.S. brake
system. The A.B.S. tone rings are pressed onto the
Fig. 2 Independent Front Suspension axle shaft near the hub and knuckle. For additional
information on the A.B.S. system refer to Group 5,
Brakes.
The Dana 44 and 60 axle has the assembly part
number and gear ratio listed on a tag. The tag is at
tached to the housing cover (Fig. 4, 5). Build date
identification codes are stamped on the axle shaft
tube cover side.
STANDARD DIFFERENTIAL OPERATION
The differential gear system divides the torque be
tween the axle shafts. It allows the axle shafts to ro
tate at different speeds when turning corners.
Each differential side gear is splined to an axle
shaft. The pinion gears are mounted on a pinion
mate shaft and are free to rotate on the shaft. The
pinion gear is fitted in a bore in the differential case
Fig. 3 Independent Front Suspension and is positioned at a right angle to the axle shafts.
In operation, power flow occurs as follows:
• Upper and lower suspension arms • Pinion gear rotates the ring gear
• Coil springs • Ring gear (bolted to the differential case) rotates
• Shock absorbers the case
• Stabilizer bar • Differential pinion gears (mounted on the pinion
The suspension arms have replaceable ball studs mate shaft in the case) rotate the side gears
which are pressed into the arms. Bushings located • Side gears (splined to the axle shafts) rotate the
inboard are not replaceable. The upper arm has a shafts
pivot bar which mounts on a frame bracket. The During straight-ahead driving, the differential pin
bracket has slotted holes this allows the arm to be ion gears do not rotate on the pinion mate shaft. This
occurs because input torque applied to the gears is
divided and distributed equally between the two side
BR FRONT SUSPENSION AND AXLE 2-3
DIFFERENTIAL
When turning corners, the outside wheel must
COVER IN STRAIGHT AHEAD DRIVING
FILL PLUG EACH WHEEL ROTATES AT 100%
OF CASE SPEED
PINION GEARS ROTATE

WITH CASE J9303-13
Fig. 6 Differential Operation—Straight-Ahead Driving

travel a greater distance than the inside wheel in or
IDENTIFICATION
TAG der to complete a turn. This difference must be com
J9202-23
pensated for in order to prevent the wheels from
Fig. 4 Model 44 Differential Cower scuffing and skidding through the turn. To accom
plish this the differential allows the axle shafts to
DIFFERENTIAL FILL P L U G turn at unequal speeds (Fig.7). In this instance, the
COVER
input torque applied to the pinion gears is not di
vided equally. The pinion gears now rotate around
the pinion mate shaft in opposite directions. This al
lows the side gear and axle shaft attached to the out
side wheel to rotate at a faster speed.
AXLE <t
OUTER WHEEL 100% DIFFERENTIAL INNER WHEEL

/
110% CASE SPEED CASE SPEED 90% CASE SPEED
MODEL
NUMBER
J9202-97
Fig. 5 Model 60 Differential Cower PINION GEARS ROTATE

ON PINION SHAFT J9303-14
gears. As a result, the pinion gears revolve with the
pinion mate shaft but do not rotate around it (Fig. 6). Fig. 7 Differential Operation—On Turns
2-4 FRONT SUSPENSION AND AXLE BR
KSSDRFF WKftUL A L I G N M E N T
GENERAL INFORMATION CAUTION:Do not attempt to modify any suspension

Front wheel alignment involves the correct posi or steering component by heating and bending.
tioning of the wheels in relation to the vehicle. The
POSITIVE NEGATIVE POSITIVE NEGATIVE
positioning is accomplished through suspension and
steering linkage adjustments. An alignment is con
sidered essential for efficient steering, good direc
tional stability and to maximize tire wear. The most
important measurements of front end alignment are
caster, camber and toe position.
Routine inspection of the front suspension STEERING AXIS INCLINATION
and steering components is a good preventative
maintenance practice. Inspection also helps to
ensure safe operation of t h e vehicle.
© CASTER is the forward or rearward tilt of the
steering knuckle from vertical. Tilting the top of the
knuckle rearward provides positive caster. Tilting the
top of the knuckle forward provides negative caster. J9402-56
Caster is a directional stability angle which enables
the front wheels to return to a straight ahead posi Fig. 1 Alignment Angles IFS
tion after turns (Fig. 1,2).
© CAMBER is the inward or outward tilt of the PRE-ALIGNMENT HSPECTiOl LINK/COIL
wheel relative to the center of the vehicle. Tilting the SUSPElSiOl
top of the wheel inward provides negative camber. Before starting a front wheel alignment, the follow
Tilting the top of the wheel outward provides positive ing inspection and necessary corrections must be
camber. Incorrect camber will cause wear on the in completed.
side or outside edge of the tire (Fig. 1,2). (1) Tires with the same recommended air pressure,
• WHEEL TOE POSITION is the difference between size, and tread wear. Refer to Group 22, Wheels and
the leading inside edges and trailing inside edges of Tires for diagnosis information.
the front tires (Fig. 1,2). Incorrect wheel toe position (2) Front wheel bearings for wear.
is the most common cause of unstable steering and (3) Ball studs, steering linkage pivot points and
uneven tire wear. The wheel toe position is the final steering gear for looseness, roughness, binding or
front wheel alignment adjustment. wear. Refer to Group 19, Steering for additional in
• STEERING AXIS INCLINATION ANGLE is mea formation.
sured in degrees. It is the angle that the steering (4) Front wheels for excessive radial or lateral
knuckles are tilted (Fig. 1). The inclination angle has runout and unbalance. Refer to Group 22, Wheels
a fixed relationship with the camber angle. It will not and Tires for diagnosis information.
change except when a spindle or ball stud is dam (5) Suspension components for wear and noise.
aged or bent. The angle is not adjustable and the Check components for correct torque. Refer to Groups
damaged component(s) must be replaced to correct 2 and 3, Suspension and Axle for additional informa
mis-alignment. tion.
B R FRONT SUSPENSION AND AXLE 2 -1
CAMBER
WHEEL
TRUE . CENTERLINE
VERTICAL NEGATIVE
CAMBER
ANGLE
, , , _
x PIVOT
/ I HTtCENTERUNE
VJLl/ SCRUB
—^llr*- RADIUS
POSITIVE CAMBER (NOT SHOWN)
TOP OF WHEEL OUTBOARD NEGATIVE TOE (TOE OUT) B > A
POSITIVE TOE (TOE IN) B < A
CASTER
POSITIVE CASTER- THRUST ANGLE
KING PIN
ANGLE OF REAR AXLE

RELATIVE TO VEHICLE CENTERLINE
VERTICAL
OF VEHICLE ( + ) AXLE POINTS LEFT (-) AXLE POINTS RIGHT
J9402-57
Fig. 2 Alignment Angles Link/Coil
AL1GN1ENT AND ADJUSTMENTS LINK/COIL (1) Start the engine and turn wheels both ways be
fore straightening the wheels. Center and Secure the
SUSPENSION steering wheel and turn off engine.
Before each alignment reading the vehicle should (2) Loosen the adjustment sleeve clamp bolts.
be jounced (rear first, then front). Grasp each (3) Adjust the right wheel toe position with the
bumper at the center and jounce the vehicle up and drag link (Fig. 4). Turn the sleeve until the right
down several times. Always release the bumper in wheel is at the correct TOE-IN position. Position
the down position. Set the front end alignment to clamp bolts to their original position and tighten to
specifications while the vehicle is in its NOR 49 N-m (36 ft. lbs.) torque. Make sure the toe set
MALLY LOADED CONDITION. ting does not change during clamp tightening.
CAMBm (4) Adjust left wheel toe position with tie rod at
The wheel camber angle is preset and is not adjust left knuckle. Turn the sleeve until the left wheel is at
able. the correct TOE-IN position. Position clamp bolts to
their original position and tighten to 27 N-m (20 ft.
CASTER Tbs.) torque. Make sure the toe setting does not
Check the caster of the front axle for correct angle. change during clamp tightening.
Be sure the axle is not bent or twisted. Road test the (5) Verify the right toe setting.
vehicle and make left and right turn. Observe the
steering wheel return-to-center position. Low caster CAB-CHASSIS ALIGNMENT
will cause poor steering wheel returnability. To determine the correct caster alignment angle for
Caster can be adjusted by rotating the cams on the Cab-Chassis vehicles the following procedure must be
lower suspension arm (Fig. 3). Refer to the Align performed.
ment Specification Chart for the correct setting. (1) Take a height measurement to the center of the
front gauge hole in the frame. Take another mean-
TOE POSITION surement to the center of the rear spring hanger bolt
The wheel toe position adjustment should be the fi (Fig. 5). Take these measurements on both sides of
nal adjustment. the vehicle.
2-1 FRONT SUSPENSION AND AXLE BR
y i ADJUSTMENT
/ I CAM DRAG UNK
Fig 4 Drag Link Adjustment

0
LOWER PRE-ALIGNMENT INSPECTION IFS SUSPENSION

AXLE SUSPENSION
BRACKET ARM Before starting a front wheel alignment, the follow
J9302-59 ing inspection and necessary corrections must be
completed.
Fig. 3 Cam Adjuster (1) Tires with the same recommended air pressure,
(2) Subtract the front measurement from the rear size, and thread wear. Refer to Group 22, Tires And
measurement and use the average between the right Wheels for diagnosis information.
and left side. Use this number with the Caster Cor (2) Front wheel bearings for wear or adjustment.
rection Chart to obtain the correct caster angle (Fig.
6).
4x2
GAUGE
HOLE HANGER
BOLT
Fig. 5 Cab-Chassis Measurement

134.7" o r 138.7" 162.7"

WHEELBASE WHEELBASI
Hangar Bolt- Caster H a n g e r Bolt- Caster

G a u g e Hole Correction G a u g e Hole Correction
(inches) (degrees) (inches) (degrees)
-5.00 -0.23 -5.00 -0.19

-4.75 -0.11 -4.75 -0.09
-4.50 0.01 -4.50 0.01
-4.25 0.14 -4.25 0.11
-4.00 0.26 -4.00 0.21
-3.75 0.38 -3.75 0.31
-3.50 0.50 -3.50 0.41
-3.25 0.62 -3.25 0.51
-3.00 0.75 -3.00 0.61
-2.75 0.87 -2.75 0.71
-2.50 0.99 -2.50 0.81
Fig. 7 Caster Camber Adjustment Location
-2.25 1.11 -2.25 0.91
-2.00 1.24 -2.00 1.01 pivot bar (Fig. 7). Refer to the Alignment Specifica
-1.75 1.36 -1.75 1.11 tion Chart for the correct setting.
-1.50 1.48 -1.50 1.21 CASTER: Move only the rear position of the pivot
-1.25 1.60 -1.25 1.31 bar in or out. This will change the caster angle sig
-1.00 1.73 -1.00 1.41
-0.75 1.85 -0.75 1.51
nificantly and camber angle only slightly. To retain
-0.50 1.97 -0.50 1.61 the camber while adjusting caster, move the rear
-0.25 2.09 -0.25 1.71 pivot bar in or out. Move the forward pivot very
0.00 2.21 0.00 1.81 slightly in the opposite direction.
For example, to increase a positive caster an
J9502-15 gle, move the rear position of the pivot bar in
ward (toward the engine). Move the front of
Fig. 6 Caster Correction Chart
pivot bar outward (away from the engine)
(3) Ball studs, linkage pivot points and steering slightly until the original camber angle is ob
gear for looseness, roughness or binding. Refer to tained.
Group 19, Steering for additional information. CAMBER: Move only the forward position of the
(4) Front wheels for excessive radial or lateral pivot bar in or out. This will change the camber an
runout and unbalance. Refer to Group 22, Tires And gle significantly and caster angle only slightly. The
Wheels for diagnosis information. camber angle should be adjusted as close as possible
(5) Suspension components for wear and noise. to the preferred service specification.
Check components for correct torque. Refer to Groups After adjustment is made tighten the pivot bar
2 and 3, Suspension and Axle for additional informa nuts to 210 N-m (155 ft. lbs.) torque.
tion.
TOE POSITION
ALIGNMENT AND ADJUSTMENTS IFS The wheel toe position adjustment should be the fi
SUSPENSION nal adjustment.
Before each alignment reading the vehicle should (1) Start the engine and turn wheels both ways be
be jounced (rear first, then front). Grasp each fore straightening the wheels. Center and secure the
bumper at the center and jounce the vehicle up and steering wheel and turn off engine.
down several times. Always release the bumper in (2) Loosen the tie rod adjustment sleeve clamp
the down position. Set the front end alignment to bolts/nuts.
specifications while the vehicle is in its NOR Each front wheel should be adjusted for one-
MALLY LOADED CONDITION. half of the total toe position specification. This
will ensure the steering wheel will be centered
CAMBER AND CASTER ADJUSTMENT when the wheels are positioned straight-ahead.
Camber and caster angle adjustments involve (3) Adjust the wheel toe position by turning the tie
changing the position of the upper suspension arm rod adjustment sleeves as necessary.
2 -8 FRONT SUSPENSION AND AXLE BR
mmmiT SPECIFICATIONS
ALIGNMENT SPECIFICATIONS 4X2 AND 4X4
PREFERRED PREFERRED
WHEEL CASTER CAMBER
4x2/4x4 BASE
(lbs) (inches)
(degrees) (degrees)
(+f-1.00) (+/- o.so)
4x2 6010 118.7 3.65 0.50
4x2 6400 118.7 3.65 0.50
4x2 6010 134.7 3.80 0.50
4x2 6400 134.7 3.80 0.50
4x2 6400 138.7 3.70 0.50
4x2 6400 154.7 3.85 0.50
4x2 7500 134.7 3.55 0.50
4x2 8800 134.7 3.45 0.50
4x2 8800 154.7 3.65 0.50
4x2 10500 134.7 3.25 0.50
4x2 10500 154.7 3.45 0.50
4x4 6400 118.7 3.35 not set
4x4 6400 134.7 3.45 not set
4x4 6400 138.7 3.40 not set
4x4 6400 154.7 3.55 not set
4x4 7500 134.7 3.00 not set
4x4 8800 134.7 3.10 not set
4x4 8800 154.7 3.25 not set
4x4 10500 134.7 2.90 not set
4x4 10500 154.7 3.00 not set
4x2/4x4 8800 134.7 not set

USE
*4x2/4x4 11000 138.7 CAB-CHASSIS not set
PROCEDURE
*4x2/4x4 11000 162.7 not set
€
Preferred Total Toe-in 0.25 > ( + / - 0.25)
* 4 x 2 11000# G V W has a solid front axle link coil suspension system.

J9502-16
LINK/COIL SUSPENSION
INDEX
page page
Coil Spring 10 Shock Diagnosis 10

Lower Suspension Arm 11 Stabilizer Bar 9
Service Information 9 Track Bar 9
Shock Absorber 10 Upper Suspension Arm ..................... 11
SERVICE INFORMATION INSTALLATION

Periodic lubrication of the steering system and sus (1) Install the track bar at axle tube bracket.
pension components is required. Refer to Group 0, Loosely install the retaining bolt and flag nut.
Lubrication And Maintenance for the service inter (2) Pry the axle assembly over to install the track
val. bar at the frame rail bracket (Fig. 1).
(3) Install the retaining nut on the stud. Tighten
CAUTION: Suspension components with rubber the ball stud nut to 84 N-m (62 ft. lbs.) torque. Install
bushings should be tightened with the vehicle at a new cotter pin.
normal height. It is important to have the springs (4) Remove the supports and lower the vehicle.
supporting the weight of the vehicle when the fas (5) Tighten the bolt at the axle shaft tube bracket
teners are torqued. If springs are not at their normal to 176 N-m (130 ft. lbs.) torque.
ride position, vehicle ride comfort could be affected
and premature bushing wear may occur. Rubber STABILIZER BAR
bushings must never be lubricated.
REMOVAL
TRAGI BAR (2) Disconnect the stabilizer bar links from the
axle brackets.
REMOVAL (3) Disconnect the stabilizer bar from the links.
(1) Raise and support the vehicle. (4) Disconnect the stabilizer bar clamps from the
(2) Remove the cotter pin and nut from the ball frame rails and remove the stabilizer bar (Fig. 2).
stud end at the frame rail bracket (Fig. 1).
(3) Remove ball stud from bracket with Puller
C-3894A
(4) Remove the bolt and flag nut from the axle
bracket and remove the track bar (Fig. 1).
Fig. 2 Stabilizer Bar
INSTALLATION
(1) Position the stabilizer bar on the frame rail and
install the clamps and bolts. Ensure the bar is cen
tered with equal spacing on both sides. Tighten the
Fig. 1 Track Bar bolts to 47 N-m (35 ft. lbs.).
2 -10 FRONT SUSPENSION AND AXLE
(2) Install the links, grommets retainers and nuts

onto the axle brackets (Fig. 2). Tighten the nuts to 37
N-m (27 ft. lbs.) torque.
(3) Install link on stabilizer bar and tighten nut to
118 N-m (87 ft. lbs.) torque.
(4) Remove the supports and lower the vehicle.
SHOCK DIAGNOSIS
A squeak noise from the shock absorber can be pro
duced if movement between the rubber bushings and
the metal occurs. This noise can usually be stopped
by tightening the attaching nuts. If the squeak noise
persists, inspect for damaged and worn bushings,
and attaching components. Repair as necessary.
The shock absorbers are not refillable or adjust
able. If a malfunction occurs, the shock absorber
must be replaced. To test a shock absorber, hold it in
an upright position and force the piston into and out SHOCK lOtJ
of the cylinder four or five times. The action through
out each stroke should be smooth and even. J9402-47
SHOCK ABSORBER Fig. 4 Shock Absorber Axle Mount
REMOVAL INSTALLATION
(1) Remove the nut, retainer and grommet from (1) Position the lower retainer and grommet on the
the upper stud in the engine compartment. upper stud. Insert the shock absorber through the
(2) Remove three nuts from the upper shock spring from engine compartment.
bracket (Fig. 3). (2) Install the lower bolt and tighten bolt to 135
(3) Install the upper shock bracket and three nuts.
Tighten nuts to 75 N-m (55 ft. lbs.) torque.
(4) Install upper grommet and retainer. Install up
per shock nut and tighten to 41 N-m (30 ft. lbs.)
torque.
COIL SPRilO
REMOVAL
(1) Raise and support the vehicle. Position a hy
draulic jack under the axle to support it.
(2) Paint or scribe alignment marks on lower sus
pension arm cam adjusters and axle bracket for in
stallation reference.
(3) Remove the upper suspension arm and loosen
lower suspension arm bolts.
(4) Mark and disconnect the front propeller shaft
from the axle 4x4 models.
(5) Disconnect the track bar from the frame rail
J9402-46 bracket.
(6) Disconnect the drag link from pitman arm.
Fig. 3 Shock Absorber and Bracket (7) Disconnect the stabilizer bar link and shock ab
(3) Remove the lower bolt from the axle bracket sorber from the axle.
(Fig. 4). Remove the shock absorber from engine com (8) Lower the axle until the spring is free from the
upper mount. Remove the coil spring.
partment.
INSTALLATION
(1) Position the coil spring on the axle pad.
FRONT SUSPENSION AND AXLE 2 -11
(3) Raise the axle into position until the spring

seats in the upper mount.
(4) Connect the stabilizer bar links and shock ab
sorbers to the axle bracket. Connect the track bar to
the frame rail bracket.
(5) Install the upper suspension arm.
(6) Install the front propeller shaft to the axle 4x4
model.
(7) Install drag link to pitman arm and tighten nut
to 88 N-m (65 ft. lbs.) torque. Install new cotter pin.
(8) Remove the supports and lower the vehicle.
(9) Tighten the following suspension components to
proper torque:
® Link to stabilizer bar tighten nut to 118 N-m (87
ft. lbs.) torque.
o Lower shock tighten bolt to 121 N-m (89 ft. lbs.)
torque.
• Tighten track bar bolt at the axle shaft tube
bracket to 176 N-m (130 ft. lbs.) torque.
•. Upper suspension arm tighten nut at the axle
bracket to 121 N-m (89 ft. lbs.) torque. Tighten nut at J9302-59
frame bracket to 84 N-m (62 ft. lbs.) torque.
• Align lower suspension arm reference marks and Fig. 5 Cam Adjuster
tighten cam nut to 149 N-m (110 ft. lbs.) torque. (2) Remove the upper suspension arm nut and bolt
Tighten rear nut to 119 N-m (88 ft. lbs.) torque. at the axle bracket (Fig. 6).
(3) Remove the nut and bolt (Fig. 6) at the frame
LOWER SUSPENSION ARM
rail and remove the upper suspension arm.
REMOVAL
(2) Paint or scribe alignment marks on the cam ad
justers and suspension arm for installation reference
(Fig. 5).
(3) Remove the lower suspension arm nut, cam
and cam bolt from the axle.
(4) Remove the nut and bolt from the frame rail
bracket and remove the lower suspension arm (Fig.
6).
INSTALLATION
(1) Position the lower suspension arm at the axle
bracket and frame rail bracket.
(2) Install the rear bolt and finger tighten the nut.
(3) Install the cam bolt, cam and nut in the axle.
Re-align the reference marks. Fig. 6 Upper and Lower Suspension Arms
(4) Remove support and lower the vehicle.
(5) Tighten cam nut to 149 N-m (110 ft. lbs.) INSTALLATION
torque. Tighten rear nut to 119 N-m (88 ft. lbs.) (1) Position the upper suspension arm at the axle
torque. and frame rail (Fig. 6).
(2) Install the bolts and finger tighten the nuts.
UPPER SUSPENSION ARM (3) Remove the supports and lower the vehicle.
(4) Tighten nut at the axle bracket to 121 N-m (89
REMOVAL ft. lbs.) torque. Tighten nut at frame bracket to 84
(1) Raise and support the vehicle. N-m (62 ft. lbs.) torque.
2 -12 FRONT SUSPENSION AND AXLE mm
INDEPENDENT FRONT S U S P E N S I O N (IFS)
INDEX
page page
Coil Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Stabilizer Bar . 12

Lower Ball Stud 14 Steering Knuckle 16
Lower Suspension Arm 14 Upper Ball Stud 15
Service Information 12 Upper Suspension Arm 15
Shock Absorber 12 Wheel Hub and Bearings 15
Shock Diagnosis 12
SERVICE INFORMATION
Periodic lubrication of the steering system and sus
pension components is required. Refer to Group 0,
Lubrication And Maintenance for the service inter
val.
CAUTION: Suspension components with rubber
bushings should be tightened with the vehicle at
normal height. It is important to have the springs
supporting the weight of the vehicle when the fas
teners are torqued. If springs are not at their normal
and premature bushing wear may occur. Rubber
STABILIZER BAR
REMOVAL
(2) Disconnect the link from lower suspension arm
and stabilizer bar (Fig. 1).
(3) Disconnect the stabilizer bar clamps from the Fig, 1 STABILIZER BAR
frame rails. Remove the stabilizer bar.
must be replaced. To test a shock absorber, hold it in
INSTALLATION an upright position and force the piston into and out
(1) Position the stabilizer bar on the frame rail and of the cylinder four or five times. The action through
install the clamps and bolts. Ensure the bar is cen out each stroke should be smooth and even.
tered with equal spacing on both sides. Tighten the
bolts to 47 N-m (35 ft. lbs.) torque. SHOCK ABSORBER
(2) Install links on stabilizer bar and lower suspen
sion arm. Install grommets, retainers and nuts. REMOVAL
Tighten nuts to 34 N-m (25 ft. lbs.) torque (Fig. 1)
(4) Remove the supports and lower the vehicle. WARNING: DO NOT REMOVE SHOCK UNTIL
L O W E R S U S P E N S I O N ARM !S S U P P O R T E D . THE
SHOCK DIAGNOSIS SHOCK HOLDS THE L O W E R S U S P E N S I O N ARM
AND S P R I N G IN POSITION.
A squeak noise from the shock absorber can be pro
duced if movement between the rubber bushings and (1) Raise and support vehicle.
the metal occurs. This noise can usually be stopped
by tightening the attaching nuts. If the squeak noise (2) Remove shock upper nut and remove retainer
persists, inspect for damaged and worn bushings, and grommet.
and attaching components. Repair as necessary. (3) Remove lower mounting bolt from suspension
The shock absorbers are not refillable or adjust arm and remove shock (Fig. 2).
able. If a malfunction occurs, the shock absorber
Fig. 2 Shock Absorber Fig. 3 Coil Spring

INSTALLATION
(1) Extend shock fully, install retainer and grom (1) Install rubber isolator on top of spring. Position
met on top of shock absorber. Check grommets and spring into upper spring seat and lower suspension
retainer for wear. arm.
(2) Guide shock up through upper suspension arm (2) Raise suspension arm with jack and position
bracket. Install top grommet, retainer and nut. shock into suspension arm mount. Install shock bolt
Tighten nut to 41 N-m (30 ft. lbs.) torque. and tighten to 135 N-m (100 ft. lbs.) torque (Fig.4).
(3) Align bottom end of shock into lower suspen
sion arm and install mounting bolt. Tighten bolt to
(4) Remove support and lower vehicle.
COIL SPRINGS
REMOVAL
WARNING: DO NOT REMOVE SHOCK UNTIL
L O W E R S U S P E N S I O N ARM IS S U P P O R T E D . THE
SHOCK HOLDS THE L O W E R S U S P E N S I O N A R M
(1) Raise and support vehicle.

(2) Remove tire and wheel assembly.
(3) Remove brake caliper assembly and rotor refer
Fig. 4 Shock Absorber
to Group 5, Brakes.
(4) Disconnect tie rod from steering knuckle. (3) Install steering knuckle on lower ball stud. In
(5) Disconnect stabilizer bar link from lower sus stall lower ball stud nut and tighten to 75 N-m (55 ft.
pension arm. lbs.) torque. Replace cotter pin and remove jack.
(6) Support lower suspension arm outboard end (4) Install stabilizer bar link on lower suspension
with jack. Place jack under arm in front of shock arm. Install grommet, retainer and nut, and tighten
mount. to 34 N-m ( 35 ft. lbs.) torque (Fig.5).
(7) Remove cotter pin and nut from lower ball (5) Install tie rod on steering knuckle and tighten
stud. Separate ball stud with remover C-4150A. nut to 88 N
(8) Remove lower shock bolt from suspension arm. 31m (65 ft. lbs.) torque.
(9) Lower jack and suspension arm until spring (6) Install brake caliper assembly and rotor refer
tension is relieved. Remove spring and rubber isola to Group 5, Brakes.
tor (Fig. 3). (7) Install tire and wheel assembly.
2-14 FRONT SUSPENSION AND AXLE — — — — — — — — — — BR
REMOVAL
(1) Follow procedure under Lower Suspension Arm
Removal.
(2) Position special tool on lower suspension arm
and press out ball stud (Fig. 6).
Pig. 5 independent Front Suspension

LOWER SUSPENSION ARM
REMOVAL SPECIAL TOOL
(1) Raise and support vehicle. C-4212F
(2) Follow procedure under Coil Spring Removal.
WARNING: DO NOT R E M O V E SHOCK UNTIL
L O W E R S U S P E N S I O N A R M I S S U P P O R T E D , THE
S H O C K HOLDS THE L O W E R S U S P E N S I O N A R M
Fig. 6 Lower Bail Stud Removal
(3) Remove bolts mounting suspension arm to INSTALLATION
crossmember and remove arm. (1) Press replacement ball stud into the lower sus
pension arm bore with special tools (Fig. 7).
INSTALLATION
(1) Position suspension arm on crossmember and
install bolts snug.
(2) Follow procedure under Coil Spring Installa
tion.
(4) Tighten suspension arm crossmember bolts to SPECIAL TOOL
176 N-m (130 ft. lbs.) torque. C4212F
LOWER BALL STUD
INSPECTION
(1) Raise the front of the vehicle. Install safety
floor stands under both lower suspension arms as far
outboard as possible. The upper suspension arms
must not contact the rebound bumpers.
(2) Install a dial indicator and clamp assembly to
the lower suspension arm.
(3) Position indicator plunger against knuckle arm
and zero indicator.
(4) Raise and lower the wheel with a pry bar un
der the center of the tire. Measure the axial move 6761 J9402-34
ment of the knuckle with respect to the suspension
Fig. 7 Lower Ball Stud Installation
arm.
(5) If the travel of the suspension arm is 0.020 (2) Install lower suspension arm using procedure
inch (0.51 mm) or more, replace the ball joint. under Lower Suspension Arm Installation.
m m — — — FRONT SUSPENSION AND AXLE 2 -15
UPPER SUSPENSION A i l
REMOVAL
(1) Raise and support vehicle
(2) Remove tire and wheel assembly
(8) Support lower suspension arm at outboard end
with jack stand.
(4) Remove upper ball stud cotter pin and nut.
(5) Separate ball stud from knuckle with remover
MB-990635 or MB-991113.
(6) Remove pivot bar bolts from upper suspension
arm bracket and remove arm from vehicle.
INSTALLATION
(1) Position upper suspension arm on bracket and
install pivot bar bolts. Tighten to 203 N-m (150 ft.
lbs.) torque.
(2) Install ball stud in knuckle. Install nut and
tighten to 75 N-m (55 ft. lbs.) torque. Install replace
ment cotter pin.
(3) Remove jack from lower suspension arm.
(4) Install tire and wheel assembly
(5) Remove support and lower vehicle 1
Fig. 8 U;. •) i âil Stud Removal
(6) Align front suspension.
UPPER BALL STUD
INSPECTION SPECIAL TOOL
(1) Position a floor jack under the lower suspension C-4212F
arm. Raise the wheel and allow the tire to lightly
contact the floor (vehicle weight relieved from the
tire).
(2) Grasp the top of the tire and apply force in and
out. Look for any movement at the ball joints be
tween the upper suspension arm and steering
knuckle.
(3) If any lateral movement is evident, replace the
ball joint.
REMOVAL
(1) Follow procedure under Upper Suspension Arm
Removal.
(2) Position special tools on upper suspension arm
and press ball stud out of arm (Fig. 8).
J9402-35
INSTALLATION
(1) Press ball stud into upper suspension arm with Fig. 9 Up -;r Bail Stud Installation
special tools (Fig. 9). (4) Remove the dust cap, cotter pin, and hub nut
(2) Follow procedure under Upper Suspension Arm
from spindle.
Installation.
CAUTION: Use care to prevent inner wheel bearing
WHEEL HUB AND BEARINGS and seal from contacting spindle threads during re
moval.
REMOVAL
(1) Raise and support the vehicle. (5) Carefully slide the hub/rotor from spindle.
(2) Remove the wheel and tire assembly.
(3) Remove disc brake caliper from steering (6) Remove the seal and inner wheel bearing from
knuckle. Refer to Group 5, Brakes. the hub/rotor.
(7) Remove inner bearing races from hub/rotor (7) The adjustment (above) should have 0.001 to
with a pin punch if bearings are going to be replaced. 0.003 inch (0.254 to 0.0762 mm) end play.
(8) Clean the dust cap and apply a coating lubri
CLEANING AND INSPECTION
cant to the internal surface. Do not fill the dust
(1) Thoroughly clean bearings and interior of hub/ cap with lubricant. Install the cap.
rotor. (9) Install disc brake caliper. Refer to Group 5,
(2) Clean the bearings with solvent and towel dry. Brakes.
(3) Rotate each bearing slowly and examine the (10) Install the wheel and tire assembly.
rollers for pitting and roughness. Replace bearing if
worn or damaged.Cup and bearing must be re STEERING KNUCKLE
placed as a matched set if wore or damaged.
(4) Pack each bearing with multi-purpose NLGI, REMOVAL
grade 2, EP-type lubricant (or an equivalent lubri- (1) Raise and support vehicle.
cant).Ensure that lubricant is forced into all the (2) Remove wheel and tire assembly. Remove the
cavities between the bearing cage and rollers.
brake caliper, refer to Group 5, Brakes.
INSTALLATION
(3) Remove the wheel hub and bearing assembly
(1) Install the new bearing cup(s) with an appro from the spindle. Refer to Wheel Hub and Bearings
priate installation tool. service removal.
(2) Apply a coating of MOPAR Wheel Bearing (4) Remove the cotter pin and nut from the tie-rod
Grease or equivalent lubricant to inner surface area end and disconnect tie rod.
of hub/rotor. Install inner wheel bearing and seal in (5) Remove the cotter pins and nuts from the up
the hub/rotor. per and lower ball studs. Separate upper ball stud
(3) Inspect bearing and seal contact surfaces on from knuckle with remover MD-990635 or
spindle for burrs and/or roughness. MD-991113. Separate lower ball stud with remover
(4) Remove all rough contact surfaces from spindle. C-4150A and remove knuckle.
Apply a coating of lubricant.
INSTALLATION
CAUTION: Use care to prevent inner wheel bearing (1) Position knuckle on ball stud and install ball
and seal from contacting spindle threads during in stud nuts. Tighten nuts to 75 N-m (55 ft. lbs.) torque.
stallation. Install cotter pins.
(2) Install the brake rotor hub and bearing assem
(5) Carefully slide the hub/rotor onto spindle. In
bly on spindle. Refer to Wheel Hub and Bearings ser
stall outer wheel bearing, washer and retaining nut.
(6) Tighten the nut to 41-54 N-m (30-40 ft. lbs.) vice installation.
torque to preload bearing while rotating the hub/ro (3) Install the brake caliper, refer to Group 5,
tor. Stop hub/rotor and loosen nut to completely re Brakes.
lease bearing preload torque. Tighten the nut finger- (4) Install wheel and tire assembly.
tight and install the nut lock. Install a new cotter (5) Remove support and lower vehicle.
pin.
AXLE NOISE/VIBRATION DIAGNOSIS
INDEX
page page
Driveline Snap 18 Low Speed Knock 18

Gear and Bearing Noise 17 Vibration 18
General Information 17
GENERAL INFORMATION Excessive bearing preload may not be noisy. This

Axle bearing problem conditions are usually caused condition will cause high temperature which can re
by: sult in bearing failure.
• Insufficient or incorrect lubricant
• Foreign matter/water contamination GEAR AID BEARING NOISE
© Incorrect bearing preload torque adjustment
GEAR NOISE
• Incorrect backlash ( to tight)
Axle gear noise can be caused by insufficient lubri
When serviced, the bearings must be cleaned thor
oughly. They should be dried with lint-free shop tow cant. Incorrect backlash, tooth contact, or worn/dam
els. Never dry bearings with compressed air. aged gears can cause noise.
This will overheat them and brinell the bearing Gear noise usually happens at a specific speed
surfaces. This will result in noisy operation af range. The range is 30 to 40 mph, or above 50 mph.
ter repair. The noise can also occur during a specific type of
Axle gear problem conditions are usually the result driving condition. These' conditions are acceleration,
of: deceleration, coast, or constant load.
• Insufficient lubrication When road testing, accelerate the vehicle to the
• Incorrect or contaminated lubricant speed range where the noise is the greatest. Shift
• Overloading (excessive engine torque) out-of-gear and coast through the peak-noise range.
• Exceeding vehicle weight capacity If the noise stops or changes greatly, check for insuf
• Incorrect clearance or backlash adjustment ficient lubricant. Incorrect ring gear backlash, or
Insufficient lubrication is usually the result of a gear damage can cause noise changes.
housing cover leak. It can also be from worn axle Differential side and pinion gears can be checked
shaft or pinion gear seals. Check for cracks or porous by turning the vehicle. They usually do not cause
areas in the housing or tubes. noise in straight-ahead driving. These gears are
Using the wrong lubricant will cause overheating loaded during vehicle turns. If noise does occur dur
and gear failure. Gear tooth cracking and bearing ing vehicle turns, the side or pinion gears could be
spalling are indicators of this. worn or damaged. A worn pinion gear mate shaft can
Axle component breakage is most often the result also cause a snapping or a knocking noise.
of:
• Severe overloading BEARING NOISE
® Insufficient lubricant The axle shaft, differential and pinion gear bear
• Incorrect lubricant ings can all produce noise when worn or damaged.
• Improperly tightened components Bearing noise can be either a whining, or a growling
Common causes of overloading is from full-throttle sound.
acceleration. Overloading happens when towing Pinion gear bearings have a constant-pitch noise.
heavier-than-recommended loads. Component break This noise changes only with vehicle speed. Pinion
age can occur when the wheels are spun excessively. bearing noise will be higher because it rotates at a
Insufficient or incorrect lubricants contribute to faster rate. Drive the vehicle and load the differen
breakage through overheating. Loose differential tial. If bearing noise occurs the pinion rear bearing is
components can also cause breakage. the source of the noise. If the bearing noise is heard
Incorrect bearing preload or gear backlash will not during a coast, front bearing is the source.
result in component breakage. This will cause accel Worn, damaged differential bearings usually pro
erated wear and contribute to early failure. Mis-ad duce a low pitch noise. Differential bearing noise is
justment will produce noise. If a mis-adjustment similar to pinion bearing. The pitch of differential
condition is not corrected, component failure can re bearing noise is also constant and varies only with
sult. vehicle speed.
Axle shaft bearings produce noise and vibration • Bent axle shaft
when worn or damaged. The noise generally changes Check for loose or damaged front-end components
when the bearings are loaded. Road test the vehicle. or engine/transmission mounts. These components
Turn the vehicle sharply to the left and to the right. can contribute to what appears to be a rear-end vi
This will load the bearings and change the noise bration. Do not overlook engine accessories, brackets
level. Where axle bearing damage is slight, the noise and drive belts.
is usually not noticeable at speeds above 30 mph. All driveline components should be examined be
fore starting any repair.
LOW SPEED KNOCK Refer to Group 22, Wheels And Tires for additional
Low speed knock is generally caused by a worn U- information.
joint or by worn side-gear thrust washers. A worn
pinion gear shaft bore will also cause low speed DRIVELINE SNAP
knock. A snap or clunk noise when the vehicle is shifted
into gear (or the clutch engaged), can be caused by:
WIBRATION • High engine idle speed
Vibration at the rear of the vehicle is usually • Loose engine/transmission/transfer case mounts
caused by a: ® Worn U-joints
• Damaged drive shaft • Loose spring mounts
• Missing drive shaft balance weight • Loose pinion gear nut and yoke
• Worn, out-of-balance wheels • Excessive ring gear backlash
• Loose wheel lug nuts • Excessive differential side gear-to-case clearance
• Worn U-joint The source of a snap or a clunk noise can be deter
• Loose spring U-bolts mined with the assistance of a helper. Raise the ve
• Loose/broken springs hicle on a hoist with the wheels free to rotate.
• Damaged axle shaft bearings Instruct the helper to shift the transmission into
• Loose pinion gear nut gear. Listen for the noise, a mechanics stethoscope is
• Excessive pinion yoke run out helpful in isolating the source of a noise.
BR FRONT SUSPENSION AND AXLE 2 - 19
SERVICE DIAGNOSIS
Condition Possible Cause Correction
WHEEL NOISE (a) Wheel loose. (a) Tighten loose nuts.
(b) Faulty, brinelled wheel bearing. (b) Faulty or brinelled bearings must be
replaced.
AXLE SHAFT NOISE (a) Misaligned axle shaft tube. (a) Inspect axle shaft tube alignment.
Correct as necessary.
(b) Bent or sprung axle shaft. (b) Replace bent or sprung axle shaft.
(c) End play in drive pinion bearing. (c) Refer to Drive Pinion Bearing Pre-Load
Adjustment.
(d) Excessive gear backlash between ring (d) Check adjustment of ring gear
gear and pinion gear. backlash and pinion gear. Correct as
necessary.
(e) Improper adjustment of drive pinion (e) Adjust drive pinion shaft bearings.
gear shaft bearings. (f) Tighten drive pinion gearshaft yoke nut
(f) Loose drive pinion gearshaft yoke nut. with specified torque.
(g) Improper wheel bearing adjustment. (g) Readjust as necessary.
(h) Scuffed gear tooth contact surfaces. (h) If necessary, replace scuffed gears.
AXLE SHAFT BROKE (a) Misaligned axle shaft tube. (a) Replace broken axle shaft after
correcting axle shaft tube alignment.
(b) Vehicle overloaded. (b) Replace broken axle shaft. Avoid
excessive weight on vehicle.
(c) Erratic clutch operation (c) Replace broken axle shaft after
inspecting for other possible causes.
Avoid erratic use of clutch.
(d) Grabbing clutch. (d) Replace broken axle shaft. Inspect
clutch and make necessary repairs or
adjustments.
DIFFERENTIAL CASE (a) Improper adjustment of differential (a) Replace cracked case; examine gears
CRACKED bearings. and bearings for possible damage. At
reassembly, adjust
differential bearings properly.
(b) Excessive ring gear backlash. (b) Replace cracked case; examine gears
and bearings for possible damage. At
reassembly, adjust ring gear backlash
properly.
(c) Vehicle overloaded. (c) Replace cracked case; examine gears
and bearings for possible damage.
Avoid excessive weight on vehicle.
(d) Erratic clutch operation. (d) Replace cracked case. After inspecting
for other possible causes, examine
gears and bearings for possible
damage. Avoid erratic use of clutch.
DIFFERENTIAL GEARS (a) Insufficient lubrication. (a) Replace scored gears. Scoring marks
SCORED on the drive face of gear teeth or in
- the bore are caused by instantaneous
fusing of the mating surfaces. Scored
gears should be replaced. Fill rear
differential housing to required capacity
with proper lubricant. Refer to
Specifications.
(b) Improper grade of lubricant. (b) Replace scored gears. Inspect all
damage. Clean and refill differential
housing to required capacity with
proper lubricant.
(c) Excessive spinning of one wheel/tire. (c) Replace scored gears. Inspect all
gears, pinion bores and shaft for
damage. Service as necessary.
LOSS OF LUBRICANT (a) Lubricant level too high. (a) Drain excess lubricant by removing fill
plug and allow lubricant to level at
lower edge of fill plug hole.
J9003-49
2 - 20 FRONT SUSPENSION AND AXLE BR
SERVICE DIAGNOSIS (CONT'D)

L O S S OF LUBRICAWT (b) Worn axle shaft seals. (b) Replace worn seals.
(Cont'd) (c) Repair or replace housing as
(c) Cracked differential housing. necessary.
(d) Replace worn drive pinion gear shaft
(d) Worn drive pinion gear shaft seal. seal.
(e) Replace worn or scored yoke and seal.
(e) Scored and worn yoke. (f) Remove cover and clean flange and
(f) Axle cover not properly sealed. reseal.
AXLE OVERHEATING (a) Lubricant level too low. (a) Refill differential housing.
(b) Incorrect grade of lubricant. (b) Drain, flush and refill with correct
amount of the correct lubricant.
(c) Bearings adjusted too tight. (c) Readjust bearings.
(d) Excessive gear wear. (d) Inspect gears for excessive wear or
scoring. Replace as necessary.
(e) Insufficient ring gear backlash, (e) Readjust ring gear backlash and
inspect gears for possible scoring.
GEAR TEETH BROKE (a) Overloading. (a) Replace gears. Examine other gears
(RING GEAR AND and bearings for possible damage.
PINION) Replace parts as needed. Avoid
overloading of vehicle.
(b) Erratic clutch operation. (b) Replace gears and examine the
remaining parts for possible damage.
Avoid erratic clutch operation.
(c) Ice-spotted pavements. (c) Replace gears. Examine the remaining
parts for possible damage. Replace
parts as required.
(d) Improper adjustments. (d) Replace gears. Examine other parts for
possible damage. Ensure ring gear
backlash is correct.
AXLE NOISE (a) Insufficient lubricant. (a) Refill axle with correct amount of the
proper lubricant. Also inspect for leaks
and correct as necessary.
(b) Improper ring gear and drive pinion (b) Check ring gear and pinion gear teeth
gear adjustment. contact pattern.
(c) Unmatched ring gear and drive
pinion gear. (c) Remove unmatched ring gear and
drive pinion gear. Replace with
matched gear and drive pinion gear
set.
(d) Worn teeth on ring gear or drive (d) Check teeth on ring gear and drive pi
pinion gear. nion gear for correct contact.
If necessary, replace with new
matched set.
(e) Loose drive pinion gear shaft bearings. (e) Adjust drive pinion gearshaft bearing
preload torque.
(f) Loose differential bearings. (!) Adjust differential bearing preload
torque.
(g) Misaligned or sprung ring gear. (g) Measure ring gear runout.
(h) Loose differential bearing cap bolts. (h) Tighten with specified torque.
J9003-50
mm FRONT SUSPENSION AND AXLE 2 - 21
HXLE SERVICE PROCEDURES
INDEX
page page
Axle Shaft Oil Seal . 33 Final Assembly 44

Axle Shaft— Cardan U-Joint 24 General Information 21
Backlash and Contact Pattern Analysis 42 Hub Bearing and Axle Shaft 24
Cleaning/Inspection 34 Lubricant Change 21
Differential and Pinion Measurement 37 Lubricant Specifications 21
Differential Assembly 35 Pinion Gear Assembly/Installation 39
Differential Disassembly 33 Pinion Gear Depth Information 35
Differential Installation 41 Pinion Removal/Disassembly 33
Differential Removal 32 Pinion Seal Replacement 23
Differential Shim Pack Measurement and Steering Knuckle and Ball Studs 29
Adjustment 40
Vacuum Disconnect 44/60 Axle . . . . . . . . . . . . . . . 25
Drive Axle Assembly Replacement 22
GENERAL INFORMATION have API GL 5 quality specifications. MOPAR® Ther

The housing for Model 44/60 front axles consists of mal Stable Multi-Purpose Gear Lubricant conforms
an iron center casting with tubes on each side. The to these specifications.
tubes are pressed into and welded to the differential • The factory fill for the Model 44/60 axle is SAE
housing. 80W-90 gear lubricant
The integral type housing, hypoid gear design has Refer to Group 0, Lubrication and Maintenance for
the centerline of the pinion set below the centerline additional information.
of the ring gear.
The axle has a vent used to relieve internal pres CAUTION: If axle is submerged in water, the lubri
sure caused by lubricant vaporization and internal cant must be replaced immediately to avoid con
expansion. tamination.
The axles are equipped with semi-floating axle
shafts, meaning that loads are supported by the hub
bearings. The axle shafts are retained by nuts at the LUBRICANT CHANGE
hub bearings. The hub bearings are bolted to the The gear lubricant will drain quicker if the vehicle
steering knuckle at the outboard end of the axle tube has been recently driven.
yoke. The hub bearings are serviced as an assembly. (1) Raise and support the vehicle.
The axles are equipped with ABS brake sensors. (2) Remove the lubricant fill hole plug from the dif
The sensors are attached to the knuckle assemblies ferential housing cover.
and tone rings are pressed on the axle shaft. Use (3) Remove the differential housing cover and
care when removing axle shafts as NOT to dam drain the lubricant from the housing.
age the tone wheel or the sensor. (4) Clean the housing cavity with a flushing oil,
The stamped steel cover provides a means for in light engine oil or lint free cloth. Do not use water,
spection and servicing the differential. steam, kerosene or gasoline for cleaning.
The Model 44/60 axle has the assembly part num (5) Remove the sealant from the housing and cover
ber and gear ratio listed on a tag. The tag is attached surfaces. Use solvent to clean the mating surfaces.
to the housing cover. Build date identification codes (6) Apply a bead of MOPAR® Silicone Rubber Seal
are stamped on the axle shaft tube cover side. ant to the housing cover (Fig. 1). Allow the sealant
The differential case is a one-piece design. The dif to cure for a few minutes.
ferential pinion mate shaft is retained with a roll Install the housing cover within 5 minutes af
pin. Differential bearing preload and ring gear back ter applying the sealant. If not installed the
lash is adjusted by the use of shims. The shims are sealant must be removed and another bead ap
located between the differential bearing cones and plied.
case. Pinion bearing preload is set and maintained by (7) Install the cover and any identification tag.
the use of a collapsible spacer. Tighten the cover bolts in a criss-cross pattern to;
• Model 44: 41 N-m (30 ft. lbs.) torque,
LUBRICANT SPECIFICATIONS o Model 60: 47 N-m (35 ft. lbs.) torque.
Thermal Stable Multi-Purpose Gear Lubricant is (8) Refill differential with the specified quantity of
used for Model 44/60 axles. The lubricant should MOPAR® Hypoid Gear Lubricant.
SEALING CONTOUR OF BEAD (12) Lower the jack enough to remove the axle.
The coil springs will drop with the axle.
(13) Remove the coil springs from the axle bracket.
INSTALLATION
CAUTION: Suspension components with rubber

bushings should be tightened with the vehicle at
normal height. It is important to have the springs
supporting the weight of the vehicle when the fas
teners are torqued. If springs are not at their normal
and premature bushing wear may occur. Rubber
(1) Install the springs, retainer clip and bolts.

(2) Support the axle on a hydraulic jack under the
differential. Position the axle under the vehicle.
(3) Raise the axle with a floor jack and align it
with the spring pads.
(4) Position the upper and lower suspension arm at
the axle bracket. Install bolts, nuts and align cams to
Fig. 1 Typical Housing Cover With Sealant reference marks. Do not tighten at this time.
CAUTSON: Overfilling the differential can result in (5) Connect the track bar to the axle bracket and
lubricant foaming and overheating. install the bolt. Do not tighten at this time.
It is important that the springs support the
(9) Install the fill hole plug and lower the vehicle. weight of the vehicle when the track bar is con
nected. If the springs are not at normal ride
DRIVE AXLE ASSEMBLY REPLACEMENT height, the vehicle ride comfort could be af
fected.
REMOVAL
(6) Install the shock absorber and tighten bolts to
(1) Raise vehicle and position support stands un 121 N-m (89 ft. lbs.) torque.
der the frame rails behind the lower suspension arm (7) Install the stabilizer bar link to the axle
brackets. bracket. Tighten the nut to 37 N-m (27 ft. lbs.)
(2) Remove the front wheels assemblies. torque.
(3) Remove the brake components and ABS brake (8) Install the drag link and tie rod to the steering
sensor (if equipped). Refer to Group 5—Brakes. knuckles and tighten the nuts to 88 N-m (65 ft. lbs.)
(4) On 4WD vehicles, disconnect the axle vent torque.
hose. Disconnect vacuum hose and electrical connec (9) Install the brake components and ABS brake
tor at disconnect housing. sensor (if equipped). Refer to Group 5—Brakes.
(5) On 4WD vehicles, mark the drive shaft yoke, (10) On 4WD vehicles, connect the vent hose to the
axle pinion yoke and transfer case flange for align tube fitting. Connect vacuum hose and electrical con
ment reference. Disconnect the drive shaft from the nector to disconnect housing.
axle and transfer case. (11) On 4WD vehicles, align the reference marks
(6) Disconnect the stabilizer bar link at the axle and connect the drive shaft to the axle yoke and
bracket. transfer case flange. Tighten the U-joint clamp bolts
(7) Disconnect the shock absorbers from axle to 19 N-m (14 ft. lbs.) torque. Tighten flange bolts to
bracket. 88 N-m (65 ft. lbs.) torque.
(8) Disconnect the track bar from the axle bracket. (12) Check differential lubricant and add if neces
(9) Disconnect the tie rod and drag link from the sary.
steering knuckle. (13) Install the wheel and tire assemblies.
(10) Support the axle with a hydraulic jack under (14) Remove the supports and lower the vehicle.
the differential. (15) Tighten the upper suspension arm nuts at
(11) Disconnect the upper and lower suspension axle to 121 N-m (89 ft. lbs.) torque. Tighten the upper
arms from the axle bracket. Mark cams for instal suspension arm nuts at frame to 84 N-m (62 ft. lbs.)
lation reference. torque.
(16) Tighten the lower suspension arm nuts at axle SPECIAL TOOL
to 84 N-m (62 ft. lbs.) torque. Tighten the lower sus 7794A
pension arm nuts at frame to 119 Nm (88 ft. lbs.)
torque.
(17) Tighten the track bar bolt at the axle bracket
to 176 N-m (130 ft. lbs.) torque.
(18) Check the front wheel alignment.
PINION SEAL REPLACEMENT

The axle assembly does not have to be removed to
replace the pinion seal.
REMOVAL PINION SEAL
(2) Remove wheel and tire assemblies J9402-59X
(3) Mark the propeller shaft yoke and pinion yoke
for installation alignment reference. Fig. 3 Seal Removal
(4) Remove the propeller shaft from the yoke. (2) Align the installation reference marks and in
(5) Rotate the pinion gear three or four times. stall yoke on pinion shaft with Installer W-162D for
Make sure brakes are not dragging during this model 44 axle. Use Installer C-3718 for model 60
procedure. axle. (Fig. 4).
(6) Measure the amount of torque necessary to ro
tate the pinion gear with a torque wrench. Note the YOKE
torque for installation reference. It must be known
to properly adjust the pinion gear bearing pre
load torque after seal installation.
(7) Remove the pinion yoke nut and washer. Use
Remover C-452 and Holder C-3281 to remove the
pinion yoke (Fig. 2).
J9402-61
Fig. 4 Yoke Installer

C-452 J9I02-31
(3) Install a new nut on the pinion gear. Tighten
Fig. 2 Pinion Yoke Removal the nut only enough to remove the shaft end
(8) Mark the positions of the yoke and pinion gear play.
for installation alignment reference. CAUTION: Exercise care during the bearing preload
(9) Use Remover 7794A and slide hammer to re torque adjustment. Do not over-tighten, or loosen
move the pinion gear seal (Fig. 3). and then re-tighten the nut. Do not exceed the bear
INSTALLATION ing preload torque or the collapsible preload spacer
on the pinion shaft will have to be replaced. The
(1) Apply a light coating of gear lubricant on the
bearing preload torque will be re-adjusted after
lip of pinion seal. Install seal Installer D-163.
ward.
2 - 24 FRONT SUSPENSION AND AXLE mm
(4) Install a socket and inch-pound torque wrench (5) Remove the hub to knuckle bolts (Fig. 6). Re
on the pinion nut. move the hub bearing from the steering knuckle and
(5) Rotate the shaft with the torque wrench and axle shaft.
note the torque.
The required preload is equal to amount re
corded during removal plus 0.56 N-m (5 in. lbs.).
The used bearing preload torque must never
exceed 2.25 N-m (20 in. lbs.)
(6) Use Yoke Holder 6719 to retain the yoke and
shaft (Fig. 5). Tighten the shaft nut in very small in
crements.
Fig. 6 Hub and Knuckle

(6) Remove the brake dust shield.
(7) On 4WD vehicles, remove the axle shaft
from the housing. Avoid damaging the axle
shaft oil seal.
INSTALLATION
(1) On 4x4 vehicles clean the axle shaft and apply
a thin film of Mopar Wheel Bearing Grease to the
shaft splines, seal contact surface, hub bore. Install
the axle shaft into the housing and differential side
gears. Avoid damaging the axle shaft oil seals in the
differential.
(2) Install dust shield and hub bearing on knuckle.
Fig. 5 Tightening Pinion Shaft Nut (3) Install the hub bearing to knuckle bolts and
(7) Continue tightening the shaft nut in small in tighten to 170 N-m (125 ft. lbs.) torque.
crements until the correct bearing preload torque is (4) Install the axle washer and nut, tighten nut to
attained. Tighten the pinion shaft nut: 237 N-m (175 ft. lbs.) torque. Align nut to next cotter
• Model 44; No less than 258 N-m (190 ft. lbs.) pin hole and install new cotter pin.
torque. No greater than 393 N-m (290 ft. lbs.) (5) Install the brake components, refer to Group 5,
torque Brakes.
• Model m i No less than 292 N-m- (215 ft. lbs.) (6) Install the wheel and tire assembly.
torque. No greater than 427 N-m (315 ft. lbs.) (7) Remove support and lower the vehicle.
torque AXLE SHAFT— CARDAN U-JOINT
(8) Align the installation reference marks and at
tach the propeller shaft to the yoke. DISASSEMBLY
(9) Add API grade GL 5 hypoid gear lubricant to Single cardan U-joints are not serviceable. If defec
the differential housing, if necessary. tive, they must be replaced as a unit. If the bearings,
(10) Install wheel and tire assemblies seals, spider or bearing caps are damaged or worn,
(11) Remove support and lower the vehicle. replace the complete U-joint.
HUB BEARING AND AXLE SHAFT CAUTION: Clamp only the forged portion of the
yoke in the vise. Also, to avoid distorting the yoke,
REMOVAL do not over tighten the vise jaws.
(2) Remove the wheel and tire assembly. (1) Remove the bearing cap retaining snap rings
(3) Remove the brake components from the axle, (Fig. 7).
refer to Group 5 Brakes. It can be helpful to saturate the bearing caps
(4) Remove the cotter pin and axle hub nut. with penetrating oil prior to removal.
BEARING CLEANING AND INSPECTION

(1) Clean all the U-joint yoke bores with cleaning
solvent and a wire brush. Ensure that all the rust
and foreign matter are removed from the bores.
(2) Inspect the yokes for distortion, cracks and
worn bearing cap bores.
(3) Replace the complete U-joint if any of the com
ponents are defective.
ASSEMBLY
(1) Pack the bearing caps 1/3 full of wheel bearing
lubricant. Apply extreme pressure (EP), lithium-base
lubricant to aid in installation.
(2) Position the spider in the yoke. Insert the seals
and bearings. Tap the bearing caps into the yoke
bores far enough to hold the spider in position.
(3) Place the socket (driver) against one bearing
SNAP CAP cap. Position the yoke with the socket wrench in a
RINGS vise.
J8902-15 (4) Compress the vise to force the bearing caps into
the yoke. Force the caps enough to install the retain
Fig. 7 Axle Shaft Outer U-Joint ing clips.
(2) Locate a socket that is larger in diameter than (5) Install the bearing cap retaining clips.
the bearing cap. Place the socket (receiver) against (6) Install the axle shaft, refer to Hub Bearing and
the yoke and around the perimeter of the bearing cap Axle Shaft installation.
to be removed. Locate a socket that is smaller in di
ameter than the bearing cap. Place the socket (driv VACUUM DISCONNECT 44/60 AXLE
er) against the opposite bearing cap. Position the
yoke with the sockets in a vise (Fig. 8). VACUUM CONTROL SYSTEM
The disconnect axle control system consists of;
LARGE- • Shift motor
DIAMETER • Indicator switch
SOCKET
WRENCH • Vacuum switch
• Vacuum harness (Fig. 9)
CHECK
VALVE
J8902-16
Fig. 8 Yoke Bearing Cap Removal
(3) Compress the vise jaws to force the bearing cap
into the larger socket (receiver).
(4) Release the vise jaws. Remove the sockets and
bearing cap that was partially forced out of the yoke. SHIFT-
MOTOR J9202-55
(5) Repeat the above procedure for the remaining
Fig. 9 Vacuum Control System
bearing cap.
(6) Remove the remaining bearing cap, bearings, Refer to Group 21 Transmissions for addi
seals and spider from the propeller shaft yoke. tional information.
2 • 26 FRONT SUSPENSION AND AXLE - BR
DISCONNECT AXLE/SHIFT MOTOR DIAGNOSIS
T W O - W H E E L DRIVE OPERATION D I A G N O S I S
FOUR-WHEEL DRIVE
INDICATOR LIGHT WILL
NOT G O OUT W H E N
TRANSFER CASE SELECTOR
IS MOVED FROM 4H TO
2H P O S I T I O N .
YES i
START E N G I N E DEPRESS BRAKE TEST COMPLETE

INSPECT INDICATOR PEDAL. PLACE TRANSFER
RAISE VEHICLE S O ALL SWITCH A N D W I R I N G O N CASE SELECTOR IN 2H POSITION
FOUR W H E E L S ARE SHIFT MOTOR H O U S I N G A N D T R A N S M I S S I O N IN
FREE TO ROTATE. FOR DAMAGE A N D DRIVE (AUTOMATIC) OR FIRST
SHORT-CIRCUIT. GEAR (MANUAL). EASE OFF FROM
REPAIR AS NECESSARY. BRAKE A N D LET W H E E L S ROTATE
SLOWLY.
FRONT DRIVE FRONT DRIVE

SHAFT DOES SHAFT ROTATES.
NOT ROTATE.
INSPECT TRANSFER
FOUR-WHEEL DRIVE CASE LINKAGE.
INDICATOR LIGHT
REMAINS O N .
CHECK TRANSFER
CASE. REPAIR
PLACE T R A N S M I S S I O N A S NECESSARY.
IN NEUTRAL. TEST FOR VACUUM
IN VACUUM H O S E
THAT CONNECTS TO
INBOARD SHIFT
DICONNECT THE MOTOR PORT.
SHIFT MOTOR VACUUM (VACUUM SHOULD BE
HOSES. B E T W E E N 10-20 I N . HG.)
1
VACUUM OK
N O VACUUM
OR L O W VACUUM.
~"T~
STOP E N G I N E
INSPECT INTAKE MANIFOLD

VACUUM SUPPLY H O S E C O N N E C T I O N ,
TRANSFER CASE VACUUM SWITCH CONNECT A VACUUM
C O N N E C T I O N , VACUUM RESERVOIR, PUMP TO THE INBOARD
A N D SHIFT SYSTEM VACUUM H O S E S SHIFT MOTOR PORT.
FOR PROPER C O N N E C T I O N , RESTRICTION, APPLY 15 I N . H G
AIR LEAKS, A N D DAMAGE. REPAIR OR REPLACE VACUUM A N D ROTATE
A S NECESSARY. RIGHT W H E E L .
FRONT AXLE FRONT AXLE

DISCONNECTS. DOES NOT
DISCONNECT.
INSPECT VACUUM
H O S E S FOR AIR LEAKS, KINKS, ETC.
REPAIR A S NECESSARY. REMOVE SHIFT MOTOR
H O U S I N G COVER. CONNECT
VACUUM PUMP TO
SHIFT MOTOR PORT. FRONT AXLE
REPLACE SHIFT MOTOR WILL NOT DISCONNECT.
IF ARMATURE DOES
NOT MOVE IN A N D OUT
FREELY.
REMOVE SHIFT MOTOR H O U S I N G
COVER. INSPECT SHIFT FORK,
COLLAR, A N D AXLE SHAFTS.
REPAIR OR REPLACE A S
J9002-95 NECESSARY.
B R FRONT SUSPENSION AND AXLE 2 - 27
DISCONNECT AXLE/SHIFT MOTOR DIAGNOSIS (CONT'D)

FOUR-WHEEL DRIVE OPERATION DIAGNOSIS
FOUR-WHEEL DRIVE INDICATOR

LIGHT DOES NOT LIGHT W H E N
TRANSFER CASE SELECTOR IN
4H OR 4L POSITION.
RAISE VEHICLE SO ALL FOUR

WHEELS ARE FREE TO ROTATE.
START ENGINE, DEPRESS BRAKE PEDAL.

PLACE TRANSFER CASE SELECTOR IN 4H
POSITION AND TRANSMISSION LEVER IN
DRIVE (AUTOMATIC) OR IN FIRST GEAR
(MANUAL) TO CONFIRM TRANSFER CASE
ENGAGEMENT IN 4H. LET W H E E L S
ROTATE SLOWLY.
FRONT DRIVE FRONT DRIVE

SHAFT DOES SHAFT TURNS.
NOT ROTATE.
INSPECT TRANSFER FRONT AXLE RECOMMENDATION:

CHECK VACUUM PLACE TRANSMISSION FRONT AXLE
CASE LINKAGE. CONNECTS. LEVER IN NEUTRAL DOES NOT
SHIFT SYSTEM
POSITION. CONNECT.
FOR PROPER
OPERATION.
CHECK TRANSFER FOUR-WHEEL DRIVE
CASE. REPAIR AS INDICATOR LIGHT
NECESSARY. DOES NOT LIGHT. REMOVE VACUUM HOSES
FROM AXLE SHIFT
MOTOR PORTS.
INSPECT FWD INDICATOR

SWITCH, W I R I N G , AND START E N G I N E . TEST FOR VACUUM
LAMP FOR DAMAGE. AT HOSE REMOVED FROM OUT
REPAIR AS NECESSARY. BOARD PORT O N SHIFT MOTOR,
SHOULD BE BETWEEN 10-20 IN HG.
N O VACUUM
OR LOW VACUUM.
STOP ENGINE
K VACUUM OK
CONNECT A VACUUM PUMP

INSPECT INTAKE MANIFOLD TO THE OUTBOARD
VACUUM SUPPLY HOSE CONNECTION, SHIFT MOTOR PORT.
TRANSFER CASE VACUUM SWITCH APPLY 15 INCHES HG. VACUUM
CONNECTION, VACUUM RESERVOIR, AND SHIFT AND ROTATE LEFT WHEEL.
SYSTEM VACUUM HOSES FOR PROPER CONNECTION,
RESTRICTION, LEAKS, AND DAMAGE.
REPAIR OR REPLACE AS NECESSARY.
FRONT AXLE FRONT AXLE

N O VACUUM CONNECTED. DOES NOT
CONNECT.
CHECK TRANSFER CASE

VACUUM SWITCH. REPLACE INSPECT VACUUM HOSES
OR REPAIR IF SWITCH FOR LEAKS, KINKS, ETC. REMOVE SHIFT MOTOR
PLUNGER IS DIFFICULT TO REPAIR AS NECESSARY. H O U S I N G COVER. CONNECT
MOVE OR BINDS. VACUUM PUMP TO
SHIFT MOTOR PORT.
REPLACE SHIFT MOTOR
IF ARMATURE DOES
NOT MOVE IN AND OUT
FREELY.
REMOVE SHIFT MOTOR H O U S I N G

COVER. INSPECT SHIFT FORK,
t
FRONT AXLE
COLLAR, AND AXLE SHAFTS.
WILL NOT CONNECT.
REPAIR OR REPLACE AS
NECESSARY.
J9002-96
SHIFT MOTOR — REMOVAL/DISASSEMBLY (3) Install the E-clips on the shift motor shaft and
(1) Disconnect the vacuum and wiring connector housing.
from the shift housing. (4) Install the shift motor housing gasket and
(2) Remove indicator switch. cover. Ensure the shift fork is correctly guided
(3) Remove the shift motor housing cover, gasket into the shift collar groove.
and shield from the housing (Fig. 10). (5) Install the shift motor housing shield and at
taching bolts. Tighten the bolts to 11 N-m (96 in. lbs.)
DISCONNECT VACUUM torque.
INDICATOR LAMP HOUSING SHIFT
SWITCH MOTOR
(6) Add 148 ml (5 ounces) of API grade GL 5 hy
poid gear lubricant to the shift motor housing. Add
lubricant through indicator switch mounting hole.
INTERMEDIATE (7) Install indicator switch, electrical connector
AXLE SHAFT
and vacuum harness.
INTERMEDIATE AXLE SHAFT—REMOVAL/
DISASSEMBLY
Service to the Disconnect axle seals and bearing re
quire the use of Tool Set 5041 (J34659) and Seal In
BEARING staller D-354.
SHIFT (1) Remove the vacuum motor housing. Refer to
SHIFT FORK SEAL
COLLAR
J9402-63 Shift Motor Removal in this section.
(3) Remove the outer axle shaft. Refer to Hub
Fig. 10 Shift Motor Housing Bearing and Axle Shaft in this section.
(4) Remove shift collar and intermediate axle
(4) Remove the E-clips from the shift motor hous
shaft.
ing and shaft. Remove shift motor and shift fork from
(5) Remove the inner axle shaft seal from the shift
the housing (Fig. 11).
motor housing with a long drift or punch. Be careful
INDICATOR not to damage housing.
SWITCH (6) Remove the intermediate axle shaft bearing
(Fig. 12).
SHIFT MOTOR LOCATION
HOUSING OPENING FOR OPEN-END
o o "oi BEARING
WRENCH
Li
DISCONNECT HOUSING
AND GASKET
SHIFT FORK VACUUM
PORTS
J9202-54
SPECIAL TOOL
5041-2
Fig. 11 Shift Motor Components SPECIAL TOOL
NUT
(5) Remove the O-ring seal from the shift motor D-354-2
Jf402-18
shaft.
(6) Clean and inspect all components. If any com Fig. 12 Bearing Removal Tool Installed
ponent is excessively worn or damaged, it should be
ASSEMBLY/INSTALLATION
replaced.
(1) Position the bearing on installation tool. Seat
ASSEMBLY/INSTALLATION the bearing in the housing bore (Fig. 13).
(1) Install a new O-ring seal on the shift motor (2) Clean the inside perimeter of the axle shaft
shaft. tube with fine crocus cloth.
(2) Insert the shift motor shaft through the hole in (3) Apply a light film of oil to the inside lip of the
new axle shaft seal.
the housing and shift fork. The shift fork offset
(4) Install the inner axle seal (Fig. 14) 44 axle (Fig.
should be toward the differential.
15) 60 axle.
(R FRONT SUSPENSION AND AXLE 2 - 29
, SHIFT MOTOR SHIFT MOTOR AXLE LOCATION

SPECIAL TOOL SEAL TU1E TOR OPEN-END
HOUSING OPINING HOUSING OPENING
5041-3 WRENCH
0
SPECIAL TOOL SPECIAL TOOL
M54-3 5041-2 SPECIAL TOOL
5041-60F SPECIAL TOOL
5041-3
BEARING
J9402-19 J9402-23
Fig. 13 intermediate Shaft Bearing installation Fig. 15 Inner axle seal installation 60 axle
The inner axle seal position is different on a (8) Insert the axle shaft into the tube. Engage the
44 then a 60 axle. Be sure to use the correct in splined-end of the shaft with the shift collar. Refer to
staller, if wrong installer is use axle will not Hub Bearing and Axle Shaft in this section.
seal. (9) Install the vacuum motor housing. Refer to
Shift Motor Installation in this section.
SHIFT MOTOR LOCATION
STEERING KNUCKLE AND BALL STUDS
Ball Stud service procedures below require removal
of the hub bearing and axle shaft. Removal and in
stallation of upper and lower ball studs requires Spe
cial Tools.
knuckle removal
(1) Remove hub bearing and axle shaft. Refer to
the Removal procedures in this Group.
(2) Remove tie-rod or drag link end from the steer
ing knuckle arm. Remove the ABS sensor wire and
5041-44 SPECIAL TOOL 5041-2 bracket from knuckle.
5041-3
(3) Remove the cotter pin from the upper ball stud
J9402-22
nut. Remove the upper and lower ball stud nuts.
(4) Strike the steering knuckle with a brass ham
Fig. 14 Inner axle seal installation 44 axle
mer to loosen. Remove knuckle from axle tube yokes.
(5) Insert the intermediate axle shaft into the dif
UPPER BALL STUD REPLACEMENT 44 AXLE
ferential side gear.
(1) Position tools as shown to remove ball stud
(6) Install the shift collar on the splined end of the
(Fig. 16).
intermediate axle shaft. (2) Position tools as shown to install ball stud (Fig.
(7) Lubricate the splined end of the intermediate 17).
axle shaft with multi-purpose lubricant.
LOWER BALL STUD REPLACEMENT 44 AXLE
CAUTION:Apply all-purpose lubricant to the axle (1) Position tools as shown to remove ball stud
shaft splines to prevent damage to the seal during (Fig. 18).
axle shaft installation. (2) Position tools as shown to install ball stud (Fig.
19).
Fig. 17 Upper Ball Stud Install Fig. 19 Lower Ball Stud Install
U P P E R BALL STUD REPLACEMENT 60 AXLE KNUCKLE

(1) Position tools as shown to remove ball stud
(Fig. 20).
SPECIAL TOOL
C-4212F
SPECIAL TOOL
6756
SPECIAL TOOL
6756
SPECIAL TOOL
6757
SPECIAL TOOL
6757
SPECIAL TOOL
KNUCKLE
C-4212F J9402-40
Fig. 22 Lower Ball Stud Remove

(2) Position tools as shown to install ball stud (Fig.
J9402-38 23).
KNUCKLE
Fig. 20 Upper Ball Stud Remove
(2) Position tools as shown to install ball stud (Fig.

21).
SPECIAL l O O l
SPECIAL TOOL
6759
SPECIAL TOOL
6758
SPECIAL TOOL
6760
KNUCKLE SPECIAL TOOL

C-4212F J9402-41
Fig. 23 Lower Ball Stud Install

KNUCKLE INSTALLATION MODEL 44
J9402-39 (1) Position the steering knuckle on the ball studs.
(2) Install and tighten lower ball stud nut to 108
Fig. 2f Upper Ball Stud Install N-m (80 ft. lbs.) torque. Advance nut to next slot to
LOWER BALL STUD REPLACEMENT 60 AXLE line up hole and install new cotter pin.
(1) Position tools as shown to remove ball stud (3) Install and tighten upper ball stud nut to 101
(Fig. 22). N-m (75 ft. lbs.) torque. Advance nut to next slot to
line up hole and install new cotter pin.
2 - 32 FRONT SUSPENSION AND AXLE B R
(4) Install the Hub Bearing and Axle Shaft. Refer

to the installation procedure.
(5) Install tie-rod or drag link end onto the steer
ing knuckle arm. Install the ABS sensor wire and
bracket to the knuckle, refer to Group 5, Brakes for
proper set-up.
KNUCKLE INSTALLATION MODEL BO
(1) Position the steering knuckle on the ball studs.
(2) Install and tighten lower ball stud nut to 47
N-m (35 ft. lbs.) torque. Do not install cotter pin
at this time.
(3) Install and tighten upper ball stud nut to 94
N-m (70 ft. lbs.) torque. Advance nut to next slot to
line up hole and install new cotter pin.
(4) Retorque lower ball stud nut to 190 - 217 N-m
(140 - 160 ft. lbs.) torque. Advance nut to next slot to Fig. 25 Spread Differential Housing
line up hole and install new cotter pin. stud. Load the indicator plunger against the opposite
(5) Install the Hub Bearing and Axle Shaft. Refer side of the housing (Fig. 25) and zero, the indicator.
to the installation procedure.
(6) Install tie-rod or drag link end onto the steer CAUTION: Do not spread over 0.38 mm (0.015 in.). If
ing knuckle arm. Install the ABS sensor wire and the housing is spread too much, it could be dis
torted or damaged.
bracket to the knuckle, refer to Group 5, Brakes for
proper set-up. (5) Separate the housing a maximum of 0.38 mm
(0.015 in.). Measure the distance with the dial indi
DIFFERENTIAL REiOWAL cator (Fig. 25).
To service the differential the axle assembly and (6) Remove the dial indicator.
axle shafts must be removed. Refer to the removal (7) Pry the differential case loose from the housing.
procedures in this Group. To prevent damage, pivot on housing with the end of
(1) Note the installation reference letters the pry bar against spreader (Fig. 26).
stamped on the bearing caps and housing ma
chined sealing surface (Fig. 24). DIFFERENTIAL PRY BAR
Fig. 24 Bearing Cap identification

(2) Remove the differential bearing caps.
(3) Position Spreader W-129-B with the tool dowel
pins seated in the locating holes (Fig. 25). Install the
holddown clamps and tighten the tool turnbuckle fin Fig. 26 Differential Removal
ger-tight. (8) Remove the case from housing. Mark or tag
(4) Install a pilot stud at the left side of the differ bearing cups indicating which side they were re
ential housing. Attach Dial Indicator to housing pilot moved. Remove spreader from housing.
BR ^ ^ FRONT SUSPENSION AND AXLE 2 - 33
AXLE SHAFT OIL SEAL

(1) Remove the axle shaft seal from the differential
housing with a long drift or punch. B e careful not
to damage housing.
(2) Clean the inside perimeter of the differential
housing with fine crocus cloth.
(3) Apply a light film of oil to the inside lip of the
new axle shaft seal.
(4) Install the inner axle seal (Fig. 27) 44 axle (Fig.
28) 60 axle.
DIFFERENTIAL POSITION
^ HOUSING FOR OPEN-END
Fig. 29 Differential Bearing Removal
5041-7 J9402-21
Fig. 27 Axle seal installation 44 axle
DIFFERENTIAL HOUSING POSITION
Fig. 30 Ring Gear Removal

SPECIAL TOOL (4) Remove the pinion gear mate shaft roll pin and
5041-7 shaft.
Jf402-20
(5) Rotate the differential side gears and remove
Fig. 28 Axle seal installation 60 axle the pinion mate gears and thrust washers (Fig. 31).
(7) Remove the differential side gears and thrust
DIFFERENTIAL DISASSEMBLY washers.
(1) Remove the bearings from the differential case (8) Remove the case from the vise.
with Bearing Splitter 1130, Bearing Splitter Bridge
938 and button. On 44 axle use Button C-293-3 on 60 PINION REMOVAL/DISASSEMBLY
axle use Button DD-914-42 (Fig. 29).
(2) Remove bearing shims from case hubs and (1) Remove the pinion yoke nut and washer. Use
mark them (with hub identity) for assembly refer yoke Holder C3281 and yoke Remover C-452 to re
ence. Record the thickness of the shims. move pinion yoke (Fig. 32).
(3) Clamp the differential case in a vise equipped (2) Drive out pinion gear from housing with raw
with soft jaws. Remove and discard the ring gear hide or plastic hammer (Fig. 33). Catch the pinion
bolts. Tap the ring gear with a rawhide or plastic with your hand to prevent it from falling and being
mallet and remove (Fig. 30). damaged.
THRUST RAWHIDE
WASHER
MATE'GEAR SIDE GEAR . J9203-61
Fig. 31 Pinion Mate Gear Removal Fig. 33 Remove Pinion Gear
C-452 J9102-31
Fig. 32 Pinion Yoke Removal

(3) Remove the pinion gear seal with a slide ham
mer or pry out with bar.
(4) Remove oil slinger, front bearing.
(5) Remove the front pinion bearing cup with Han
dle C-4171 and Remover D-147 for 44 axle. Use Han Fig. 34 Front Bearing Cup Removal
dle C-4171 and Remover D-158 for 60 axle (Fig. 34). CLEANING/INSPECTION
(6) Remove the rear bearing cup with Handle
Wash differential components with cleaning solvent
C-4171 and Remover D-148 for 44 axle. Use Handle
and dry with compressed air. Do not steam clean
C-4171 and Remover D-162 for 60 axle (Fig. 35).
the differential components.
(7) Remove the collapsible preload spacer (Fig. 36).
Wash bearings with solvent and towel dry, do not
(8) Remove the inner bearing from the pinion with
dry with compressed air. Cup and bearing must be
Bearing Splitter 1130 and Bearing Splitter Bridge
replaced as matched sets only.
938 (Fig. 37).
Clean the axle shaft tubes with a stiff wire brush
(9) Remove the oil slinger (select thickness-produc
or clean cloth. Clean oil channels in housing.
tion) from the pinion gear shaft. Record the thick
Inspect the components for;
ness of slinger.
J9302-23
Fig. 35 Rear Bearing Cup Removal
Fig. 37 Inner Bearing Removal
• Ring gear for damaged bolt threads. -Replaced as a

matched set only.
• Pinion yoke for cracks, worn splines, pitted areas,
and a rough/corroded seal contact surface. Repair or
replace as necessary.
• Preload shims for damage and distortion. Install
new shims if necessary.
DIFFERENTIAL ASSEMBLY
(1) Install the following components in the differ
ential case.
• Differential side gears and thrust washers
© Pinion gears and thrust washers
• Pinion gear mate shaft (align holes in shaft and
case)
• Pinion gear mate shaft roll pin
if replacement gears and thrust washers were
installed, it is not necessary to measure the
gear backlash. Correct fit is due to close ma
chining tolerances during manufacture.
(2) Invert the differential case and start two ring
Fig. 36 Collapsible Spacer
gear bolts. This will provide case-to-ring gear bolt
• Smooth appearance with no broken/dented sur hole alignment.
faces on the bearing rollers or the roller contact sur (3) Install new ring gear bolts and alternately
faces tighten to 95-122 N-m (70-90 ft. lbs.) torque for
• Bearing cups must not be distorted or cracked Model 44 axle. Model 60 axle tighten to 163-193 N-m
• Machined surfaces should be smooth and without (120-140 ft. lbs.) torque (Fig. 38).
any raised edges (4) Lubricate all differential components with a
• Raised metal on shoulders of cup bores should be light coat of grease or hypoid gear lubricant.
removed with a hand stone
• Wear and damage to pinion gear mate shaft, pin PINION GEAR DEPTH INFORMATION
ion gears, side gears and thrust washers. Replace as Ring and pinion gears are supplied as matched sets
a matched set only. only. The identifying numbers for the ring and pinion
• Ring and pinion gear for worn and chipped teeth gear are etched into the face of each gear (Fig. 39). A
2 - 36 FRONT SUSPENSION AND AXLE mm
TORQUE INNER PINION
WRENCH
SEARING
RING GEAR
BOLT
. rON END
CENTERLINE OF
RING GEAR
J9403-56
Fig. 40 Pinion Gear Standard Depth/Distance

Compensation for depth variance is achieved by a
selected thickness oil slinger (production) or shims
J9202-77
(service). The slinger is placed between the inner pin
ion bearing cone and gear head (Fig. 41). The shim
Fig. 38 Ring Gear Bolt Installation pack is placed under the inner (rear) bearing cup. To
plus (+) number, minus (-) number or zero (0) is change the pinion adjustment, shims are available in
etched into the face of the pinion gear. This number thicknesses of 0.003, 0.005, and 0.010 inch. If
is the amount (in thousandths of an inch) the depth equipped, the oil slinger or baffle must be mea
varies from the standard depth setting of a pinion sured and the thickness included with the total
shim pack.
etched with a (0). The standard setting from the cen
terline of the ring gear to the back face of the pinion HOUSING SHIM PACK
is; (SELECT THICKNESS)
SERVICE
• Model 44 axle: 109.5 mm (4.312 inches) Fig. 40. COLLAPSIBLE
• Model 60 axle: 127 mm (5.000 inches) Fig. 40. SPACER
The standard depth provides the best teeth contact REAR (INNER)
pattern. BEARING
CUP REAR (INNER)
DRIVE PINION
PRODUCTION GEAR DEPTH BEARING
VARIANCE CONE
NUMBERS
OIL SLINGER
(SELECT THICKNESS)
PRODUCTION
PINION
GEAR
HEAD J9302-32
GEAR MATCHING NUMBER
(SAME AS RING GEAR NUMBER) J9003-100
Fig. 41 Shim and Slinger Location
Fig. 39 Pinion Gear ID Numbers
If a new gear set is being installed, note the
THE BUTTON END ON THE PINION GEAR number etched into both pinion gears. Add or
HEAD IS NO LONGER A MACHINED-TO-SPECIFI- subtract the thickness of original depth shims
CATIONS SURFACE. DO NOT USE THIS SUR to compensate for the difference in depth vari
FACE FOR PINION DEPTH SET-UP OR ances. Refer to the Depth Variance charts.
CHECKING (Fig. 40).
FRONT SUSPENSION AND AXLE 2 - 37
PINION GEAR DEPTH VARIANCE
Original Pinion Replacement Pinion Gear Depth Variance

Gear Depth
Variance _4 -3 -2 -1 § + 1" +2 • +3 +4
+ 0.008 + 0.007 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0
+3 + 0.007 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0 -0.001
+2 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0 -0.001 -0.002
+1 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0 -0.001 -0.002 -0.003
§ + 0.004 + 0.003 + 0.002 + 0.001 0 -0.001 -0.002 -0.003 -0.004
-1 + 0.003 + 0.002 + 0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005
-2 + 0.002 + 0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006
-3 + 0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007
-4 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007 -0.008
J8902-46
Note where Old and New Pinion Marking columns

intersect. Intersecting figure represents plus or mi
nus amount needed.
For example, if old pinion is plus (+) 1 and the new
pinion is minus (-) 3, intersecting figure is (+)0.004
inch (0.10mm). Add this amount to the original shim.
Or if the old pinion is (-) 3 and the new pinion is (-)
2, intersecting figure is (-)O.OOl inch (0.025mm). Sub
tract this amount from original shim. Refer to the
Pinion Gear Depth Variance Chart.
DIFFERENTIAL AND PINION MEASUREMENT
DIFFERENTIAL ZERO END PLAY

MEASUREMENT
(1) Place Master Differential Bearing D-345 for 44
axle or D-343 for 60 axle on the case hubs (Fig. 42).
(2) Install a pilot stud at the right side of housing.
Attach Dial Indicator to the pilot stud. Load indica
tor plunger against the back of trie ring gear (Fig.
J9402-64
43).
(3) Insert a small pry bar between the bearing cap
Fig. 42 Master Bearing Tools On Hubs
and left side of differential case. Pry the case as far
as possible to right side (Fig. 43). Zero the dial indi PINION GEAR DEPTH MEASUREMENT
cator pointer. Pinion gear depth measurement is necessary
(4) Pry the case to left side and record the travel when;
distance. • Axle housing or differential case is replaced
The measurement above is the shim thickness • Pinion select shim pack is unknown
necessary for case zero end-play. The total • Ring and pinion gears are replaced
thickness will be determined during the ring Measurements are done with pinion cups and pin
gear backlash adjustment. ion bearings installed in housing. Take measure-
(5) Remove indicator and pilot stud.
Fig. 45 Pinion Height Block

axle sizes. Pick correct size step for axle being
serviced.
Fig. 43 Differential Case End Play Measurement

merits with Pinion Gauge Set 6730. Use Pinion Block
from gauge set 6734 for 44 axle or 6736 for 60 axle
(Fig. 44).
DIAL INDICATOR
Fig. 46 Gauge Tools In Housing

(3) Firmly place Scooter Block and Dial Indicator
on pinion height block tool and zero the dial indicator
pointer.
(4) Slide the Scooter Block across the arbor while
observing indicator (Fig. 47). Eecord the longest
travel distance, whether inward (-) or outward (+),
indicated by the pointer.
ARBOR DISC Take the plunger travel indicated, plus or mi
nus the variance etched in the gear. This will
J9403-45 be the required thickness for the depth shims.
(5) Measure the thickness of each depth shim with
Fig. 44 Pinion Gear Depth Gauge Tools
a micrometer. Combine the shims necessary for total
(1) Assemble Pinion Gauge Set, Pinion Block and required shim pack thickness. Include oil slinger
pinion bearings. Install assembly into differential or baffle thickness with the total shim pack
pinion gear bore and hand tighten cone (Fig. 45). thickness.
(2) Place Arbor Disc 6732 on Arbor D-115-3 and po (6) Remove the measurement tools from the differ
sition in the bearing cradles (Fig. 46). Install differ ential housing.
ential bearing caps on Arbor Discs and tighten caps
snug only.
Arbor Discs have different steps to fit other
INSTALLER HANDLE
Fig. 47 Pinion Gear Depth Measurement Fig. 49 Pinion Front Bearing Cup Installation
PINION GEAR ASSEMBLY/INSTALLATION
(1) Place the needed shim pack thickness in the
pinion gear rear bearing bore (service only). Install
bearing cup with Driver Handle C-4171 and Installer
D-145 for 44 axle or Installer D-lll for 60 axle (Fig.
48). Ensure cup is correctly seated.
INSTALLER
Fig. 50 Rear Bearing Installation

(4) Install a new collapsible preload spacer on pin
ion shaft. (Fig. 51).
(5) Install pinion front bearing and oil slinger. Ap
HANDLE J9402-66 ply a light coating of gear lubricant on the lip of pin
ion seal. Install seal with Handle C-4171 and
Fig. 48 Pinion Rear Bearing Cup Installation Installer D-163 for 44/60 axle.
(6) Install pinion gear into differential housing.
(2) Install pinion front bearing cup with Handle
(7) Install yoke with Holder 6719 and Installer
C-4171 and Installer D-144 for 44 axle or Installer
W-162D for 44 axle. Installer C-3716A for 60 axle
C-4203 for 60 axle (Fig. 49). Ensure cup is correctly
(Fig. 52).
seated.
(8) Install the yoke washer AND A NEW NUT on
(3) If used, place the oil slinger on the pinion gear.
the pinion gear. Tighten the nut to;
Install rear (inner) bearing on pinion gear with In
• Model 44: 258 N-m (190 ft. lbs.)
staller W-262 for 44 axle or Installer C-3095A for 60
axle (Fig. 50). Use press and installer for this opera • Model 60: 291 N-m (215 ft. lbs.)
tion.
(9) Use Holder 6719 to retain the yoke (Fig. 53).

Slowly tighten the nut in small increments until the
rotating torque is achieved. Measure the preload
torque frequently to avoid over-tightening the
nut.
Fig. 51 Collapsible Preload Spacer
YOKE
Fig. 53 Tightening Pinion Nut

(10) Check bearing preload torque with an inch
pound torque wrench (Fig. 54). The torque necessary
to rotate the pinion gear should be;
• Original Bearings: 1 to 3 N-m (10 to 20 in. lbs.).
• New Bearings: 2.26 to 4.52 N-m (20 to 40 in. lbs.).
DIFFERENTIAL SHIM PACI MEASUREMENT AND

ADJUSTMENT
(1) Place Master Differential Bearing D-345 for 44
axle or D-343 for 60 axle on the case hubs.
(2) Place Differential assembly in the housing. As
semble Differential bearing caps.
(3) Install a pilot stud at the left side of housing.
Attach Dial Indicator to housing. Load the indicator
J9402-61 plunger against the back of the ring gear (Fig. 55).
Ensure ring and pinion gear teeth are tightly
Fig. 52 Pinion Yoke Installation meshed. Zero the indicator.
CAUTION: Never loosen pinion gear nut to decrease (4) Insert a small pry bar between the bearing cap
pinion gear bearing preload torque and never ex and left side of differential case. Pry the case as far
ceed specified preload torque. If preload torque is as possible to right side. Zero the dial indicator
exceeded a new collapsible spacer must be in pointer.
stalled. The torque sequence will have to be re (5) Repeat the measurement several times to check
peated. consistency. Record the travel distance.
The measurement above shows shim thick
The specified preload torque should not exceed; ness necessary to eliminate ring gear backlash.
• Model 44: 393 N-m (290 ft. lbs.) Subtract this thickness from case zero end-play
• Model 60: 426 N-m (315 ft. lbs.)
For Example:
Indicator Reading LESS PINION 0.085 in. total
Indicator Reading WITH PINION 0.055 in. total .
BALANCE OF SHIM PACK 0.030 in. total—,
Place BALANCE of shims at opposite

side of ring gear
ADD an additional 0.015 in. shim to opposite side

of ring gear for bearing preload
Ring Gear Side (Flange Side) 0.055 i n . ^
Opposite Side 0.030 i n . - *
Opposite Side Preload 0.015 in.
J9303-10 Total Opposite Side 0.045 in. J9302-65
Fig. 54 Check Pinion Gear Torque Fig. 56 Shim Pack Calculations
PRY ing Installer C-3716A for 44 axle. Use Bearing

BAR Installer C-4190 for 60 axle.
(10) Position the remaining zero end-play shims on
DIAL hub at opposite side of case. Include an additional
INDICATOR
TOOLC-3339
0.015 in. (0.38 mm) thick shim on this hub. This will
provide the required differential bearing preload.
(11) Install bearing on the hub with Driver Handle
C-4171 and Bearing Installer C-3716A for 44 axle.
Use Bearing Installer C-4190 for 60 axle.
(12) Match each bearing cup with bearing (origi
nal). Install the cups on the bearings.
DIFFERENTIAL INSTALLATION
(1) Position Spreader W-129-B with the tool dowel
holddown clamps and tighten the tool turnbuckle fin
ger-tight.
(2) Install a pilot stud at the left side of the differ
ential housing. Attach Dial Indicator to housing pilot
stud. Load the indicator plunger against the opposite
IJ9003-99 _ side of the housing and zero the indicator.
Fig. 55 Shim Pack Measurement CAUTION: Do not spread over 0.38 mm (0.015 in). If
shim thickness (Fig. 56). The shims must be the housing is over-separated, it could be distorted
placed at the ring gear side between the case or damaged.
and bearing.
(6) Remove indicator and pilot stud. (3) Separate the housing enough to install the case
(7) Remove the differential case from housing. in the housing. Measure the distance with the dial
(8) Remove the master bearing tools from the dif indicator (Fig. 57).
ferential case hubs. (4) Remove the dial indicator.
(9) Position the backlash shims (with determined (5) Install case in the housing. Tap the differential
thickness) on case hub (ring gear side). Install bear case to ensure the bearings are fully seated. Remove
ing on the hub with Driver Handle C-4171 and Bear- the spreader.
SPECIAL TOOL | FOR MORE BACKLASH •—
DECREASE SHIM INCREASE SHIM
Fig. 57 Spread Differential Housing

(6) Install the bearing caps at their original loca
tions. Tighten the bearing cap bolts to 108 N-m (80
ft. lbs.) torque. • ^ — — FOR LESS BACKLASH — — — 1
J9302-28
BACKLASH AND CONTACT PATTERN ANALYSIS Fig. 59 Backlash Shim Adjustment
(1) Rotate assembly several revolutions to seat
bearings. Measure backlash at three equally spaced The ring gear teeth contact patterns will show if
locations around the ring gear with a dial indicator the pinion gear depth shim(s) have the correct thick
(Fig. 58). ness. It will also show if the ring gear backlash has
been adjusted correctly. The backlash must be main
tained within the specified limits until the correct
tooth contact patterns are obtained.
(2) Apply a thin coat of hydrated ferric oxide to
the drive and coast side of the ring gear.
(3) Rotate the ring gear several revolutions in both
directions while a load is being applied. Insert a pry
bar between the differential housing and the case
flange. This action will produce distinct contact pat
terns on both the drive side and coast side of the ring
gear teeth.
(4) Note patterns in compound. Refer to (Fig. 60)
for interpretation of contact patterns and adjust ac
cordingly.
Fig. 58 Ring Gear Backlash Measurement

The ring gear backlash must be within 0.005 -
0.008 inch (0.12 - 0.20 mm). It cannot vary more
than 0.002 inch (0.05 mm) between the points
checked.
If backlash must be adjusted, transfer shims from
one side of carrier to the other side. Adjust the back
lash accordingly (Fig. 59). DO NOT INCEEASE
THE TOTAL SHIM PACK THICKNESS, EXCES
SIVE BEARING PRELOAD AND DAMAGE MAY
OCCUR.
If the mesh and backlash steps have been followed
in the procedures above, good gear teeth contact pat
terns should exist.
DRIVE SIDE COAST SIDE

OF RING OF RING
GEAR TEETH GEAR TEETH
DESIRABLE CONTACT PATTERN.

PATTERN SHOULD BE CENTERED
O N THE DRIVE SIDE OF T O O T H .
H E E ^ ^ ^ ^ ^ ^ ^ T O E T O E ^ ^ ^ ^ ^ ^ ^ HEEL
PATTERN SHOULD BE CENTERED O N
THE COAST SIDE OF T O O T H ,
BUT MAY BE SLIGHTLY TOWARD
THE TOE. THERE SHOULD ALWAYS
BE'SOME CLEARANCE BETWEEN
CONTACT PATTERN A N D TOP OF
THE T O O T H .
RING GEAR BACKLASH CORRECT.

THINNER PINION GEAR DEPTH
SHIM REQUIRED.

THICKER PINION GEAR DEPTH
SHIM REQUIRED.
PINION GEAR DEPTH SHIM

CORRECT. DECREASE RING
GEAR BACKLASH.

CORRECT. INCREASE RING
Ha GEAR BACKLASH.
J9003-24
Fig. 60 Gear Tooth Contact Patterns

FINAL ASSEMBLY SEALING CONTOUR OF BEAD

(1) Install the axle shafts. Refer to Axle Shaft In
stallation in this Group.
(2) Scrape the residual sealant from the housing
and cover mating surfaces. Clean the mating surfaces
with mineral spirits. Apply a bead of MOPAR® Sili
cone Rubber Sealant on the housing cover (Fig. 61).
Allow the sealant to cure for a few minutes.
Install the housing cover within 5 minutes af
ter applying the sealant. If not installed the
sealant must be removed and another bead ap
plied.
(3) Install the cover on the differential with the at
taching bolts. Install the identification tag. Tighten
the cover bolts to;
• Model 44: 41 N-m (30 ft. lbs.) torque.
* Model 60: 47 N-m (35 ft. lbs.) torque.
CAUTION: Overfilling the differential can result in
lubricant foaming and overheating.
(4) Refill the differential housing with the specified Fig. 61 Typical Housing Cover With Sealant
quantity of MOPAR® Hypoid Gear Lubricant.
(5) Install the fill hole plug and tighten to 34 N-m
(25 ft. lbs.) torque.
AXLE SPECIFICATIONS
MODEL 44 FRONT AXLE MODEL I I FRONT AXLE

Axle Type Hypoid Axle Type ............. ...Hypoid
Lubricant .....Thermal Stable SAE 80W-90 Lubricant Thermal Stable SAE 80W-90
Lube Capacity 2.28 L (4.8 pts.) Lube Capacity... ...3.61 L (122 oz.)
Axle Ratio... ...3.54 3.55 3.92 4.09 Axle Ratio 3.54 4.10
Ring Gear Diameter 215.9 mm (8.50 in.) Ring Gear Diameter 247.6 mm (9.75 in.)
Pinion Standard Setting 109.5 mm (4.312 in.) Pinion Standard Setting 127 mm (5.000 in.)
Pinion Bearing Preload Pinion Bearing Preload
Original Bearing 1-2 N-m (10-20 in. lbs.) Original Bearing ..1-2 N-m (10-20 in. lbs.)
New Bearing 2.3-4.5 N-m (20-40 in. lbs.) New Bearing .2.3-4.5 N-m (20-40 in. lbs.)
LINK/COIL FRONT SUSPENSION COMPONENTS MODEL 44 AXLE

DESCRIPTION TORQUE DESCRIPTION TORQUE
Shock Absorber Fill Hole Plug 34 N-m (25 ft. lbs.)
Upper Nut 41 N-m (30 ft. lbs.) Diff. Cover Bolt 42 N-m (31 ft. lbs.)
Lower Bolt 135 N-m (100 ft. lbs.) Bearing Cap Bolt 108 N-m (80 ft. lbs.)
Bracket 75 N-m (55 ft. lbs.) Pinion Nut 258-393 N-m (190-290 ft.lbs.)
Suspension Arm Upper Ring Gear Bolt 95-122 N-m (70-90 ft. lbs.)
Axle Nut 121 N-m (89 ft. lbs.) Shift Motor Bolt 11 N-m (8 ft. lbs.)
Frame Nut 84 N-m (62 ft. lbs.) Axle Nut 237 N-m (175 ft. lbs.)
Suspension Arm Lower Wheel Brg. Bolt 170 N-m (125 ft. lbs.)
Axle Nut 149 N-m (110 ft. lbs.) Lower Ball Stud 108 N-m (80 ft. lbs.)
Frame Nut 119 N-m (88 ft. lbs.) Upper Ball Stud 101 N-m (75 ft. lbs.)
Stabilizer Bar
RWAL/ABS Sensor Bolt 11 N-m (96 in. lbs.)
Clamp Bolt 47 N-m (35 ft. lbs.)
Link Upper Nut 37 N-m (27 ft. lbs.)
MODEL 60 AXLE
Link Lower Nut 118 N-m (87 ft. lbs.)
Track Bar DESCRIPTION TORQUE
Ball Stud Nut 84 N-m (62 ft. lbs.)
Axle Bracket Bolt 176 N-m (130 ft. lbs.) Fill Hole Plug 34 N-m (25 ft. lbs.)
Diff. Cover Bolt 47 N-m (35 ft. lbs.)
IFS FRONT SUSPENSION COMPONENTS Bearing Cap Bolt 108 N-m (80 ft. lbs.)
Pinion Nut 292-427 N-m (215-315 ft.lbs.)
DESCRIPTION TORQUE Ring Gear Bolt 95-122 N-m (70-90 ft. lbs.)
Shock Absorber Shift Motor Bolt 11 N-m (8 ft. lbs.)
Upper Nut 41 N-m (30 ft. lbs.) Axle Nut 237 N-m (175 ft. lbs.)
Lower Bolt 135 N-m (100 ft. lbs.) Wheel Brg. Bolt 170 N-m (125 ft. lbs.)
Lower Suspension Arm Lower Ball Stud 108 N-m (80 ft. lbs.)
Bolts 203 N-m (150 ft. lbs.) Upper Ball Stud 101 N-m (75 ft. lbs.)
Ball Stud Nut 75 N-m (55 ft. lbs.) RWAL/ABS Sensor Bolt 11 N-m (96 in. lbs.)
Upper Suspension Arm
Bolts 244 N-m (180 ft. lbs.)
Ball Stud Nut 75 N-m (55 ft. lbs.)
Stabilizer Bar
Clamp Bolt 47 N-m (35 ft. lbs.)
Link Nuts 34 N-m (25 ft. lbs.)
E3R — — — REAR SUSPENSION AND AXLE 3 -1
REAR SUSPENSION AND AXLE
CONTENTS
page page
9 1/4 AXLE SERVICE PROCEDURES 10 REAR SUSPENSION—2WD and 4WD

AXLE NOISE/VIBRATION DIAGNOSIS 6 VEHICLES 4
AXLE SPECIFICATIONS 51 TORQUE SPECIFICATIONS 52
GENERAL INFORMATION 1 TRAC-LOK/POWER-LOK DIFFERENTIAL 43
MODEL 60, 70 and 80 AXLE SERVICE
PROCEDURES 24
GENERAL INFORMATION
SUSPENSION spection and service without removing the axle from

Rear suspensions are comprised of (Fig. the vehicle.
• Drive axle
l); The axle are equipped with a remote vent fitting.
• Leaf springs A stamped metal axle gear ratio identification tag
• Dual-action shock absorbers is attached to the housing cover.
• Jounce bumpers The rear wheel anti-lock (RWAL) or four wheel an
ti-lock (ABS) brake speed sensor is mounted on top of
JOUNCE EYE BOLT
EYE BOLT BUMPER the differential housing. A seal is located between the
sensor and the wire harness connector. The seal
must be in-place when the wire connector is
connected to the sensor. The RWAL/ABS brake ex
citer ring is press-fitted onto the differential case
against the flange.
A limited-slip differential is available for all rear
axles. The Model 70 uses a Power-Lok™ differential
with a two-piece case. The Model 60, 80 and 9 1/4
use a Trac-Lok™ differential. The Trac-Lok differen
SHACKLE
tial uses a one-piece case for the 9 1/4 and Model 60
SPRING axles and a two-piece case for the Model 80.
CLAMP
SWING
CLAMP PLATE [IDENTIFICATION
Jf403-55
The axle differential covers can be used for identi
Fig. 1 Rear Suspension (Typical) fication (Fig. 2, 3 and 4).
Model 60 70 and 80 axles have the gear ratio listed
The Ram Truck is equipped with leaf-type rear on a tag. The tag is attached to the left side of the
springs. The springs have a rubber bushing pressed housing cover (Fig. 3, 4). Build date identification
into their main leaf front and rear eye. Model 1500, codes on axles are stamped on the axle shaft tube
2500 and 3500 vehicle have two stage leaf spring. cover side.
The 3500 cab-chassis vehicles have a single stage
spring with a auxiliary spring. The spring assemblies STANDARD DIFFERENTIAL OPERATION
are serviced as a complete unit. The differential gear system divides the torque be
tween the axle shafts. It allows the axle shafts to ro
AXLES tate at different speeds when turning corners.
The 9 1/4-Inch and Model 60, 70 and 80 axle hous Each differential side gear is splined to an axle
ings consist of a cast iron center section. They also shaft. The pinion gears are mounted on a pinion
have two steel axle shaft tubes that are pressed into mate shaft and are free to rotate on the shaft. The
and welded to the differential housing. pinion gear is fitted in a bore in the differential case
The removable steel cover provides a means for in and is positioned at a right angle to the axle shafts.
3 -2 REAR SUSPENSION AND AXLE ^ ^ ^ — — — BR
IDENTIFICATION DIFFERENTIAL
TAG COVER FILL PLUG
DIFFERENTIAL
COVER
PUSH-IN
FILL PLUG
IDENTIFICATION
J9203-32 TAG J9403-54
Fig. 2 Differential Cover—9 1/4 inch Axle Fig. 4 Model 70 and 80 Differential Cover
DIFFERENTIAL divided and distributed equally between the two side

COVER gears. As a result, the pinion gears revolve with the
FILL PLUG pinion mate shaft but do not rotate around it (Fig. 5).
When turning corners, the outside wheel must
IN STRAIGHT AHEAD DRIVING
EACH WHEEL ROTATES AT 100%
OF CASE SPEED
PINION GEARS ROTATE

WITH CASE J9303-13
IDENTIFICATION
TAG J9202-23
Fig. 5 Differential Operation—Straight-Ahead Driving
Fig. 3 Model 60 Differential Cover travel a greater distance than the inside wheel in or
In operation, power flow occurs as follows: der to complete a turn. The difference must be com
• Pinion gear rotates the ring gear pensated for, to prevent the tires from scuffing and
• Ring gear (bolted to the differential case) rotates skidding through turns. To accomplish this, the dif
the case ferential allows the axle shafts to turn at unequal
• Differential pinion gears (mounted on the pinion speeds (Fig. 6). In this instance, the input torque ap
mate shaft in the case) rotate the side gears plied to the pinion gears is not divided equally. The
• Side gears (splined to the axle shafts) rotate the pinion gears now rotate around the pinion mate shaft
shafts in opposite directions. This allows the side gear and
During straight-ahead driving, the differential pin axle shaft attached to the outside wheel to rotate at
ion gears do not rotate on the pinion mate shaft. This a faster speed.
occurs because input torque applied to the gears is
BR REAR SUSPENSION AND AXLE 3- 3
LUBRICANTS
j AXLE <cf j
Multi-purpose, hypoid gear ' lubricant should' be
OUTER WHEEL 100% DIFFERENTIAL INNER WHEEL
110% CASE SPEED CASE SPEED 90% CASE SPEED used for rear axles with standard differential. The lu
_/ / bricant should have a API GL 5 quality specifica
tions.
The lubricant recommended for Track-Lok and
Power-Lok differential is API grade GL 5. Friction
modifier must also be added to the lubricant.
Refer to Group 0, Lubrication and Maintenance for
additional information.
If the rear axle is submerged in water, the lu
bricant must be replaced immediately. Avoid
axle failure resulting from water contamination
of the lubricant.
Fig. 6 Differential Operation—On Turns

3 -4 REAR SUSPENSION AND AXLE BR
R E A R SUSPENSION—2WD and 4WD VEHICLES
SPRING AND SHOCK DIAGNOSIS (2) Install bolts through the brackets and shock.
A squeak noise from shock absorber or spring bush Install flag nut on top bolt and nut on lower bolt.
ings can be caused if movement between rubber (5) Tighten upper bolt to 95 N-m (70 ft. lbs.)
bushings and metal occurs. This noise can usually be torque. Tighten lower bolt to 136 N-m (100 ft. lbs.)
stopped by tightening the attaching nuts. If the noise torque.
persists, inspect for damaged or worn bushings and (6) Remove the support and lower vehicle.
attaching components.
SPFtiNGS
The shock absorber bushings do not require any
type of lubrication. Do not lubricate the bushings to REMOVAL
reduce bushing noise. Grease or mineral oil-base lu (1) Raise vehicle and support axle to remove all
bricants will deteriorate the bushing rubber. weight from springs.
The shock absorbers are not refillable or adjust (2) Remove the nuts and spring clamp bolts that
able. If a malfunction occurs, the shock absorber attach the spring to the axle (Fig. 1, 2, 3,).
must be replaced. To test a shock absorber, hold it in (3) Remove the nuts and bolts from the spring
an upright position and force the piston into and out front and rear shackle eyes. Note:To remove front
of the cylinder four or five times. The action through eye bolt on left side spring, fuel tank must be
out each stroke should be smooth and even. removed. Refer to Group 14 for fuel tank proce
The spring eye and shock absorber bushings do not dure.
require any type of lubrication. Do not attempt to (4) Remove spring from vehicle.
stop spring bushing noise by lubricating them. (5) Remove shackle from spring.
Grease and mineral oil-base lubricants will deterio
rate the bushing rubber.
If the vehicle is used for severe off-road operation,
the springs should be examined periodically. Check
for broken or shifted leafs, loose missing clips and
broken center spring bolts.
VEHICLE LOADING AND WEIGHT DISTRIBUTION
A vehicle should always be loaded so the vehicle
weight center-line is located immediately forward of
the rear axle. Correct vehicle loading provides proper
front tire-to-road contact. This results in maximum
vehicle handling stability and safety. Refer to Spring
and Shock Absorber Diagnosis chart for further infor
mation.
Incorrect weight distribution should be con
sidered as a possible cause for erratic steering, Fig. 1 Rear Spring—4X2
spring failure or tire wear.
INSTALLATION
SHOCK ABSORBER (1) Install shackle on rear spring eye and install
The shock absorbers are mounted with the right bolt and nut.
shock mounted forward of the axle and left shock (2) Position spring on axle shaft tube so spring
mounted rearward. - center bolt is inserted into the locating hole in the
axle tube spring pad or spacer.
REMOVAL (3) Align spring front eye with bolt hole in the
(1) Raise vehicle and support axle. front bracket. Install the eye pivot bolt and nut.
(2) Remove the bolt and flag nut from the frame (4) Align shackle eye with bolt hole in rear
crossmember bracket. bracket. Install bolt and nut.
(3) Remove the bolt and nut from the axle bracket. (5) Tighten the spring front and rear eye pivot bolt
(4) Remove the rear shock absorber from the vehi snug do not torque.
cle. (6) Install spring clamp bolts and the retaining
nuts (Figs. 1, 2, 3, ).
INSTALLATION
(1) Position shock absorber in brackets.
BR REAR SUSPENSION AND AILE 3- 5
(7) Align the auxiliary spring with the primary

spring if equipped. Tighten the nuts until they force
the plate flush against the axle tube.
(8) Remove the supports and lower the vehicle so
that the weight is being supported by the tires.
(9) On 6,010 to 10,500 GVW vehicles, tighten the
spring clamp retaining nuts to 149 N-m (110ft.lbs.)
torque. On 11,000 GVW cab-chassis vehicles tighten
nuts to 163 N-m (120 ft. lbs.) torque.
(10) On 6,010 to 7,500 GVW vehicles, tighten
spring front and rear eye pivot bolt nuts and shackle
eye to 136 N-m (100 ft. lbs.) torque. On 8,800 to
11,000 GVW vehicles, tighten nuts to 190 N-m (140
ft. lbs.) torque.
1-61
Fig. 2 Rear Spring—4X4
Fig. 3 Rear Spring—Cab-Chassis 11000 GVW

AXLE HOISE/VIBRATION DIAGNOSIS
INDEX
page page
Driveline Snap 7 Low Speed Knock 7

Gear and Bearing Noise 6 Rear Axle Alignment 7
General Information 6 Vibration 7
Limited Slip Differential 7
GENERAL INFORMATION GEAft AND BEARING NOISE

Axle bearing problem conditions are usually caused
GEAR NOISE
by:
Axle gear noise can be caused by insufficient lubri
• Insufficient or incorrect lubricant
cant. Incorrect backlash, tooth contact, or worn/dam
• Foreign matter/water contamination aged gears can cause noise.
• Incorrect bearing preload torque adjustment Gear noise usually happens at a specific speed
When serviced, the bearings must be cleaned thor range. The range is 30 to 40 mph, or above 50 mph.
oughly. They should be dried with lint-free shop tow The noise can also occur during a specific type of
els. Never spin bearings with compressed air. driving condition. These conditions are acceleration,
This will overheat them and brinell the bearing deceleration, coast, or constant load.
surfaces. This will result in noisy operation af When road testing, accelerate the vehicle to the
ter repair. speed range where the noise is the greatest. Shift
Axle gear problem conditions are usually the result out-of-gear and coast through the peak-noise range.
of: If the noise stops or changes greatly, check for insuf
• Insufficient lubrication ficient lubricant. Incorrect ring gear backlash, or
• Incorrect or contaminated lubricant gear damage can cause noise changes.
• Overloading (excessive engine torque) Differential side and pinion gears can be checked
© Incorrect clearance or backlash adjustment by turning the vehicle. They usually do not cause
Insufficient lubrication is usually the result of a noise in straight-ahead driving. These gears are
housing cover leak. It can also be from worn axle loaded during vehicle turns. If noise does occur dur
shaft or pinion gear seals. Check for cracks or porous ing vehicle turns, the side or pinion gears could be
areas in the housing or tubes. worn or damaged. A worn pinion gear mate shaft can
Using the wrong lubricant or over filling will cause also cause a snapping or a knocking noise.
overheating and gear failure. Gear tooth cracking
BEARING NOISE
and bearing spalling are indicators of this.
Axle component breakage is most often the result The axle shaft, differential and pinion gear bear
of: ings can all produce noise when worn or damaged.
Bearing noise can be either a whining, or a growling
• Severe overloading
sound.
• Insufficient lubricant
Pinion gear bearings have a constant-pitch noise.
• Incorrect lubricant This noise changes only with vehicle speed. Pinion
• Improperly tightened components bearing noise will be higher because it rotates at a
Common causes of overloading is from full-throttle faster rate. Drive the vehicle and load the differen
acceleration. Overloading happens when towing tial. If bearing noise occurs the pinion rear bearing is
heavier-than-recommended loads. Component break the source of the noise. If the bearing noise is heard
age can occur when the wheels are spun excessively. during a coast, front bearing is the source.
Insufficient or incorrect lubricants contribute to Worn, damaged differential bearings usually pro
breakage through overheating. Loose differential duce a low pitch noise. Differential bearing noise is
components can also cause breakage. similar to pinion bearing. The pitch of differential
Incorrect bearing preload or gear backlash will not bearing noise is also constant and varies only with
result in component breakage. Mis-adjustment will vehicle speed.
produce enough noise to cause service repair before a Axle shaft bearings produce noise and vibration
failure occurs. If a mis-adjustment condition is not when worn or damaged. The noise generally changes
corrected, component failure can result. when the bearings are loaded. Road test the vehicle.
Turn the vehicle sharply to the left and to the right.
This will load the bearings' and change the noise (2) Attach a one-inch long piece of masking tape at
level. Where axle bearing damage is slight, the noise the center of each tire tread for use as reference
is usually not noticeable at speeds above 80 mph. marks.
(3) Rotate the rear wheels until both reference
LOW SPEED KNOCK marks face the front of the vehicle. Measure the dis
Low speed knock is generally caused by a worn U- tance between the outside edges of the two pieces of
joint or by worn side-gear thrust washers. A worn tape. Record this measurement as the front of tire
pinion gear shaft bore will also cause low speed (FTR) measurement.
knock. (4) Rotate the rear wheels until both reference
marks face the rear of the vehicle. Measure the dis
WiBRAIiON tance between the outside edges of the two pieces of
Vibration at the rear of the vehicle is usually tape. Record this measurement as the rear of tire
caused by a: (RTR) measurement.
© Damaged drive shaft (5) Subtract the (RTR) measurement from the
© Missing drive shaft balance weight (FTR) measurement to obtain the amount of wheel
3 Worn, out-of-balance wheels toe. The acceptable rear wheel toe-in position is 1/16
© Loose wheel lug nuts inch (1.6 mm) to 3/16 inch (4.8 mm) toe-out.
© Worn U-joint
® Loose spring clamp bolts (6) Rotate the rear wheels until the reference
^ Loose/broken springs marks are facing downward. Measure the distance
* Damaged axle shaft bearings between the outside edges of the two pieces of tape.
© Loose pinion gear nut Record this measurement as the bottom of tire (BTR)
© Excessive pinion yoke run out measurement.
© Bent axle shaft (7) Average the (FTR) and the (RTR) distance mea
Check for loose or damaged front end components surements. Subtract the (BTR) measurement from
or engine/transmission mounts. These components this average distance to obtain the camber. The ac
can contribute to what appears to be a rear end vi ceptable amount of camber is 1/16 inch to 3/32 inch
bration. Do not overlook engine accessories, brackets (1.6. to 2.4 mm).
and drive belts. (FTE + BTR) DIVIDED BY 2 (TWO) MINUS
All driveline components should be examined be BTR EQUALS CAMBER
fore starting any repair. If the (BTR) distance measurement is less
Refer to Group 22, Wheels and Tires for additional than the average FTR and RTR distance mea
information. surement, the camber will be positive ( 4- ), If
the (BTR) distance measurement is greater
DRIVELINE SNAP than the average FTR and RTR distance, the
A snap or clunk noise when the vehicle is shifted camber will be negative ( - ).
into gear (or the clutch engaged), can be caused by; If the toe position or camber is not acceptable, a
« High engine idle speed bent or deformed rear axle shaft is most likely the
© Loose engine/transmission/transfer case mounts cause.
o Worn U-joints
© Loose spring mounts JMITED SLIP DIFFERENTIAL
© Loose pinion gear nut and yoke Under normal traction conditions, engine torque is
o Excessive ring gear backlash divided evenly. With low-traction surfaces, engine
o Excessive differential side gear-to-case clearance torque is transferred to the wheel with the most tire
The source of a snap or a clunk noise can be deter
mined with the assistance of a helper. Raise the ve traction. When diagnosing a limited-slip differential
hicle on a hoist with the wheels free to rotate. problem condition, the wheel with the least traction
Instruct the helper to shift the transmission into can continue spinning.
gear. Listen for the noise, a mechanics stethoscope is The most common problem is a chatter noise when
helpful in isolating the source of a noise. turning corners. Check for incorrect or contaminated
lubricant. Replace the gear lubricant if necessary,
REAR AXLE ALIGNMENT o With Trac-Lok or Power-Lok differentials MO
PAR friction modifier must be added to the lubricant.
This will correct the condition in most instances. If
The following procedure can be used to determine the chatter persists, clutch damage could have oc
if abnormal rear tire tread wear is the result of a curred.
bent or deformed rear axle shaft. After changing the lubricant, drive the vehicle and
(1) Raise both rear wheels off the surface with a make 10 to 12 slow, figure-eight turns. This maneu
frame contact hoist. ver will pump lubricant through the clutches.
3 -S REAR SUSPENSION AND AXLE mm
SERVICE DIAGNOSIS

WHEEL NOISE (a) Wheel loose. (a) Tighten loose nuts.
(b) Faulty, brinelled wheel bearing. (b) Faulty or brinelled bearings must be
replaced.
AXLE SHAFT NOISE (a) Misaligned axle shaft tube. (a) Inspect axle shaft tube alignment.
(b) Bent or sprung axle shaft. (b) Replace bent or sprung axle shaft.
(c) End play in drive pinion bearings. (c) Refer to Drive Pinion Bearing Pre-Load
Adjustment.
(d) Excessive gear backlash between ring (d) Check adjustment of ring gear
gear and pinion gear. backlash and pinion gear. Correct as
necessary.
(e) Improper adjustment of drive pinion (e) Adjust drive pinion shaft bearings.
gear shaft bearings. (f) Tighten drive pinion gearshaft yoke nut
(!) Loose drive pinion gearshaft yoke nut. with specified torque.
(g) Improper wheel bearing adjustment. (g) Readjust as necessary.
(h) Scuffed gear tooth contact surfaces. (h) If necessary, replace scuffed gears.
AXLE SHAFT BROKE (a) Misaligned axle shaft tube. (a) Replace broken axle shaft after
correcting axle shaft tube alignment.
(b) Vehicle overloaded. (b) Replace broken axle shaft. Avoid
excessive weight on vehicle.
(c) Erratic clutch operation (c) Replace broken axle shaft after
inspecting for other possible causes.
Avoid erratic use of clutch.
(d) Grabbing clutch. (d) Replace broken axle shaft. Inspect
clutch and make necessary repairs or
adjustments.
DIFFERENTIAL CASE (a) Improper adjustment of differential (a) Replace cracked case; examine gears
CRACKED bearings. and bearings for possible damage. At
reassembly, adjust
differential bearings properly.
(b) Excessive ring gear backlash. (b) Replace cracked case; examine gears
and bearings for possible damage. At
reassembly, adjust ring gear backlash
properly.
(c) Vehicle overloaded. (c) Replace cracked case; examine gears
and bearings for possible damage.
Avoid excessive weight on vehicle.
(d) Erratic clutch operation. (d) Replace cracked case. After inspecting
for other possible causes, examine
damage. Avoid erratic use of clutch.
DIFFERENTIAL GEARS (a) Insufficient lubrication. (a) Replace scored gears. Scoring marks
SCORED on the drive face of gear teeth or in
the bore are caused by instantaneous
fusing of the mating surfaces. Scored
gears should be replaced. Fill rear
differential housing to required capacity
with proper lubricant. Refer to
Specifications.
(b) Improper grade of lubricant. (b) Replace scored gears. Inspect all
damage. Clean and refill differential
housing to required capacity with
proper lubricant.
(c) Excessive spinning of one wheel/tire. (c) Replace scored gears. Inspect all
gears, pinion bores and shaft for
damage. Service as necessary.
LOSS OF LUBRICANT (a) Lubricant level too high. (a) Drain excess lubricant by removing fill
plug and allow lubricant to level at
lower edge of fill plug hole.
J9003-49
BR m m suspension A N D axle 3- 9
SERVICE DIAGNOSIS (CONT'D}

L O S S OF LUBRICANT (b) Worn axle shaft seals. (b) Replace worn seals.
(Cont'd) (c) Repair or replace housing as
(c) Cracked differential housing. necessary.
(d) Replace worn drive pinion gear shaft
(d) Worn drive pinion gear shaft seal. seal.
(e) Replace worn or scored yoke and seal.
(e) Scored and worn yoke. (!) Remove cover and clean flange and
(!) Axle cover not properly sealed. reseal.
AXLE OVERHEATING (a) Lubricant level too low. (a) Refill differential housing.
(b) Incorrect grade of lubricant. (b) Drain, flush and refill with correct
amount of the correct lubricant.
(c) Bearings adjusted too tight. (c) Readjust bearings.
(d) Excessive gear wear. (d) Inspect gears for excessive wear or
scoring. Replace as necessary.
(e) Insufficient ring gear backlash, (e) Readjust ring gear backlash and
inspect gears for possible scoring.
GEAR TEETH BROKE (a) Overloading. (a) Replace gears. Examine other gears
(RING GEAR AND and bearings for possible damage.
PINION) Replace parts as needed. Avoid
overloading of vehicle.
(b) Erratic clutch operation. (b) Replace gears and examine the
remaining parts for possible damage.
Avoid erratic clutch operation.
(c) Ice-spotted pavements. (c) Replace gears. Examine the remaining
parts for possible damage. Replace
parts as required.
(d) Improper adjustments. (d) Replace gears. Examine other parts for
possible damage. Ensure ring gear
backlash is correct.
AXLE NOISE (a) Insufficient lubricant. (a) Refill axle with correct amount of the
proper lubricant. Also inspect for leaks
and correct as necessary.
(b) Improper ring gear and drive pinion (b) Check ring gear and pinion gear teeth
gear adjustment. contact pattern.
(c) Unmatched ring gear and drive
pinion gear. (c) Remove unmatched ring gear and
drive pinion gear. Replace with
matched gear and drive pinion gear
set.
(d) Worn teeth on ring gear or drive (d) Check teeth on ring gear and drive pi
pinion gear. nion gear for correct contact.
If necessary, replace with new
matched set.
(e) Loose drive pinion gear shaft bearings. (e) Adjust drive pinion gearshaft bearing
preload torque.
(!) Loose differential bearings. (f) Adjust differential bearing preload
torque.
(g) Misaligned or sprung ring gear. (g) Measure ring gear runout.
(h) Loose differential bearing cap bolts. (h) Tighten with specified torque.
J9003-50
9 1/4 A X L E S E R V I C E P R O C E D U R E S
INDEX
page page
Axle Assembly Removal/Installation 10 Lubrication Change . . . . . . . . . . . . . . . . . . . . . . . . 10

Axle Shaft, Seal and Bearing Service 12 Pinion Depth Measurement and Adjustment . . . . . . 18
Differential Service 15 Pinion Seal Replacement 13
Information 10
INFORMATION (12) Wash and clean the outer surface of the hous
The 9 1/4 axle (Fig. 1) housing consist of a cast iron ing and tubes. Use an appropriate cleaning solution
center section. They also have two steel axle shaft and dry the surface with compressed air.
tubes that are pressed into and welded to the differ INSTALLATION
ential housing.
(1) Position the rear axle spring pads over the
The removable steel cover provides a means for in
spring center bolts.
spection and service without removing the axle from
(2) Install the spring clamp bolts and nuts, and
the vehicle.
shock absorber lower bolts. Tighten the nuts to the
AXLE ASSEMBLY REMOVAL/INSTALLATION specified torque.
(3) Connect the parking brake cables.
It is not necessary to remove the complete axle
(4) Connect the brake fluid tube fittings to the
from the vehicle for routine differential inspection
wheel cylinders. Bleed and adjust brakes refer to
and service. If the differential housing, case or axle
Group 5 Brakes for procedure.
shaft tubes are damaged the complete axle can be re
(5) Align the installation reference marks and con
moved and replaced.
nect the drive shaft yoke to the pinion yoke. Tighten
REMOVAL the U-joint clamp bolts to 19-23 N-m (170-200 in.
(1) Raise and support vehicle. lbs.) torque.
(2) Block the brake pedal in the up (non-depressed) (6) Install wheel and tire assemblies.
position with a wooden block. (7) Remove support and lower vehicle.
(3) Remove the rear wheels and brake drums.
(4) Disconnect the brake fluid tube fittings from LUBilCATJOl CHAISE
the wheel cylinders. Cap the fittings to prevent loss (1) Raise and support the vehicle.
of brake fluid. (2) Remove the lubricant fill hole plug from the dif
(5) Remove the vent hose from the brake tee nip ferential housing cover.
ple. (3) Remove the differential housing cover. Allow
(6) Remove the brake tee bolt. Carefully detach the the original lubricant to completely drain from the
brake fluid tubes from the clips. housing and axle shaft tubes.
(7) Disconnect the parking brake cables and unbolt (4) With standard differential, clean differential
backing plates. and housing with flushing oil or light engine oil. This
Mark the U-joint, pinion yoke, and pinion will remove the residual lubricant and foreign mat-
shaft for reference. ter.Do not use water, steam, kerosene or gaso
(8) Disconnect the drive shaft from the pinion line for flushing.
yoke. Secure the drive shaft in an upright position to (5) Scrape the residual sealant from the housing
prevent damage to the rear U-joint. and cover mating surfaces. Clean the mating surfaces
(9) Remove the shock absorber lower attaching with mineral spirits. Apply a bead of MOPAR® Sili
nuts and bolts. cone Rubber Sealant on the housing cover (Fig. 2).
(10) Support axle and remove rear spring U-bolts Allow the sealant to cure for a few minutes.
and the spring brackets. Install the housing cover within 5 minutes af
ter applying the sealant. If not installed, the
WARNING:AXLE MAY ROTATE ON S U P P O R T W H E N sealant must be removed and another bead ap
S P R I N G C L A M P BOLTS A R E REMOVED E N S U R E plied.
A X L E IS S E C U R E D ON SUPPORT. (6) Install the cover on the differential. Install the
identification tag. Tighten the cover bolts to 47 N-m
(11) Remove the axle assembly from the vehicle. (35 ft. lbs.) torque.
BR REAR SUSPENSION AND AXLE 3-11
HUB AXLE DIFFERENTIAL

SHAFT HOUSING
FRONT
BEARING
VENT
FITTING
NUT
SEAL
AXLE AXLE
SHAFT SHAFT
BEARING TUBE
BEARING
CAP
WASHER STUD
LOCK
BOLT
DIFFERENTIAL
BEARING
BEARING
CUP
SIDE
GEAR
CLIP ADJUSTER
LOCK
COVER
BOLT
HOUSING
PLUG COVER BOLT J9003-109
Fig. 1 9 1/4 Axle

3 - 12 REAR SUSPENSION AND AXLE BR
Fig. 2 Typical Housing Cower Fig. 3 Pinion Mate Shaft Lock Screw
CAUTION: Overfilling the differential can result in
the lubricant foaming and overheating.
(7) Refill the differential with the specified quan

tity of MOPAR® Hypoid Gear Lubricant.
(8) Install the fill hole plug.
AXLE SHAFT, SEAL AND BEARING SERVICE

CAUTION: When rear axle service is necessary,
both rear wheels must be raised off the surface so
that they are free to rotate. B e cautious when the
tires are being rotated by the engine or by other
means.
AXLE SHAFT REMOVAL

(2) Remove tire wheel assembly.
(3) Remove the brake drum.
(4) Clean all the foreign material from housing
cover area.
(5) Remove differential cover and drain the lubri
Fig. 4 Axle Shaft C-Clip Lock
cant from the housing.
(6) Remove the lock screw and the pinion mate to foe lightly dented. If any of these conditions
gear shaft from the case (Fig. 3). exist, the axle shaft and bearing must be re
(7) Push the axle shaft in and remove axle shaft C- placed.
clip lock from axle shaft (Fig. 4).
(8) Remove the axle shaft. Use care to prevent AXLE SHAFT SEAL AND BEARING REMOVAL
damage to the axle shaft bearing. (1) Remove the axle shaft seal with a small pry
(9) Inspect the axle shaft bearing contact surface bar (Fig. 5).
area for indications of wear. (2) Remove the axle shaft bearing with Remover
If wear exists the axle shaft and bearing C-4828 (Fig. 6).
should be replaced. Normal bearing contact on (3) Inspect the axle shaft seal surface and tube
the shaft will be a dull gray and could appear bore for roughness and burrs. Polish each axle
BR REAR SUSPENSION AND AXLE 3 -13
Fig. 7 Axle Shaft Seal Installation

AXLE SHAFT INSTALLATION
(1) Lubricate the bearing bore and seal lip. Insert
the axle shaft and engage the splines with the side
gear. Use care to prevent the shaft splines from
damaging the axle shaft seal lip.
(2) Insert the C-clip lock in the recessed groove
(Fig. 4). Push the axle shaft outward to seat the C-
clip lock.
(3) Align and install pinion gear mate shaft in the
case. Align hole in shaft with lock screw hole. Install
the lock screw with Loctite® on the threads. Tighten
the screw to 11 N-m (8 ft. lbs.) torque.
(4) Clean the cover and apply a bead of sealant.
Refer to the Drain and Refill in this section.
(5) Install the brake drum.
(6) Install the wheel and tire assembly.
Fig. 6 Bearing Removal (7) Fill the differential with lubricant. Refer to the
shaft with No. 600 crocus cloth. This can re Specifications chart for the type and quantity. Install
move slight surface damage. Do not reduce the the fill hole plug.
diameter of the axle shaft seal contact surface. (8) Remove support and lower vehicle. Test the
brakes and axle for correct operation.
When polishing, the crocus cloth should be
moved around the circumference of the shaft PINION SEAL REPLACEMENT
(not in-line with the shaft).
CAUTION: The following procedures must be used
BEARING AND SEAL INSTALLATION
so the correct pinion bearing preload torque is re
Always install a new seal when servicing the tained. If not completely followed, the result can be
axle or bearing. failure of the rear axle.
(1) Wipe the bore in the axle shaft tube clean.
(2) Install a new bearing with Installer C-4826 and
Handle C-4171. Ensure that the bearing is not REMOVAL
cocked and is seated firmly against the tube shoul (1) Raise and support the vehicle.
der. (2) Mark the U-joint, pinion yoke, and pinion shaft
for reference.
CAUTION: DO NOT use the new axle shaft seal to (3) Disconnect t h e drive shaft from the pinion
position or seat the bearing in the axle shaft bore. yoke. Secure the drive shaft in an upright position to
prevent damage to the rear U-joint.
(3) Install the new axle shaft seal with Installer (4) Remove wheel and tire assemblies, and brake
C-4826 and Handle C-4171 (Fig. 7). drums. Brake drag can cause a false bearing
(4) When the tool contacts the end of the tube preload torque measurement.
(face), the seal is at the correct position and depth. (5) Use a Newton-meter or an inch-pound torque
S • II. REAR SOSPENSIQM HMD AXLE — —
wrench to measure the pinion bearing preload. Ro (2) Inspect the pinion yoke for cracks, worn splines
tate the pinion shaft several times with the torque and worn seal contact surface. Repair or replace the
wrench. Note the indicated torque as the wrench is yoke as necessary.
moved through several revolutions. The outer perimeter of the seal is pre-coated
This measurement important because, bear with a special sealant additional sealant is not
ing preload torque must b e ' carefully re-ad required.
justed after t h e n e w seal i s installed. (3) Install pinion shaft seal with Installer C-4109A
(c) Hold yoke with Holder 6719 and remove the and Handle C-4735. Seal is correctly installed when
pinion shaft nut and Belleville washer. seal flange contacts face of differential housing
(7) Remove the yoke with Remover C-452 (Fig. 8). flange.
(4) Install yoke on pinion shaft with the reference
marks aligned.
(5) Seat the yoke on pinion shaft with Installer
W-162D and Holder 6719 (Fig. 10).
YOKE
Fig. 8 Yoke Removal

(8) Remove the pinion shaft seal with Puller C-748
and clean seal contact surface in housing bore (Fig.
9).
J9402-61
Fig. 10 Yoke Installation

(6) Remove tools and install the Belleville washer.
The convex side of the washer must face outward.
(7) Hold yoke with Holder 6719 and tighten the
shaft nut to 285 N-m (210 ft. lbs.) torque (Fig. 11).
Rotate pinion shaft several complete revolutions to
ensure the bearing rollers are seated.
CAUTION: Never loosen the pinion gear nut to de
crease the pinion gear bearing preload torque. If the
G748 specified preload torque is exceeded, a new col
lapsible spacer must be installed. The torque se
quence will have to be repeated.
J9403-20
(8) Continue tightening and measuring bearing
Fig, 9 Pinion Seal Removal preload torque until the torque is the same as origi
nal measurement. The bearing preload torque
INSTALLATION should never exceed 1 N-m (10 in. lbs.) more
(1) Inspect splines on pinion shaft for burrs or than original value.
wear, remove any burrs and clean the shaft. The bearing preload torque should be con
stant during a complete revolution of the pin-
en — _ — REAR SUSPENSION AID AXLE 3 -15
Fig. 12 Ring Gear Runout Measurement

runout areas. The ring gear runout should not exceed
0.005 inch (0.13 mm). If runout exceeds 0.005 inch
(0.13 mm), a damaged differential case could be the
cause.
The marking on the differential case will be
Fig. 11 Tightening Pinion Shaft Nut very useful later during the differential case
i o n gear. I f preload, torque varies, t h i s indicates runout.
a b i n d i n g condition a n d must be c o r r e c t e d . (4) Remove RWAL/ABS sensor from housing.
(9) The seal replacement is unacceptable if the fi (5) Mark the differential housing and the differen
nal nut torque is less than 285 N-m (210 ft. lbs.) tial bearing caps for installation reference (Fig. 13).
torque.
(10) Install drive shaft with the installation refer
ence marks aligned. Tighten the U-joint yoke clamp
screws to 19 N-m (14 ft. lbs./170 in. lbs.) torque.
(11) Install the brake drums, and wheel and tire
assemblies.
(12) Check the differential lubricant level and add
if necessary.
DIFFERENTIAL SERVICE
SERVICE INFORMATION
It is not necessary to remove the complete axle to
service the differential.
DIFFERENTIAL CASE REMOVAL
Fig. 13 Mark For installation Reference
(1) Remove the axle shafts, refer to Axle Shaft Re
moval. (6) Remove bearing threaded adjuster lock from
Side play resulting from bearing races being each bearing cap. Loosen the bolts, but do not re
loose on case hubs requires replacement of the move the bearing caps.
differential case. Otherwise, use threaded ad (7) Loosen the threaded adjusters with Wrench
juster to remove the side play before measuring C-4164 (Fig. 14).
the ring gear runout. (8) Hold the differential case while removing bear
(2) Attach Dial Indicator to Pilot stud C-3288B. ing caps and adjusters.
Place the indicator plunger at a right angle (90°) to (9) Remove the differential case.
the ring gear (Fig. 12). Each differential bearing cup and threaded
(3) Measure runout by turning the ring gear sev adjuster must be kept with their respective
eral complete revolutions. Observe dial indicator and bearing.
mark the ring gear and differential case at maximum
3 - 16 REAR SUSPENSION AND AXLE — — — BR
(1) Clamp the case (with the ring gear bolts facing
upward). Use a vise equipped with soft jaws (brass).
(2) Remove and discard the ring gear bolts. The
bolts have left-hand threads. Use a hammer and a
brass drift to force the ring gear loose from the case
pilots. Remove the ring gear.
CASE FLANGE RUNOUT MEASUREMENT
(1) If the ring gear runout exceeded 0.005 inch
(0.13 mm), case flange runout should be measured.
Install the case with the bearing cups and the
threaded adjusters close to their original position.
(2) Install the bearing caps and bolts. Tighten the
bolts lightly. Use Wrench C-4164 to thread both ad
justers inward. Remove all side play.
(3) Attach Dial Indicator to measure the flange
Fig. 14 Threaded Adjuster Toot runout. The plunger should contact the ring squarely
PINION GEAR SHAFT REMOVAL between the outer edge and the gear attaching bolt
(1) Remove pinion gear nut and washer. Use Puller holes (Fig. 16).
C-452 and Wrench C-3281 to remove the pinion yoke.
(2) Drive pinion gear out of housing with plastic or
rawhide hammer. This will damage the front
bearing rollers and bearing cup. The front
bearing and cup must be replaced.
(3) Remove the collapsible preload spacer
(4) Remove the pinion seal with Puller C-748.
(5) Remove the front and rear bearing cups with
Remover Set C-4306 and Handle C-4171.
(6) Remove rear bearing from pinion shaft (Fig.
15). Remove and record the pinion gear depth shims.
Fig. 16 Case Flange Runout Measurement

(4) Rotate the differential case several times and
observe the dial indicator. Mark the area of maxi
mum flange runout. The differential case flange
runout must not exceed 0.003 inch (0.08 mm). If the
runout exceeds this amount replace the differential
case.
To reduce ring gear runout positioning the
ring gear runout mark 180 degrees opposite the
flange runout mark.
(5) Remove the differential bearing cap bolts. Re
move the differential case from the differential hous
ing.
DIFFERENTIAL CASE DISASSEMBLY
(1) Rotate the side gears until the pinion gears are
located at differential case opening and remove them.
Fig. 15 inner Bearing Removal (2) Remove the side gears and the thrust washers.
RING GEAR (3) Remove the differential bearings from the case
Do not remove ring gear from case unless hubs with Bearing Splitter Bridge 938 and Bearing
runout must be measured. Splitter 1130 (Fig. 17).
BR — REAR SUSPENSION AND AXLE 3 -17
(3) After heating, quickly position the exciter ring

on the differential case adjacent to the flange.
DIFFERENTIAL CASE ASSEMBLY
When replacing a pinion or differential bear
ings always replace bearing and cup as a
matched set.
(1) Lubricate all the differential case components
with gear lubricant.
(2) Place thrust washers on differential side gears.
Position the gears in the differential case counter-
bores.
If replacement side gears or thrust washers
are used, refer to Differential Side Gear Clear
ance Measurement And Adjustment.
(3) Position thrust washers on differential pinion
gears. Mesh the pinion gears with the side gears.
Ensure that the pinion gears are exactly 180 de
grees opposite each other.
(4) Rotate the side gears to align the pinion gears
and thrust washers. Align components with the mate
shaft bores in the case.
Fig. 17 Differentia/ Bearing Removal
' (5) If the ring gear was removed, clean all contact
CLEANING AND INSPECTION surfaces. Use a fine file to remove any sharp areas
(1) Clean all of the differential components in from chamfered inside diameter. Heat ring gear with
cleaning solvent. Allow the bearings to either air dry a heat lamp or immerse in a hot fluid. The tempera
or dry them with a lint-free cloth. Dry the other com ture should not exceed 149°C (300°F). Do not use a
ponents with compressed air. torch to heat the ring.
(2) Examine each component for wear or damage. (6) Position heated gear on case. Use two equally
(3) Replace shims, bearings and cups as a set only. spaced Pilot Studs C-3288B to align the gear with
Replace bearings and cups if either is galled, worn, the flange holes (Fig. 18).
cracked, or damaged.
(4) Inspect the differential side and pinion gears. PILOT
Replace any gear that is worn, cracked or chipped.
(5) Inspect the differential case. Replace the case if
cracked or damaged.
Polish each axle shaft with No. 600 crocus
cloth. This can remove slight surface damage.
Do not reduce the diameter of the axle shaft
seal contact surface. When polishing, the crocus
cloth should be moved around the circumfer
ence of t h e shaft (not in-line with t h e shaft).
(6) Inspect the axle shaft C-clip locks for cracks
and excessive wear. Replace them if necessary.
(7) Test each threaded adjuster to determine if it
rotates freely. If an adjuster binds, repair the dam
aged threads or replace the adjuster.
Fig. 18 Case-To-Ring Gear Alignment
EXCITER RING REPLACEMENT (7) Install replacement ring gear bolts (with left
The ring gear must be removed before the RWAL/ hand threads). Alternately and evenly tighten each
ABS brake exciter ring can be replaced. bolt to 102 N-m (75 ft. lbs.) torque.
(1) Remove exciter ring with a hammer and drift.
(2) Heat the replacement exciter ring with a heat CAUTION: When installing a differential bearing,
lamp or by immersing in a hot fluid. The tempera never apply force to the bearing cage because bear
ture should not exceed 149°C (300°F). Do not use a ing damage will result.
torch to heat the ring.
(8) Install a differential bearing on each hub with

Installer C-4213 and Handle C-4171.
PINION DEPTH MEASUREMENT AND ADJUSTMENT

Pinion measurement are taken with C-758-D6 Tool
Set (Fig. 19) with pinion bearing cups installed.
SPECIAL TOOL
Fig. 20 Gauge Block

bearing caps on the arbor tool. Install the attaching
bolts. Tighten the cap bolts to 14 N-m (10 ft. lbs.)
torque.
SP-536-^ J9203-52 (7) Trial fit depth shim(s) between the crossbore
arbor and gauge block (Fig. 21). The depth shim(s)
Fig. 19 9 1/4 Axle Pinion Adjustment Toois fit must be snug but not tight (drag friction of a
feeler gauge blade).
(1) Install front (outer) bearing cup with Tool Set
C-4306 and Handle C-4171.
(2) Install rear (inner) bearing cup with Tool Set
• Position Spacer (SP-6017) over Shaft (SP-526)
• Position pinion rear bearing on shaft
• Position tools (with bearing) in the housing
• Install Sleeve (SP-1730)
• Install pinion front bearing
• Install Spacer (SP-6022)
• Install Sleeve (SP-535-A), Washer (SP-534) and
Nut (SP-533)
(3) Tighten the nut to seat the pinion bearings in
the housing. Allow the sleeve to turn several times
during the tightening to prevent brinelling the bear
ing cups or the bearings.
Depth shim(s) are positioned between the pin Fig. 21 Depth Shim(s) Selection
ion gear rear bearing and pinion gear to pro Depth shims are available in 0.001-inch incre
vide the separation distance. The required ments from 0.020 inch to 0.038 inch.
thickness of the depth shim(s) is determined ac (8) Note the etched number on the face of the drive
cording to the following information. pinion gear (e.g., -0, -1, -2, +1, +2, etc.). The numbers
(4) Loosen the compression nut tool. Lubricate the represent thousands-of-an-inch deviation from the
pinion gear front and rear bearings with gear lubri standard. If the number is - (negative) add that value
cant. Re-tighten the compression nut tool to 1-3 N-m to the required thickness of the depth shim(s). If the
(15-25 in. lbs.) torque. Rotate the pinion gear several
number is + (positive) subtract that value from the
complete revolutions to align the bearing rollers.
thickness of the depth shim(s). If the number is 0 no
• Install Gauge Block SP-6020 at the end of SP-526
change is necessary.
• Install Cap Screw (SP-536) and tighten with
Wrench SP-531 (Fig. 20). (9) Remove the tools from the differential housing.
(5) Position Crossbore Arbor SP-6018 in the differ (10) Position depth shim(s) on pinion gear shaft
ential housing. and install rear bearing with Installer C-3095A (Fig.
(6) Center the tool and place a piece of 0.002 inch 22).
shim stock at each end of the arbor. Position the
R REAR SUSPENSION AND AXLE 3 - 19
r
Original Pinion '-v-y.'^-v.-iont Pinion Gear Depth kr-y.':)r,s
Gear Depth
Variance -3 - I -1 i +1 +2 +3
+4 + 0.008 + 0.007 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0
+3 + 0.007 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0 -0.0 .
+ 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0 -0.001 -0.002
+1 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0 -0.001 -0.002 -o.oo3 j
§ + 0.004 + 0.003 + 0.002 + 0.001 0 -0.001 -0.002 -0.003 -0.004
+ 0.003 + 0.002 + 0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005
+ 0.002 + 0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006
-3 + 0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007
-4 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007 -0.008
• ' J8902-46
(14) Install the pinion yoke with Installer W-162D

and Holder 6719 (Fig. 23).
'PSESS
It is necessary to use tools above to correctly
seat the front bearing on drive pinion gear
shaft (Fig. 28). '
YOKE
INSTALLER
SPECIAL
TOOL <
C-3095A
PINION
BEAHNG
YOKE
HOLDER
Fig, 22 Shaft Rear Bearing installation
(11) Install front pinion bearing and install pinion
shaft seal with Installer C-4109A and Handle
C-4735. J9402-61
The outer perimeter of the seal is pre-coated
with a special sealant. An additional applica Fig. 23 Pinion Yoke Installation
tion of sealant is not required. CAUTION: Use care to prevent collapsing preload
(12) Lubricate the pinion gear front and rear bear collapsible spacer during installation of the yoke
ings with gear lubricant. and seating the front bearing.
(13) Install new collapsible spacer on pinion gear
shaft. Install pinion gear in housing. (15) Remove yoke and tools from the pinion gear.
3 - 20 BEAR SUSPENSION AND AXLE BR
(16) Install the Belleville washer. The convex side

of the washer must face outward. Install the pinion
nut.
(17) Retain pinion yoke with Holder 6719. Initially
tighten the drive pinion gear shaft nut enough to re
move the bearing end play. While tightening, rotate
the pinion shaft to ensure the bearing rollers are cor
rectly seated.
(18) Tighten the pinion nut to (Fig. 24) 285 N-m
(210 ft. lbs.) torque (minimum).
DIFFERENTIAL
Fig. 25 Bearing Preload Torque Measurement

pinion gear shaft. If preload torque varies
while rotating the shaft, there is an internal
binding that must be corrected before assem
bly.
(21) If specified torque is not obtained, tighten the
nut in small increments until preload torque is ob
tained.
The differential will be unacceptable for use
if the final nut torque is less than 285 N-m (210
ft. lbs.) torque. If preload torque is not within
the specified range this is also unacceptable.
DIFFERENTIAL CASE INSTALLATION
(1) Apply a coating of hypoid gear lubricant to the
differential bearings, bearing cups and threaded ad
Fig. 24 Tightening Pinion Gear Nut justers. A dab of grease can be used to keep the ad
(19) Remove the tools from the shaft. Rotate the justers in position. Carefully position the assembled
pinion several complete revolutions (both directions) differential case in the housing.
to additionally seat the bearing rollers. (2) Observe the reference marks and install the
differential bearing caps at their original locations
CAUTION: Never loosen pinion gear nut to decrease (Fig. 26).
pinion gear bearing preload torque and never ex
ceed specified preload torque. If preload torque is
exceeded a new collapsible spacer must be in
stalled. The torque sequence will have to be re
peated.
(20) Measure the pinion bearing preload torque by

rotating pinion shaft with a Newton-meter or an
inch-pound torque wrench. The correct bearing pre
load torque is 2-4 N-m (20-30 in. lbs.). This torque
value is with replacement bearings and pinion nut
tightened to a minimum of 285 N-m (210 ft. lbs.)
torque (Fig. 25)
When using original pinion rear bearing and
a replacement front bearing. The correct pre
load torque is 1 N-m (10 in. lbs.) plus the torque
measured and recorded during disassembly.
The bearing preload torque should be con Fig. 26 Bearing Caps & Bolts
stant during a complete revolution of the drive
BR REAR SUSPENSION AND AXLE 3 - 21
(3) Install the bearing cap bolts (Fig. 26). Tighten Measure the backlash at 4 positions (90 degrees
the upper bolts to 14 N-m (10 ft. lbs.) torque. Tighten apart) around the ring gear. Locate and mark the
the lower bolts finger-tight until the bolt head is area of minimum backlash.
lightly seated. (3) Rotate the ring gear to the position of the least
backlash. Mark the gear so that all future backlash
DIFFERENTIAL BEARING PRELOAD AMD RING measurements will be taken with the same gear
GEAR BACKLASH ADJUSTMENT teeth meshed.
The following must be considered when adjusting
bearing preload and gear backlash:
• The maximum ring gear backlash variation is
0.003 inch (0.076 mm)
• Mark the gears so the same teeth are meshed dur
ing all backlash measurements
• Maintain the torque while adjusting the bearing
preload and ring gear backlash
• Excessive adjuster torque will introduce a high
bearing load and cause premature bearing failure.
Insufficient torque can cause excessive differential
case free-play and ring gear noise
• Insufficient adjuster torque will not support the
ring gear correctly. This can cause excessive differen
tial case free-play and ring gear noise.
The differential bearing cups will not always
immediately follow the threaded adjusters as
they are moved during adjustment. Ensure ac Fig. 28 Ring Gear Backlash Measurement
curate bearing cup responses to the adjust (4) Loosen the right-side, tighten the left-side
ments. Maintain the gear teeth engaged threaded adjuster. Obtain backlash of 0.003 to 0.004
(meshed) as marked. The bearings must be inch (0.076 to 0.102 mm) with each adjuster tight
seated by rapidly rotating the pinion gear a ened to 14 N-m (10 ft. lbs.) torque. Seat the bearing
half turn back and forth. Do this five to ten cups with the procedure described above.
times each time the threaded adjusters are ad (5) Tighten the differential bearing cap bolts to 136
justed. N-31m (100 ft. lbs.) torque.
(1) Use Wrench C-4164 to adjust each threaded ad (6) Use Wrench C-4164 to tighten the right-side
juster inward (Fig. 27). Adjust until the differential
threaded adjuster to 102 N-m (75 ft. lbs.) torque. Seat
bearing free-play is eliminated. Allow some ring gear
backlash (approximately 0.01 inch/0.25 mm) between the bearing cups with the procedure described above.
the ring and pinion gear. Seat the bearing cups with Continue to tighten the right-side adjuster and seat
the procedure described above. bearing cups until the torque remains constant at
102 N-m (75 ft. lbs.)
(7) Measure the ring gear backlash. The range of
backlash is 0.006 to 0.008 inch (0.15 to 0.203 mm).
Continue increasing the torque at the right-side
threaded adjuster until the specified backlash is ob
tained.
The left-side threaded adjuster torque should
have approximately 102 N-m (75 ft. lbs.) torque.
If the torque is considerably less, the complete
adjustment procedure must be repeated.
(8) Tighten the left-side threaded adjuster until
102 N-m (75 ft. lbs.) torque is indicated. Seat the
bearing rollers with the procedure described above.
Do this until the torque remains constant.
(9) Install the threaded adjuster locks . Ensure the
lock finger is engaged with the adjuster hole. Tighten
Fig. 27 Threaded Adjuster Tooi the lock screws to 10 N-m (90 in. lbs.) torque.
(2) Install Dial Indicator (Fig. 28). Position the
plunger against the drive side of a ring gear tooth.
3 -12 REAR SUSPENSION M i l AXLE — —
s i b * c-E4 ;? GULZE&MGSI TM^MMMMMR MM SIDE GEAR CLEARANCE 0.007

THRUST WASHER THICKNESS + 0.033
When measuring side gear clearance, check each TOTAL 0.040
gear independently. If it necessary to replace a side L—^^^^mr^^r-^^^m 0.040
gear, replace both gears as a matched set. REPLACEMENT WASHER THICKNESS "0.037
(1) Install the axle shafts and C-clip locks and pin NEW SIDE GEAR CLEARANCE 0.0)3
J9203-31
ion mate shaft. If necessary, refer to the installation
located within this group. Fig. 30 Side Gear Calculations
(2) Measure each side gear clearance. Insert a
matched pair of feeler gauge blades between the gear measure the thrust washer thickness. Record the
and differential housing on opposite sides of the hub thickness and re-install the thrust washer. Assemble
(Fig. 29). the differential case without the C-clip lock installed
and re-measure the side gear clearance.
(6) Compare both clearance measurements. If the
difference is less than 0.012 inch (0.305 mm), add
clearance recorded when the C-clip lock was installed
to thrust washer thickness measured. The sum will
determine the required thickness of the replacement
thrust washer.
(7) If clearance is 0.012 inch (0.305 mm) or greater,
both side gears must be replaced (matched set) and
the clearance measurements repeated.
(8) If clearance (above) continues to be ,0.012 inch
(0.305 mm) or greater, the case must be replaced.
r i n g MMM TEETH E&mwACw MWWMM
ANALYSIS
The ring gear teeth contact patterns will show if
the pinion gear depth shim(s) have the correct thick
FIG, 29 Side Gear Clearance Measurement ness. It will also show if the ring gear backlash has
(3) If side gear clearances is no more than 0.005 been adjusted correctly. The backlash must be main
inch. Determine if the shaft is contacting the pinion tained within the specified limits until the correct
gear mate shaft. Do not remove the feeler teeth contact patterns are obtained.
gauges, Inspect the axle shaft w i t h the feeler © Excessive backlash is corrected by moving the ring
gauge i n s e r t e d b e h i n d the side gear. If the end of gear teeth closer to the pinion gear teeth
the axle shaft is not contacting the pinion gear mate- ® Insufficient backlash is corrected by moving the
shaft, the side gear clearance is acceptable. ring gear away from the pinion gear
(4) If clearance is more than 0.005 inch (axle shaft (1) Apply yellow ferrous (iron) oxide compound to
not contacting mate shaft), record the side gear clear both drive and coast sides of ring gear teeth.
ance. Remove the thrust washer and measure its (2) Rotate the ring gear one complete revolution in
thickness with a micrometer. Add the washer thick both directions.
ness to the recorded side gear clearance. The sum of (3) Note patterns in compound. Refer to (Fig. 31)
gear clearance and washer thickness will determine for interpretation of contact patterns and adjust ac
required thickness of replacement thrust washer cordingly.
(Fig. 30). (4) Install the axle shafts. Refer to Axle Shaft In
In some cases, the end of the axle shaft will move stallation within this group.
and contact the mate shaft when the feeler gauge is (5) Install the housing cover. Refill the differential
inserted. The C-clip lock is preventing the side gear with lubricant.
from sliding on the axle shaft. (6) Install the RWAL/ABS brake speed sensor and
(5) If there is no side gear clearance, remove the cover onto the axle housing. Tighten the sensor to 13
C-clip lock from the axle shaft. Use a micrometer to N-m (10 ft. lbs.) torque.
mm mm SUSPENSION and 'axle • 3 - 23

O F RING O F RING

O N THE DRIVE SIDE O F T O O T H .
HEEL TOE TOE HEEL
PATTERN SHOULD BE CENTERED O N
THE COAST SIDE O F T O O T H ,
BE SOME CLEARANCE BETWEEN
CONTACT PATTERN A N D TOP OF
THE T O O T H .

SHIM REQUIRED.
RING GEAR BACKLASH CORRECT

SHIM REQUIRED.

GEAR BACKLASH.

GEAR BACKLASH.
J9003-24
Fig. 31 Gear Teeth Contact Patterns

M O D E L 6 0 , 70 a n d 80 A X L E S E R V I C E P R O C E D U R E S
INDEX
page page
Axle Assembly Removal/Installation 26 Pinion Measurement and Assembly . 36

Axle Shaft Removal/1 nstallation . 29 Pinion Removal/Disassembly 31
Differential Assembly 33 Pinion Seal Replacement—Model 60 27
Differential Disassembly 30 Pinion Seal Replacement—Model 70 and 80 27
Drain and Refill 26 Ring Gear Backlash and Contact Pattern . . . . . . . . 39
General Information 24 Wheel Bearing Service 29
Lubricant 24
GENERAL INFOilAIION The differential case is a one-piece design. The dif

The housing (Fig. 1) consists of an iron center cast ferential pinion mate shaft. is retained with a roll
ing with axle shaft tubes extending from either side. pin. Model 70 axles with the optional Power-Lok use
The tubes are pressed in to form a one-piece axle a two piece differential case. Model 80 axles with the
housing. optional Trac-lok also uses a two piece case. Differen
The integral type housing, hypoid gear design has tial bearing preload and ring gear backlash are ad
the centerline of the pinion set below the centerline justed with shims located between the differential
of the ring gear. bearing cones and case.
The axles are equipped with full-floating axle For complete drive axle assembly removal
shafts, meaning that loads are supported by the axle and installation refer to Drive Axle Assembly
housing tubes. The full-float axle shafts are retained Replacement in this Group.
by bolts attached to the hub. The hub rides on two
bearings at the outboard end of the axle tube. The LUBRICANT
axle shafts can be removed without disturbing or re Dana® axles use a thermally stable Lubricant,
moving the wheel bearings. The wheel bearings are 80W-90 or equivalent GL-5 grade lubricant. Vehicles
opposed tapered roller bearings that are part of the with Trac-Lok/Power-Lok also use 6 oz. of friction
hub assembly. modifier added to the lubricant. Dana 80 4x4 vehicles
The removable steel cover provides a means for in use 10 oz. of friction modifier added to the lubricant.
spection and service without removing the axle from
the vehicle. CAUTION: If axle is submerged in water, lubricant
A stamped metal axle gear ratio identification tag must be replaced immediately to avoid possible
is attached to the housing cover with one cover bolts. premature axle failure.
This tag also identifies the number of ring and pinion
teeth. An addition tag will be attached if equipped
with a limited-slip differential.
Fig. 1 Model 70 and 80 Rear Axle '
cn
3 - 26 REAR SUSPENSION AND A X L E
AXLE ASSEMBLY REMOVAL/INSTALLATION DRAIN AND REFILL

It is not necessary to remove the complete axle (1) Drive the vehicle until the gear lubricant
from the vehicle for routine differential inspection reaches normal operating temperature.
and service. If the differential housing, case or axle (2) Raise and support the vehicle.
shaft tubes are damaged the complete axle can be re (3) Remove the lubricant fill hole plug from the dif
moved and replaced. ferential housing cover.
(4) Remove the differential housing cover. Allow
REMOVAL the lubricant to completely drain from the housing
(1) Raise the rear of the vehicle until the rear and axle shaft tubes.
wheels are not contacting the surface. Support the (5) Flush the differential and housing cavity with
vehicle body at the front of the rear springs. flushing oil to remove residual lubricant and foreign
(2) Use a wooden block to retain the brake pedal in matter. Do not use water, steam, kerosene or
the up position. gasoline for flushing.
(3) Remove wheels, axle shafts, brake drums and (6) Scrape the residual gasket from the housing
hubs. Refer to axle shaft removal procedure. and cover mating surfaces. Clean the mating surfaces
(4) Disconnect the brake line and cap the fittings with mineral spirits. Apply a bead of MOPAR® Sili
to prevent loss of brake fluid. cone Rubber Sealant on the housing cover (Fig. 2).
(5) Disconnect the parking brake cables. Allow the sealant to cure for a few minutes.
Scribe installation alignment reference marks SEALING CONTOUR OF BEAD
on drive shaft U-joint and on pinion yoke.
(6) Disconnect the drive shaft U-joint from the pin
ion yoke. Secure it in an upright position to prevent
damage to the U-joint.
WARNING:AXLE MAY ROTATE ON S U P P O R T W H E N
S P R I N G CLAMP BOLTS A R E REMOVED E N S U R E
A X L E I S S E C U R E D ON S U P P O R T
(7) Support axle, remove lower shock absorber

bolts and spring clamp bolts from the axle.
(8) Remove the rear axle from the vehicle.
INSTALLATION
(1) Position the axle under the rear springs.
(2) Install the spring clamp bolts and tighten the
nuts to specified torque.
(3) Install shock absorbers bolts at axle brackets
and tighten to specified.
(4) Connect the parking brake cables and brake
line.
(5) Install the hubs, axles and brake drums. Refer Fig, 2 Typical Housing Cover
axle installation procedure. . Install the housing cover within 5 minutes af
(6) Remove the block from the brake pedal. Bleed ter applying the sealant. If not installed, the
and adjust the brakes. Refer to Group 5 brakes for sealant must be removed and another bead ap
procedure. plied.
(7) Connect drive shaft to pinion yoke with the ref (7) Install the cover on the differential. Install the
erence marks aligned. Tighten U-joint clamp bolts to identification tag. Tighten the cover bolts to 47 N-m
21 N-m (16 ft. lbs./186 in. lbs.) torque. (35 ft. lbs.) torque.
(8) Install wheels and tire assemblies
(9) Fill the differential housing to the correct level. CAUTION: Overfilling the differential can result in
lubricant foaming and overheating.
Add MOPAR Hypoid Gear Lubricant Additive
for Trac-Lok and Power-Lok equipped axles. (8) Refill the differential housing with the specified
(10) Remove the supports and lower vehicle. quantity of MOPAR Hypoid Gear Lubricant. Vehicles
(11) Road test the vehicle to evaluate the results of with Trac-Lok/Power-Lok also use 6 oz. of friction
the repair. modifier added to the lubricant. Dana 80 4x4 vehicles
use 10 oz. of friction modifier added to the lubricant.
(9) Install the fill hole plug. Tighten to 34 N-m (25 .INSTALLATION
ft. lbs.) torque. (1) Apply a light coating of gear lubricant on the
(10) Road test vehicles with Trac-Lok/Power-Lok lip of pinion seal. Install the new seal with Installer
and make 10 to 12 slow, figure-eight turns. This ma D-187B.
neuver will pump lubricant through clutch discs. (2) Align the installation reference marks and po
sition the yoke on the pinion gear.
PINION SEAL REPLACEMENT—MODEL 70 AND 80 (3) Install yoke with Installer D-191 (Fig. 5).
•REMOVAL YOKE
(2) Mark the U-joint, pinion yoke, and pinion shaft
for reference.
(3) Disconnect the drive shaft from the pinion
yoke. Secure the drive shaft in an upright position to
prevent damage to the rear U-joint.
(4) Mark the positions of the yoke and pinion gear
for installation alignment reference.
(5) Remove the pinion yoke nut and washer. Use
Remover C-452 and Wrench C-3281 to remove the
pinion yoke (Fig. 3).
J9402-61
Fig. 5 Yoke Installation

(4) Install washer with concave surface against
yoke on Model 70 axle. Install nut on shaft and
tighten nut to (Fig. 6);
• Model 70: 298-379 N-m (220-280 ft. lbs.) torque
C-452 J9102-31 • Model 80: 597-678 N-m (440-500 ft. lbs.) torque
Optional Torque Method Dana 80: Torque pin
Fig. 3 Pinion Yoke Removal ion nut to 339 N-m (250 ft. lbs.). Then scribe a line
(6) Use Remover 7794A and slide hammer to re on the yoke 3/8 of an inch from one point of the pin
move pinion seal (Fig. 4). ion nut (Fig. 7). Tighten the nut until the point of the
nut lines up with the scribe mark. This will tighten
SPECIAL TOOL
7794A
the nut to the correct torque.
tach the drive shaft to the yoke.
(6) Add gear lubricant to the differential housing if
necessary.
PINION SEAL REPLACEMENT—MODEL 60
REMOVAL
PINION SEAL (2) Remove wheel and tire assemblies
(3) Mark the propeller shaft yoke and pinion yoke
J9402-59X for installation alignment reference.
(4) Remove the propeller shaft from the yoke.
Fig. 4 Pinion Seal Removal
3 - 28 MM SUSPENSION AND AXLE BR
DIFFERENTIAL
C-452 J9102-31
Fig. 8 Pinion Yoke Removal
SPECIAL TOOL
7794A
Fig. 6 Tightening Pinion Shaft Nut
PINION SEAL
J9402-59X
Fig. 9 Seal Removal

INSTALLATION
lip of pinion seal. Install seal Installer D-163.
(2) Align the installation reference marks and in
stall yoke on pinion shaft with Installer C-3718 (Fig.
Fig. 7 Pinion Nut
10).
(5) Rotate the pinion gear three or four times. (3) Install washer with concave surface against the
Make sure brakes are not dragging during this yoke. Install new nut on the pinion gear. Tighten
procedure. the nut to 292 N-m (215 ft. lbs.) torque to re
(6) Measure the amount of torque necessary to ro move the shaft end play.
tate the pinion gear with a torque wrench. Note the
torque for installation reference. This must be CAUTION: Exercise care during the bearing preload
known to properly adjust t h e pinion gear bear torque adjustment. Do not over-tighten, or loosen
ing preload torque after seal installation. and then re-tighten the nut. Do not exceed the bear
(7) Remove the pinion yoke nut and washer. Use ing preload torque. The collapsible preload spacer
Remover C-452 and Holder C-3281 to remove the on the pinion shaft will have to be replaced. The
pinion yoke (Fig. 8). bearing preload torque will be re-adjusted after
ward.
(8) Mark the positions of the yoke and pinion gear
for installation alignment reference. (4) Install a socket and inch-pound torque wrench
(9) Use Remover 7794A and slide hammer to re on the pinion nut.
move the pinion gear seal (Fig. 9). (5) Rotate the shaft with the torque wrench and
note the torque.
BR REAR SUSPENSION A N D AXLE 3 - 29
292 to 427 N-m (215 to 315 ft. lbs.) torque.

YOKE
tach the propeller shaft to the yoke.
(9) Add gear lubricant to the differential housing if
necessary.
(10) Install wheel and tire assemblies
AXLE SHAFT REMOVAL/INSTALLATION
CAUTION: R A I S E BOTH REAR W H E E L S off the sur

face whenever a rear axle is being serviced.
REMOVAL
(1) Remove the axle shaft flange bolts.
(2) Slide the axle shaft out from the axle tube (Fig.
1).
imSTALLATIOm
J9402-61 (1) Clean the gasket contact surface area on the
flange with an appropriate solvent. Install a new
Fig. 10 Yoke Installer flange gasket and slide the axle shaft into the tube.
(2) Install the bolts and tighten to 122 N-m (90 ft.
The required preload is equal to amount re
corded during removal pirns 0.56 N-m (5 in. lbs.). lbs.) torque.
The used bearing preload torque must never WHEEL BEARING SERWiCE
exceed 2.25 N-m (20 in. lbs.)
(6) Use Flange Holder 6719 to retain the yoke and REMOVAL
shaft (Fig. 11). Tighten the shaft nut in very small
(1) Remove the axle shaft, refer to the removal
increments.
procedure.
DIFFERENTIAL (2) Remove the nut lock and adjustment nut.
(3) Remove drum and hub. The outer wheel bear
ing will slide of with the hub.
(4) Place hub on bench and remove inner grease
seal and discard seal.
Remove inner and outer bearings.
(1) Thoroughly clean both wheel bearings and inte
rior of the hub. Remove all of the residual lubricant.
(2) To clean the bearings:
• Soak them in an appropriate cleaning solvent
© Strike the flat of each bearing against a hardwood
block several times
• Flush bearing between strikes
® Repeat the procedure above until each bearing is
clean
© Dry the bearings with compressed air but do not
spin them
(3) After cleaning, apply engine oil to each bearing.
(4) Rotate each bearing slowly while applying
downward force. Examine the rollers for pitting and
Fig. 11 Tightening Pinion Shaft Nut roughness. Replace worn or otherwise defective bear
(7) Continue tightening the shaft nut in small in ings. If a bearing has pitted or has rough surfaced
crements until the correct bearing preload torque is rollers replace bearing.Always replace bearing
attained. Tighten the pinion shaft nut to cone and cup as a set.
3 - 30 REAR SUSPENSION AND AXLE
(5) If reusable, remove the engine oil from each

bearing. Pack each bearing with multi-purpose
NLGI, grade 2, EP-type lubricant.
Ensure that lubricant is forced into all the
cavities between the bearing cage and rollers.
INSTALLATION
(1) If a bearing and cup must be replaced, remove
the cup from the hub bore. Use a brass drift or an
appropriate removal tool to tap out the cup.
(2) Install the replacement bearing cup(s) with an
appropriate installation tool.
(3) Apply lubricant to surface area of the hub bore.
Install the inner wheel bearing in the hub. Install a
replacement bearing seal with an appropriate seal in
stallation tool.
(4) Inspect the bearing and seal contact surfaces Fig. 12 Bearing Cap identification
on the axle for burrs and/or roughness.
(5) Remove all the rough contact surfaces from the
axle. Apply a coating of multi-purpose NLGI, grade 2,
EP-type lubricant to the axle.
CAUTION: Use care to prevent the inner wheel bear
ing and bearing seal from contacting the axle
threads during installation.
(6) Carefully slide the hub onto the axle and in
stall outer wheel bearing.
(7) Install adjustment nut and tighten to 163-190
N-m (120-140 ft. lbs.) torque while rotating the
wheel.
(8) Back off adjustment nut 1/8 to 1/3 of a turn to
provide 0.001-inch to 0.010-inch wheel bearing end
play. Fig. 13 Differential Housing Spreader
(9) Tap locking wedge into the spindle keyway and
adjustment nut. CAUTION: Do not spread over 0.38 mm (0.015 in). If
(10) Install the axle shaft, refer to the installation the housing is over-separated, it could be distorted
procedure. or damaged.
DIFFERENTIAL DISASSEMBLY (4) Separate the housing enough to remove the

case from the housing. Separate housing a maxi
MEMOWALmiSASSEmBLW mum distance of 0.38 mm (0.015 in) with the
Remove RWAL/ABS brake sensor hold-down spreader tool. Measure the distance with the dial
bolt and pull the sensor from the differential indicator (Fig. 13).
housing. The sensor must be removed to pre (5) Remove the dial indicator.
vent damage when disassembling or assembling (6) Pry the differential case loose from the housing.
the differential components. To prevent damage, pivot on housing with the end of
(1) Note reference letters located on bearing caps the pry bar against case.
and housing machined sealing surface (Fig. 12). Re (7) Remove the case from housing. If they are re
move the differential bearing caps. usable, retain the differential bearing cups and bear
(2) Position Spreader W-129B with the tool dowel ings together as matched sets.
pins seated in the locating holes (Fig. 13). Install the (8) Clamp the differential case in a vise equipped
holddown clamps and tighten the tool turnbuckle fin with soft jaws. Remove and discard the ring gear
ger-tight.
bolts. Tap the ring gear off with a rawhide or plastic
(3) Install a pilot stud at the left side of the differ
mallet (Fig. 14).
ential housing. Attach Dial Indicator to housing pilot
stud. Load the indicator plunger against the opposite (9) The exciter ring can be removed with a soft-
side of the housing (Fig. 13) and zero the indicator. - faced hammer (Fig. 15). Discard after removal.
mm REAR SUSPENSION AND AXLE 3 - 31
CASE RING GEAR
SPECIAL TOOL
1130
SPECIAL TOOL
938
RAWHIDE
HAMMER
J9202-76
Fig 14 Ring Gear Removal BUTTON DIFFERENTIAL

B
BEARING
J9403-48
Fig. 16 Differential Bearing Removal
DRIFT
EXCSTOR
RING
8903-33
Fig. 15 Exciter Ring Removal

(10) Remove bearings and shims from case hubs
and mark them (with hub identity) for assembly ref
erence (Fig. 16). Record the thickness of the shims.
(11) Clamp the differential case in a vise equipped
with soft jaws. Use a pin punch to remove the pinion
gear mate shaft lock pin (Fig. 17).
(12) Remove the mate shaft with a drift and ham J9302-33
mer (Fig. 18).
(13) Rotate the differential side gears and remove Fig. 17 Mate Shaft Lock Pin Removal
the pinion mate gears and thrust washers (Fig. 19 ). (2) Remove pinion, and remove pinion seal with
(14) Remove the differential side gears and thrust Remover 7797 and slide hammer (Fig. 21).
washers. (3) Remove oil slinger, front bearing and shims or
collapsible spacer. Record the thickness of the shims
PINION REMOVAL/DISASSEMBLY (Fig. 22).
(4) Remove front pinion bearing cup with;
meMOWAl/DISASSEMBlY • Model 60 and 70: Remover D-158 and Handle
(1) Remove the pinion yoke nut and washer. Use C-4171
Remover C-452 and Wrench C-3281 to remove pinion • Model 80: Remover C-4307 and Handle C-4171
yoke (Fig. 20). (5) Remove rear bearing cup with;
C-452 J9102-31
Fig. 18 Mate Shaft Removal Fig. 20 Pinion Yoke Removal
THRUST SPECIAL TOOL

WASHER
7794A
PINION SEAL
J9402-59X
Fig. 21 Pinion Seal Removal

housing opening. Draw the wire (and cloth) from the
housing outward through the tube. Clean oil chan
nels in housing.
MATE GEAR SIDE GEAR J9203-61
(3) Inspect the differential and pinion gear bear
Fig. 19 Pinion Mate Gear Removal
ings. Inspect the differential case and housing.
• Bearings and cups should have a smooth appear
» Model 60 and 70: Remover D-162 and Handle ance. With no broken/dented surfaces on the bearing
C-4171 rollers or roller contact surfaces
e Model 80: Remover D-159 and Handle C-4171 • Bearing races must not be distorted or cracked
(6) Remove depth shims from the housing bore if Cup and bearing must be replaced as a
used. Record the thickness of the depth shims. matched sets only.
(7) Remove the pinion rear bearing and selective • All machined surfaces in the housing and on bear
pinion position shim (Fig. 23). ing caps should be smooth and without any raised
edges
CLEANING/INSPECTION
• Pinion gear front and rear bearing cup bores
(1) Wash and clean all components with cleaning
should be smooth
solvent and dry with compressed air.
© Raised metal on shoulders of cup bores should be
Do not steam clean the differential compo
removed with a hand stone
nents.
(4) Examine the differential pinion gear mate
(2) Clean the axle shaft tubes. Insert a stiff wire
shaft, pinion gears, side gears and thrust washers for
into each tube, attach a clean cloth to the wire at the
wear and damage. Replace all defective components.
PINION WASHER
YOKE
PINION
NUT
SLINGER
FRONT
BEARING
CUP
PINION
PRELOAD
SHIMS PINION
OIL SEAL
PINION PRELOAD
SPACER
FRONT
BEARING
CONE
SHOULDER FOR
' PINION PRELOAD SPACER J9203-63
Fig. 22 Pinion Front Bearing and Preload Shims Model 70

(5) Examine the ring gear and the pinion gear for
worn and chipped teeth. Examine the ring gear for
damaged attaching bolt threads.
SPECIAL TOOL
If replacement of either gear is necessary,
938
both must be replaced as a matched set only.
(6) Inspect the pinion yoke for cracks, worn
splines, pitted areas, and a rough/corroded seal con
tact surface. Repair or replace the yoke as necessary.
(7) Inspect the pinion bearing preload shims for
cracks, damage and distortion. Install replacement
shims (if necessary) for the preload torque adjust
ment.
(8) Inspect the RWAL/ABS brake exciter ring for
SPECIAL TOOL damage and missing teeth. If not removed, ensure
1130 the ring is firmly pressed onto the differential case.
PINION
Replace the ring if loose or damaged.
DIFFERENTIAL ASSEMBLY
ASSEMBLY
J9403-44 (1) Lubricate all differential components with hy
poid gear lubricant.
Fig. 23 Pinion Rear Bearing Removal (2) Install the following components in the differ
If either differential pinion gear is not reus ential case.
able, both gears must be replaced as a matched • Differential side gears and thrust washers
set only. Do not replace only one gear. • Pinion gears and thrust washers
• Pinion gear mate shaft (align holes in shaft and
case)
(3) Install and seat the lock pin in differential case (6) Press the exciter ring onto the differential case
and mate shaft with a punch and hammer (Fig. 24). using the ring gear as a pilot (Fig. 26).
Peen metal part of case over pin in two places 180
degrees apart.
SLOT 8903-36
Fig. 26 Ring Gear Bolt Hole Alignment

(7) Install new ring gear bolts and alternately
tighten to;
• Model 60 and 70: 163-190 N-m (120-140 ft. lbs.)
torque
(8) Place Master Differential Bearing D-343 on
Fig. 24 Mate Shaft Pin Installation case hubs for Model 60 or D-343 for Models 70 and
If replacement gears and thrust washers were 80 (Fig. 27). Install assembly into housing.
installed, it is not necessary to measure the
gear backlash. Correct fit is due to close ma
chining tolerances during manufacture.
(4) If exciter ring was removed, align exciter ring
tab with slot in differential case (Fig. 25).
J9402-64
Fig. 27 Master Bearing Tools On Hubs

Fig. 25 Exciter Ring Alignment Attach Dial Indicator C-3339 to the pilot stud. Load
(5) Invert the differential case and start two ring indicator plunger against the back of the ring gear
gear bolts. This will provide case-to-ring gear bolt (Fig. 28).
hole alignment.
REAR SUSPENSION AND AXLE 3-35
TOOL G3339 DRIVE PINION

PRODUCTION GEAR DEPTH
VARIANCE
NUMBERS
GEAR MATCHING NUMBER

(SAME AS RING GEAR NUMBER; J9003-100
Fig. 29 Pinion Gear ID Numbers
INNER PINION
BEARING
8903-29
Fig. 28 Differential Case End Play Measurement

(10) Insert a small pry bar between the bearing
cap and left side of differential case. Pry the case as
far as possible to right side (Fig. 28). Zero the dial BUTTON END
indicator pointer.
(11) Pry the case to left side and record the travel CENTERLINE OF
distance. RING GEAR
The measurement above is the shim thickness
necessary for case zero end-play. The total
thickness will be determined during the ring J9403-56
gear backlash adjustment.
(12) Remove indicator and pilot stud. Fig. 30 Pinion Gear Standard Depth/Distance
31). The second method is selective shim between the
PINION GEAR DEPTH INFORMATION
pinion gear head and bearing cone.
Gears are supplied as matched sets only. The iden If new gear set is being installed, note the depth
tifying numbers for the ring and pinion gear are variance etched into original and new pinion gear.
etched into the face of each gear (Fig. 29). A plus (+) Add or subtract the thickness of the original depth
number, minus (-) number or zero (0) is etched into shims to compensate for the difference in the depth
the face of the pinion gear. This number is the variances. Refer to the Depth Variance charts.
amount (in thousandths of an inch) the depth varies For example, if old pinion is plus (+) 1 and the new
from the standard depth setting. The standard depth pinion is minus (-) 3, intersecting figure is (+)0.004
provides the best teeth contact pattern. inch (0.10mm). Add this amount to the original shim.
The standard depth is the distance (Fig. 30) from Or if the old pinion is (-) 3 and the new pinion is (-)
the centerline of the axle shaft/ring gear to the shoul 2, intersecting figure is (-)0.001 inch (0.025mm). Sub
der of the rear pinion bearing. tract this amount from original shim. Refer to the
@ Model 60 axle, the standard depth/distance I S Pinion Gear Depth Variance Chart.
127.00 mm (5.000 inches)
If equipped, the oil slinger must be measured
• Model 70 axle, the standard depth/distance I S and the thickness included with the total shim
136.525 mm (5.375 inches). pack thickness.
• Model 80 axle, the standard depth/distance is Depth shim thickness for the new pinion gear must
147.625 mm (5.812 inches). be determined before installing differential case in
Compensation for depth variance is achieved by housing.
two methods. One method is shims placed between
the pinion gear rear bearing cup and housing (Fig.
between the pinion gear and the inner pinion bearing

cone. For service the shims are placed under the in
ner pinion bearing cup.
Measurements are taken with pinion cups and pin
ion bearings installed in housing. Take measure
ments with Pinion Gauge Set 6730 and Dial
Indicator C-3339 (Fig. 32).
DIAL INDICATOR
Fig. 31 Shim Locations

PINION MEASUREMENT AND ASSEMBLY
PINION GEAR DEPTH MEASUREMENT ARBOR DISC
Pinion gear depth measurement is necessary
when; J9403-45
© Axle housing or differential case is replaced
• Pinion select shim pack is unknown ' Fig. 32 Pinion Gear Depth Gauge Tools
• Ring and pinion gears are replaced (1) Install front pinion bearing cup with (Fig. 33);
Compensation for pinion depth variance is achieved • Model 60 and 70: Installer C-4203 and Handle
with select shims. In production the shims are placed C-4171
Original Pinion Replacement Pinion Gear Depth Variance

Gear Depth
Variance -4 -3 -2 -1 0 +1 +2 +3
+4 + 0.008 + 0.007 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0
+S + 0.007 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0 -0.001
+2 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0 -0.001 -0.002
+1 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 0 -0.001 -0.002 -0.003
§ + 0.004 + 0.003 + 0.002 + 0.001 0 -0.001 -0.002 -0.003 -0.004
+ 0.003 + 0.002 + 0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005
-2 + 0.002 + 0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006
-3 + 0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007
-4 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007 -0.008

J8902-46
• Model 80: Installer C-4308 and Handle C-4171 PINION BLOCK
INSTALLER HANDLE
\ /
PINION HEIGHT
BLOCK
J9403-39
J9402-65
Fig. 35 Pinion Height Block
Fig. 33 Pinion Front Bearing Cup Installation
ARBOR DISC ^ -PINION BLOCK
(2) Install rear pinion bearing cup with (Fig. 34);
• Model 60 and 70: Installer D-lll and Handle
C-4171
• Model 80: Installer C-4204 and Handle C-4171
INSTALLER
PINION
HEIGHT BLOCK
Fig. 36 Gauge Tools In Housing

(5) Firmly place Scooter Block and Dial Indicator
on pinion height block tool and zero the dial indicator
pointer.
(6) Slide the Scooter Block across the arbor while
observing indicator (Fig. 37). Record the longest
travel distance, whether inward (-) or outward (+),
indicated by the pointer.
The plunger travel indicated, plus or minus
HANDLE J9402-66 the variance etched in the gear is the required
thickness for the depth shims.
Fig. 34 Pinion Rear Bearing Cup Installation (7) Measure thickness of each depth shim with a
(3) Assemble Pinion Gauge Set, Pinion Block and micrometer. Then combine shims necessary for the
pinion bearings. Install assembly into differential total shim pack thickness. Include oil slinger or
pinion gear bore and hand tighten cone (Fig. 35). baffle thickness with the total shim pack thick
(4) Place Arbor Disc 6732 on Arbor D-115-3 and po ness.
sition in the bearing cradles (Fig. 36). Install differ (8) Remove measurement tools from differential
ential bearing caps on Arbor Discs and tighten caps housing. Remove rear pinion bearing cup with;
snug only. • Model 60 and 70: Remover D-162 and Handle
Arbor Discs have different steps to fit other C-4171
axle sizes. Pick correct size step for axle being • Model 80: Remover D-159 and Handle C-4171
serviced. (9) Place depth shims in pinion gear rear bearing
bore (Fig. 38). Install bearing cup with;
Fig. 37 Pinion Gear Depth Measurement

• Model • 60 and 70: Installer D-lll and • Handle
c-4171 :
• Model 80: Installer C-4204 and Handle C-4171
INSTALLER
Fig. 39 Pinion Rear Bearing Installation
(14) Install yoke, washer and nut (Fig. 40).Model
60 and 70 install washer with concave surface
against the yoke. Install the yoke with;
• Model 60 and 70: Installer C-3716 and Holder
6719
• Model 80: Installer D-191 and Holder 6719
YOKE
HANDLE J9402-66
Fig. 38 Pinion Rear Bearing Cup instaiiation

(10) Install rear bearing (and slinger if used) on
pinion gear (Fig. 39);
• Model 60: Installer C-3095A
• Model 70 and 80: Installer D-389
(11) Assemble preload shims or collapsible spacer
if used onto pinion and install pinion gear in hous
ing. J9402-61
(12) Install pinion front bearing and oil slinger.
Fig. 40 Pinion Yoke Installation
lip of pinion seal. Install the new seal with; (15) Tighten the yoke nut (Fig. 41) to;
• Model 60 and 70: Installer D-163 and Handle
C-4735
• Model 80: Installer D-187B
REAR SUSPENSION AND AXLE 3 - 39
CAUTION: When collapsible spacer is used newer on the yoke 3/8 of an inch from one point of the pin
loosen pinion gear nut to decrease pinion gear ion nut (Fig. 42). Tighten the nut until the point of
bearing preload torque. Never exceed specified pre the nut lines up with the scribe mark. This will
load torque. If preload torque is exceeded a new tighten the nut to the correct torque.
collapsible spacer must be installed. The torque se (16) Check bearing preload torque with an inch
quence will have to be repeated. pound torque wrench (Fig. 43). The torque necessary
to rotate the pinion gear should be;
On Model 60 with a collapsible spacer tighten nut • Original Bearings — 1-3 N-m (10-20 in. lbs.)
in small increments until rotating torque is achieved. • New Bearings — 2-5 N-m (20-40 in. lbs.)
Measure the preload torque frequently to avoid
over-tightening the nut.
& Model 60: 292-427 N-m (215-315 ft. lbs.) torque
© Model 70: 298-379 N-m (220-280 ft. lbs.) torque
DIFFERENTIAL
Fig. 43 Rotating Torque

Axles equipped with shims, if preload torque is not
within specified tolerance, correct the shim thickness
accordingly (Fig. 44);
• Increase the preload torque, decrease the shim
Fig, 41 Torque Yoke thickness
• Decrease the preload torque, increase the shim
thickness
RING GEAR BACKLASH AND CONTACT PATTERN

RING GEAR BACKLASH MEASUREMENT
(1) Place Master Differential Bearing case hubs;
• Model 60 and 70: Master Bearings D-343
• Model 80: Master Bearings D-346
Attach Dial Indicator C-3339 to the pilot stud. Load
indicator plunger against the back of the ring gear
(Fig. 45). Ensure ring and pinion gear teeth are
tightly meshed. Zero the indicator.
(3) Insert a small pry bar between the bearing cap
and right side of differential case. Pry the case as far
as possible to left side (Fig. 45). Zero the dial indica
Fig. 42 Pinion Nut
tor pointer.
Optional Torque Method Dana 80: Torque pin (4) Repeat the measurement several times to check
ion nut to 339 N-m (250 ft. lbs.). Then scribe a line consistency. Record the travel distance.
3 - 40 REAR SUSPENSION AND AXLE _ _ _ BR
preload and backlash. These shim must be

placed on the opposite side.
(5) Remove indicator and pilot stud.
(6) Remove the differential case from housing.
(7) Remove the master bearing tools from the dif
ferential case hubs.
(8) Position the backlash shims (with determined
thickness) on case hub (ring gear side). Install bear
ing on the hub with Installer C-4190 and Handle
C-4171.
(9) Position the remaining zero end-play shims on
hub at opposite side of case. Include an additional
0.015-in (0.38-mm) thick shim on this hub. This will
provide the required differential bearing preload
torque.
(10) Install bearing on the hub with Installer
(11) Match each bearing cup with bearing (origi
nal). Install the cups on the bearings.
(12) Position Spreader W-129B with the tool dowel
holddown clamps and tighten the tool turnbuckle fin
ger-tight.
SPECIAL TOOL
Fig. 44 Shim Locations
Fig. 46 Differential Housing Separation

(13) Install a pilot stud at the left side of the dif
ferential housing. Attach Dial Indicator to housing
pilot stud. Load the indicator plunger against the op
posite side of the housing (Fig. 46) and zero the indi
cator.
CAUTION: Do not spread over 0.38 mm (0.015 in), if
Fig. 45 Ring Gear Backlash Measurement the housing is over-separated, it could be distorted
The measurement above shows shim thick or damaged.
ness necessary to eliminate ring gear backlash. (14) Separate the housing enough to install the
The shims must be placed at the ring gear case in the housing. Separate housing a maxi
flange side between the case and bearing. Sub mum distance of 0.38 mm (0.015 in) with the
tract this thickness from case zero end-play spreader tool. Measure the distance with the dial
shim thickness. This amount pirns 0.38mm (0.015 indicator.
in.) will be required for differential bearing (15) Remove the dial indicator.
(16) Install case in the housing. Ensure the differ

ential bearings are fully seated. Remove the
spreader.
(17) Observe the assembly reference marks and po
sition the bearing caps at their original locations
(Fig. 47). Tighten the bearing cap bolts to 95-122 N-m
(70-90 ft. lbs.) torque.
Fig. 48 Ring Gear Backlash Measurement

RING GEAR TEETH CONTACT PATTERN
ANALYSIS
The ring gear teeth contact patterns will show if
the pinion gear depth shim(s) have the correct thick
ness. It will also show if the ring gear backlash has
been adjusted correctly. The backlash must be main
Fig. 47 Differential Bearing Cap Reference Letters tained within the specified limits until the correct
teeth contact patterns are obtained.
(18) Rotate the assembly several revolutions to
(1) Apply a thin coat of hydrated ferric oxide, to
seat bearings. Measure backlash at three equally the drive and coast side of ring gear teeth.
spaced locations with a dial indicator (Fig. 48). (2) Rotate the ring gear one complete revolution in
The ring gear backlash must be within 0.18 - both directions while a load is being applied. Insert a
0.23 mm (0.005 - 0.009 inch). It cannot vary pry bar between the differential housing and the case
more than 0.05 mm (0.002 inch) between t h e flange. This action will produce distinct contact pat
points checked. terns on both the drive side and coast side of the ring
(19) Excessive backlash is corrected by moving the gear teeth.
ring gear teeth closer to the pinion gear teeth. Insuf (3) Note patterns in compound. Refer to (Fig. 49)
ficient backlash is corrected by moving the ring gear for interpretation of contact patterns and adjust ac
away from the pinion gear. Backlash correction is ac cordingly.
complished by transferring shims from one side to (4) Install the axle shafts. Refer to Axle Shaft In
stallation within this group.
the other. (5) Install the housing cover. Refill the differential
If the mesh and backlash steps have been followed with lubricant.
in the procedures above, good gear teeth contact pat (6) Install the RWAL/ABS brake speed sensor and
terns should exist. cover onto the axle housing. Tighten the sensor to 24

OF RING OF RING

ON THE DRIVE SIDE OF TOOTH.
HEEL TOE TOE HEEL PATTERN SHOULD BE CENTERED ON
THE COAST SIDE OF TOOTH,
BE SOME CLEARANCE BETWEEN
CONTACT PATTERN AND TOP OF
THE TOOTH.

SHIM REQUIRED.
RING GEAR BACKLASH CORRECT

SHIM REQUIRED.

GEAR BACKLASH.

GEAR BACKLASH.
J9003-24
Fig. 49 Gear Teeth Contact Patterns

TRAC-LOK/POWER-LOK DIFFERENTIAL
SERVICE INFORMATION
Trac-Lok differential is available on 9 1/4 axles and
Model 60 and 80 axles. Power-Lok differential is RING DRIVE
GEAR PINION
available on Model 70 axles. ,
In a conventional differential, torque applied to the CASE
ring gear is transmitted to the axle shafts through
differential gears. During normal operation, the PINION GEAR
torque transmitted to each wheel is equal at all
times. However, if one wheel spins, the opposite MATE
wheel will generate only as much torque as the spin SHAFT
ning wheel.
In the Trac-Lok/Power-Lok differential, part of the
ring gear torque is transmitted through clutch packs.
The clutch packs contain multiple disc clutches, that
have radial grooves on the plates and concentric
grooves on the discs.
Trac-Lok differentials can also use plates and discs
with bonded fiber material that is smooth in appear
ance. CLUTCH
In operation, the Trac-Lok/Power-Lok clutches are PACK
engaged by two concurrent forces. The first being
preload force exerted through dished spring washers
contained in the clutch packs. The second from sepa SIDE GEAR CLUTCH
PACK
rating forces generated by the side gears as torque is
applied through the ring gear (Fig. 1).
The Trac-Lok design provides differential action J9303-15
needed for turning corners and for driving straight
ahead. However, when one wheel looses traction, the Fig. 1 Limited Slip Differential Operation—Both
clutch packs transfer additional torque to the wheel Wheels Driving
having the most traction. Trac-Lok differentials resist TRAC-LOK/POWER-LOK DIFFERENTIAL TEST
wheel spin on bumpy roads and provide more pulling
power when one wheel looses traction. Pulling power WARNING: WHEN SERVICING VEHICLES WITH A
is provided continuously until both wheels loose trac LIMITED SLIP DIFFERENTIAL DO NOT USE THE EN
tion. If both wheels slip due to unequal traction, GINE TO TURN THE AXLE AND WHEELS. BOTH
Trac-Lok operation is normal. In extreme cases of dif REAR WHEELS i i U S T BE RAISED AND THE VEHI
ferences of traction, the wheel with the least traction CLE SUPPORTED, A LIMITED SLIP AXLE CAN EX
may spin. ERT ENOUGH FORCE (IF ONE WHEEL IS IN
CONTACT WITH THE SURFACE) TO CAUSE THE
NOISE DIAGNOSIS VEHICLE TO MOVE.
If a noise occurs when turning corners, the most
probable cause is incorrect or contaminated lubri The differential can be tested without removing the
cant. Before removing the Trac-Lok unit for repair, differential case by measuring rotating torque. Make
sure brakes are not dragging during this measure
drain, flush and refill the axle with the specified lu
ment.
bricant. Refer to Lubricant change in this Group. (1) Engine off, transmission in neutral, and park
A friction modifier must be added after repair ser ing brake off.
vice or a lubricant change. (2) Place blocks in front and rear of both front
Vehicles with a limited slip differential should be wheels.
road tested by making 10 to 12 slow figure-eight (3) Jack up one rear wheel until it is completely off
turns. This maneuver will pump the lubricant the ground.
through the clutch discs to eliminate a possible chat (4) Remove wheel and bolt Special Tool 6790 for
ter or pop noise complaint. Trac-Lok or Special Tool for Power-Lok to studs.
Refer to Group 0, Lubrication and Maintenance for (5) Use torque wrench on special tool • to rotate
additional information. wheel and read rotating torque (Fig. 2,3).
SPECIAL
TOOL TORQUE
6im WRENCH
J9403-52
Fig. 3 Power-Lok Test

Fig. 2 Trac-Loc Test
fer to this illustration during repair service for com
(6) If rotating torque is less than 22 N-m (30 ft.
ponent detail and their location.
lbs.) or more than 271 N-m (200 ft. lbs.) on either
wheel the unit should be service. DISASSEMBLY
Service to the Trac-Lok differential requires the
LUBRICANTS
use of Tool Set C-4487 (J-23781). Refer to differential
The lubricant recommended for Trac-Lok/Power-
overhaul in the Model 60 section for differential case
Lok differential is API grade GL 5. A friction modifier
removal and installation.
must be added.
(1) Clamp one axle shaft in a vise (with protective
Refer to Group 0, Lubrication and Maintenance for
jaws) with the splined end upward (Fig. 5).
additional information.
(2) Place shop towels on vise to avoid gear damage
TRAC-LOK 9 1 \ AND MODEL 60 AXLES during removal of the ring gear. Position the differ
ential case on the axle shaft (Fig. 6).
The Trac-Lok (limited-slip) differential used on 9 (3) Remove and discard the ring gear bolts. They
1/4 and Model 60 axles has a one-piece differential are not reusable.
case. The components are illustrated in (Fig. 4). Re-
DIFFERNTIAL
CASE
SHAFT
LOCK
PIN
CLUTCH PACK PINION

MATE
SHAFT J9203-13
Fig. 4 Trac-Lok Differential

DIFFERENTIAL
Fig. 7 Pinion Gear Mate Shaft Lock Pin Removal
SPECIAL
TOOL
C-4487-1
J8903-42
Fig. 5 Axle Shaft As Holding Fixture
RING GEAR
DIFFERENTIAL SIDE
CASE GEAR J9203-4
Fig. 8 Step Plate Tool Installation

(10) Use a small screw driver, position it in slot of
J8903-43
Threaded Adapter C-4487-3 (Fig. 9). This will pre
vent adapter from turning.
Fig. 6 Differential Case On Shaft (11) Tighten forcing screw tool enough to relieve
(4) Remove the case from the fixture. Remove the clutch pack tension. Remove both pinion thrust
ring gear from the case by tapping it with brass drift washers (Fig. 10).
and a hammer. . (12) Loosen the forcing screw tool until the clutch
(5) Position the case on the fixture. pack tension is relieved.
(6) Remove the pinion gear mate shaft retaining (13) Insert Turning Bar C-4487-4 in case. Rotate
roll pin (Fig. 7). case with tool until pinion gears can be removed (Fig.
(7) Remove the pinion gear mate shaft. Use a ham 11). Remove tools from the case.
mer and a brass drift and tap the shaft out. (14) Remove top side gear and clutch pack. Keep
(8) Install and lubricate Step Plate C-4487-1 (Fig. plates in correct order during removal.
8). (15) Remove case from fixture. Remove remaining
(9) Assemble Threaded Adapter C-4487-3 into top clutch pack (Fig. 12).
side gear. Thread forcing Screw C-4487-2 into (16) Remove clutch pack retaining clips. Mark each
adapter until it becomes centered in adapter plate. clutch pack for installation reference.
3 - 46 BEAR SUSPENSION AND AXLE BR
SOCKET
DISC
C-4487-1
Fig. 11 Pinion Gear Removal
Fig, § Threaded Adapter Installation
SIDE GEAR DIFFERENTIAL
SPECIAL AND CLUTCH DISC CASE
Fig. 10 Remove Pinion Thrust Washer

GLEAMING AND INSPECTION
(1) Clean all components in cleaning solvent. Dry Fig. 12 Side Gear & Clutch Disc Removal
components with compressed air. PRESOAK PLATES AND DISC
(2) Inspect clutch pack plates for wear, scoring or Plates and disc with fiber coating (no groves or
damage. Replace both clutch packs if any one compo lines) must be presoaked in Friction Modifier before
nent in either pack is damaged. assembly. Soak plates and discs for a minimum of 20
(3) Inspect side and pinion gears. Replace any gear minutes. Add remaining Friction Modifier to differen
that is worn, cracked, chipped or damaged. tial after assembly.
(4) Inspect differential case and pinion shaft. Re
place if worn or damaged. ASSEMBLY
(1) The clutch discs are replaceable as complete
sets only. If one clutch disc pack is damaged,
both packs must be replaced. Lubricate each com UPPER SIDE

ponent with gear lube before assembly and installa GEAR AND CLUTCH
DISC PACK
tion.
(2) Assemble the clutch discs into packs (Fig. 13).
(3) Secure disc packs with retaining clips (Fig. 13).
(4) Position assembled clutch disc packs on the
side gear hubs.
DIFFERENTIAL
CLUTCH PACK CASE .
RETAINER
SPECIAL TOOL
C-4487-1 J9203-6
Fig. 15 Upper Side Gear & Clutch Disc Pack

Installation
SIDE GEAR
(9) Hold assembly in position. Insert Threaded
Adapter C-4487-3 into top side gear, insert forcing
RETAINER Screw C-4487-2.
J8903-50 (10) Tighten forcing screw tool to compress clutch
discs.
Fig. 13 dutch Disc Pack
(11) Install pinion gears. Rotate case with Turning
(5) Position case on fixture. Bar C-4487-4. Make sure holes of pinion mate gears
(6) Install clutch pack and side gear in lower bore are aligned with case.
(Fig. 14). Be sure clutch pack retaining clips re (12) Tighten forcing screw to compress the conned
main in position and are seated in the case plates. Lubricate and install pinion gear thrust wash
pockets. ers 'with a small screw driver or shim driver.
(13) Insert and tap the pinion shaft into the differ
LOWER
DIFFERENTIAL SIDE GEAR ential case (Fig. 16).
CASE AND
PINION MATE
CLUTCH DISC DIFFERENTIAL
SHAFT
PACK CASE
/
/
J9003-4
Fig. 14 Clutch Discs & Lower Side Gear Installation
(7) Install lubricated Step Plate C-4487-1 on first

clutch pack (Fig. 15). Fig. 16 Pinion Gear Mate Shaft Installation
(8) Install the upper side gear and clutch disc pack (14) Secure pinion shaft with new roll pin. Stake
(Fig. 15). roll pin to differential case.
POWER-LOK MODEL 70 AXLE AND TRAC-LOK

MODEL 10 AXLE
The Trac-Lok differential for the Model 80 axle
looks like the Power-Lok differential for the Model 70
BUTTON
axle but their are differences. HALF
The Model 80 Trac-Lok differential has a one-piece
cross shaft and uses 6 disc and 5 plates for each
CLUTCH
clutch pack. Only one disc in each clutch pack is PLATES
dished.
The Model 70 Power-Lok differential has a two-
piece cross shaft and uses 2 disc and 3 plates for
FLANGE
each clutch pack. All disc are dished in this unit. HALF
DISASSEMBLY
Pay close attention to the clutch pack ar
rangement during this procedure. Note the di
rection of the concave and convex side of the
plates and discs.
(1) Mark the ring gear half and cover half for in
stallation reference (Fig. 18). J9203-73
Fig. 19 Cover Half Removal
(2) Inspect clutch pack plates for wear, scoring or
damage. Replace both clutch packs if any one compo
nent in either pack is damaged.
(3) Inspect side and pinion gears. Replace any gear
that is worn, cracked, chipped or damaged.
(4) Inspect differential case and pinion shaft. Re
place if worn or damaged.
ASSEMBLY
The clutch discs are replaceable as complete sets
only. If one clutch disc pack is damaged, both
packs must be replaced. Lubricate each component
with gear lube before assembly and installation.
(1) Saturate the clutch plates with Hypoid Gear
Lubricant or Additive. Assemble clutch packs into the
side gear plate in exactly the same position as re
moved (Fig. 20, 21, 22).
(2) Line up the plate ears and install the assem
J9203-72 bled pack into the flange half (Fig. 23). Make sure
the clutch plate lugs enter the slots in the case.
Fig. 18 Case Marked
Also make sure the clutch pack bottoms out on
(2) Remove the case attaching bolts and remove the case.
the button cover half (Fig. . 19). (3) Install pinion mate shafts and pinion mate
(3) Remove the pinion mate gear, side gear (clutch) gears (Fig. 24).Make sure shafts are correctly in
ring and clutch pack cross shaft (Fig. 20, 21). Keep stalled according to the alignment marks.
these parts with the button cover half for correct in (4) Lubricate and install the other side gear and
stallation in their original positions. clutch pack as done above in Step 3.
(4) Remove the same parts listed above from the (5) Correctly align and assemble button half to
ring gear flange half of the case. Keep these parts flange half. Install case body screws finger tight.
with the flange cover half for correct installation in (6) Tighten body screws alternately and evenly.
their original positions. Tighten screws to 89-94 N-m (65 to 70 ft. lbs.) torque
(Fig. 25).
CLEANING AND INSPECTION If bolt heads have 7 radial lines or the number 180
(1) Clean all components in cleaning solvent. Dry stamped on the head, tighten these bolts to 122-136
components with compressed air. N-m (90 to 100 ft. lbs.) torque.
FLANGE HALF SIDE

GEAR
PINION MATE
GEAR
BUTTON HALF
PLATE
CROSS SHAFT
J9503-8
Fig. 20 Trac-Lok Dana., 80 Components
FLANGE HALF CLUTCH PINION MATE

RING GEAR
SCREW
PLATE DISHED PLATE DISHED PINION MATE

DISC DISC CROSS SHAFT BUTTON HALF
J9203-74
Fig. 21 Power-Lok Components

- 50 REAR SUSPENSION AND AXLE BR
Fig. 23 Clutch Pack Installation Fig. 25 Case Half Installation

AXLE SPECIFICATIONS
11/4 AXLE MODEL 70 AXLE

Axle Type Semi-floating, hypoid Axle Type Hypoid
Lubricant.. ..................SAE 80W-90 Lubricant ..Thermally Stable SAE 80W-90
Lube Capacity..............................2.26 L (4.77 pts.) Lube Capacity
Axle Ratio Options...........................3.21 3.55 3.92 4x2............... 3.311 L (7.0 pts.)
Differential 4x4...... ......................................3.666 L (7.75 pts.)
Case Clearance 0.12 mm (0.005 in.) Axle Ratio 3.54 4.10
Case Flange Runout 0.076 mm (0.003 in.) Ring Gear
Bearing Preload 102 N-m (75 ft. lbs.) Diameter 266.7 mm (10.50 in.)
Ring Gear Backlash ...0.10-0.23 mm (0.004-0.009 in.)
Diameter 23.50 cm (9.25 in.) Pinion Std. Depth 136.525 mm (5.375 in.)
Backlash 0.12-0.20 mm (0.005-0.008 in.)
Pinion Bearing Preload
Runout 0.127 mm (0.005 in.)
Pinion Bearing Original Bearing 1-3 N-m (10-20 in. lbs.)
Preload 1-2 N-m (10-20 in.lbs.) New Bearing 2-5 N-m (20-40 in. lbs.)
MODEL 60 AXLE MODEL 80 AXLE

Axle Type Hypoid Axle Type Hypoid
Lubricant Thermally Stable SAE 80W-90 Lubricant .Thermally Stable SAE 80W-90
Lube Capacity Lube Capacity
4x2......................................... ......2.95 L (6.26 pts.)' " 4x2 3.22 L (6.8 pts.)
4x4 .......3.43 L (7.25 pts.) 4x4 4.79 L (10.1 pts.)
Axle Ratio 3.54 4.09 Axle Ratio 3.54 4.10
Ring Gear Ring Gear
Diameter 247.7 mm (9.75 in.) Diameter 279.4 mm (11.00 in.)
Backlash .0.10-0.23 mm (0.004-0.009 in.) Backlash ....0.13-0.23 mm (0.005-0.009 in.)
Pinion Std. Depth 127.0 mm (5.000 in.) Pinion Std, Depth ,. 124.625 mm (5.812 in.)
Pinion Bearing Preload Pinion Bearing Preload
Original Bearing 1-3 N-m (10-20 in. lbs.) Original Bearing 1-3 N-m (10-20 in. lbs.)
New Bearing 2-5 N-m (20-40 in. lbs.) New Bearing ...2-5 N-m (20-40 in. lbs.)
REAR SUSPENSION COMPONENTS MODEL 60 70 and 80 AXLE

Shock Absorber Differential
Lower Nut 136 N-m (100 ft. lbs.) Fill Hole Plug ....34 N-m (25 ft. lbs.)
Shock Upper Nut 95 N-m (70 ft. lbs.) Cover Bolts 47 N-m (35 ft, lbs.)
Jounce Bumper Bolts 45 N-m (33 ft. lbs.) Bearing Cap Bolts 108 N-m (80 ft. lbs.)
Spring Clamp Nut Pinion Nut
6,010-10,500 GVW 149 N-m (110 ft. lbs.) Model 60 292-427 N-m (215-315 ft. lbs.)
11,000 GVW Cab-Chassis 163 N-m (120 ft. lbs.) Model 70 298-379 N-m (220-280 ft. lbs.)
Spring Front and Rear Eye Model 80 597-678 N-m (440-500 ft. lbs.)
Bolt/Nut 6,010-7,500 GVW 136 N-m (100 ft. lbs.) Ring Gear Bolt
Bolt/Nut 8,800-1,100 GVW 190 N-m (140 ft. lbs.)
Model 60 & 70 163-190 N-m (120-140 ft. lbs.)
9 1/4 INCH AXLE Model 80 272-325 N-m (200-240 ft. lbs.)
Axle to Hub Bolt 123 N-m (90 ft. lbs.)
DESCRIPTION TORQUE Power-Lok Case Bolt
Diff. Cover Bolt 47 N-m (35 ft. lbs.) Standard 89-94 N-m (65-70 ft. lbs.)
Bearing Cap Bolt 136 N-m (100 ft, lbs.) Heavy Duty 122-136 N-m (90-100 ft. lbs.)
Pinion Nut 285 N-m (210 ft. lbs.) RWAL/ABS Sensor Bolt 24 N-m (18 ft. lbs.)
Ring Gear Bolt 102 N-m (75 ft. lbs.)
Backing Plate Bolt 64 N-m (48 ft. lbs.)
RWAL/ABS Sensor Bolt 24 N-m (18 ft. lbs.)
BR BRAKES 5 -1
BRAKES
CONTENTS
page page
ALL-WHEEL ANTILOCK BRAKE SYSTEM (ABS) . 36 POWER BRAKE VACUUM PUMP (DIESEL
DISC BRAKES 48 MODELS) 21
DRUM BRAKES 63 REAR WHEEL ANTILOCK BRAKE (RWAL)
GENERAL INFORMATION 1 SYSTEM ?M
MASTER CYLINDER 9 SERVICE BRAKE DIAGNOSIS 3
PARKING BRAKES 73 SPECIFICATIONS 77
POWER BRAKE BOOSTER—BRAKE PEDAL—
BRAKELIGHT SWITCH 16
GENERAL INFORMATION
INDEX
page page
Antilock Brake Systems 1 Brake Warning Lights 2

Brake Fluid/Lubricants/Cleaning Solvents 2 Model Identification 2
Brake Safety Precautions 2 Service Brake Components . . . . . . . . . . . . . . . . . . . 1
SERVICE BRAKE COMPONENTS Brakelining Material

All BR models are equipped with power assisted, Factory installed front and rear brakelining is as
front disc and rear drum brakes. Rear wheel antilock bestos free. Service replacement brakelining from the
(RWAL) brakes are standard. All-wheel antilock Mopar parts system will also be asbestos free.
(ABS) brakes are available as an option.
Master Cylinder/Power Brake Booster
Front Disc Brakes A two section master cylinder and tandem (dual)
Front disc brakes consist of single piston calipers, diaphragm, vacuum power brake booster is used for
semi metallic brakelining, and vented disc brake ro all applications.
tors. The master cylinder on all models is serviceable.
Three different calipers are used. They are identi Models with the Cummins diesel engine, are also
fied by caliper piston diameter and model application equipped with a vacuum pump. The pump supplies
which are: the vacuum necessary for power booster operation.
• calipers on 1500 models have a 75 mm (2.95 in.)
piston Combination Valve
• calipers on 2500 models have an 80 mm (3.1 in.) A combination valve is used on all models. The
piston valve consists of a front brake metering (hold-off)
• calipers on 3500 models and 2500 4x4 models with valve and a front/rear pressure differential switch.
Dana 60 front axle, have an 86 mm (3.385 in.) piston
ANTILOCK BRAKE SYSTEMS
Rear Drum Brakes A rear wheel antilock (RWAL) brake system is
Rear drum brakes are dual shoe units with an au standard on all models. An all-wheel antilock brake
tomatic adjustment mechanism. Three different system (ABS) is available as an option. Both antilock
drum brake assemblies are used: systems are manufactured by the Kelsey-Hayes Cor
• 1500 models have 11 x 2 in. rear drum brakes poration.
• 2500 models have 13 x 2.5 in. rear drum brakes The RWAL and ABS antilock systems are designed
• 3500 models have 13 x 3.5 in. rear drum brakes to prevent wheel lockup during periods of high wheel
5 -2 BRAKES BR
slip when braking. Preventing lockup is accomplished i i i E L iiElTiFiCATiOl

by modulating fluid pressure to the wheel brake Truck model and capacity designations are:
units. Refer to the antilock brake sections for opera
• 1500 indicates 1/2 ton models
tion and service information.
The RWAL antilock system uses one control valve. • 2500 indicates 3/4 ton model
The ABS antilock system uses two control valves. Re • 3500 indicates 1-ton model
fer to the appropriate antilock brake section for valve The model identification and capacity ratings are
operation, diagnosis and service procedures. used throughout this group to differentiate from, or
indicate application of a specific brake component.
BRAKE WARNING LIGHTS BRAKE SAFETY PRECAUTIONS
A red warning light alerts the driver if a pressure
differential exists between the front and rear hydrau WARNING: ALTHOUGH A S B E S T O S F R E E B R A K E -
lic systems. The light also alerts the driver when the LINING IS FACTORY INSTALLED ON A L L B R MOD
parking brakes are applied. The light is located in E L S , E X E R C I S E C A R E W H E N REPAIRING A
the instrument cluster. VEHICLE WITH PRIOR B R A K E S E R V I C E . SOME AF
An amber warning light is used for the antilock T E R MARKET BRAKELINING MAY CONTAIN A S
system. This light is located in the same side of the B E S T O S . A S A RESULT, DUST AND DIRT ON
instrument cluster as the red indicator light. The an B R A K E PARTS MAY CONTAIN A S B E S T O S F I B E R S .
tilock light alerts the driver if a system fault occurs. BREATHING E X C E S S I V E CONCENTRATIONS OF
A S B E S T O S F I B E R S CAN C A U S E S E R I O U S BODILY
B i A I E FLUiD/LUBliCllTS/CLElliie SQLVE1TS
HARM. E X E R C I S E C A R E W H E N SERVICING B R A K E
Recommended fluid for all BR models is Mopar COMPONENTS. DO NOT C L E A N B R A K E COMPO
brake fluid or equivalent meeting SAE standard NENTS WITH C O M P R E S S E D AIR OR B Y DRY
J1703 and Federal standard DOT 3. BRUSHING. U S E A VACUUM C L E A N E R S P E C I F I
Use Mopar multi mileage grease to lubricate cali CALLY DESIGNED FOR REMOVING B R A K E DUST.
per slide surfaces, drum brake pivot pins and shoe IF A SUITABLE VACUUM C L E A N E R IS NOT AVAIL
contact points on the backing plates. Use GE 661 or A B L E , CLEANING SHOULD B E DONE USING A WA
Dow 111 silicone grease (or equivalent) on caliper TER DAMPENED CLOTH. DO NOT CREATE DUST
bushings and mounting bolts.
B Y SANDING, GRINDING, OR SHAVING B R A K E LIN
Use Mopar brake cleaner, or denatured alcohol to
INGS U N L E S S P R O P E R L Y VENTED EQUIPMENT IS
clean or flush brake system components. These are
U S E D . DISPOSE OF A L L DUST AND DIRT THAT
the only cleaning materials recommended.
MAY CONTAIN A S B E S T O S F I B E R S IN S E A L E D
CAUTION: Newer use gasoline, kerosene, methyl B A G S OR CONTAINERS. THIS WILL MINIMIZE E X
(wood) alcohol, motor oil, transmission fluid, or any P O S U R E TO Y O U R S E L F AND OTHERS. FOLLOW
fluid containing mineral' oil to clean the system ALL RECOMMENDED P R A C T I C E S P R E S C R I B E D B Y
components. These fluids damage rubber cups and THE OCCUPATIONAL S A F E T Y AND HEALTH ADMIN
seals. If system contamination is suspected, check ISTRATION AND THE ENVIRONMENTAL PROTEC
the'fluid for dirt, discoloration, or separation into TION AGENCY FOR THE HANDLING, P R O C E S S I N G ,
distinct layers. Drain and flush the system with new AND DISPOSITION OF DUST OR DIRT WHICH MAY
brake fluid if contamination is suspected. CONTAIN A S B E S T O S F I B E R S .
BR SERVICE BRAKE DIAGNOSIS 5-3
SERVICE BRAKE DIAGNOSIS
INDEX
page page
Brake Drag .. 5 Hard Pedal or High Pedal Effort 5

Brake Fade 5 Low Brake Pedal 4
Brake Fluid Contamination 6 Low Vacuum Switch—Diesel Models . 3
Brake Noise . 6 Master Cylinder/Power Booster Test . 7
Brake Pedal Has Spongy Feel . . . . . . . . . . . . . . . . 4 Pedal Falls Away 4
Brake Pedal Pulsation 5 Power Booster Check Valve Test 7
Brake Pull . . 5 Power Booster Vacuum Test 7
Brake Warning Lights 3 Preliminary Brake Check 4
Brakes Do Not Hold After Driving Through Deep Rear Brake Grab or Pull 5
Water Puddles , 6 Road Testing 4
Component Inspection 4
Service Brake Diagnosis Procedures . . . . . . . . . . . . 3
Contaminated Brakelining 6
General Information 3 Testing Diesel Engine Vacuum Pump Output . . . . . . 7
GENERAL INFORMATION The red light illuminates when the parking brakes
The diagnosis information in this section covers are applied, or when a pressure drop occurs in the
service brake components only. front or rear brake hydraulic circuit.
Antilock system diagnosis is provided in the appro The red light also illuminates for approximately
priate antilock brake section. Refer to the Rear 2-4 seconds at every engine start up. This is a self
Wheel Antilock Brake System (RWAL) and All-Wheel test feature designed to check bulb and circuit oper
Antilock Brake System (ABS) sections as necessary. ation.
Service brake components consist of the brake- A pressure drop in the front or rear brake hydrau
shoes, calipers, wheel cylinders, brake drums and ro lic circuit activates the pressure differential valve in
tors, brakelines, master cylinder, brake booster, and side the combination valve. A pressure decrease
parking brake components. moves the valve toward the low pressure side. As the
valve moves, it pushes the pressure differential
SERVICE BRAKE DIAGNOSIS PROCEDURES switch contact plunger upward. This closes the
Brake diagnosis involves determining if the prob switch internal contacts and completes the circuit to
lem is related to a mechanical, hydraulic or vacuum the red warning light. The light will remain on until
operated component. A preliminary check, road test repairs are made and normal fluid pressure restored.
ing and component inspection can all be used to de
termine a problem cause. LOW VACUUM SWITCH—DIESEL MODELS
Road testing will either verify proper brake opera
tion or confirm the existence of a problem. Compo On diesel models, the red brake warning light is
nent inspection will, in most cases, identify the also used to alert the driver of a low brake booster
actual part causing a problem. vacuum condition. The warning light is in circuit
The first diagnosis step is the preliminary check. with a vacuum warning switch mounted on the
This involves inspecting fluid level, parking brake ac driver side fender panel. The vacuum side of the
tion, wheel and tire condition, checking for obvious switch is connected to the power brake booster. The
leaks or component damage and testing brake pedal electrical side of the switch is connected to the red
response. brake warning light.
The low vacuum switch monitors booster vacuum
BRAKE WARNING LIGHTS level whenever the engine is running. If booster vac
The red light is in circuit with the parking brake uum falls below 8.5 inches for a minimum of 10 sec
switch and pressure differential switch in the combi onds, the switch completes the circuit to the warning
nation valve. On diesel models, the red light is also light causing it to illuminate. The warning light is
in circuit with the low vacuum switch. designed to differentiate between a low vacuum con
The amber antilock light is connected to the an dition and a hydraulic circuit fault.
tilock system. The light illuminates only when a fault
occurs within the RWAL or ABS system.
5 -4 SERVICE BRAKE DIAGNOSIS BR
PRELIMINARY BRAKE CHECK (3) During road test, make normal and firm brake
(1) Check condition of tires and wheels. Damaged stops in 25-40 mph (40-64 Km/h) range. Note faulty
wheels and worn, damaged, or underinflated tires operation such as pull, grab, drag, noise, low pedal,
can cause pull, shudder, tramp, and a condition sim hard pedal, noise, etc. If constant scraping noise is
ilar to grab. noted, brakeshoe wear tabs are probably contacting
(2) If complaint was based on noise when braking, rotor surface.
check suspension components. Jounce front and rear (4) Return to shop, disassemble and inspect as
of vehicle and listen for noise that might be caused needed. Refer to problem diagnosis information for
by loose, worn or damaged suspension or steering causes of various brake conditions.
components.
(3) Inspect brake fluid level and condition. Note COMPONENT INSPECTION
that reservoir fluid level will decrease as normal Fluid leak points and dragging brake units can
brake lining wear occurs. Also note that b r a k e usually be located without removing any components.
fluid tends to darken over time. This is normal The area around a leak point will be wet with fluid.
and should not be mistaken for contamination, The components at a dragging brake unit (wheel,
if the fluid is clear and free of contaminants, it tire, rotor) will be quite warm or hot to the touch.
is still OK. Other brake problem conditions will require compo
(a) If fluid level is abnormally low, look for evi nent removal for proper inspection. Raise the vehicle
dence of leaks at calipers, wheel cylinders, brake- and remove the necessary wheels for better visual ac
lines and master cylinder. cess.
(b) If fluid appears contaminated, drain out a
sample. If fluid is separated into layers, or obvi PEDAL FALLS AWAY
ously contains oil, or a substance other than brake A brake pedal that falls off under steady foot pres
fluid, system seals and cups will have to be re sure is the result of a system leak. The leak point
placed and hydraulic system flushed. could be at a brakeline, fitting, hose, or caliper. In
(4) Check parking brake operation. Verify free ternal leakage in the master cylinder caused by worn
movement and full release of cables and pedal. Also or damaged piston cups, may also be the problem
note if vehicle was being operated with parking cause.
brake partially applied. If leakage is severe, fluid will be evident at or
(5) Check brake pedal height and feel. Verify that around the leaking component. However, internal
pedal does not bind and has adequate free play. Note leakage in the master cylinder may not be physically
if pedal is low, or spongy. Do not road test if pedal is evident. Refer to the cylinder test procedure in this
extremely low; inspect, identify, and correct faulty section.
component.
(a) If pedal lacks free play, check pedal and LOW BRAKE PEDAL
power booster for being loose, or for bind condition. If low pedal is experienced, pump the pedal several
(b) If pedal is'extremely low and red light is on, times. If the pedal comes back up, worn lining and
do not road test as serious leak has developed in worn rotors or drums are the likely causes.
hydraulic system. Locate leak source and repair as If the pedal is extremely low and the red light
needed. comes on, there is a major leak in the hydraulic sys
(6) If components checked appear OK, road test ve tem.
hicle. Note that a decrease in fluid level in the master
ROAD TESTING cylinder reservoir may only be the result of normal
(1) If complaint involved low brake pedal, pump lining wear. Fluid level will decrease in proportion to
pedal and note if pedal returns to normal height. Do wear. It is a result of the outward movement of cali
not road test if pedal remains low, or falls off. This per and wheel cylinder pistons to compensate for nor
indicates system leak or severely worn brake parts. mal wear. Top off the reservoir fluid level and check
(2) Check pedal response with transmission in brake operation to verify proper brake action.
Neutral and engine running. Pedal should remain
firm under steady foot pressure. Do not road test if BRAKE PEDAL HAS SPONGY FEEL
pedal falls away as master cylinder fault has oc A spongy pedal is caused by air in the system. Thin
curred. brake drums, or substandard brake lines and hoses
(3) If hard pedal or excessive pedal effort is expe can also cause a spongy pedal. The proper course of
rienced, return to shop. Problem is caused by faulty action is to bleed the system or replace thin drums
brake booster, booster check valve, binding pedal, or and suspect quality brake parts.
master cylinder.
HARD PEDAL OR HIGH PEDAL EFFORT BRAKE FADE

A hard pedal can be caused by a faulty power Brake fade is a product of overheating caused by
booster, booster check valve, or binding pedal or brake drag. However, overheating and subsequent
booster. High pedal effort is usually due to lining fade can also be caused by riding the brake pedal,
that is water soaked, contaminated, glazed, or badly making repeated high deceleration stops in a short
worn. time span, or constant braking on steep mountain
On diesel engine models, high pedal effort may be roads. Refer to the Brake Drag information in this
the result of a low vacuum condition. If the booster section for additional causes.
and check valve are OK, the problem may be related
to a vacuum pump hose, hose connection, hose fit BRAKE PEDAL PULSATION
ting, pump diaphragm, or drive gear. Pedal pulsation in RWAL equipped models, is
Vacuum pump output can be checked with a stan caused by brake parts that are loose, or out of toler
dard vacuum gauge. Vacuum output should range ance limits. This type of pulsation is experienced ev
from 8.5 to 25 inches vacuum. If vacuum pump out ery time the brakes are applied.
put is within limits, check the power booster and Disc brake rotors with excessive lateral runout or
check valve as described in this section. thickness variation, or out of round brake drums are
the primary causes of pulsation.
BRAKE DRAI On vehicles with ABS brakes, remember that pedal
Brake drag occurs when the lining is in constant pulsation is normal during antilock mode brake
contact with the rotor or drum. Drag can occur at one stops. If pulsation occurs during light to moderate
wheel, all wheels, fronts only, or rears only. It is a brake stops, a standard brake part is either loose, or
product of incomplete brakeshoe release. Drag can be worn beyond tolerance.
minor, or severe enough to overheat the linings, ro
tors and drums. BRAKE PULL
Brake drag can also effect fuel economy. If undetec A front pull condition could be the result of contam
ted, minor brake drag can be misdiagnosed as an en inated lining in one caliper, seized caliper piston,
gine, torque converter, or transmission problem. binding caliper, loose caliper, loose or corroded slide
Minor drag will usually cause slight surface char pins, improper brakeshoes, or a damaged rotor.
ring of the lining. It can also generate hard spots in A worn, damaged wheel bearing or suspension com
rotors and drums from the overheat-cool down pro ponent are further causes of pull. A damaged front
cess. In most cases, the rotors, drums, wheels and tire (bruised, ply separation) can also cause pull.
tires are quite warm to the touch after the vehicle is A common and frequently misdiagnosed pull condi
stopped. • tion is where direction of pull changes after a few
Severe drag can char the brake lining all the way stops. The cause is a combination of brake drag fol
through. It can also distort and score rotors and lowed by fade at one of the brake units.
drums to the point of replacement. The wheels, tires As the dragging brake overheats, efficiency is so re
and brake components will be extremely hot. In se duced that fade occurs. Since the opposite brake unit
vere cases, the lining may generate smoke as it chars is still functioning normally, its braking effect is
from overheating. magnified. This causes pull to switch direction in fa
Some common causes of brake drag are: vor of the normally functioning brake unit.
• seized or improperly adjusted parking brake cables When diagnosing a change in pull condition, re
• loose/worn wheel bearing member that pull will return to the original direction
• seized caliper or wheel cylinder piston if the dragging brake unit is allowed to cool down
• caliper binding on corroded bushings or rusted (and is not seriously damaged).
slide surfaces
• loose caliper mounting bracket REAR BRAKE GRAB OR PULL
• drum brakeshoes binding on worn or damaged Rear grab or pull is usually caused by an improp
support plates erly adjusted or seized parking brake cable, contam
• misassembled components inated lining, bent or binding shoes and support
• adjuster screws reversed plates, or improperly assembled components. This is
If brake drag occurs at all wheels, the problem may particularly true when only one rear wheel is in
be related to a blocked master cylinder return port, volved. However, when both rear wheels are affected,
or faulty power booster that binds and does not re the master cylinder or proportioning valve could be
lease. at fault.
5 -i SERVICE BRAKE DIAGNOSIS BR
BRAKES DO NOT HOLD AFTER DRIVING THROUGH verely worn tires with very little tread left can pro
duce a grab-like condition as the tire loses and
DEEP WATER PUDDLES recovers traction.
This condition is generally .caused by water soaked Flat-spotted tires can cause vibration and wheel
lining. If the lining is only wet, it can be dried by tramp and generate shudder during brake operation.
driving with the brakes very lightly applied for a few A tire with internal damage such as a severe bruise
minutes. However, if the lining is thoroughly wet and or ply separation can cause pull and vibration.
dirty, disassembly and cleaning will be necessary.
CONTAMINATED BRAKELINING
BRAKE NOISE
Contaminated brakelining will cause pull, noise,
Squeak/Squeal grab, and will increase stopping distance. Road
Factory installed brakelining is made from as splash and leaking caliper, wheel cylinder, or axle
bestos free materials. These materials have dif seals are the primary causes.
ferent operating characteristics than previous Brakelining contaminated by water only can be sal
brakelining material. Under certain conditions, vaged. The lining can either be air dried or dried us
asbestos free lining may generate some squeak, ing heat.
groan or chirp noise. This noise is considered In cases where brakelining is contaminated by oil,
normal and does not indicate a problem. The grease, or brake fluid, the lining should be replaced.
only time inspection is necessary, is when noise Replacement is especially necessary when fluids/lu
becomes constant or when grinding, scraping bricants have actually soaked into the lining mate
noises occur. rial. However, grease or dirt that gets onto the lining
Brake squeak or squeal may be due to linings that surface (from handling) during brake repairs, can be
are wet or contaminated with brake fluid, grease, or cleaned off. Simply spray the lining surface clean
oil. Glazed linings and rotors with hard spots can with Mopar brake cleaner.
also contribute to squeak. Dirt and foreign material
embedded in the brake lining can also cause squeak/ BRAKE FLUID CONTAMINATION
squeal. The basic causes of brake fluid contamination are
A very loud squeak or squeal is frequently a sign of threefold. The first involves allowing dirt, debris, or
severely worn brake lining. If the lining has worn other materials to enter the cylinder reservoir when
through to the brakeshoes in spots, metal-to-metal the cover is off. The second involves filling, or adding
contact occurs. If the condition is allowed to continue, non-recommended fluid to the system. A third cause
rotors and drums can become so heavily scored that involves a loose reservoir, or mispositioned cover seal;
replacement is necessary. either condition will allow moisture and dirt to enter
the fluid.
Thump/Clunk Brake fluid contaminated with only dirt, or debris
Thumping or clunk noises during braking are fre usually retains a normal appearance. Generally, the
quently not caused by brake components. In many foreign material will remain suspended in the fluid
cases, such noises are caused by loose or damaged and be visible. The fluid and foreign material can be
steering, suspension, or engine components. However, removed from the reservoir with a suction gun but
calipers that bind on the slide pins, or slide surfaces, only if the brakes have not been applied. If the
can generate a thump or clunk noise. Worn out, im brakes are applied after contamination, system flush
properly adjusted, or improperly assembled rear ing will be required. The master cylinder will also
brakeshoes can also produce a thump noise. have to be flushed or replaced if the contaminants
cannot be removed. Foreign material lodged in the
Chatter reservoir compensator/return ports can cause brake
Brake chatter is usually caused by loose or worn drag by restricting fluid return after brake applica
components, or glazed/burnt lining. Rotors with hard tion.
spots can also contribute to chatter. Additional causes Brake fluid contaminated by a non-recommended
of chatter are out of tolerance rotors, brake lining not fluid, may appear highly discolored, milky, oily look
securely attached to the shoes, loose wheel bearings ing, or foamy. In some cases, the fluid may even ap
and contaminated brake lining. pear to contain sludge. However, be advised that
brake fluid will darken in time and occasion
Wheel and Tire Problems ally be cloudy in appearance. These are normal
Some conditions attributed to brake components conditions and should not be mistaken for con
may actually be caused by a wheel or tire problem. tamination.
A damaged wheel can cause shudder, vibration and If some type of oil has been added to the system,
pull. A worn or damaged tire can also cause pull. Se the fluid will separate into distinct layers. To verify
this, drain off a sample with a clean suction gun. BOOSTER

Then pour the sample into a glass container and ob CHECK
serve fluid action. If the fluid separates into distinct
layers, it is definitely contaminated.
The only'real correction for contamination, is to
disassemble, and flush the entire hydraulic system
and replace all seals.
MASTER CYLINDER/POWER BOOSTER TEST
(1) Start engine and check booster vacuum hose
connections. Hissing noise indicates a vacuum leak.
Correct any leaks before proceeding.
(2) Stop engine and shift transmission into Neu
tral.
(3) Pump brake pedal until all vacuum reserve in
booster is depleted. Fig. 1 Vacuum Check Valve And Seal
(4) Press and hold brake pedal under light foot
pressure.
(a) If pedal holds firm, proceed to step (5).
(b) If pedal does not hold firm and falls away,
master cylinder is faulty (internal leakage).
(5) Start engine and note pedal action.
(a) If pedal falls away slightly under light foot
pressure then holds firm, proceed to step (6).
(b) If pedal is hard, or no pedal action is discern J9005-80
ible, power booster or vacuum check valve is faulty.
Install known good check valve and repeat steps (2) Fig. 2 Typical Hand Operated Vacuum Pump
through (5). POWER BOOSTER WACUU1 TEST
(c) On diesel models, vacuum pump hose or
pump component may have malfunctioned. Check (1) Connect a vacuum gauge to the booster check
pump output with vacuum gauge and repair as valve with a short length of hose and a T-fitting (Fig.
necessary. Refer to service procedures in Power 3).
Booster/Vacuum Pump section. (2) Start and run engine at idle speed for one
(6) Rebuild booster vacuum reserve and check minute.
brake action as follows: (3) Clamp hose shut between vacuum source and
check valve (Fig. 3).
(a) Release brake pedal.' Then start engine, in
(4) Stop engine and observe vacuum gauge.
crease rpm to 1500, close throttle, and immediately
(5) If vacuum drops more than one inch vacuum
turn off ignition.
(33 millibars) within 15 seconds, either booster dia
(b) Wait at least 90 seconds and try brake action
phragm or check valve are faulty.
again. Booster should provide two or more vacuum
assisted pedal applications. If vacuum assist is not TESTING DIESEL ENGINE VACUUM PUMP OUTPUT
provided, perform booster and check valve vacuum
tests. Also check vacuum output on diesel models. On diesel engine models, a low vacuum condition in
the brake booster will cause the brake warning light
POWER BOOSTER CHECK VALVE TEST to illuminate.
The following test checks output and condition of
(1) Disconnect vacuum hose from check valve. the vacuum pump and interconnecting hoses. How
(2) Remove check valve and valve seal from ever, a more comprehensive testing procedure is pro
booster (Fig. 1). vided in the Power Brake Booster-Brake Pedal-
(3) Hand operated vacuum pump can be used for Vacuum Pump section. Refer to the procedure for
test (Fig. 2). "Diagnosing A Low Vacuum Condition" in that sec
(4) Apply 15-20 inches (50-67 kPa) vacuum at tion.
large end of check valve (Fig. 1). (1) Inspect vacuum pump and booster hoses and
(5) Vacuum should hold steady. If gauge on pump connections. Make sure hoses are in good condition
indicates any vacuum loss, valve is faulty and must and securely attached. Run engine and check for vac
be replaced. ' uum leaks. Replace leaking hoses before proceeding.
5 -8 SERVICE BRAKE DIAGNOSIS BR
SHORT (3) Run engine at curb idle speed and note vacuum
CONNECTING CHECK reading. Then run engine at 1/2 to 3/4 throttle and
HOSE VALVE
note vacuum reading again.
TEE
FITTING (4) Vacuum should range from 8.5 to 25 inches vac
uum at various throttle openings. Vacuum should
hold steady and not drop below 8.5 inches.
(5) If vacuum output is OK, check booster and
check valve as described in this section. However, if
CHECK vacuum is low, or does not hold steady, vacuum hoses
VALVE
HOSE and/or pump are faulty.
INTAKE
MANIFOLD
VACUUM
GAUGE
J9005-81
Fig. 3 Booster Vacuum Test Connections

(2) Disconnect vacuum hose at booster and connect
vacuum gauge to hose end.
BR MASTER CYLINDER 5 -1
MASTER CYLINDER
INDEX
page page
Brake Fluid Contamination . 10 Master Cylinder Identification Codes 9

Brake Fluid Level 10 Master Cylinder Installation . . . . . . . . . . . . . . . . . . 15
Description . 9 Master Cylinder Reassembly . 13
Master Cylinder Application . 9 Master Cylinder Removal 11
Master Cylinder Bleeding (On Bench) 14 Master Cylinder Serviceability 9
Master Cylinder Cleaning and Inspection 13 Recommended Brake Fluid 10
Master Cylinder Disassembly and Overhaul . . . . . . 12
DESCRIPTION'
BR models are equipped with a Delco, two-section
master cylinder assembly. Major components are the
aluminum cylinder body and a removable plastic res
ervoir (Fig. 1).
The primary and secondary pistons are located in
the cylinder body. Grommets are used to secure and
seal the reservoir in the cylinder body. The reservoir
cover is equipped with diaphragm seal and is a snap
fit on the reservoir.
The cylinder body is equipped with a quick take-up
valve located in the primary piston inlet port (Fig. 1).
The valve provides an extra volume of low pressure
fluid during initial brake apply. Extra fluid volume
provides faster take-up of normal clearances in the
calipers and wheel cylinders.
MASTER CYLINDER SERVICEABILITY

The cylinder body, piston assemblies, reservoir,
grommets, seal and cover are all serviceable parts.
The take-up valve is the only non-serviceable compo
nent. The valve is available only as part of a com
plete cylinder body assembly.
MASTER CYLINDER APPLICATION
Three master cylinders are used in BR models. The
differences between them concern cylinder bore size
and fluid reservoir capacity.
• The master cylinder in 1500 models has a 28.6
mm (1.125 in.) bore.
• The master cylinder in 2500 and 3500 models has
a 31.8 mm (1.252 in.) bore.
PISTON
Although the master cylinders used in 2500 and
ASSEMBLY J9405-13
3500 models have the same bore size, they have dif
ferent piston stroke lengths and fluid reservoir ca Fig. 1 Delco Master Cylinder
pacities. Refer to Brake Fluid Level and Master
M A S T E R C Y L I N D E R IDENTIFICATION C O D E S
Cylinder Identification in this section for details.
Master cylinders and reservoirs must never The master cylinder and reservoir are coded for
be interchanged. This practice will cause unsat identification. Code letters are provided on the cylin
isfactory operation and improper brake bal der body and reservoir for proper component match
ance. ing.
5 - 10 MASTER CYLINDER Bfl
The cylinder body code letters are etched into the cover before removing the cover to add fluid. If this is
front end of the cylinder (Fig. 2). The reservoir code not done, dirt from the cover or reservoir could enter
letters are on an adhesive backed tag attached to the the fluid.
front face of the reservoir (Fig. 2). I.D. Add fluid to the correct level if necessary. Note that
Code letters are as follows: fluid level in the reservoirs will decrease slightly in
© 1/2 ton (model 1500) code letters are NK proportion to lining wear. This is a normal condition.
• 3/4 ton (model 2500) code letters are NL If fluid is needed, use Mopar brake fluid or an equiv
• 1 ton (model 3500) code letters are NP alent meeting SAE standard J1703 and Federal stan
dard DOT 3.
Check the cover diaphragm seal and replace it if
torn or distorted. Snap the seal into place before in
stalling the cover.
CAUTION: Verify that the diaphragm seal is firmly
CODE
LETTER seated in the reservoir cover. If the seal is improp
RESERVOIR TAG erly seated, it will shift out of position when the
cover is installed resulting in fluid leakage and
eventual contamination.
CYLINDER
INDICATOR
BODY CODE WINDOW
LETTERS
CORRECT
FLUID LEVEL
(TO TOP OF
WINDOW)
J9405-21
trig. 2 Identification Code Locations For Cylinder

Body And Reservoir
RECOMMENDED BRAKE FLUID
Recommended brake fluid for all BR models is Mo
par brake fluid, or an equivalent meeting SAE stan
dard J1703 and Federal standard DOT 3. Do not use
any other type of fluid.
CAUTION: Use recommended brake fluid when add J9405-22
ing fluid or refilling the system. Use clean, fresh
brake fluid from a sealed container only. Never use Fig. 3 Reservoir And Fluid Level Indicator
reclaimed fluid, fluid not meeting the SAE/DOT (Model 1500)
standards, fluid marked 70R1, or fluid from a con
tainer that has been left open for any length of time. BRAKE FLUID CONTAMINATION
Using non-recommended fluid can result in brake Oil in the fluid will cause brake system rubber
failure after hard, prolonged braking. seals to soften and swell. The seals may also become
porous and deteriorate in short time.
If fluid contamination is suspected, drain off a sam
BRAKE FLUID LEVEL ple from the master cylinder. A suction gun or similar
Correct fluid level is to the top of the oval indicator device can be used for this purpose.
window on the side of the reservoir (Figs. 3, 4 and 5). Empty the drained fluid into a glass container.
An acceptable level is between the top of the indica Contaminants in the fluid will cause the fluid to turn
tor window and the MIN mark. milky, or separate into distinct layers. If contamina
The hydraulic system should be checked for tion has occurred, the system rubber seals, hoses and
leaks, or the brakeshoes for excessive wear, if cups must be replaced. The system must also be thor
fluid level is very near the MIN level. oughly flushed with clean brake fluid.
Always clean the master cylinder reservoir and
Bit MASTER CYLINDER 5-11
INDICATOR (2) Remove brakelines connecting master cylinder

WINDOW to combination valve (Fig. 6). Use flare nut wrench to
loosen and disconnect fittings.
CORRECT
FLUID
LEVEL
(TO TOP
OF WINDOW)
J94Q5-23
Fig. 4 Reservoir And Fluid Level Indicator (Model 2500)
LINE TO
CORRECT
FLUID REAR BRAKES / ^ X ^ Z > V ^ \ ^ \ J9405-1
LEVEL Fig. 6 Combination Valve-To-Master Cylinder Brakelines
(TO TOP OF
INDICATOR (3) Disconnect line that connects RWAL valve to
WINDOWS) combination valve.
(4) Disconnect harness wires from RWAL valve and
combination valve switch (Fig. 7).
(5) Disconnect antilock harness ground wire from
combination valve bracket (Fig. 7).
J9405-24
Fig. 5 Reservoir And Fluid Level Indicators (Model 3500)
MASTER CYLINDER REMOVAL
Exercise care when removing/installing the mas
ter cylinder, combination valve and antilock valve
connecting lines. The threads in the cylinder and
valve fluid ports can be damaged if care is hot ex
ercised. Use a flare nut wrench to loosen or
LINES FROM
tighten the fittings and start all brakeline fittings COMBINATION
by hand to avoid cross threading. /. VALVE TO
(1) Apply Mopar rust penetrant to master cylinder, ^FRONT/REAR BRAKES J9405-2
combination valve, and antilock valve brakeline fit
Fig. 7 VAL Valve Harness And Ground Wire
tings. Work penetrant between fittings and brake-
Connections
lines to ease removal.
5 -12 MASTER CYLINDER BR
(6) Remove bolt attaching RWAL valve to combina and grommets (Fig. 10). If reservoir is to be re
tion valve bracket (Fig. 8). placed, note and record reservoir code letters
(Fig. 2).
Fig. 8 RWAL Valve Attaching Bolt Location

(7) Remove nuts attaching combination valve
bracket and master cylinder to brake booster mount
ing studs (Fig. 6).
(8) Slide combination valve bracket off booster
mounting studs.
(9) Remove master cylinder. Fig. 10 Reservoir Removal
(5) Remove grommets from cylinder body (Fig. 11).
MASTER CYLINDER DISASSEMBLY AND Discard grommets as they are not reusable.
OfERHAUL
The master cylinder primary piston is serviced as
an assembly. Only the secondary piston can be disas
sembled for service.
(1) Remove reservoir cover and seal (Fig. 9).
DIAPHRAGM
SEAL
i-9
Fig. 11 Reservoir Grommet Removal

(6) Remove master cylinder piston retaining snap
ring with small pointed tool and flat blade screw
-7 driver.
(7) Remove primary piston and spring assembly
Fig. 9 Reservoir Seal And Cover Removal (Fig. 12). Discard assembly after removal. Do not
(2) Drain reservoir fluid into drain container. disassemble piston components as primary pis
(3) Clamp cylinder body in vise. Clamp vise jaws ton is serviced as complete assembly only.
on one of the cylinder mounting ears as shown (Fig. (8) Remove secondary piston (Fig. 12). Apply air
10). pressure through rear outlet port to ease piston out
(4) Remove reservoir with a rocking motion. Use a of bore.
pry tool to help ease reservoir out of cylinder body
BR MASTER CYLINDER 5-13
(9) Remove secondary piston spring (Fig. 12). Tilt Inspect the cylinder bore. A light discoloration of
cylinder body downward so spring will slide out of the bore surface is normal and acceptable. However,
bore. replace the cylinder body if the bore is scored, pitted,
CYLINDER
or corroded.
BODY Inspect the cylinder cover and diaphragm seal. Re
place the seal if torn, or distorted. Replace the cover
if warped, cracked, or the snap fasteners are dam
aged.
Inspect the reservoir. A slight discoloration of the
reservoir surface is normal. Replace the reservoir if
distorted, cracked, or otherwise damaged.
Inspect the take up valve in the cylinder body. The
valve should move freely and not be stuck or seized.
The valve is not serviceable. It will be necessary to
replace the cylinder body if the valve is faulty.
Inspect condition of the secondary piston. Replace
the piston if it is scored, corroded, or doubt exists
about its condition.
MASTER CYLINDER REASSEMBLY

(1) Coat cylinder body bore, piston components and
reservoir grommets with fresh, clean brake fluid.
J9405-10
(2) Mount cylinder body in vise. Clamp one cylin
der mounting ear in vise jaws.
Fig. 12 Master Cylinder Piston Removal (3) Assemble secondary piston * components (Fig.
13). Be careful when installing seals. Avoid distorting
(10) Disassemble secondary piston. Remove seal them during installation.
retainer from piston. Then remove front and rear
seals from piston (Fig. 13). Discard seals, spring, and CAUTION: Do not use any kind of metal tool to ease
retainer after removal. These parts are not reusable. piston seal installation in the cylinder bore. Metal
tools will cut the seals and scratch the bore. If a
SPRING
tool is needed, use a small flexible item made from
nylon, rubber or plastic only.
(4) Install secondary piston assembly (spring end

first), in cylinder bore. Do not force piston into
bore. Work it into place with a twisting/turning
motion.
(5) Install primary piston in cylinder bore (spring
end first). Do not force piston into bore. Work it
into place with a twisting/turning motion.
(6) Insert piston retaining snap ring in cylinder
body. Then push pistons inward with wood dowel and
seat snap ring.
PISTON J9405-11
CAUTION: B e very sure the piston retaining snap
ring is fully seated. Recheck snap ring installation
Fig. 13 Secondary Piston Components before proceeding.
11STER CYLINDER CLEANING AND INSPECTION
(7) Install new grommets on cylinder body (Fig.
Clean the cylinder body and reservoir with Mopar
14).
brake cleaner only. Do not use any other type of
(8) Remove cylinder body from vise.
cleaning solvent. Dry the cylinder parts with com (9) Position reservoir on clean work surface with
pressed air. The reservoir can be air dried or wiped fluid inlet necks facing upward (Fig. 14). Padding
dry with lint-free shop towels. work surface with clean shop towels will keep reser
voir in place during installation. It will also keep dirt
out as well.
5 -14 MASTER CYLINDER BR
(10) Install cylinder body on reservoir (Fig. 14). Bench Bleeding Procedure
Use a rocking motion to slide the reservoir necks into (1) Mount master cylinder in vise. Clamp vise jaws
the grommets. on one of the cylinder mounting ears.
(2) Install bleed tubes in cylinder outlet ports and
direct tube ends into appropriate reservoir chambers
(Fig. 15).
WOOD
FLUID) J9405-71
RESERVOIR
Fig. 15 Master Cylinder Bleeding
J9405-12 (3) Fill reservoir chambers about 3/4 full with
fresh, clean brake fluid.
. Fig. 14 Assembling Reservoir And Cylinder Body (4) Bleed cylinder by stroking cylinder pistons in
(11) Verify that reservoir is properly seated and ward then allowing them to return under spring
that grommets have not slipped out of place. pressure. Use a wood dowel, or similar tool to stroke
(12) Bleed master cylinder on bench before install pistons (Fig. 15).
ing it in vehicle. Refer to procedure in this section. (5) Continue stroking pistons until bubbles no
longer appear in fluid entering reservoir.
MASTER CYLINDER BLEEDINi (ON BENCH)* (6) Remove bleed tubes and install plastic plugs in
cylinder outlet ports. Plugs will prevent fluid loss
An overhauled, or new master cylinder should al and keep dirt out until cylinder assembly is ready for
ways be bled before installation in the vehicle. This installation.
practice saves time during brake bleeding because air (7) Top off reservoir fluid level and install cover
in the cylinder will not be pumped into the lines. and seal.
The only tools needed for bench bleeding are a vise,
a pair of bleed tubes, and a length of wood dowel. CAUTION: Be sure the seal is properly positioned
Bleed tubes can either be purchased or fabricated on the reservoir cover. The seal can shift out of po
sition during installation if care is not exercised.
from spare brakelines and fittings.
This will result in leakage and possible fluid con
tamination.
MASTER CYLINDER 5 -15
MASTER CYLINDER INSTALLATION valve bracket (Fig. 17). Be sure bracket tab is seated
(1) Position master cylinder on booster mounting in valve before installing valve attaching bolt. Then
studs. Be sure booster push rod is aligned and seated install and tighten valve bolt to 17 N-m (13 ft. lbs.)
in primary piston. torque.
(2) Install combination valve bracket on mounting (5) Tighten valve and cylinder brakeline fittings to
studs. Bracket goes on top of cylinder mounting ears 16-23 N-m (140-200 in. lbs.) torque.
as shown (Fig. 16). MASTER
ABS VALVE SECONDARY UNE J9405-72
Fig. 17 Master Cylinder And Valve Brakeline

Fig. 16 Master Cylinder/Combination Valve Bracket Connections
Mounting (6) Install master cylinder attaching nuts on
(3) Start all brakeline fittings in cylinder and booster studs. Tighten nuts to 23-34 N-m (200-300 in.
valves by hand (Fig. 17). Tighten fittings about 3-4 lbs.) torque.
threads to secure each line in place. (7) Fill and bleed brake system. Refer to bleeding
(4) Install rear brake antilock valve in combination procedure in appropriate antilock brake section.
5-16 POWER BRAKE BOOSTER—BRAKE PEDAL—BRAKELIGHT SWITCH
POWER BRAKE B O O S T E R — B R ^ K E PEDAL™BRAKELI@HT SWITCH
INDEX
page page
Brake Pedal Installation 20 Power Brake Booster Identification . 16

Brake Pedal Removal 19 Power Brake Booster Installation 18
Brakelight Switch Adjustment and Installation 19 Power Brake Booster Operation 17
Brakelight Switch Removal 18 Power Brake Booster Removal 17
Brakelight Switch Test and Diagnosis 19 Power Brake Booster Serviceability 17
Component Description 16
COMPONENT DESCRIPTION panel. The pedal shaft is supported by bushings in

the pedal and mounting bracket.
Power Brake Booster
Brakelight Switch
All BR models are equipped with a Delco 260T,
tandem (dual) diaphragm power brake booster (Fig. A plunger style, self adjusting brakelight switch is
used for all applications. The switch is positioned in
1).
a separate bracket attached to the pedal mounting
Two versions of the 260T booster are used. A stan bracket (Fig. 3).
dard duty version is used in all 1/2 ton models. A
higher output version is used in 3/4 and 1 ton mod 3
0WER BRAKE BOOSTER IDENTIFICATION
els. The standard and high output boosters are identified
Brake Pedal by code letters on the forward face of the booster (Fig.
The brake booster is operated by a suspended type 1).
brake pedal (Fig. 2). The pedal pivots on a shaft lo Booster I.D. code letters are as follows:
• 1/2 ton booster code is ZK
cated in a mounting bracket attached to the dash
© 3/4 and 1 ton booster code is ZL
IDENTIFICATION BOOSTER INTEGRAL BOOSTER
CODE PUSH ROD MOUNTING PUSH ROD
LOCATION (TO MASTER BRACKET (TO BRAKE
MOUNTING
STUDS
FRONT VIEW SIDE VIEW REAR VIEW
J9405-20
Fig, 1 Delco 260T Power Brake Booster
BR POWER BRAKE BOOSTER—BRAKE PEDAL—BRAKELIGHT SWITCH 5-17
PEDAL SHAFT second push rod (at the forward end of the housing),
strokes the master cylinder pistons. The rear push rod is
connected to the two diaphragms in the booster housing.
The atmospheric inlet valve is opened and closed by
the push rod connected to the brake pedal. The booster
vacuum supply is through a hose attached to a fitting on
the intake manifold. The hose is connected to a vacuum
check valve in the booster housing. The check valve is a
one-way device that prevents vacuum leak back.
How Brake Boost Is Generated
Power assist is generated by utilizing the pressure
differential between normal atmospheric pressure
and a vacuum. The vacuum needed for booster oper
ation is taken directly from the engine intake mani
fold. The entry point for atmospheric pressure is
through an inlet valve at the rear of the housing.
The forward portion of the booster housing (area in
front of the two diaphragms), is exposed to manifold
vacuum. The rear portion (area behind the dia
phragms), is exposed to normal atmospheric pressure
of 101.3 kilopascals (14.7 pounds/square in.).
Fig. 2 Suspended Style Brake Pedal Pressing the brake pedal causes the rear push rod
to open the inlet valve. This exposes the area behind
the diaphragms to atmospheric pressure. The result
ing force applied to the diaphragms is what provides
the extra boost in apply pressure for power assist.
POWER BRAKE BOOSTER REMOVAL

(1) Disconnect harness wires from differential
switch on combination valve and from RWAL valve.
(2) Disconnect brakeline from combination valve to
front brakes, or ABS valve. Then disconnect brake-
line from RWAL valve to rear brakes.
(3) Remove nuts attaching master cylinder and
valves to power brake booster studs. Then remove
master cylinder and valves as assembly (Fig. 4).
Fig. 3 Brakelight Switch Location And Mounting
POWER BRAKE BOOSTER SERf ICEABiLITY

The only serviceable power brake booster compo
nents are the vacuum hose and check valve. The
booster itself is not a repairable component. The
booster must be replaced as an assembly whenever
diagnosis indicates a fault has occurred.
POWER BRAKE BOOSTER OPERATION

Booster Components
The booster assembly consists of a housing divided
into separate chambers by two internal diaphragms.
The outer edge of each diaphragm is attached to the
booster housing. The diaphragms are in turn, con Fig. 4 Removing/Installing Master Cylinder And
nected to the booster push rod. Valves As Assembly
Two push rods are used to operate the booster. One
push rod connects the booster to the brake pedal. The
5-18 POWER BRAKE BOOSTER—BRAKE PEDAL—BRAKELIGHT SWITCH BR
(4) Disconnect vacuum hose at booster check valve.

(5) Remove knee bolster for access to brake pedal
(Fig. 5).
Fig. 7 Power Brake Booster Mounting

(5) Install knee bolster.
(6) Connect vacuum hose to booster check valve.
Fig. 5 Knee Bolster Removal (7) Install master cylinder and valves on booster as
(6) Remove clip and washer securing booster push assembly (Fig. 2). Tighten mounting nuts to 23-34
rod to brake pedal (Fig. 6). Then slide booster push N-m (200-300 in. lbs.) torque.
rod off pedal. (8) Connect front/rear brakelines to combination
valve and RWAL valve. Tighten brakeline fittings to
BOOSTER WASHER CUP 16-23 N-m (140-200 in. lbs.) torque.
(9) Connect harness wires to RWAL valve and
pressure differential switch on combination valve.
(10) Fill and bleed brake system. Refer to proce
dures in appropriate antilock brake section.
BRAKELIGHT SWITCH REMOVAL

(1) Remove knee bolster (Fig. 5) for access to
brakelight switch and pedal.
(2) Disconnect switch harness (Fig. 8).
(3) Press and hold brake pedal in applied position.
(4) Rotate brakelight counterclockwise about 30° to
align switch lock tab with notch in bracket.
(5) Pull switch rearward out of mounting bracket
and release brake pedal.
Fig. 6 Booster Push Rod Attachment At Brake Pedal
(7) Remove nuts attaching booster mounting studs
to dash panel and pedal mounting bracket (Fig. 7).
(8) Remove booster from engine compartment.
(9) If booster will be replaced, note and record code
letters on front face of booster.
POWER BRAKE BOOSTER INSTALLATION

(1) If new booster is being installed, check code let
ters to verify that correct booster is being installed.
(2) Position booster on engine compartment dash
panel. Have helper hold booster in position if neces
sary.
(3) Install and tighten booster mounting stud nuts
to 23-34 N-m (200-300 in. lbs.) torque.
(4) Connect booster push rod to brake pedal (Fig.
4). Fig. 8 Brakelight Switch And Harness Connector
BR POWER BRAKE BOOSTER—BRAKE PEDAL—BRAKELIGHT SWITCH 5-19
BRAKELIGHT SWITCH TEST AND DIAGNOSIS (a) Pull switch plunger all the way out to fully
Brakelight switch operation can be tested with an extended position.
ohmmeter. The ohmmeter is used to check continuity (b) Push switch plunger inward 4 detent posi
between the pin terminals at different plunger posi tions (or clicks). This is required preset position for
switch installation. Plunger will extend approxi
tions (Fig. 9).
mately 14 mm (0.55 in.) out of housing at this set
T h e s w i t c h w i r e harness must be discon
ting.
n e c t e d "before testing s w i t c h continuity.
(2) Connect harness wires to switch (Fig. 8).
Switch Circuit Identification (3) Press and hold brake pedal down.
• Switch terminals 1 and 2 are for the brake sensor (4) Install switch. Align tab on switch with notch
circuit in switch bracket (Fig. 10). Then insert switch in
• Switch terminals 5 and 6 are for the brakelight bracket and turn it clockwise about 30° to lock it in
circuit place.
(5) Release brake pedal. Then lightly pull pedal
• Switch terminals 3 and 4 are for the speed control
fully rearward. Pedal will adjust switch plunger to
circuit correct position as pedal is moved to rear.
TERMINAL
PINS CAUTION: Do not use excessive force to move the
pedal rearward for switch adjustment. Excessive
force will damage the switch.
J9405-88
Fig. 9 Brakelight Switch Terminal Identification And

Plunger Test Position
Switch Continuity Test Procedure
(1) Check continuity between terminal pins 5 and
6 as follows: Fig. 10 Brakelight Switch Installation
(a) Pull plunger all the way out to fully extended BRAKE PEDAL REiOWAL
position. (1) Remove knee bolster for access to brakelight
(b) Attach test leads to pins 5 and 6 and note switch and pedal (Fig. 5).
ohmmeter reading. (2) Remove brakelight switch (Fig. 8).
(c) If continuity exists, proceed to next test. Re (3) Remove switches from tabs on brakelight
place switch if meter indicates lack of continuity switch bracket.
(shorted or open). (4) Remove brakelight switch bracket (Fig. 11).
(2) Check continuity between terminal pins 1 and Bracket is attached to pedal mounting bracket with
2 and pins 3 and 4 as follows: two screws.
(a) Push switch plunger inward to fully retracted (5) Remove clip and washer attaching booster push
position. rod to brake pedal (Fig. 6). Then slide push rod off
(b) Attach test leads to pins 1 and 2 and note pedal.
ohmmeter reading. (6) Remove E-clip from passenger side of pedal
(c) If continuity exists, switch is OK. Replace shaft (Fig. 12). Use flat blade screwdriver to pry clip
switch if meter indicates lack of continuity (switch out of shaft groove.
is shorted/open). (7) Push shaft toward driver side of bracket just
enough to expose opposite E-clip. Then remove E-Clip
BRAKELIGHT SWITCH ADJUSTMENT AND with flat blade screwdriver.
INSTALLATION (8) Push pedal shaft back and out of passenger
(1) Preset switch plunger as follows: side of bracket (Fig. 12).
5 - 20 POWER BRAKE BOOSTER—BRAKE PEDAL—BRAKELIGHT SWITCH BR
PEDAL SHAFT
Fig. 11 Brakelight Switch Bracket Position

(9) Remove brake pedal and pedal shaft from vehi
cle.
BRAKE PEDAL INSTALLAT101

(1) Replace bracket and pedal bushings if neces
sary. Lubricate shaft bores in bracket and pedal be Fig. 12 Brake Pedal Mounting (With Automatic
fore installing bushings. Use Mopar Multi-mileage, or Transmission)
DOW/GE silicone grease. (6) Push pedal shaft back toward passenger side of
(2) Apply liberal quantity of Mopar multi-mileage bracket and install remaining E-clip on pedal shaft.
grease, or DOW/GE silicone grease, to pedal shaft (7) Install booster push rod on brake pedal. Secure
and to pedal and bracket bushings. push rod to pedal with washer and retaining clip
(3) Position brake pedal in mounting bracket. (Fig. 6).
(4) Slide pedal shaft into bracket and through (8) Install brakelight switch bracket.
pedal from passenger side. (9) Install brakelight switch.
(5) Push pedal shaft out driver side of mounting (10) Install knee bolster.
bracket just enough to allow installation of retaining
E-clip (Fig. 12). •
BR POWER BRAKE VACUUM PUMP (DIESEL MODELS) 5 - 21
POWER BRÎCE WmWMM PUHP (DIESEL MODELS)
INDEX
page page
General Information 21 Vacuum Pump Replacement 24

Low Vacuum Warning Switch 21 Vacuum Pump Serviceability 21
Pump Adapter Replacement . 24 Vacuum—Steering Pump Assembly Installation . . . 25
Vacuum Pump Diagnosis 22 Vacuum—Steering Pump Assembly Removal 22
Vacuum Pump Operation 21
GENERAL INFORMATION VACUUM

The power brake vacuum pump and the power
steering pump are combined into a single assembly
on diesel engine models (Fig. 1). Both pumps are op
erated by a drive gear attached to the vacuum pump
shaft. The shaft gear is driven by the camshaft gear.
The vacuum pump is a constant displacement,
vane-type pump. Vacuum is generated by four vanes
mounted in the pump rotor. The rotor is located in
the pump housing and is pressed onto the pump
shaft.
The vacuum and steering pumps are operated by a
single drive gear pressed onto the vacuum pump
shaft. The drive gear is operated by the engine cam
shaft gear.
The vacuum and power steering pump shafts are
connected by a coupling. Each pump shaft has an
adapter with drive lugs that engage in the coupling. DRIVE PUMP
The vacuum pump rotating components are lubri GEAR ADAPTER
cated by engine oil. Lubricating oil is supplied to the J9105-94
pump through an oil line at the underside of the
pump housing. Fig. 1 Diesel Vacuum And Power Steering Pump
The complete assembly must be removed in Assembly
order to service either pump. However, the A vacuum hose connects the switch to the power
power steering pump can be removed and ser brake booster. A wire harness connects the switch to
viced separately when necessary. the brake warning light.
The switch is mounted on the driver side inner
VACUUM PUMP SERVICEABILITY fender panel just below the hood hinge (Fig. 2). The
The vacuum pump is not a serviceable component. switch is located just under the front antilock valve
If diagnosis indicates a pump malfunction, the pump on ABS models.
must be replaced as an assembly. Do not disassemble
or attempt to repair the pump. VACUUM PUMP OPERATION
The combined vacuum and steering pump assembly
must be removed for access to either pump. However, Vacuum pump output is transmitted to the power
the vacuum pump can be removed without having to brake booster through a supply hose. The hose is con
disassemble the power steering pump. nected to an outlet port on the pump housing and to
If the power steering pump requires service, simply the check valve in the power brake booster.
remove the assembly and separate the two pumps. Pump output ranges from a minimum of 8.5 to 25
Refer to the pump removal and installation proce inches vacuum.
dures in this section. The pump rotor and vanes are rotated by the pump
drive gear. The drive gear is operated by the cam
LOW VACUUM WARNING SWITCH shaft gear.
A vacuum switch is used to monitor output of the Booster vacuum level is monitored by a warning
vacuum pump. The switch is in circuit with the red switch (Fig. 2). The switch consists of a vacuum
brake warning light.
5 - 22 POWER BRAKE VACUUM PUMP (DIESEL MODELS)
8.5 inches, problem is with vacuum hoses or pump

component. If output is within specified limits, con
tinue testing.
(3) Check booster operation as described in diagno
sis section. Replace check valve, vacuum hoses, or
booster if necessary. However, if booster operation is
correct but warning light is still on, continue testing.
(4) Disconnect vacuum hose at warning switch.
Plug hose and connect hand vacuum pump to switch.
(5) Start and run engine.
(6) Apply 8.5 to 9 inches of vacuum to warning
switch and observe warning light. If light goes out,
switch vacuum hose is either loose or leaking. If light
remains on, leave engine running and continue test
ing.
(7) Apply 20-25 inches vacuum to switch and ob
Fig. 2 Diesel Vacuum Switch Location (Without serve warning light operation. If light now goes out,
ABS) switch is at fault and should be replaced. If light re
mains on, continue testing.
chamber that measures vacuum level and a sensor in
(8) Reconnect vacuum hoses and replace original
circuit with the red brake warning light. warning switch with known good switch. Run engine
The vacuum chamber is connected to the booster and observe warning light operation. If light is now
check valve by a vacuum supply hose. A wire harness off, old switch is faulty. If light remains on, problem
connects the switch sensor to the brake warning is in wiring between switch and warning light.
light. If booster vacuum falls below 8.5 inches for
8-10 seconds or more, the switch sensor completes VACUUM—STEERING PUMP ASSEMBLY REMOVAL
the circuit to the warning light causing it to illumi (1) Disconnect battery negative cable.
nate. (2) Position drain pan under power steering pump.
(3) Disconnect vacuum and steering pump hoses
VACUUM PUMP DIAGNOSIS from respective pumps (Fig. 3).
Vacuum pump diagnosis involves checking pump
output with a vacuum gauge. The low vacuum warn
ing switch can also be checked with a vacuum gauge.
Refer to the diagnosis procedure in this section.
A standard vacuum gauge can be used to check
pump output when necessary. Simply disconnect the
pump supply hose and connect a vacuum gauge to
the outlet port for testing purposes. Vacuum should
hold steady in a range of approximately 8.5 to 25
inches at various engine speeds.
DIAGNOSING LOW VACUUM OUTPUT
CONDITION
A low booster vacuum condition or a faulty low vac
uum warning switch will cause the brake warning
light to illuminate. If the light does go on and indi
cates the existence of a low vacuum condition, check
the vacuum pump, booster and warning switch as fol
lows:
(1) Check vacuum pump oil feed line. Verify that
line connections are secure and not leaking. If leak
age is noted and pump is noisy, replace pump.
Fig. 3 Vacuum And Steering Pump Hose
(2) Disconnect supply hose to booster. Connect vac
Connections
uum gauge to this hose and run engine at various
throttle openings. Output should range from 8.5 to
25 inches vacuum. If vacuum is consistently below
_R POWER BRAKE VACUUM PUMP (DIESEL MODELS) 5 - 23
(4) Disconnect oil pressure sender wires at sender (7) Remove lower bolt that attaches pump assem
(Fig. 4). bly to engine block (Fig. 6).
(5) Remove oil pressure sender (Fig. 4). (8) Remove bottom, inboard nut that attaches
adapter to steering pump (Fig. 6). This nut secures a
small bracket to engine block. Nut and bracket must
be removed before pump assembly can be removed
from block.
PUMP ASSEMBLY
LOWER MOUNTING
STEERING
PUMP ENGINE BLOCK J9119-74
Fig. 4 Oii Pressure Sender Location
(6) Disconnect lubricating oil feed line from fitting

at underside of vacuum pump (Fig. 5). BOTTOM-INBOARD
J9105-97
ADAPTER BRACKET NUT
VACUUM Fig. 6 Adapter And Pump Mounting Fastener

PUMP Location
(9) Remove upper bolt that attaches pump assem

bly to engine block (Fig. 7).
OIL FEED
LINE J9105-96
Fig. 5 Oii Feed Line Connection At Pump
J9119-76
Fig. 7 Removing Pump Assembly Upper Mounting

Bolt
5 - 24 POWER BRAKE VACUUM PUMP (DIESEL MODELS) mm
(10) Remove pump assembly from vehicle (Fig. 8). ROTATE DRIVE
GEARTOAUGN
SHAFT TANGS
VACUUM PUMP REPLACEMENT WITH COUPUNG
(1) Remove nuts attaching vacuum pump to
adapter (Fig. 8).
VACUUM STEERING
PUMP
PUMP*
PUMP
SHAFT
ADAPTER DRIVE
J9105-98 TANGS J9105-102
Fig. 8 Pump Assembly Removal
Fig. 10 Aligning Pump Shaft Drive Tangs
(2) Remove vacuum pump from adapter (Fig. 9). (2) Remove remaining adapter attaching nuts and
Turn pump gear back and forth to disengage pump remove adapter from steering pump (Fig. 12).
shaft from coupling if necessary. (3) If steering pump will be serviced, remove
(3) Inspect adapter O-ring (Fig. 9). Replace O-ring spacer from each inboard mounting stud on pump
if cut or torn. (Fig. 12).
COUPUNG ADAPTER
O-RING
O-RING PUMP
ADAPTER
J9105-99
STEERING
PUMP
Fig. 9 Vacuum Pump Removed From Adapter SHAFT
(4) Lubricate adapter O-ring with engine oil.
(5) Note position of drive slots in coupling. Then
rotate drive gear to align tangs on vacuum pump DRIVE
shaft with coupling (Fig. 10). COUPUNG
J9105-100
(6) Verify that pump is seated in adapter and cou
pling. Fig. 11 Pump Drive Coupling Removal/Installation
(7) Install and tighten pump attaching nuts and (4) Clean and lubricate pump shaft with engine oil.
washers. (5) Install spacers on steering pump studs (Fig.
12).
PUMP ADAPTER REPLACEMENT (6) Install O-ring on adapter (Fig. 11).
(1) Remove coupling from adapter (Fig. 11). (7) Position adapter on pump studs.
BR POWER BRAKE 1ACUUM P U i P (DIESEL MODELS) I - 25
Fig. 13 Positioning Gasket On Pump Mounting Flange
Fig. 12 Steering Pump Mounting Stud Spacer

Locations
(8) Install attaching nuts on outboard stud and on
the two upper pump studs. Do not install nut on
lower, inboard stud at this time. Tighten nuts to 24
(9) Install coupling on pump shaft. Be sure cou
pling is securely engaged in shaft drive tangs.
(10) Install vacuum pump on adapter. Eotate drive
gear until tangs on pump shaft engage in coupling. Ver
ify that pump is seated before installing attaching nuts.
(11) Install and tighten vacuum pump attaching nuts.
VACUUM—STEERING PUMP ASSEMBLY

INSTALLATION
(1) Position new gasket on vacuum pump mount
ing flange (Fig. 13). Use Mopar Perfect Seal, or sili
cone adhesive/sealer to hold gasket in place. Fig. 14 Installing Pump Assembly On Engine
(2) Insert pump assembly upper attaching bolt in (8) Connect steering pump pressure and return
mounting flange and gasket. Use sealer or grease to lines to pump. Tighten pressure line fitting to 30 N-m
hold bolt in place if necessary. (22 ft. lbs.) torque.
(3) Position pump assembly on engine and install (9) Connect vacuum hose to vacuum pump.
upper bolt (Fig. 14). Tighten upper bolt only enough (10) Connect battery cables, if removed.
to hold assembly in place at this time. (11) Fill power steering pump reservoir.
(4) Working from under vehicle, install pump as (12) Purge air from steering pump lines. Start en
sembly lower attaching bolt. Then tighten upper and gine and slowly turn steering wheel left and right to
lower bolt to 77 N-m (57 ft. lbs.) torque. circulate fluid and purge air from system.
(5) Position bracket on steering pump inboard (13) Stop engine and top off power steering reser
stud. Then install remaining adapter attaching nut voir fluid level.
on stud. Tighten nut to 24 N-m (18 ft. lbs.) torque. (14) Start engine and check brake and steering op
(6) Connect oil feed line to vacuum pump connec eration. Verify that power brake booster is providing
tor. Tighten line fitting securely. vacuum assist and firm brake pedal is obtained.
(7) Install oil pressure sender and connect sender Then verify that steering action is correct. Do this
wires. before moving vehicle.
5 - 21 BEAR WHEEL ANTILOCK BRAKE (RWAL) SYSTEM BR
REAR W H E E L ANTILOCK BRAKE (RWAL) S Y S T E M
INDE1
page page
Antilock Component Serviceability 30 Rear Speed Sensor Removal/I nstallation 32

Clearing A Fault Code 29 Rear Wheel Antilock System Diagnosis . . . . . . . . . 29
Combination Valve Operation 28 Rear Wheel Antilock System Operation 28
Control Module Removal/Installation . 31 RWAL Diagnostic Connector 29
Diagnostic Fault Flash Codes 29 RWAL System Brake Bleeding 33
Fault Code Capacity 29 RWAL System Components . 26
Fault Code Identification . . . . . . . . . . . . . . . . . . . . 29 RWAL Valve/Combination Installation . . . . . . . . . . . 31
Fault Condition Causes 29 RWAL Valve/Combination Valve Removal . 30
General Information . . . . . . . . . . . . . . . . . . . . . . . 26
Rear Speed Sensor Rear Harness Removal/
Installation 33
GENERAL INFORMATION control module for processing. The control module de
A rear wheel antilock (RWAL) brake system is termines rate of deceleration and wheel slip from
standard equipment on all BR models (Fig. 1). The these signals.
system is controlled by a separate electronic control RWAL SYSTEM COMPONENTS
module.
RWAL system components include:
© electronic control module
• rear brake antilock (RWAL) valve
o speed sensor and exciter ring
® antilock warning lamp
A standard master cylinder and vacuum power
brake booster are used for all applications. All of the
RWAL system hydraulic components are located on
SPEED the driver side of the engine compartment (Fig. 2).
SENSOR ANTILOCK
VALVE MASTER
CYLINDER
ASSEMBLY
EXCITER
RING
J9305-45
Fig. 1 Rear Wheel Antilock (RWAL) Brake System

The RWAL system retards rear wheel lockup dur
ing periods of high wheel slip and deceleration. Re
tarding lockup is accomplished by modulating fluid
pressure to the rear brake units.
Rear brake fluid apply pressure is modulated ac
cording to wheel speed, degree of wheel slip and rate
RWAL
of deceleration. A sensor in the rear axle housing con
VALVE J9405-76
verts differential rotating speed into electronic sig
nals. The signals are transmitted to the electronic Fig. 2 RWAL System Hydraulic Component Location
BR REAR WHEEL ANTILOCK liAKE (RWAL) SYSTEM 5 - 27
ElectronicControl Module During normal braking, the valves allows free flow
The electronic module controls operation of the so of brake fluid to the rear brake units. In antilock
lenoids in the rear brake antilock valve. The module mode, the valve will decrease, hold or increase fluid
is separate from other electrical circuits in the vehi apply pressure as needed.
cle and operates independently.
The module is located under the central portion of
the instrument panel (Fig. 3). The module is accessi
ble through the opening created by removal of the
knee bolster.
The RWAL valve, speed sensor and indicator lamps
are all in circuit with the module. The module con
tains a microprocessor that operates the system and
performs system diagnostic checks.
Speed sensor inputs are continuously monitored
and interpreted by the module. The module deter
mines wheel speed and rate of deceleration from
these inputs and activates the appropriate solenoid
in the hydraulic valve when necessary.
The module microprocessor also contains a self test
program. The program is activated when the ignition
switch is turned to the On position. In this mode, the Fig. 4 Combination Valve And RWAL Valve
module checks indicator light operation, the system Combination Valve
electrical circuits and the pressure limiting valve so A combination valve is used with the RWAL sys
lenoids. tem. The valve is attached to an integral bracket
The brake warning and antilock indicator lamps that is mounted to the studs on the power brake
are illuminated for approximately two seconds during booster. The valve bracket is also used to mount the
the system self test cycle. RWAL valve (Fig. 4). The mounting bracket and com
bination valve are serviced as an assembly.
The combination valve contains a front brake me
tering valve and a pressure differential switch and
valve. The differential switch is in circuit with the
red brake warning light.
The metering valve balances brake action between
the front disc and rear drum brakes. The valve
meters (holds-off) full apply pressure to the front disc
brakes until the rear brakeshoes are in full contact
with the drums.
SPEED SENSOR AND EXCITER RING
A speed sensor is used to transmit speed and rate
of deceleration inputs to the electronic control mod
ule (Fig. 5). The sensor is actuated by an exciter ring
on the differential case.
Fig. 3 RWAL Electronic Module And Bracket The sensor is mounted at the top of the rear axle
Location housing directly over the gear-type exciter ring (Fig.
RWAL VALVE 5). The exciter ring is pressed onto the differential
The RWAL (rear brake antilock) valve controls rear case adjacent to the ring gear.
brake fluid apply pressure during antilock mode The exciter ring is the sensor trigger mechanism.
braking. The valve is operated by the electronic con Exciter ring rotation causes the teeth on the ring to
trol module. The valve is mounted on the combina interrupt the magnetic field around the sensor pole.
tion valve bracket (Fig. 3). The rate of interruption is converted into speed sig
The valve contains two solenoid valves that are in nals which are transmitted to the control module.
active during periods of normal braking. The solenoid The sensor is not adjustable and must be replaced
valves are activated only when braking effort and whenever diagnosis indicates a fault has occurred.
rate of wheel slip and deceleration are high (antilock The exciter ring is serviceable and can be replaced
mode). when necessary.
5 - 28 REAR WHEEL ANHLOCK BRAKE (RWAL) SYSTEM BR
Start Of Antilock Modi Braking

When high pedal effort braking occurs, the de
crease in exciter wheel rotating speed is noted and
converted into an electronic signal by the sensor. The
signal is transmitted to and processed by the control
module. The module determines that acceptable lim
its of wheel slip/deceleration are about to be ex
ceeded. The module activates the antilock solenoid
valves at this point.
The module transmits a signal that activates the
solenoid valves. The valves then decrease, or isolate
fluid apply pressure to the rear wheel cylinders as
needed.
Closing the valves prevents further fluid flow to
the rear wheel cylinders. This action isolates the rear
brakes from the master cylinder. The net effect is to
decrease rear brake apply pressure to the point
where the wheels will continue to rotate but not lock.
When rear brake pressure requirements return to
normal levels, the solenoid valves are inactivated.
This action allows the resumption of normal fluid
flow to the wheel cylinders.
Solenoid Valve Cycle Times
Activation (opening/closing) of the solenoid valves
is not static during antilock mode braking. Valve op
eration is continuous as they are rapidly cycled in re
Fig. 5 Rear Wheel Speed Sensor Location sponse to sensor inputs and control module
ANTILOCK WARNING LAMP commands. Cycle times are measured in millisec
The amber warning lamp is located in the instru onds.
ment cluster adjacent to the standard brake warning As the demand for antilock mode brake operation
lamp. The antilock lamp alerts the driver if a system is decreased, the module deactivates the hydraulic
fault occurs. valve components to restore normal brake operation.
The antilock lamp is also used for troubleshooting
COMBINATION WALVE OPERATION
purposes. The lamp is in circuit with the control
module which has a self test program. If a system Pressure Differential Switch
fault occurs, the test program will flash the lamp The pressure differential switch is connected to the
when the diagnostic connector is grounded. The flash brake warning light. The switch is triggered by
codes are used to identify a problem component. movement of the switch valve. The purpose of the
switch is to monitor fluid pressure in the separate
REAR WHEEL ANTILOCK SYSTEM OPERATION front/rear brake hydraulic circuits.
During light brake application, rear wheel deceler A decrease or loss of fluid pressure in either hy
ation and/or slip is not sufficient to activate the an draulic circuit will cause the switch valve to shuttle
tilock system components. Brake fluid apply pressure forward or rearward in response to the pressure dif
to the rear wheels remains normal and is not modu ferential. Movement of the switch valve will push the
lated. However, when braking effort, degree of wheel switch plunger upward. This closes the switch inter
slip, and rate of deceleration approach programmed nal contacts completing the electrical circuit to the
limits, sensor inputs will cause the module to acti warning light. The switch valve will remain in an ac
vate the system. tuated position until repair restores system pressures
to normal levels.
Normal Braking Mode
In normal braking mode, the antilock solenoid Metering Valve
valves are inactive. The valves are open allowing nor The metering valve is used to balance brake action
mal fluid flow to the rear wheel cylinders. between the front disc and rear drum brakes. The
valve meters (holds-off) full apply pressure to the
front disc brakes until the rear brakeshoes are in full
BR REAR WHEEL ANTILOCK BRAKE (RWAL) SYSTEM 5 - 29
contact with the drams. The valve is designed to The black, 2-way diagnostic connector has only one
maintain front brake fluid pressure at 21-207 kPa wire attached to it. This is the 20 gauge black with
(3-30 psi) until the hold-off limit of approximately white tracer wire from test terminal 12 on the con
807 kPa (117 psi) is reached. At this point, the me trol module.
tering valve opens completely permitting full fluid The RWAL diagnostic connector is plugged into the
apply pressure to the front disc brake calipers. data link wire connector.
REAR WHEEL ANTILOCK SYSTEM DIAGNOSIS How To Generate Flash Codes

An antilock system malfunction will be indicated Flash codes are generated by momentarily ground
by illumination of the amber warning lamp. ing the diagnostic connector black wire and counting
If a problem occurs, system diagnosis should begin the warning light flashes.
with a fluid level check followed by a visual exami (a) Unplug the data link wire connector from the
nation of the system electrical and hydraulic connec RWAL diagnostic connector.
tions. If obvious defects (low fluid, leaks, loose (b) Momentarily ground the RWAL diagnostic
connections, etc.) are not evident, road test the vehi connector black wire with a jumper wire (maintain
cle. A road test should help determine if a malfunc ground for about 2 seconds).
tion is actually related to an antilock component. (c) Immediately note and record the number of
During the road test, note if other conditions are flashes at the antilock warning light.
evident such as a low pedal, pull, grab, or similar
condition. Remember that brake malfunctions such FAULT CODE IDENTIFICATION
as low fluid, system leaks, or parking brakes par When a fault code is generated, the red brake
tially applied will affect antilock system operation. warning lamp will also illuminate. To determine
The idea is to determine if a malfunction is actually what the fault code is, momentarily ground the diag
related to an antilock component. nostic connector and count the number of times the
If a visual inspection and road test do not indicate antilock indicator lamp flashes. Fault codes and typ
the problem cause, check the system fault codes. Re ical malfunctions are outlined in Figure 6.
fer to the system fault code information in this sec The initial flash will be a long flash followed by a
tion. number of short flashes. The long flash indicates the
beginning _ of the fault number sequence and the
DIAGNOSTIC FAULT FLASH CODES short flashes are a continuation of that sequence.
The microprocessor in the electronic control module You must count the long flash along with the
has a self test feature. This feature is activated short flashes for an accurate fault code count.
whenever the ignition switch is in the On and Run
positions. CLEARING A FAULT CODE
If a system fault is detected, the control module il To clear a fault code, disconnect the control module
luminates the antilock light and stores the fault code connector or disconnect the battery for a minimum of
in the microprocessor memory. If a fault code is gen five seconds. During system retest, wait 30 seconds
erated, the module will retain the code after turning to be sure the fault code does not reappear.
the ignition switch to Off position.
System faults are identified by a series of flash FAULT CONDITION CAUSES
codes that operate through the antilock warning RWA1 system faults can be generated by component
light. Temporarily grounding the antilock diagnostic malfunction, or by the driver.
connector will produce the flash code sequence. Refer Component malfunctions will most frequently be
to Fault Code Identification in this section. related to problems in the RWAL valve wire harness.
Look for loose connections, corroded terminals, dam
FAULT CODE CAPACITY aged wires, or loss of continuity due to connectors
The microprocessor memory will store and display filled with water or dirt. Blown circuit fuses and poor
only one fault code at a time. The stored code can be ground connections are also common causes for sys
displayed by grounding the antilock diagnostic con tem faults. A misadjusted, or faulty stop lamp switch
nector. will also cause a system fault.
Speed sensor and control module failures, although
RWAL DIAGNOSTIC CONNECTOR infrequent, will be indicated by flash codes. The sen
sor or module should not be replaced until diagnosis
Connector Location indicates this is necessary.
The RWAL diagnostic connector is at the left side The driver can induce system faults by riding the
of the steering column near the parking brake re brake pedal or leaving the parking brakes partially
lease handle. applied. Either condition will cause the antilock
5-30 REAR WHEEL ANTILOCK BRAKE (RWAL) SYSTEM BR
FAULT
ANTILOCK COMPONENT SERVICEABILITY
COM The RWAL valve, combination valve, electronic
NUMBER T Y P I C A L FAILURE DETECTED module, rear wheel speed sensor, exciter ring and in
terconnecting brakelines are not repairable. These
1 Not used.
components are serviced by replacement only.
The combination valve mounting bracket is not ser
2 Open isolation valve wiring or bad control viced separately. The bracket and valve are serviced
module. as an assembly.
3 Open dump valve wiring or bad control RWAL VALVE/COMBINATION VALVE REMOVAL
module. (1) Disconnect ground wire and harness wires from
combination valve switch and RWAL valve (Fig. 7).
4 Closed RWAL valve switch.
5 Over 16 dump pulses generated in 2WD

vehicles (disabled for 4WD).
6 Erratic speed sensor reading while rolling.
7 Electronic control module fuse pellet open,

isolation output missing, or valve wiring
shorted to ground.
8 Dump output missing or valve wiring shorted to

ground.
9 Speed sensor wiring/resistance (usually high

reading).
10 Sensor wiring/resistance (usually low reading).

Fig. 7 Valve Harness Connector And Ground Wire
11 Brake switch always on. RWAL light comes on Locations
when speed exceeds 40 mph. (2) Disconnect lines to front and rear brakes from
RWAL and combination valves (Fig. 8).
12 Not used.
13 Electronic control module phase lock loop

failure.
14 Electronic control module program check

failure.
15 Electronic control module RAM failure.
J9005-101
Fig. 6 RWAL Antilock System Flash Codes

warning light to illuminate, despite the fact that an
actual fault has not occurred.
Another driver induced fault involves holding the
brake pedal in an applied position while starting the
engine. This practice causes the stoplamp switch to
be in a closed position when the engine is started.
With the switch closed, the RWAL system self check
feature will not be completed. The result is illumina
tion of both warning lights and trouble code 11 to be BRAKES J9405-82
registered in system memory.
Fig. 8 Master Cylinder Brakeline Removal
BR REAR WHEEL ANTILOCK BRAKE (RWAL) SYSTEM 5 - 31
(3) Remove brakelines connecting master cylinder

VALVE
to combination valve (Fig. 9). INTEGRAL
MOUNTING
BRACKET
RWAL
VALVE
ATTACHING
BOLT
J9405-84
Fig. 10 RWAL Valve/Combination Valve Disassembly

J9405-83
(8) Install and connect all remaining brakelines
Fig. 9 Master Cylinder Brakeline Removal/ (Figs. 11 and 12). Tighten line fittings to 16-23 N-m
Installation (140-200 in. lbs.) torque.
(4) Remove nutsattaching master cylinder and
combination valve bracket to booster studs (Fig. 9).
(5) Remove master cylinder.
(6) Remove combination valve, valve bracket and
RWAL valve as assembly.
(7) Remove brakeline connecting combination valve
to RWAL valve (Fig. 10).
(8) Remove bolt attaching RWAL valve to combina
tion valve bracket (Fig. 10). Then separate RWAL
valve from bracket.
RWAL VALVE/COMBINATION INSTALLATION

(1) Install RWAL valve on combination valve
bracket (Fig. 10). Do not tighten RWAL valve bolt
completely at this time.
(2) Install short brakeline that connects RWAL
valve to combination valve (Fig. 10). Tighten line fit
tings to 16-23 N-m (140-200 in. lbs.) torque.
(3) Tighten RWAL valve attaching bolt to 23-34
N-m (200-300 in. lbs.) torque. J9405-1
(4) Install master cylinder on booster mounting
studs. Fig. 11 Master Cylinder Brakeline Connections
(5) Attach antilock harness ground wire to combi (9) Connect harness wires to RWAL valve and to
nation valve bracket. combination valve switch (Fig. 7).
(6) Install combination valve bracket on booster (10) Fill and bleed brake system.
mounting studs and against master cylinder.
(7) Loosely install nuts that retain master cylinder CONTROL MODULE REMOVAL/INSTALLATION
and combination valve on booster studs.
The RWAL electronic control module is located un
der the central portion of the instrument panel. It is
5 - 32 REAR WHEEL ANTILOCK BRAKE (RWAL) SYSTEM - — — — — - BR
J948F-7
Fig. 14 RWAL Mule Lower Attaching Screw

Location
LINES FROM
COMBINATION
/. VALVE TO
^FRONT/REAR BRAKES J9405-2
Fig. 12 Master Cylinder And Combination Valve

Mounting
mounted on a bracket attached to the back side of
the panel. The module is accessible through the
panel opening created by removal of the knee bolster.
(1) Remove knee bolster (Fig. 13). Bolster is at
tached to panel flanges with screws.
J948F-8
Fig. 15 RWAL Module Upper Attaching Screw

Location
(6) If module is to be replaced, remove module
from bracket. However, if module is only being re
moved for access to another component, leave module
in place on bracket.
(7) Install module on mounting bracket, if re
moved.
(8) Connect harness wires to module.
(9) Position module and bracket on instrument
panel and install attaching screws (Figs. 14 and 15).
Fig. 13 Knee Bolster Removal (10) Install knee bolster.
(2) Remove module lower attaching screws (Fig.
REAR SPEED SENSOR REMOVAL/INSTALLATION
14). Screws are partially hidden by air duct but can
be removed with long shank, number 2 Phillips (1) Raise vehicle on hoist.
screwdriver as shown. (2) Clean sensor, cover and sensor mounting area
(3) Remove module upper attaching screw (Fig. of axle housing (Figs. 16 and 17). This is necessary to
15). prevent dirt entry when sensor is removed from
(4) Remove module and bracket from underside of housing. Mopar brake cleaner or carb cleaner are
instrument panel. equally acceptable for cleaning purposes.
(5) Disconnect harness wires from module. (3) Disconnect harness wires from sensor (Fig. 16).
B R REAR WHEEL ANTILOCK 1RAKE (RWAL) SYSTEM 5 - 33
(6) Cover sensor opening in axle housing to pre

vent dirt entry.
(7) Insert sensor in axle housing opening. Then po
sition cover over sensor and install cover and sensor
attaching screw.
(8) Connect harness wires to sensor and lower ve
hicle.
REAR SPEED SENSOR REAR HARNESS

REM0WAL/1NSTALLAT10N
(1) Raise vehicle on hoist.
(2) Disconnect sensor harness at sensor. Then dis
engage small harness clip from sensor cover (Fig. 18).
(3) Disconnect sensor harness at axle connector.
(4) Unclip sensor harness from plastic retainer
that secures harness and rear brake hose (Fig. 19).
(5) Remove rear harness from vehicle.
(6) Install new harness and secure it in retainers.
(7) Connect each end of new harness and lower ve
hicle.
RWAL SYSTEM BRAKE BLEEDING

Use Mopar DOT 3 brake fluid, or an equivalent
meeting SAE J1703-F and DOT 3 standards, to fill
and bleed the system.
Bleeding can be performed either manually or with
pressure equipment. However, if pressure equipment
Fig. 16 Rear Speed Sensor Mounting is used, it will be necessary to hold the front brake
(4) Remove screw that secures brake cable, brake- metering valve open in order to bleed the front
line, sensor cover and sensor in axle housing (Figs. brakes. The valve can be held open with a tension
16. and 17). clip tool or by hand. It will also be necessary that a
(5) Remove sensor and cover. suitable size pressure tank hose adapter be available
for use on the master cylinder reservoir caps.
REAR
BRAKE
HOSE
5 - 34 REAR WHEEL ANTILOCK BRAKE (RWAL) SYSTEM Bit
(6) Top off master cylinder reservoir again.

HARNESS (7) Bleed brakes in following sequence:
CUP
• master cylinder
SENSOR • combination valve
HARNESS
CONNECTOR • rear antilock valve
• passenger side rear wheel
• driver side rear wheel
• passenger side front wheel
• driver side front wheel
(8) Observe following precautions during bleeding
procedure:
• Do not pump brake pedal at any time while bleed
ing. Air in system will be compressed into small bub
bles that are distributed throughout hydraulic
J9405-92 system. This will make a second and third bleeding
ctorAt Rear
operation necessary.
Fig. 18 Disengaging Harness
Sensor
• Bleed only one valve, or wheel brake unit at a
time and use a bleed hose on each wheel cylinder
SENSOR HOSE and caliper bleed screw.
HARNESS U-CLIP • Attach one end of bleed hose to bleed screw and
insert opposite end in glass container partially filled
with brake fluid (Fig. 20). Glass container makes it
easier to see air bubbles as they exit the bleed hose.
• Be sure end of bleed hose is immersed in fluid. Im
mersing hose end in fluid prevents air from being
drawn back into cylinder and brakeline.
(9) Bleed master cylinder first. Have helper oper
ate brake pedal while bleeding each master cylinder
fluid outlet line.
CAUTION: Do not allow the master cylinder to run
out of fluid during bleed operations. An empty cyl
inder will allow additional air to be drawn into the
system. Check the cylinder fluid level frequently
and add fluid as needed.
J9405-93
Fig. 19 Sensor Rear Harness Attachment

M A N U A L BLEEDING PROCEDURE
(1) If master cylinder has been overhauled or a
new cylinder will be installed, bleed cylinder on
bench before installation. This shortens time needed
to bleed system and ensures proper cylinder opera
tion.
(2) Wipe master cylinder reservoir and filler caps
FLUID
clean with shop towels. Use Mopar brake cleaner if CONTAINER
exterior of reservoir and filler caps are extremely PARTIALLY
dirty. FILLED WITH
(3) Remove reservoir filler caps and fill reservoir FLUID
with Mopar, or equivalent DOT 3 brake fluid.
(4) Open all caliper and wheel cylinder bleed
screws. J8905-1I
(5) Close bleed screws when fluid starts dripping
from bleed screws. Fig. 20 Typical Fluid Container And Bleed Hose
REAR WHEEL ANTILOCK BRAKE (RWAL) SYSTEM 5 - 35
(10) Bleed combination valve next and rear brake (6) Bleed master cylinder and valves. Bleed master
antilock valve afterward. Bleed valves at brakeline cylinder first, combination valve second and RWAL/
fittings one at a time. Surround line fittings with ABS valves third.
shop towels to catch fluid bled from valve. (7) Bleed rear wheel brake units as described in
(11) Bleed first wheel brake unit as follows. Start manual bleeding procedure.
at passenger side rear wheel: (8) Bleed front wheel brake units. Use a clip style
(a) Open caliper or wheel cylinder bleed fitting tool to hold metering valve in or out. Or have a
1/2 to 3/4 turn. helper hold valve in or out by hand. Amount of valve
(b) Have helper press and hold brake pedal to stem movement needed to hold valve open is quite
floor. modest. Do not use excessive force.
(c) Tighten bleed fitting and have helper release (9) Remove pressure bleeding equipment and top
brake pedal. off master cylinder reservoir.
(d) Continue bleeding operation until fluid enter
ing bleed container is clear and free of bubbles. CAUTION: Verify that the diaphragm seal is firmly
(12) Repeat bleeding operation at remaining wheel seated in the master cylinder cover. If the seal is
brake units. Discard fluid bled into glass container. It improperly seated, it will be displaced when the
should not be reused. cover is installed. This will result in fluid leakage
(13) Check and top off master cylinder reservoir and eventual contamination.
fluid level.
(14) Verify proper brake operation before moving (10) Verify firm brake pedal before moving vehicle.
vehicle. (11) Repeat bleeding procedure if system warning
PRESSURE BLEEDING lights come on, remain on, or if pedal is still spongy.
The front brake metering valve (in the combi
nation valve), must be held open when using
pressure bleeding equipment. This is necessary
because the 20 psi exerted by pressure equip
ment exceeds the valve hold off point causing it
to close. The metering valve is in the forward
end of the combination valve. The valve stem is
accessible after removing the rubber protector
cap that covers the stem. The stem must be ei
ther pressed inward, or held outward slightly
in order to bleed the front brakes. Use a clip
style tool such as Special Tool C-4121 to hold
the stem in or out. Do not use pliers or similar
tools a the stem and valve will be damaged.
(1) Fill bleeder tank if necessary.
(2) Purge air from bleeder tank and lines before
proceeding.
(3) Clean master cylinder reservoir and cover thor
oughly.
(4) Remove master cylinder cover and install suit
able adapter (Fig. 21). Various types of adapters are
usually available from the pressure tank manufac
turer.
(5) Connect bleeder tank pressure hose to adapter Fig. 21 Typical Pressure Bleeder Tank And Adapter
(Fig. 21). END OF DOC BR9505.1
5 - 36 ALL-WHEEL ANIiLOCI BFtAlE SYSTEM (ABS) B R
ALL-WHEEL A H Y I L O C 1 C B R A K E SYSTEM {ABS}
iiDEX
page page
ABS Components 36 All Wheel Antilock System (ABS) Operation 38

ABS Control Module Diagnosis 40 Combination Valve Operation 39
ABS Diagnostic Connector Location . . . . . . . . . . . 40 Combination Valve Testing 41
ABS Manual Brake Bleeding Procedure . . 46 Front Speed Sensor Installation 43
ABS Normal and Fault Conditions 40 Front Speed Sensor Removal 43
ABS System Brake Bleeding 44 Front Tone Wheel Service . . . . . . . . . . . . . . . . . . . 44
ABS System Diagnosis 39 Rear Speed Sensor Harness Replacement . . . . . . 44
ABS Valve and Control Module Installation . . . . . . . 41 Rear Speed Sensor Installation . 44
ABS Valve and Control Module Removal . . . . . . . . 41 Rear Speed Sensor Removal/Installation . . . . . . . . 44
ABS Valve Service and Diagnosis . . . . . . . . . . . . . 41 RWAL Valve/Combination Installation . . . . . . . . . . . 43
ABS Warning Light Display 40 RWAL Valve/Combination Valve Removal . . . . . . . 42
ABS COMPONENTS tronic control module. The pump supplies the addi
The all-wheel antilock brake system (ABS), is a tional fluid volume needed during antilock braking.
unique combined system. It consists of the standard
rear wheel antilock (RWAL) system components, plus
the additional parts needed to create an all wheel an
tilock brake system.
ABS components include:
© rear brake (RWAL) antilock valve
® rear wheel speed sensor and exciter ring
• front wheel speed sensors and tone rings
• front brake antilock valve
© ABS electronic control module
o electrical harnesses
o combination valve
© diagnostic connector
Front Brake ABS Valve
The front brake ABS valve consists of a solenoid
valve body and pump/motor unit combined into a sin
gle assembly (Fig. 1).
The valve is mounted on the driver side inner
fender panel (Fig. 1). The valve and motor assembly
are attached to a one piece mounting bracket and a
stud plate. A molded, flexible shield is used to protect
the top of the valve * assembly.
Fig. 1 ABS Component Location
The valve body contains the solenoid valves that
modulate brake fluid apply pressure during antilock RWAL Valve
braking. The valves are operated by the antilock sys The RWAL valve is mounted on the combination
tem electronic control module. valve bracket (Fig. 2). The bracket is secured to the
The antilock valve provides two channel pressure master cylinder mounting studs on the power brake
control of the front brakes. One channel controls the booster.
left front brake unit. The second channel controls the The RWAL valve modulates rear brake apply pres
right front brake unit. Each front brake unit is con sure during antilock braking. The valve is controlled
trolled independently. and operated by the electronic control module. Two
The solenoid valves are cycled open and closed as solenoid valves in the RWAL valve isolate, decrease,
needed during antilock braking. The valves are not or increase rear brake pressure as needed during an
static. They are cycled rapidly and continuously to tilock braking.
modulate pressure and control wheel slip and decel The solenoid valves are inactive during periods of
eration. normal braking. The solenoids allow free flow of
The pump and motor are controlled by the elec- brake fluid to the wheel cylinders during normal
BR ALL-WHEEL ANTILOCK BRAKE SYSTEM (ABS) 5 - 37
braking. The solenoid valves are activated only when COMBINATION

braking effort and rate of wheel slip and deceleration VALVE
exceed normal limits. AND MOUNTING
BRACKET
MASTER ASSEMBLY
CYLINDER
ASSEMBLY
J9405-96
Fig. 3 Combination Waive And integral Mounting

Bracket
The module controls front/rear valve solenoid oper
ation during all phases of antilock braking. Module
electrical inputs are provided by wheel speed signals
from the front and rear wheel speed sensors.
ABS Diagnostic Connector
The ABS diagnostic connector is at the underside of
the knee bolster. The connector is a six-way style and
is either black, or blue in color. The connector is the
RWAL ABS access point for the DRB scan tool. System cir
VALVE J9405-76
cuits can be checked once the scan tool is plugged
Fig. 2 RWAL Waive And Combination Waive Location into the connector.
Combination Valve Wheel Speed Sensors And Tone Wheels
The combination valve used with the ABS system Three wheel speed sensors are used in the ABS
contains a front disc brake metering valve and a system. A separate sensor is used at each front
front/rear pressure differential valve and switch. wheel. A single sensor is used for both rear wheels
The metering valve controls fluid apply pressure to (Fig. 4).
the front disc brake calipers. Caliper apply pressure The sensors convert wheel speed into an electrical
is temporarily limited until the rear drum brake- signal. The signal is transmitted to the electronic
shoes contact the drum surface. This feature provides control module for processing.
balanced front/rear braking. The trigger mechanism for each front wheel sensor
The pressure differential valve is connected to the is a gear-type tone wheel. The tone wheels are
front and rear brake hydraulic systems. A leak in ei mounted on the inboard side of the disc brake rotor
ther part of the system will actuate the valve causing hub (Fig. 5).
it to shuttle toward the leaking side of the system. A single sensor is used to monitor rear wheel speed
Movement of the valve trips the warning switch and rate of deceleration. The sensor is mounted at
plunger which closes the electrical circuit to the red the top of the rear axle housing (Fig. 6). The trigger
warning light. mechanism for the sensor, is an exciter ring pressed
The combination valve is permanently attached to onto the differential case next to the ring gear.
its mounting bracket. The valve bracket is also used The teeth on the tone wheels and exciter ring in
to mount the rear brake antilock valve (Fig. 3). terrupt the sensor magnetic field as they rotate. The
Combination valve operation and testing is fully rate of interruption is converted into speed signals
described in the antilock system diagnosis section. which are transmitted to the electronic control mod
Refer to this information when diagnosing system ule.
faults. The front and rear sensors are fixed and not ad
ABS Control Module justable. A front or rear sensor must be replaced
A separate electronic control module is used to when diagnosis indicates a fault has occurred.
monitor and operate the ABS system. The module is Master Cylinder And Power Brake Booster
located at the drivers inner fender panel (Fig. 1). The
module is attached to the forward side of the front A standard master cylinder and vacuum power
antilock valve mounting bracket. brake booster are used with the ABS system. The
S - 38 ILL-WHEEL ANTILOCK BRAKE SYSTEM (ABS) Bit
RFTAINING _
SCREW
SENSOR CABLE ~~~~~~~~~~
BOLTS (2)
CLAMP——""^
BRAKE
LINE
COVER-^*"^
SENSOR' ~~~~~
AXLE_„—
STEERING
KNUCKLE HOUSING
SPLASH
SHIELD FRONT
SENSOR J9505-118
Fig. 4 Front Wheel Sensor Location
-ROTOR
Fig. 6 Rear Wheel Sensor Location

The ABS valve provides two channel pressure con
trol of the front brakes. Each front wheel brake unit
J9305-71 is controlled separately. Two solenoid valves are used
in each control channel.
Fig. 5 Front Tone Wheel Location (In Rotor) The RWAL valve controls the rear wheel brakes in
same master cylinder and dual or single diaphragm tandem. The rear brake valve contains two solenoid
boosters are used with either antilock system. valves.
During antilock braking, the solenoid valves are
ALL WHEEL ANTILOCK SYSTEM (ABS) OPERATION opened and closed as needed. The valves are not
static. They are cycled rapidly and continuously to
The all wheel ABS system is a three channel de
modulate pressure and control wheel slip and decel
sign. The front wheel brakes are controlled individu
eration.
ally and the rear wheel brakes in tandem (Fig. 7).
The ABS system is designed to retard wheel lockup The pump/motor assembly on the front antilock
during periods of high wheel slip when braking. Re valve provides the fluid volume needed during an
tarding wheel lockup is accomplished by modulating tilock braking. The pump is operated by an integral
fluid pressure to the wheel brake units. electric motor. The DC type motor is controlled by
The antilock electrical system is separate from the ABS control module.
other electrical circuits in the vehicle. A specially pro mS O P E R A T I O N IN NORMAL BRAKING MODE
grammed electronic control module is used to operate The ABS electronic control module monitors wheel
the system components. speed sensor inputs continuously while the vehicle is
The front and rear antilock valves contain electri in motion. However, the module will not activate any
cally operated solenoid valves. The solenoid valves ABS components as long as sensor inputs indicate
modulate brake fluid apply pressure during antilock normal braking.
braking. The valves are operated by the antilock elec During normal braking, the master cylinder, power
tronic module. booster and wheel brake units all function as they
would in a vehicle without ABS. The solenoid valves
are not activated.
BR ILL-WHEEL ANTILOCK BRAKE SYSTEM (ABS) §- 39
POWER
BRAKE
BOOSTER
MASTER hj=(Jf-*
CYLINDER #
FRONT
ANTILOCK
VALVE
J""L-Tj,
RF RR
WHEEL WHEEL
COMBINATION REAR
VALVE ANTILOCK
VALVE
LF LR
WHEEL WHEEL
J9305-113
Fig. 7 ABS Hydraulic System Connections

ABS OPERATION IN ANTILOCK BRAKING switch valve pushes the switch plunger upward. This
MODE action closes the switch internal contacts completing
The ABS module activates the system whenever the electrical circuit to the warning light. The switch
sensor signals indicate the onset of high wheel slip. valve will remain in an actuated position until repair
High wheel slip can be described as the point restores system pressures to normal levels.
where wheel rotation begins approaching zero (or
lockup) during braking. The antilock system retards Metering Valve
lockup during high slip conditions by modulating The metering valve is used to balance brake action
fluid apply pressure to the wheel brake units. between the front disc and rear drum brakes. The
Brake fluid apply pressure is modulated according valve meters (holds-off) full apply pressure to the
to wheel speed, degree of slip and rate of decelera front disc brakes until the rear brakeshoes are in full
tion. A sensor at each wheel converts wheel speed contact with the drums. The valve is designed to
into electrical signals. These signals are transmitted maintain front brake fluid pressure at 21-207 kPa
to the module for processing and determination of (3-30 psi) until the hold-off limit of 807 kPa (117 psi)
wheel slip and deceleration rate. is reached. At this point, the metering valve opens
The ABS system has three fluid pressure control completely permitting full fluid apply pressure to the
channels. The front brakes are controlled separately front disc brakes.
and the rear brakes in tandem. A speed sensor input
signal indicating high slip conditions activates the ABS SYSTEM DIAGNOSIS
control module antilock program. ABS system diagnosis involves checking only those
The solenoid valves are not static during antilock components that form the antilock system. Antilock
braking. They are cycled continuously to modulate system diagnosis involves three basic steps which
pressure. Solenoid cycle time in antilock mode can be are:
measured in milliseconds. • observation of the warning light display
• visual examination for low fluid, leaks, or dam
COMBINATION ¥ALWE OPERATION aged wires
• identification of the problem circuit
Pressure Differential Switch Visual examination includes a check of reservoir
The pressure differential switch is connected to the fluid level and condition of the system components.
red brake warning light. The switch is triggered by This includes inspection of the sensor wires and elec
movement of the switch valve. A decrease or loss of trical connections. Things to look for are leaks, loose
fluid pressure in either hydraulic circuit will cause connections, or obvious component damage. Identifi
the switch valve to shuttle forward or rearward in re cation involves using the DRB scan tool to identify
sponse to the pressure differential. Movement of the the faulty circuit.
5 - 40 ALL-WHEEL ANTILOCK BRAKE SYSTEM (ABS) BR
ABS DIAGNOSTIC CONNECTOR LOCATION differing traction surfaces would be when the left
The ABS diagnostic connector is clipped to the un side wheels are on ice and the right side wheels are
der side of the knee bolster (Fig. 8). The connector is on relatively dry pavement.
positioned just below the steering column.
Brake Pedal Pulsing
The diagnostic connector is a six-way type, is either
light blue or black in color, and is the ABS access A pulsing sensation may be felt through the brake
point for the DRB scan tool. System circuits can be pedal during antilock mode braking. This is a nor
tested once the scan tool is plugged into the connec mal occurrence and should not be mistaken for a sys
tor. tem fault.
Loss Of Sensor Input
Wheel speed sensor malfunctions will most likely
be due to loose connections, damaged sensor wires, or
incorrect sensor air gap. An additional fault would be
a result of sensor and tone wheel misalignment or
physical damage. A faulty sensor can be located with
the scan tool.
Driver Induced Faults
The driver can induce system faults by pumping or
riding the brake pedal, or leaving the parking brakes
partially applied. Either condition will cause the an
tilock warning light to illuminate, despite the fact
J9405-164 that an actual malfunction has not occurred.
Another driver induced fault involves holding the
Fig. 8 ABS Diagnostic Connector Location brake pedal in an applied position while starting the
ABS NORMAL AND FAULT CONDITIONS engine. This practice causes the stoplamp switch to
be in a closed position when the engine is started.
Wheel/Tire Size And Input Signals With the switch closed, the ABS system self check
Antilock system operation depends on accurate sig feature will not be completed. The result is illumina
nals from the wheel speed sensors. Ideally, the vehi tion of both warning lights and the entry of a trouble
cle wheels and tires should all be the same size and code in system memory.
type to ensure accurate signals and satisfactory oper
ation. A1S WARNING LIGHT DISPLAY
Operating Sound Levels Light Illuminates At Startup
The pump, motor, and antilock valve solenoids may The amber antilock light illuminates at startup as
produce some sound as they cycle on and off. This is part of the system self check feature. The light illu
a normal condition and should not be mistaken for minates for 2-3 seconds then goes off as part of the
faulty operation. Under most conditions however, normal self check routine.
pump and solenoid valve operating sounds should not
be audible. Light Remains On After Startup
An ABS fault is indicated when the amber light re
Vehicle Response In Antilock Mode mains on after startup. Diagnosis with the DRB scan
During antilock braking, the front/rear solenoid tool will be necessary to determine the faulty circuit.
valves cycle rapidly in response to antilock electronic
control unit inputs. Light Illuminates During Brake Stop
The driver will experience a light pulsing sensation A system fault such as loss of speed sensor signal
in the brake pedal and in the vehicle. This occurs as or solenoid failure, will cause the amber warning
the solenoid valves modulate fluid pressure as light to illuminate. The most effective procedure here
needed. This is a normal condition during antilock is to check for obvious damage first. Then check elec
mode braking. tronic circuits with the scan tool.
Steering Response ABS CONTROL MODULE DIAGNOSIS .
A modest amount of steering input is required dur The electronic module controls all phases of an
ing extremely high deceleration braking, or when tilock system operation. The module also differenti
braking on differing traction surfaces. An example of ates between normal and antilock mode braking.
BR ALL-WHEEL ANTILOCK BRAKE SYSTEM (ABS) 5 - 41
The module monitors and processes signals gener ABS VALVE AND CONTROL MODULE REMOVAL
ated by the system sensors at all times. (1) If desired, battery can be removed for improved
The module operating program includes a self access to ABS valve and connecting lines.
check routine that tests each of the system compo (2) Disconnect ABS harness at valve (Fig. 9).
nents. A failure of the self check program will cause (3) Unlatch and disconnect harness at ABS mod
illumination of the amber warning light. The light ule.
will also illuminate if a solenoid or other system com
ponent fails during the dynamic phase of initializa
tion.
If a system malfunction should occur, do not imme
diately replace the control module. A blown system
fuse, bad ground, low voltage, or loss of feed voltage
will cause system faults similar to a module failure.
Never replace the module unless scan tool diag
nosis indicates replacement is actually neces
sary.
ABS VALWE SERWICE AND DIAGNOSIS

The front and rear antilock valves are serviced only
as assemblies. Neither valve should be replaced un
less a fault has actually been confirmed.
COMBINATION ¥AL¥E TESTING Fig. 9 ABS Valve Harness Connections
(4) Disconnect lines to front brakes at ABS valve
TESTING METERING VALVE (Fig. 10).
Metering valve operation can be checked visually
and with the aid of a helper. Observe the metering
valve stem while a helper applies and releases the
brakes. If the valve is operating correctly, the stem
will extend slightly when the brakes are applied and
retract when the brakes are released. If the valve is
faulty, replace the entire combination valve as an as
sembly.
TESTING PRESSURE DIFFERENTIAL SWITCH

(1) Have helper sit in drivers seat to apply brake
pedal and observe red brake warning light.
(3) Connect bleed hose to a rear wheel cylinder
and immerse hose end in container partially filled
with brake fluid.
(4) Have helper press and hold brake pedal to floor Fig. 10 ABS Valve Hydraulic Connections
and observe warning light. (5) Remove stud nuts and bolt that attach ABS
(a) If warning light illuminates, switch is operat valve to inner fender panel (Fig. 11). Then remove
ing correctly. valve from engine compartment.
(b) If light fails to illuminate, check circuit fuse, (6) If valve is only being removed for access to an
bulb and wiring. Repair as necessary and repeat other component, cover brakeline fluid ports with
test steps (3) and (4). tape or plugs to prevent dirt entry.
(5) If warning light still fails to illuminate, check (7) Remove bolts attaching module to valve and re
brakelight and parking brake switches and wiring move module.
with test lamp. Repair or replace parts as necessary
and test differential pressure switch operation again. ABS VALVE AND CONTROL MODULE
(6) If warning light still does not illuminate, switch INSTALLATION
is faulty. Replace combination valve assembly, bleed
brake system and verify proper switch and valve op (1) Install replacement module on valve if neces
eration. sary.
(2) Position ABS valve on mounting studs.
5 - 42 ALL-WHEEL ANTILOCK BRAKE SYSTEM (ABS)
ABS VALVE
AND MODULE
ASSEMBLY
INNER
FENDER
PANEL
STUD COMBINATION
PLATE VALVE
(ON UNDERBODY) J9405-99
RWAL VALVE
Fig. 11 ABS Valve Mounting
(3) Install and tighten mounting bolt and stud LINE
nuts. Tighten bolts and nuts to 10-13 N-m (92-112 in. TO
lbs.) torque. FRONT
BRAKES J9405-82
(4) Connect ABS harnesses to valve and electronic
module. Be sure module harness is securely latched
Fig. 13 Master Cylinder Brakeline Removal
in place.
(5) Connect brakelines to ABS valve. Tighten line
fittings to 19-23 N-m (170-200 in. lbs.) torque.
(6) Install battery, if removed.
(7) Fill and bleed brake system. Refer to procedure
in this section.
RWAL VALVE/COMBINATION VALVE REMOVAL

(1) Disconnect ground wire and harness wires from
combination valve switch and RWAL valve (Fig. 12).
GROUND.
x
SECONDARY
BRAKEUNE \
PRESSURE
DIFFERENTIAL
SWITCH
WIRE J9405-83
RWAL
VALVE
HARNESS Fig. 14 Master Cylinder Brakeline Removal/
AND Installation
CONNECTOR J9405-77
(5) Remove master cylinder.
Fig. 12 Valve Harness Connector And Ground Wire (6) Remove combination valve, valve bracket and
Locations RWAL valve as assembly.
(2) Disconnect lines to front and rear brakes from (7) Remove brakeline connecting combination valve
RWAL and combination valves (Fig. 13). to RWAL valve.
(3) Remove brakelines connecting master cylinder (8) Remove bolt attaching RWAL valve to combina
to combination valve (Fig. 14). tion valve bracket (Fig. 15). Then separate RWAL
(4) Remove nuts attaching master cylinder and valve from bracket.
combination valve bracket to booster studs.
BR ILL-WHEEL ANTILOCK BRAKE SYSTEM (ABS) I - 43
VALVE
INTEGRAL
MOUNTING
BRACKET
RWAL
VALVE
ATTACHING
HOLT
J9405-84 J9405-1
Fig. 15 RWAL Valve/Combination Valve Disassembly Fia. II faster Cylinder Brakeline Connections
iWAL WALWE/COMBINATION INSTALLATION
(1) Install RWAL valve on combination valve
bracket (Fig. 15). Do not tighten RWAL valve bolt
completely at this time.
(2) Install short brakeline that connects RWAL
valve to combination valve (Fig. 15). Tighten line fit
tings to 16-23 N-m (140-200 in. lbs.) torque.
(3) Tighten RWAL valve attaching bolt to 23-34
N-m (200-300 in. lbs.) torque.
(4) Install master cylinder on booster mounting
studs.
(5) Attach antilock harness ground wire to combi
nation valve bracket.
(6) Install combination valve bracket on booster
mounting studs and against master cylinder.
(7) Loosely install nuts that retain master cylinder
and combination valve on booster studs.
(8) Install and connect all remaining brakelines
(Figs. 16 and 17). Tighten line fittings to 16-23 N-m LINES FROM
COMBINATION
(140-200 in. lbs.) torque. / VALVE TO
(9) Connect harness wires to RWAL valve and to ^FRONT/REAR BRAKES J9405-2
combination valve switch (Fig. 17).
(10) Fill and bleed brake system. Refer to manual Fig. 17 Master Cylinder And Combination Valve
bleeding procedure in this section. Mounting
(5) Remove rotor.
FRONT SPEED SENSOR REMOVAL (6) Remove bolts attaching sensor to steering
(1) Raise vehicle and support vehicle front end. knuckle (Fig. 18). Retain bolts. They are special and
(2) Remove wheel and tire assembly. must be reused if in good condition.
(3) Press caliper piston back into bore with pry (7) Disconnect sensor wire and remove sensor from
tool. vehicle.
(4) Remove brake caliper bolts and lift caliper from
knuckle and rotor. Secure caliper to frame or chassis FRONT SPEED SENSOR INSTALLATION
component with wire. Do not allow brake hose to
support caliper weight. (1) Position sensor in knuckle.
5 - 44 ALL-WHEEL ANTILOCK BRAKE SYSTEM (ABS) — — — Bit
RETAINING
SCREW
SENSOR
BOLTS (2)
STEERING
KNUCKLE
SPLASH
SHIELD FRONT
SENSOR J9505-118
fig. 18 Front Speed Sensor Mounting (2-Wheel

Drive Shown)
(2) Install and tighten sensor bolts to 21-25 N-m
(190-250 in. lbs.) torque. Use original or replace
ment sensor bolts only. The bolts are special
and must not be substituted.
(3) Connect sensor wire to harness wire from ABS
controller.
(4) Install rotor and brake caliper.
(5) Install wheel and tire assembly. J9405-80
(6) Lower vehicle.
(7) Verify sensor operation with scan tool. Fig. 19 Rear Speed Sensor Mounting
REAR SPEED SENSOR INSTALLATION

FRONT TONE WHEEL SERVICE
(1) Insert sensor in axle housing opening.
The tone wheel for the front speed sensor is located
(2) Position cover over sensor and install cover and
in the rotor hub on 2-wheel drive models. On 4-wheel
sensor attaching screw.
drive models, the tone wheel is located on the drive-
(3) Connect harness wires to sensor.
shaft.
(4) Lower vehicle.
The tone wheel is not a serviceable component. On
2-wheel drive models, the complete rotor and hub as REAR SPEED SENSOR HARNESS REPLACEMENT
sembly will have to be replaced if the tone wheel be
comes damaged. On 4-wheel drive models, the
(2) Disconnect wire harness at sensor. Then disen
driveshaft is necessary if the tone wheel becomes
gage
damaged.
small harness clip from sensor cover (Fig. 21).
REAR SPEED SENSOR REMOVAL/INSTALLATION (3) Disconnect sensor harness at axle connector.
(4) Unclip sensor harness from plastic retainer
that secures harness and rear brake hose (Fig. 22).
(2) Clean sensor, cover and sensor mounting area
(5) Remove rear harness from vehicle.
of axle housing (Figs. 19 and 20). This is necessary to
(6) Install and connect new rear harness. Verify
prevent dirt entry when sensor is removed from
that harness is securely clipped to retainers.
housing. Mopar brake cleaner or carb cleaner are
(7) Lower vehicle.
equally acceptable for cleaning purposes.
(3) Disconnect harness wires from sensor. ABS SYSTEM BRAKE BLEEDING
(4) Remove screw that secures brake cable, brake-
line, sensor cover and sensor in axle housing (Figs. Use Mopar DOT 3 brake fluid, or equivalent meet
19 and 20). ing SAE J1703-F and DOT 3 standards, to fill and
(5) Remove sensor and cover. bleed the system.
(6) Cover sensor opening in axle housing to pre Bleeding can be performed manually, with vacuum
vent dirt entry. equipment, or with pressure equipment. Manual
bleeding is preferred. If vacuum or pressure equip-
B R ALL-WHEEL ANTILOCK BRAKE SYSTEM (ABS) 5 - 45
REAR REAR
BRAKE SENSOR
HOSE HARNESS
CONNECTOR
REAR
SENSOR
REAR
AXLE
HOUSING J9405-81
Fig. 20 Rear Speed Sensor Harness Routing And Attachment
SENSOR HOSE
HARNESS UCLIP
SENSOR
HARNESS
CONNECTOR
J9405-92
Fig. 21 Disengaging Harness Connector At Rear

Sensor
ment is used, it is important that the manufacturers

instructions be followed for proper results.
J9405-93
Vacuum bleeding does not require that the front
brake metering valve be held open. However, if pres Fig. 22 Sensor Rear Harness Attachment
sure equipment is used, it will be necessary to hold
the front brake metering valve open in order to bleed • front antilock valve
the front brakes. The valve can be held open with a • left rear wheel
tension clip tool or by hand. It will also be necessary • right rear wheel
that a suitable size pressure tank hose adapter be • right front wheel
available for use on the master cylinder reservoir • left front wheel
Observe following precautions while bleeding the
caps.
brake system:
Recommended bleeding sequence is: ® Bleed only one valve, or wheel brake unit at a
• master cylinder time. Use a bleed hose on each wheel cylinder and
• rear antilock valve caliper bleed screw.
• combination valve • Attach one end of the bleed hose to the bleed
5 - 46 ALL-WHEEL ANTILOCK BRAKE SYSTEM (ABS) BR
screw and insert the opposite end of the hose in glass (6) There are two bleed procedures for the front
container partially filled with brake fluid (Fig. 23). A antilock valve. If a new front valve is being installed,
glass container makes it easier to see air bubbles as bleed the valve as described in step (7). However, if
they exit the bleed hose. the original valve is still in the vehicle, bleed the
• Be sure the end of the bleed hose remains im valve as described in step (8).
mersed in fluid. This is necessary to prevent air from (7) If a new front antilock valve and motor as
being drawn back into the cylinder or caliper and sembly is being installed, bleed new valve as fol
brakeline. lows:
Do not allow the master cylinder to run out of fluid (a) Loosen bleed plug on new front valve about
when bleeding the brakes. An empty cylinder will al 1/4 to one full turn (Fig. 23). Plug must be open to
low additional air to be drawn into the system. fully bleed upper and lower sections of front an
Check the cylinder fluid level frequently and add tilock valve.
fluid as needed. (b) Remove cap from bleed valve stem (Fig. 24).
(c) Install Valve Depressor Tool 6670 on bleed
valve stem (Figs. 24 and 25). To install tool, slide
notched side of tool onto boss that surrounds bleed
valve stem (Fig. 25). Stem must be held inward (in
open position) to fully bleed upper section of new
valve assembly.
(d) Tighten thumbscrew on bleed Tool 6670 just
enough to push valve stem inward about 0.51 -
0.76 mm (0.020 - 0.030 in.).
(e) Apply brake pedal. Pedal will fall off signifi
cantly when bleed plug is properly open and bleed
valve stem is correctly unseated (pressed inward)
by tool.
(f) Stroke brake pedal rapidly 5-10 times. This
action will fill upper and lower sections of valve
rapidly.
(g) Bleed new valve assembly at each brakeline
fitting one at a time. Remember to close valve
J8905-18 bleed plug before each brake pedal stroke. Con
tinue bleeding until fluid flowing from fittings is
Fig. 23 Typical Fluid Container And Bleed Hose clear and free of bubbles.
ABS MANUAL BRAKE BLEEDING PROCEDURE (h) Remove depressor tool from valve stem and
install cap on stem. Then tighten bleed plug to 7-9
(1) If master cylinder has been overhauled, or a N-m (60-84 in. lbs.) torque.
new cylinder will be installed, bleed cylinder on
bench before installation. This shortens bleed time (8) If original front antilock valve assembly is
and ensures proper cylinder operation. Refer to pro still in place, bleed plug and bleed valve do not
cedure in Master Cylinder Service section. have to be open during bleeding operations.
(2) If master cylinder was not serviced, wipe cylin Just bleed the valve assembly at each brakeline fit
der reservoir and cover clean with shop towels. Use ting one at a time.
Mopar brake cleaner if reservoir and cover are ex (9) Bleed wheel brake units one at a time in rec
tremely dirty. Then remove cover and fill reservoir ommended sequence and as follows:
with Mopar, DOT 3 brake fluid. (a) Bleed first wheel brake unit as follows. Start
(3) Open all caliper and wheel cylinder bleed at left rear wheel.
screws. Close bleed screws when fluid starts dripping (b) Open caliper or wheel cylinder bleed fitting
from bleed screws. Then top off master cylinder res 1/2 to 3/4 turn.
ervoir again. (c) Have helper press and hold brake pedal to
(4) Bleed master cylinder first. Have helper oper floor.
ate brake pedal while bleeding each master cylinder (d) Tighten bleed fitting and have helper release
fluid outlet line. brake pedal.
(5) Bleed RWAL valve next and combination valve (e) Continue bleeding operation until fluid flow
afterward. Bleed each valve at brakeline fittings one ing into bleed fluid container is clear and free of
at a time. Surround line fittings with shop towels to bubbles.
catch fluid from fittings.
IR ALL-WHEEL ANTILOCK BRAKE SYSTEM (ABS) 5 - 47
(10) Check and top off master cylinder reservoir

fluid level. Then verify proper brake operation before
moving vehicle.
(11) Repeat bleeding procedure if either brake
warning light illuminates, or if pedal is still spongy.
BLEED
VALVE
STEM
Fig. 25 Front Antilock Valve Bleed Tool Installation

Pressure Heeding
If pressure bleeding equipment will be used, the
metering valve stem in the combination valve must
be either pressed inward, or held outward slightly in
order to bleed front brakes. The stem can be held
open, or pressed inward with a tension clip tool, or
by hand.
Follow the bleed equipment manufacturers instruc
tions for use. Also do not pressure bleed without a
proper adapter for the master cylinder reservoir.
Fig. 24 Location Of Front Antilock Valve Bleed Valve

Stern And Plug
Vacuum Brake Bleeding
If vacuum bleeding equipment is used, no special
precautions are required. Just bleed the brakes in ac
cordance with the equipment manufacturers instruc
tions.
5 - 43 DISC BRAKES
D I S C BRAKES
INDEX
page page
Caliper Operation and Wear Compensation . . . . . . 48 Disc Brake Rotor Removal (With Tapered Bearings) . . 58
Disc Brake Caliper Cleaning and Inspection . . . . . . 54 Disc Brake Rotor Removal (With Unit Bearings) . . . 60
Disc Brake Caliper Disassembly 53 Disc Brakeshoe and Caliper Inspection 51
Disc Brake Caliper Installation 56 Disc Brakeshoe Installation 51
Disc Brake Caliper Overhaul and Reassembly . . . . 55 Disc Brakeshoe Removal . 50
Disc Brake Caliper Removal 53 Front Wheel Bearing Replacement 62
Disc Brake Rotor Inspection and Service 57 General Service Information 48
Disc Brake Rotor Installation (With Tapered Wheel Bearing Adjustment (With Tapered Bearings) . . 59
Bearings) 59 Wheel Nut Tightening 62
Disc Brake Rotor Installation (With Unit Bearings) . 61
GENERAL SERVICE INFORMATION

Caliper Tpes
BR models are equipped with Delco slider type,
front disc brake calipers. The calipers slide laterally
on the mounting bolts attaching each caliper to the
steering knuckle.
Caliper Sizes A i l Application
Two different caliper styles and three different cal
iper bore sizes are used on BR models (Figs. 1, 2 and
3). Caliper styles are similar in appearance. The
main difference between them being physical size
and caliper mounting bolt bushing type.
Caliper piston bore sizes are:
• calipers on 1/2 ton models have a 75 mm (2.95 in.)
bore
• calipers on 3/4 ton models have an 80 mm (3.14
in.) bore
• calipers on 1 ton models have an 86 mm (3.38 in.) bore
The three different size calipers are not inter
changeable. Use the specified caliper or compo
nents when diagnosis indicates caliper or Fig. 1 Model 1500 Disc Brake Caliper (75 mm Piston)
component replacement is necessary. Do not in
termix calipers, or components. knuckles. Separate mounting brackets are not re
quired. Caliper mounting arms are built right into
Brakeshoe Types And Wear Tabs the knuckle (Fig. 4).
The outboard brakeshoes on all BR models have The caliper mounting bolts are encased within steel
wear tabs. The metal tabs are attached to the trail collars. The collars are permanently attached to the
ing end of each outboard brakeshoe (Figs. 1, 2 and 3). bolts and cannot be serviced separately.
The tabs contact the rotor surface when lining mate
rial has worn to a thickness of approximately 5 to 6 CALIPER OPERATION AND WEAR COMPENSATION
mm (3/16 to 1/4 in.). The resulting noise alerts the
driver that brakeshoe replacement is necessary. Caliper Operation
The brakeshoes on 1/2 ton models are different The significant feature of single piston caliper op
from those used on 3/4 and 1 ton models. Do not in eration is that the calipers are free to slide laterally
termix the shoes for any reason. on the mounting bolts. It is the freedom of lateral
movement that allows continuous compensation for
Caliper Mounting lining wear.
The calipers are attached directly to the steering
BR DISC BRAKES I - 41
WEAR CALIPER
«gfcy:- TAB MOUNTING
ARMS
(PART
OF
KNUCKLE)
80MM CALIPER INBOARD

(3/4 TON) BRAKESHOE
J9405-45 J9405-26
Fig, 2 Model 2500 Disc Brake Caliper (80 mm Fig. 4 Caliper Mounting (in Steering Knuckle)
Piston) the same as pressure on the piston. In other words,
86MM CALIPER pressure against piston and caliper bore will be
(1 TON) equal. .
Fluid pressure applied to the piston is transmitted
directly to the inboard brakeshoe. This forces the
shoe lining against the inner surface of the disc
brake rotor (Fig. 5).
At the same time, fluid pressure within the piston
bore, forces the caliper to slide inward on the mount
ing bolts. This action brings the outboard brakeshoe
lining into contact with the outer surface of the disc
brake rotor (Fig. 5). . '
In summary, fluid pressure acting simultaneously
on both piston and caliper, produces a strong clamp
ing action. When sufficient force is applied, friction
will stop the rotors from turning and bring the vehi
cle to a stop.
Brakeshoe Wear Compensation
Application and release of the brake pedal gener
WEAR OUTBOARD
TAB BRAKESHOE ates only a very slight movement of the caliper and
J9405-46
piston. Upon release of the pedal, the caliper and pis
Fig. 3 Model 3500 Disc Brake Caliper (86 mm ton return to a rest position. The brakeshoes do not
Piston) retract an appreciable distance from the rotor. In
fact, clearance is usually at, or close to zero. The rea
A simplified cross section of a single piston caliper sons for this are to keep road debris from getting be
is shown in Figure 1. The illustration graphically tween the rotor and lining and in wiping the rotor
portrays the forces at work when the brakes are ap
surface clear each revolution.
plied.
Upon brake application, fluid pressure exerted The caliper piston seal controls the amount of pis
against the caliper piston increases greatly. Of equal ton extension needed to compensate for normal lining
importance, is the fact that this fluid pressure is ex wear.
erted equally and in all directions. What this means, During brake application, the seal is deflected out
is that pressure in the caliper bore, will be exactly ward by fluid pressure and piston movement (Fig. 6).
5 - li iiSC BRAKES mi
Fig. 7 Pressing Caliper Piston Back Into Bore
SHOE
w
° J9405-102
Fig. 5 Disc Brake Caliper Operation

When the brakes and fluid pressure are released, the
seal relaxes and retracts the piston.
The amount of piston retraction is determined by
brakelining wear. Generally, the amount is just
enough to maintain contact between the piston and
inboard brakeshoe. In addition, running clearance at
the rotor will be held between zero and a maximum
of 0.12 mm (0.005 in.).
Fig. 8 Caliper Mounting Bolt Removal/Installation

(1/2 Ton)
Fig. 6 Lining Wear Compensation (By Piston Seal)

DISC BRAKESHOE RE10WAL
(1) Raise vehicle.
(2) Remove wheel and tire assemblies.
(3) Press caliper piston back into bore with large
flat blade screwdriver (Fig. 7). Use large C-clamp to
bottom piston in bore if additional force is required.
(4) Remove caliper mounting bolts with 3/8 hex Fig. 9 Caliper Mounting Bolt Removal/Installation
wrench or socket (Figs. 8 and 9). (3/4 and 1 Ton)
(5) Rotate caliper rearward off rotor and out of in caliper piston. Tilt this shoe out at top to unseat
steering knuckle support ledges (Fig. 10).
(6) Remove inboard and outboard brakeshoes (Figs.
11 and 12). Inboard shoe has spring clip that holds it
DISC BRAKES 5 - 51
Fig. 12 Outboard Brakeshoe Removal
J9405-28
Fig. 10 Caiiper Removai/instailation

clip. Outboard shoe has retaining spring that secures
it in caliper. Unseat one spring end and rotate shoe
out of caliper.
INBOARD
J9405-30
Fig. 13 Supporting 2-Wheel Drive Caliper

DISC BRAKESHOE AND CALIPER INSPECTION
Inspect the brakeshoe lining for wear. Replace riv
eted lining if worn to within 1.5 mm (1/16 in.) of
rivet heads. Replace bonded lining if thickness is 3
mm (3/16 in.) or less.
If the brakeshoes will be reused, do not intermix
J9405-49 them. Keep the brakeshoes with the caliper they
were removed from.
Fig. 11 inboard Brakeshoe Removal Examine the caliper piston area for evidence of
(7) Secure caliper to convenient chassis or suspen leaks. Also check condition of the piston boot. Over
haul the caliper if leakage is evident or the boot is
sion component with wire (Figs. 13 and 14).
cut or torn.
CAUTION: Do not allow the brake hose to support Inspect condition of the caliper and steering
the caliper. Suspending the caliper by the brake knuckle arm slide surfaces (Fig. 15). Remove rust
hose can damage the hose and fitting joints. Use and corrosion from the these surfaces with a wire
wire to support and secure the caliper to a chassis brush. Then lubricate the surfaces with Mopar multi-
or suspension component. mileage grease, or equivalent.
DISC BRAKESHOE INSTALLATION

(1) Clean caliper and steering knuckle slide sur
faces with wire brush (Fig. 15). Then apply coat of
Mopar multi-mileage grease to slide surfaces.
I -12 DISC BRAKES BR
APPLY SILICONE
GREASE WHERE
INDICATED
BUSHINGS
J9405-32
Fig. 14 Supporting 4-Wheel Drive Caliper Fig. 16 Mounting Bolt Lubrication (75mm Caliper)
APPLY SILICONE GREASE MOUNTING

WHERE INDICATED BOLT
Fig. 15 Caliper And Steering Knuckle Slide Surfaces

(2) Lubricate caliper mounting bolts, collars, bush
ings and bores with Dow 111, or GE 661 silicone
grease as follows: J9405-33
(a) On 1/2 ton models with 75 mm caliper, apply
silicone grease to mounting pins and collars. Then Fig. 17 Mounting Bolt Lubrication (80 or 86mm Caliper)
fill space between bushings in caliper as shown
(5) Install caliper over rotor and into steering
(Fig. 16).
knuckle mounting arms. Be sure caliper is seated
(b) On 3/4 and 1 ton models with 80 or 86 mm
flush on mounting arm surfaces as shown (Fig.
calipers, coat mounting pin and interior of bushing
20).
with silicone grease as shown (Fig. 17). (6) Start caliper mounting bolts by hand to avoid
(3) Install inboard brakeshoe in caliper. Be sure cross threading. Then tighten mounting bolts to 51
spring clip on shoe is properly aligned and seated in N-m (38 ft.lbs.) torque.
caliper piston (Fig. 18 and 19). (7) Install wheel and tire assemblies.
(4) Install outboard brakeshoe in caliper. Be sure (8) Lower vehicle and tighten wheel lug nuts to fol
spring ends are seated in dimples in caliper (Fig. 19). lowing torque:
• 108-150 N-m (80-110 ft. lbs.) on 5 stud wheel
BR DISC BRAKES 5 -13
Fig, 20 Caliper installation

(6) Rotate caliper rearward off rotor and out of
steering knuckle support ledges (Fig. 10).
(7) Remove front brake hose fitting bolt completely
and remove caliper and brakeshoes as assembly..
(8) Cover open end of front brake hose fitting to
prevent dirt entry.
DISC BRAKE CALIPER D1SASSE1BLY

(1) Drain brake fluid from caliper.
(2) Remove brakeshoes from caliper.
(3) Pad interior of caliper with minimum, one-inch
thickness of shop towels (Fig. 21). Towels will cush
ion and protect caliper piston during removal.
(4) Remove caliper piston with several short bursts
of low pressure compressed air. Direct air through fluid
inlet port to ease piston out of bore (Fig. 21).
CAUTION: Do not blow the piston out of the bore
with sustained high pressure. This practice will re
sult in a chipped, or cracked piston. In addition,
Fig, 19 Correct Brakeshoe Position in Caliper NEVER attempt to catch the piston as it exits the
• 168-203 N-m (120-150 ft. lbs.) on 8 stud single wheel bore. This will result in personal injury.
(9) Pump brake pedal to reseat caliper pistons and
brakeshoes. Do not move vehicle until shoes
have been properly seated.
(10) Check brake fluid level and add fluid if neces
sary.
DISC BRAKE CALIPER REMOVAL
(3) Press caliper piston back into bore with large
flat blade screwdriver (Fig. 7). Use large C-clamp if
more force is required to bottom piston in bore.
(4) Loosen bolt that secures front brake hose fit
ting bolt in caliper. INLET
(5) Remove caliper mounting bolts with 3/8 hex J9405-38
wrench or socket (Figs. 8 and 9).
Fig. 21 Caliper Piston Removal
(5) Remove piston dust boot with a suitable pry (8) Remove caliper bleed screw (Figs. 23 and 24).
tool (Fig. 22). Discard dust boot as it is not reusable.
Do not scratch piston bore while removing DISC BRAKE CALIPER CLEANING AND
boot. INSPECTION
Clean the caliper and piston with Mopar brake
cleaner, clean brake fluid, or denatured alcohol. Do
PRY not use any other cleaning agents.
TOOL
Inspect condition of the caliper piston bore. A fiber
brush can be used to clean the bore if necessary. The
bore should be free of corrosion, pitting, or scoring.
Discoloration of the bore is a normal condition and
not cause for replacement. The bore can be lightly
polished by hand but only with crocus cloth. Do NOT
use any other type of abrasive material for polishing.
Check condition of the caliper piston carefully. The
piston must be free of corrosion, rust, pitting, or scor
DUST ing, replace the piston if it exhibits any of these con
BOOT ditions. Do NOT use any kind of abrasive material to
J9405-39 restore surface finish of the piston. Abrasives will
damage, or destroy the coating applied to the piston
Fig. 22 Dust Boot Removal
during manufacture.
(6) Remove seal from caliper piston (Figs. 23 and CAUTION; Never hone the caliper piston bore, or
24). Discard seal as it is not reusable. use any kind of abrasive material on the piston sur
(7) Remove mounting bolts from calipers and in face. Honing will result in an oversize bore and
spect seals, boots, and bushings (Figs. 23 and 24). abrasives will damage the piston coating. Either of
Remove these components only if cut, worn, or dam these practices will result in piston bind and even
aged. tual seizure.
Fig. 23 Caliper Components (75mm Caliper)

BR DISC BRAKES 5 - 55
MOUNTING
BOLTS
CALIPER
PISTON
SEAL
INBOARD
BRAKESHOE
OUTBOARD
BRAKESHOE
/
BUSHINGS
j
CALIPER
PISTON
BLEED DUST
BOOT
SCREW
J9405-37
Fig. 24 Caliper Components (80/86mm Caliper)

Inspect condition of the threads in the inlet and
bleed screw ports. Replace the caliper if thread dam
age is evident. Do not attempt to salvage the threads.
Check the bushings in the caliper mounting bolt
bores. Replace the bushings if worn, cut, or torn.
Bushing condition is important as they keep road
dirt and water from the mounting bolts.
DISC BRAKE CALIPER OVERHAUL AND

REASSEMBLY
(1) Be sure caliper assembly area of workbench is
clean and dry. This is important as dust, dirt, foreign • CALIPER IN PISTON
material, oil, or solvents can damage seals, harm pis PISTON GROOVE
ton surfaces and contaminate fluid.
(2) Lubricate caliper piston, piston seal and piston
bore with liberal quantity of clean, fresh brake fluid.
(3) Install new dust boot on piston as follows:
(a) Lightly lubricate lip of new boot with Dow or
GE silicone grease. Then work boot lip into boot
groove at top of piston (Fig. 25).
•(b) Stretch boot rearward as shown to straighten
boot folds. Then move boot forward until folds snap
into place (Fig. 25).
(4) Install new seal on piston. Slide seal onto pis
ton and seat in groove. Be sure square cut seal is
fully seated and is not twisted.
(5) Install caliper piston. Apply more brake fluid to ^J9405-40
piston, seal and bore. Then work caliper piston into
bore. Once piston seal is properly started, press pis Fig. 25 Installing Dust Boot On Caliper Piston
ton 3/4 of way to bottom of bore by hand or with • use Installer Tool 6754 on 80 mm (3/4 ton) caliper
hammer handle. • use Installer Tool 6755 on 86mm (1 ton) caliper
(6) Seat dust boot in caliper with appropriate in (7) Finish pressing caliper piston to bottom of bore
staller tool (Fig. 26): after dust boot is seated.
• use Installer Tool 6753 on 75mm (1/2 ton) caliper
I -II DISC BRAKES
OUTBOARD
SHOE BRAKESHOE
RETAINING
SPRING
J9405-43
Fig. 28 Outboard Brakeshoe Installation

DISC BRAKE CALIPER INSTALLATION
(1) Clean caliper and steering knuckle slide sur
J9405-41 faces with wire brush (Fig. 16). Then apply coat of
Mopar multi-mileage grease, or Dow/GE silicone
Fig. 26 Seating Dust Boot in Caliper grease to slide surfaces.
(8) Lubricate caliper mounting bolts, collars, bush (2) Install caliper over rotor and seat it on steering
ings and bores with Dow 111, or GE 661 silicone knuckle mounting arms.
grease (Figs. 16 and 17). (3) Start caliper mounting bolts by hand to avoid
(9) Install bushings, seals, boots and mounting cross threading. Then tighten mounting bolts to 51
bolts in caliper (Figs. 23 and 24). N-m (38 ft.lbs.) torque.
(10) Install but do not fully tighten caliper bleed (4) Connect brake hose to caliper (Figs. 29 and 30).
screw. Be sure brake hose fitting is correctly seated
(11) Install inboard brakeshoe in caliper. Be sure against locating shoulder on caliper before
brakeshoe spring clip is centered and seated in cali tightening fitting bolt.
per piston (Fig. 27).
CAUTION: B e very sure the front brake hose is not
twisted, or kinked. Also be sure the hose is cor
INBOARD rectly routed and clear of adjacent chassis and sus
pension components. This is important as hose
damage will result if it is twisted or incorrectly
routed.
Fig. 27 inboard Brakeshoe installation

(12) Install outboard brakeshoe in caliper (Fig. 28).
Align shoe and retaining spring in caliper. Then push
shoe downward into place. Be sure spring ends are
correctly seated in caliper dimples.
Fig. 29 Front Brake Hose Attachment
BR DISC BRAKES I -17
CONTROL Measure rotor thickness at 6 to 12 points around

the rotor face (Fig. 31). Position the micrometer ap
proximately 25.4 mm (1 in.) from the rotor outer cir
cumference for each measurement.
Thickness should not vary by more than 0.025 mm
(0.001 in.) from point-to-point on the rotor. Refinish
or replace the rotor if necessary.
FRONT HOSE
AND TUBE
ASSEMBLY J9405-51
Fig. 30 Front Brake Hose Routing (4-Wheel Drive)

(5) Fill and bleed brake system. Refer to procedure
in appropriate antilock brake section.
(6) Install wheel and tire assemblies and lower ve
hicle.
DISC BRAKE ROTOR INSPECTION AND SERVICE

Rotor condition and tolerances can be checked with
the rotor mounted in a brake lathe, or on the axle. If
the rotor is checked on the axle, be sure wheel bear
ing end play is reduced to zero before measuring lat
eral runout.
The rotor braking surfaces should not be machined
unless actually necessary. Light surface rust and
scale can be removed in a lathe equipped with dual
sanding discs. Fig. 31 Measuring Rotor Thickness Variation
Worn, or scored rotor surfaces can be restored by Checking Rotor Lateral Runout
machining in a disc brake lathe but only if surface Check rotor lateral runout if constant pedal pulsa
scoring and wear are light. tion or an occasional low pedal condition was experi
The rotor should be replaced if: enced. Excessive lateral runout will cause pedal
• severely scored pulsation, uneven wear of the brakeshoes, and brake-
• tapered shoe knockback. Measure runout with a dial indica
• has hard spots tor (Fig. 32).
• cracked Check runout with Dial Indicator C-3339 (Fig. 32).
• warped Position the indicator plunger at least 25.4 mm ( 1
• too thin in.) inward from the outer edge of the rotor. On
• machining would take rotor below minimum thick 2-wheel drive models, be sure wheel bearing
ness end play is reduced to zero before checking
CHECKING ROTOR MINIMUM THICKNESS runout.
Measure rotor thickness at the center of the brake- Maximum allowable lateral runout is 0.127 mm
shoe contact surface. Replace the rotor if it is worn (0.005 in.).
below minimum thickness, or if refinishing would re
duce thickness below the allowable minimum. Rotor mOTOm MEFINISHING
minimum thickness is usually specified on the rotor Rotor braking surfaces can be refinished by sand
hub, or on the outer edge of the rotor ventilated sur ing and/or machining in a disc brake lathe (Fig. 33).
face. The lathe must be capable of machining both rotor
surfaces simultaneously with dual cutter heads.
ROTOR THICKNESS VARIATION Equipment capable of machining only one side at a
Variations in rotor thickness will cause pedal pul time will produce a tapered rotor.
sation, noise and shudder.
5 - 58 DISC BRAKES BR
INDICATOR J 8 9 Q M 8
Fig. 32 Measuring Rotor Lateral Runout

The lathe should also be equipped with a grinder
attachment or dual sanding discs for light refinish-
ing, or final cleanup.
If the rotor surfaces only need minor cleanup of
rust, scale, or scoring, use abrasive discs to clean up
the rotor surfaces. However, when a rotor is scored or
worn, machining with cutting tools will be required.
CAUTION: Do not refinish a rotor if machining
would cause the rotor t o fall below minimum allow
able thickness.
The recommended final finish on a rotor braking

surface is shown in Figure 34. The final finish should
be a non-directional, cross hatch pattern. Sanding
discs are required to produce this type of finish.
DISC BRAKE ROTOR REMOVAL (WITH TAPERED

BEARINGS)
(1) Raise vehicle.
(2) Remove wheel and tire assembly.
(3) Bottom caliper piston in bore. Use screwdriver
or large C-clamp to press piston back to bottom of
J8905-70
caliper bore (Fig. 7).
(4) Remove caliper mounting bolts (Figs. 8 and 9). Fig. 33 Rotor Refinishing Equipment
(5) Remove caliper from rotor. Position caliper on
steering knuckle and secure it with wire (Figs. 13 (7) On models with one-piece rotor and hub assem
and 14). bly, remove grease cap that covers cotter pin and hub
nut.
CAUTION: Do not allow the brake hose to support (8) Remove grease cap from hub. On models with
the caliper. Suspending the caliper by the brake long adapter, use long pry tool with angled end to re
hose can damage the hose and fitting joints. Use move grease cap. Pry against flats at each side of cap
wire to support and secure the caliper to a suspen to loosen and remove it.
sion component as shown (Figs. 13 and 14). (9) Remove cotter pin from spindle and wheel bear
ing adjusting nut (Fig. 35).
(6) On models with removable adapter hub, re (10) Remove locknut from wheel bearing adjusting
move hub from rotor. nut. Then remove tabbed thrust washer and outer
wheel bearing (Fig. 35).
BR DISC BRAKES 5 - 51
FINAL FINISH SHOULD BE ABS SENSOR

NON-DIRECTIONAL FRONT WIRE
CROSSHATCH PATTERN
SPLASH
SHIELD
J8905-71 J9405-177
Fig. 34 Recommended Rotor Surface Finish Fig. 36 Front Sensor Tone Wheel Location (2-Wheel
(11) Remove rotor and hub assembly from spindle. Drive With ABS Brakes)
(12) Inspect wheel bearings and interior of hub. If
DISC BRAKE ROTOR INSTALLATION (WITH
bearings need repacking, remove grease seal and in
ner wheel bearing from rotor hub. On 2-wheel drive TAPERED BEARINOS)
models with ABS brakes, also check condition of front (1) Repack wheel bearings, if necessary, with Mo
sensor tone wheel located in rotor hub (Fig. 36). En par high temperature bearing grease. Apply grease to
tire rotor and hub assembly will have to be re bearing races as well. Then install inner bearing in
placed if tone wheel is damaged. Tone wheel is hub and install new grease seal.
not available as a separate part. (2) Apply liberal coat of bearing grease to spindle,
interior of rotor hub, grease seal lip and seal surface
SPLASH of spindle.
SHIELD (3) Install rotor and hub assembly on spindle.
(4) Install outer wheel bearing, tabbed thrust
washer and bearing adjusting nut. Tighten nut only
enough to remove end play at this time.
(5) Install disc brake caliper and tighten caliper
mounting bolts to 51 N-m (38 ft. lbs.) torque. Do not
seat caliper pistons at this time. Pistons must
not be seated until after wheel bearing adjust
ment has been completed.
(6) On models with removable hub adapter (Fig.
37), install adapter on rotor.
(7) Install wheel and tire assembly. Tighten wheel
nuts snug but not to final torque at this time.
(8) Adjust wheel bearings. Refer to procedure in
this section.
(9) Lower vehicle and tighten wheel lug nuts to fol
lowing torque:
CAP
J9405-178 (10) Install grease cap and wheel cover/hub cap.
Fig. 35 Rotor And Huh Assembly (With Tapered WHEEL BEARING ADJUSTMENT (WITH TAPERED
Bearings) BEARINGS)
(1) Raise vehicle front end.
I - il DISC BRAKES BR
(2) Remove front wheel covers/hub caps. HUB

(3) Remove grease caps. AND ROTOR
(4) Remove cotter pin and nut lock. ASSEMBLY ADAPTER
HUB
(5) Rotate wheel and fully tighten bearing adjust
ing nut to seat bearings.
(6) Loosen and tighten bearing adjusting nut once
again while rotating wheel.
(7) Continue rotating wheel and back off adjusting
nut until wheel end play is no more than 0.0254 to
0.0508 mm (0.001 to 0.002 in.).
(8) Install nut lock on adjusting nut and install
new cotter pin. Adjusting nut can be tightened
slightly to align cotter pin holes if necessary. Verify
that wheel bearing adjustment is still OK. Readjust
if needed. J9405-53
(9) Lower vehicle and tighten wheel lug nuts to- fol
lowing torque: 37 Adapter Hub Removal/Installation
• 163-203 N-m (120-150 ft. lbs.) on 8 stud wheel COTTER
PIN
(10) Install wheel covers/hub caps.
DISC BRAKE ROTOR REMOVAL (WITH UNIT

BEARIN0S)
(1) Raise vehicle.
(2) Remove wheel and tire assembly.
(3) Bottom caliper piston in bore. Use screwdriver
or large C-clamp to press piston back to bottom of
caliper bore (Fig. 7). J9405-54
(4) Remove caliper mounting bolts (Figs. 8 and 9).
(5) Remove caliper from rotor. Position caliper on Fig. 38 Hub Nut Cotter Pin Removal
steering knuckle and secure it in place with wire. Or
suspend caliper from adjacent chassis or suspension
component with wire (Figs. 13 and 14).
CAUTION; Do not allow the brake hose to support
the caliper. Suspending the caliper by the hose can
damage the hose and fitting joints. Use wire to sup
port and secure the caliper to a suspension compo
nent as shown (Figs. 13 and 14).
(6) On models with removable adapter hub, re

move hub from rotor (Fig. 37). Then remove grease
cap. SUITABLE
SIZE
(7) On models with one-piece rotor and hub assem 3/4 INCH SOCKET
bly, remove grease cap that covers cotter pin and hub DRIVE RATCHET
nut. J9405-55
(8) Remove cotter pin from rotor hub nut (Fig. 38).
(9) Remove rotor hub nut (Fig. 39). An appropriate Fig. 39 Hub Nut Removal/Installation
size, 3/4 in. drive socket and ratchet wrench will be
required for removal.
IBIR DISC BRAKES 5 • 61
(10) Remove bolts that secure rotor arid hub to

steering knuckle. Bolts are accessible from inboard
(back) side of steering knuckle (Fig. 40).
Fig. 42 Hub Spacer Removal

(3) Insert two rearmost, top and bottom rotor hub
bolts in steering knuckle. Insert bolts through back
Fig. 40 Rotor And Hub Attaching Bolt Location side of knuckle so they extend out front face as
(11) Remove rotor and hub assembly. Turn assem shown (Fig. 43).
bly over and check unit bearing and seal (Fig. 41). (4) Position hub spacer on bolts just installed in
Replace seal if necessary. Replace bearing assembly if knuckle. Be sure flat on spacer is positioned toward
damaged. rear (Fig. 43). Use chassis grease to hold spacer in
place on knuckle.
Fig. 41 Rotor Hub And Unit Wheel Bearing

Assembly Fig. 43 Hub Spacer Positioning And Installation
(12) Remove hub spacer from steering knuckle (5) Apply 1-2 drops of Mopar Lock N' Seal, or Loc-
(Fig. 42). Note spacer position for installation refer tite 242 to threads of rotor and hub retaining bolts.
ence. (6) Align rotor hub with drive shaft. Then start
shaft into rotor hub splines.
DISC BRAKE ROTOR INSTALLATION (WITH UNIT (7) Align bolt holes in unit bearing flange with
BEARINGS) bolts previously installed in knuckle. Then thread
(1) Apply liberal quantity of Mopar, or Permatex bolts into bearing flange far enough to hold assembly
anti-seize compound to splines of front drive shaft in place.
(Fig. 43). (8) Install remaining rotor retaining bolts. Tighten
(2) Replace grease seal in wheel hub if old one is all bolts securely
damaged (Fig. 43). Install new wheel bearing assem (9) Install washer and hub nut. Tighten nut se
bly in rotor hub if necessary. Refer to procedure in curely.
this section.
5 - §2 DISC BRAKES BR
(10) Install new cotter pin in hub nut. Tighten nut Impact wrenches are not the best tools for tighten
as needed to align cotter pin hole in shaft with open ing wheel nuts. A torque wrench should be used for
ing in nut. this purpose at all times.
(11) Install disc brake caliper. Tighten caliper The correct tightening sequence is important in
mounting bolts to 51 N-m (38 ft. lbs.) torque. avoiding rotor and drum distortion. The correct se
(12) Install wheel and tire assemblies and lower quence is in a diagonal crossing pattern as shown
vehicle. (Figs 45 and 46).
(13) Tighten wheel lug nuts to following torque: Seat the wheel and install the wheel nuts finger
• 108-150 N-m (80-110 ft. lbs.) on 5 stud wheel tight. Tighten the nuts in recommended sequence to
* 163-203 N-m (120-150 ft. lbs.) on 8 stud single 1/2 required torque. Then repeat the tightening se
wheel quence to final specified torque.
(14) Apply brakes several times to reseat brake- Wheel nut torques are:
shoes and caliper piston. Do not move vehicle until
• 163-203 N-m (120-150 ft. lbs.) on 8 stud single
firm brake pedal is obtained.
wheel
• 176-217 N-m (130-160 ft. lbs.) on 8 stud dual
FRONT WHEEL BEARING REPLACEMENT wheels
On models with tapered roller front wheel bear
ings, the bearings and races can be serviced sepa
rately when necessary. The bearing races do not
require special tools for removal. Either race can be
removed with a long tapered brass drift.
On models with unit style wheel bearings (Fig. 41),
the rotor, hub and bearing assembly are all pressed
together. However, it is only necessary to drive out
the wheel studs with a copper mallet, in order to sep
arate the rotor, bearing and hub for replacement pur
poses (Fig. 44).
Fig. 44 Front Wheel Stud Removal (With Unit Style

Bearing)
WHEEL NUT TIGHTENING
The wheel attaching nuts should be properly tight
ened to ensure efficient brake operation. Overtighten
ing the nuts or tightening them in the wrong
sequence could cause distortion of the brake rotors
and drums. Fig. 46 Wheel Nut Tightening Sequence (8 Stud
Wheel)
DRUM BRAKES I - 63
mmmm b h a i c e s
iiiEX
page page
Brake Drum Service 72 Drum Brake Adjustment 71

Brake Support Plate Installation 71 Drum Brake Operation 63
Brake Support Plate Removal 71 General Service Information . . . . . . . . . . . . . . . . . 63
Brakelining Wear Compensation . 63 Wheel Cylinder Installation (All) . . . . ....... 70
Brakeshoe Installation (11-Inch Brake) . . . . . . . . . . 65 Wheel Cylinder Overhaul (All) 69
Brakeshoe Installation (13-Inch Brake) . . 67 Wheel Cylinder Removal (All) . 69
Brakeshoe Removal (11-Inch Brake) 63 Wheel Nut Tightening 72
Brakeshoe Removal (13-Inch Brake) 66
GENERAL SERVICE INFORMATION ates the wedging (or wrap) effect which produces
All BR models are equipped with Delco rear drum increased force on the drum braking surface.
brake assemblies. They are two-shoe, duo-servo units
with an automatic adjuster mechanism. BRAKELINING WEAR COMPENSATION
' Three different size drum brake assemblies are All drum brake assemblies used on BR models are
used which are: equipped with a self adjusting mechanism. The com
® 1/2 ton (1500) models have 11 x 2 in. drum brakes ponents forming the mechanism consist of the: ad
• 3/4 ton (2500) models have 13 x 2.5 in. drum juster screw, adjuster lever, actuating lever (11 inch
brakes brake), lever return spring and the adjuster lever
• 1 ton (3500) models have 13 x 3.5 in. drum brakes spring. The adjuster lever on the 13 inch brake, is
Two different wheel cylinders are used. The differ also equipped with a lever and tension spring.
The adjuster mechanism performs two important
ence being cylinder bore size. The cylinders used on
functions. First, is in maintaining proper brakeshoe
1/2 and 3/4 ton models have a bore diameter of 23.8 operating clearance. And second, is to maintain brake
mm (0.937 or 15/16 in.). The cylinders used on 1 ton pedal height. The mechanism does so, by adjusting
models have a bore diameter of 27 mm (1.06 or the shoes in small increments to compensate for lin
1-1/16 in.). ing wear. The adjustment process is continuous
throughout the useful life of the brakelining.
DRUM BRAKE OPERATION The adjuster components are all connected to the
Drum brakes on BR models are a semi-floating, secondary brakeshoes. Actual adjustment only occurs
self-energizing, servo action design. The brakeshoes during reverse brake stops. Secondary brakeshoe
are not fixed on the support plate. This type of brake movement (during reverse stops), is what activates
allows the shoes to pivot and move vertically to a cer the adjuster components.
tain extent. In operation, secondary shoe movement causes the
In operation, fluid apply pressure causes the wheel adjuster lever spring to exert pull on the lever. This
cylinder pistons to move outward. This movement is pivots the lever away from the adjuster screw teeth.
transferred directly to the brakeshoes by the cylinder When the stop is completed and the brakes released,
connecting links. The resulting brakeshoe expansion the adjuster lever pivots back to a normal position. It
brings the lining material into contact with the rotat is during this return movement of the lever when ad
ing brake drum. justment occurs. At this point, the lever comes back
Two forces affect the brakeshoes once they contact into contact with the adjuster screw teeth as it moves
the drum. The first force being hydraulic pressure ex upward. The lever will then rotate the adjuster screw
erted through the wheel cylinder pistons. And the one or two teeth as needed for adjustment.
second force is the friction generated turning torque The adjustment process requires a complete
of the rotating drum. stop to actually occur. Rolling stops will NOT
The drum forces both brakeshoes to move in the activate the adjuster components. In addition,
same direction of rotation. Servo action begins with the adjuster screws are left and right hand
the primary brakeshoe which begins to wedge (or parts and must NOT be interchanged.
wrap) itself against the rotating drum surface. This
force is transmitted equally to the secondary brake- BRAKESHOE REMOVAL (11-INCH BRAKE)
shoe through the adjuster screw and anchor pin. The (1) Raise vehicle.
net result is that each shoe helps the other exert ex (2) Remove rear wheels.
tra force against the drum. It is servo action that cre- (3) Remove brake drums.
14 DRUM BRAKES — — — — — — — — — — — ™ — — — — BR
(4) Remove primary (front) brakeshoe return (5) Remove primary shoe holddown spring, pin and
spring (Fig. 1). Use brake spring pliers to unseat and retainers. Use brake spring tool to rotate retainers
remove spring from anchor pin. and disengage pins.
ADJUSTER SPRING (6) Tilt primary brakeshoe outward. Then disen
PRIMARY SHOE SECONDARY gage shoe spring and remove primary brakeshoe.
AND SHOE AND
RETURN SPRING (7) Remove adjuster screw, shoe spring and park
RETURN SPRING
brake strut and spring.
STRUT
CAUTION: The adjuster screw assemblies have dif
ferent threads and must be kept separate. The
driver side adjuster screw has a right hand thread.
And the passenger side adjuster screw has a left
hand thread. Do not interchange them as the brake
shoes will not adjust properly.
(8) Remove secondary brakeshoe holddown spring,

pin and retainers (Fig. 1).
(9) Pull adjuster lever and retainer out of second
ary brakeshoe. Then rotate brakeshoe out and up
SHOE
and remove adjuster spring and secondary shoe re
turn spring.
SPRING
ACTUATOR (10) Disconnect park brake cable from lever on sec
LEVER AND
ADJUSTER SPRING ondary brakeshoe. Then remove brakeshoe.
SCREW (11) If brakeshoes are to be replaced, remove E-clip
ASSEMBLY J9405-16 (or U-clip) that attaches park brake lever to second
Fig. 1 Brakeshoe Mounting And Spring Attachment ary brakeshoe and remove lever.
(11-Inch Brake) (12) Inspect wheel cylinder (Fig. 2). If leakage is
evident, remove and overhaul cylinder. Refer to over
haul procedure in this section.
CYLINDER SUPPORT PARK
BRAKE
SCREWS PLATE LEVER
HOLDDOWN
PINS
LINK
SECONDARY SHOE
RETURN
PRIMARY SPRING
(FRONT)
BRAKESHOE
PRIMARY SHOE
ADJUSTER HOLDDOWN RETURN SPRING
SCREW SPRING AND*
FRONT ASSEMBLY RETAINERS J9405-4
Fig. 2 Drum Brake Components (11-Inch Brake)
BR DRUM 1RAIES 5 - §5
BRAKESHOE INSTALLATION (11-INCH BRAKE) (11) Install primary brakeshoe on support plate.
(1) Clean support plate with Mopar brake cleaner. Use new holddown spring, pin and retainers to se
Then smooth shoe contact pads with wire brush or cure shoe. Be sure parking brake strut is seated in
emery cloth. both brakeshoes.
(2) Apply coat of Mopar multi-mileage, or high (12) Install actuator lever and spring. Hook actua
temp bearing grease to each shoe contact pad on sup tor lever under adjuster lever as shown (Fig. 4).
Large diameter end of spring goes on shoe and small
port plate (Fig. 3).
end on lever.
(13) Install adjuster screw assembly. Be sure star
wheel is positioned adjacent to adjuster lever and
that notches in buttons are properly seated on brake-
shoes.
CAUTION: B e sure the adjuster screws were not in
termixed and are installed on the correct side. The
driver side adjuster screw has right hand threads
and the passenger side has left hand threads. Also
be sure the short end of the screw is toward the
secondary brakeshoe.
(14) Attach shoe spring to primary brakeshoe.

(15) Install guide plate on anchor pin.
(16) Attach adjuster spring to adjuster lever.
' (17) Install secondary brakeshoe return spring in
shoe.
(18) Attach secondary shoe return spring to ad
juster spring. Then install adjuster spring on anchor
pin (Fig. 4).
(19) Install primary brakeshoe return spring (Fig.
4).
Fig. 3 Typical Contact Pad Locations On Support Plate (20) Verify that adjuster and return springs are
properly installed (Fig. 5).
(3) Lubricate adjuster levers and anchor pin and (21) Adjust brakeshoes to drum with brake gauge.
shoe contact surfaces on support plate with Mopar (22) Install brake drum and wheel and tire assem
multi-mileage grease, or high temp bearing grease. blies.
(4) Clean and check operation of adjuster screw as (23) Lower vehicle.
semblies. Make sure each screw assembly rotates (24) Tighten wheel lug nuts to 108-150 N-m
freely. Lubricate screw threads with Mopar spray (80-110 ft. lbs.) torque.
lube. Replace either assembly if threads are heavily (25) Install wheel cover, or hub cap.
rusted, corroded, or damaged.
(5) Attach park brake lever to secondary brakeshoe
(Fig. 2). use new U-clip to secure lever to shoe. If U-
clip is used to secure shoe, pinch clip together with
channel lock pliers to secure it. If E-clip is used, be
sure clip is fully seated in notch.
(6) Attach park brake cable to lever.
(7) Position adjuster lever on secondary brakeshoe
(Fig. 4). Then install spring retainer with shoulder
on in lever and into shoe.
(8) Position secondary brakeshoe on support plate.
Use new holddown spring, pin and retainer to secure
shoe and adjuster lever.
(9) Attach shoe spring to secondary brakeshoe.
Connect long end of spring in secondary shoe.
(10) Engage parking brake strut in secondary
brakeshoe and install oval shaped spring on opposite
end of strut (spring end of strut goes in primary
shoe).
5 - 66 DRUM BRAKES
PRIMARY ADJUSTER LEVER

ADJUSTER LEVER SHOE SPRING
SPRING RETURN (INSTALL FIRST)
SECONDARY SPRING
SHOE RETURN SECONDARY
(INSTALL LAST) SHOE
SPRING
RETURN
ADJUSTER SPRING
LEVER
J9405-15
Fig. 5 Checking Return/Adjuster Spring installation
LEVER
ADJUSTER SPRING
SCREW
ASSEMBLY J9405-3
jf J9405-17
Fig. 4 Self Adjuster Component Installation (11 Inch Fig. 6 Return Spring Removal/Installation
Brake) HOLDDOWN
SPRING
BRAKESHOE REMOfAL (13-INCH BRAKE) TOOL
(1) Raise vehicle.
(2) Remove rear wheel and tire assemblies.
(3) Remove brake drums.
(4) Remove primary (front) brakeshoe return
spring from anchor pin with brake spring pliers (Fig.
6).
(5) Remove primary brakeshoe holddown spring,
pin and retainers with holddown spring tool (Fig. 7).
(6) Disconnect shoe spring and remove primary
brakeshoe and parking brake lever strut. HOLDDOWN
SPRING
ASSEMBLIES
PRIMARY
SHOE J9405-18
Fig. 7 Holddown Spring, Pin And Retainer Removal/
Installation
BR DRUM BRAKES 5 - 67
(7) Remove adjuster screw assembly (Fig. 8). BRAKESHOE INSTALLATION (13-INCH BRAKE)
(8) Remove secondary brakeshoe holddown spring, (1) Clean support plate with Mopar brake cleaner.
pin and retainers. Then remove adjuster lever, spring Then smooth shoe contact pads with wire brush or
and spring retainer assembly (Fig. 8). It is not nec emery cloth.
essary to disassemble adjuster lever components un (2) Lubricate adjuster levers and anchor pin and
less they are worn, or damaged. shoe contact surfaces on support plate with Mopar
(9) Disconnect parking brake cable from lever at multi-mileage grease, or high temp bearing grease.
tached to secondary brakeshoe (Fig. 8). Then remove (3) Clean and check operation of both adjuster
brakeshoe. screw assemblies. Replace either assembly if threads
(10) If brakeshoes are to be replaced, remove E-clip are heavily rusted, corroded, or damaged. Make sure
attaching parking brake lever to secondary brake- each screw assembly rotates freely. Then lubricate
shoe and remove lever (Fig. 8). adjuster screw threads with Mopar spray lube.
(11) Inspect wheel cylinder. If leakage is evident, (4) Attach parking brake lever to secondary brake-
remove and overhaul cylinder. Refer to overhaul pro shoe. Use new E-clip to secure lever to shoe. If lever
cedure in this section. is secured with U-clip, pinch new clip together with
channel lock pliers to secure it.
RETAINERS' ASSEMBLY ASSEMBLY J9405-65
Fig. 8 Drum Brake Components (13-inch Brake)

S -18 DRUM BRAKES BR
(5) Attach parking brake cable to parking brake le (c) Position adjuster lever on brakeshoe and in
ver. sert holddown spring inner retainer into lever and
(6) If adjuster lever was disassembled, reassemble shoe. Inner retainer has shoulder on it which seats
it as follows: in lever and shoe.
(a) Clamp adjuster lever in vise (Fig. 9). Clamp (d) Install holddown spring over pin and seat it
center portion of lever in vise only. Do not in inner retainer. Then install and seat holddown
clamp bottom end of lever in vise. Lever spring outer retainer on pin with holddown spring
flange that rotates adjuster screw star wheel tool (Fig. 7).
teeth is at bottom of lever .and will be dam (8) Install adjuster lever spring between brakeshoe
aged. and lever. Be sure spring is seated on lever tang.
(b) Position small, hooked spring retainer in up (9) Attach shoe spring to secondary brakeshoe.
per end of lever (Fig. 9). Be sure tang on retainer is Long end of spring goes in secondary shoe.
securely engaged in hole in lever. Locking pliers (10) Install oval shaped spring on park brake strut
can be used to hold retainer in place after position
and engage spring end of strut in secondary brake-
ing.
(c) Secure retainer in lever with retainer spring. shoe.
Hook spring over end of retainer as shown (Fig. (11) Install primary brakeshoe on support plate.
10). Needlenose pliers and number 2 Phillips Use new holddown spring, pin and retainers to se
screwdriver can, be used to attach spring to lever cure shoe. Be sure parking brake strut is seated in
and retainer. both brakeshoes.
**
(12) Install adjuster screw assembly. Be sure star

ADJUSTER wheel is positioned adjacent to adjuster lever and
ADJUSTER SPRING
LEVER RETAINER that notches in adjuster screw are properly seated on
brakeshoes.
CAUTION: B e sure the adjuster screws were not in
termixed and are installed on the correct side. The
driver side adjuster screw has right hand threads
and the passenger side has left hand threads. Also
be sure the short end of the screw is toward the
J9405-68 secondary brakeshoe.
Fig. 9 Positioning Retainer On Adjuster Lever (13) Attach shoe spring to primary brakeshoe. Use
ADJUSTER
brake spring pliers and long screwdriver to seat
ADJUSTER spring in shoe.
SPRING
LEVER RETAINER (14) Install shoe guide plate on anchor pin.
(15) Attach adjuster spring to spring retainer at
top of adjuster lever. Then seat spring on anchor pin
with brake spring pliers.
HOOK (16) Install secondary brakeshoe return spring. At
SPRING
ON RETAINER tach short end of spring to brakeshoe. Then hook op
posite end on adjuster spring (Fig. 8). Use brake
spring pliers, or a long shank screwdriver to engage
return spring in adjuster spring.
(17) Install primary brakeshoe return spring.
(18) Check component installation. Be sure ad
juster screw, wheel cylinder links and park brake
J9405-66 strut are all seated in brakeshoes (Fig. 11).
(19) Adjust brakeshoes to drum with brake gauge.
Fig. 10 Assembling Adjuster Lever, Spring And (20) Install brake drums.
Retainer (21) Install wheel and tire assemblies and lower
(7) Install secondary brakeshoe and adjuster lever vehicle.
as follows: (22) Tighten wheel lug nuts to following torque:
(a) Insert secondary shoe holddown pin through • 163-203 N-m (120-150 ft. lbs.) on 8 stud single
support plate. wheel
(b) Position secondary , brakeshoe on support • 176-217 N-m (130-160 ft. lbs.) on 8 stud dual wheel
plate and insert pin through shoe. (23) Install wheel cover or hub cap.
SECONDARY WHEEL
SHOE CYLINDER
RETURN ADJUSTER SUPPORT
SPRING LEVER PLATE ANCHOR
SPRING PIN
SECONDARY
BRAKESHOE SHOE
GUIDE
PLATE
SPRING
RETAINER PARK
BRAKE
STRUT PRIMARY
RETAINER AND BRAKESHOE
SPRING SPRING
PRIMARY
SHOE
RETURN
SPRING
. ADJUSTER
LEVER
HOLDDOWN
SPRING, PARK
PIN, BRAKE
RETAINERS STRUT
LEVER
SPRING
HOLDDOWN
SPRING, PIN,
ADJUSTER RETAINERS "
SCREW SHOE
ASSEMBLY SPRING J9405-19
Fig. 11 Brakeshoe Component installation (13 Inch Brake)
WHEEL CYLINDER REMOVAL (ALL) Wheel Cylinder Cleaning And Inspection

(1) Lift adjuster lever away from adjuster screw. Clean the cylinder, pistons and links with Mopar
Then turn screw star wheel until screw is fully re brake cleaner. Clean the wheel cylinder and support
tracted. plate mounting surfaces with a wire brush to ensure
(2) Remove brakeshoe return springs, adjuster proper seating at installation.
spring and adjuster screw. Move upper ends of brake- Inspect the cylinder bore. The bore should be
shoes apart to provide removal clearance for wheel smooth and free of scoring, corrosion, or pitting.
cylinder links. Light discoloration of the bore is a normal condition
(3) If brakeline and fitting are rusty, or corroded, and does indicate replacement is necessary. Very
apply liberal quantity of Mopar rust penetrant to line slight scratches, or nicks can be polished out by hand
and fitting. This will break corrosion and avoid dam with crocus cloth.
aging brakeline during removal. The cylinder bore can be cleaned out with a fiber
(4) Disconnect brakeline from wheel cylinder. bristle brush if necessary. However, DO NOT hone
(5) Remove wheel cylinder attaching screws and the cylinder bore. Replace the wheel cylinder
remove cylinder from support plate as an assembly if the bore surface is corroded,
pitted or scored.
WHEEL CYLINDER OWERHAUL (ALL) _ Check condition of the cylinder brakeline and bleed
screw threads. Replace the wheel cylinder if the
Wheel Cylinder Disassembly
threads are damaged in any way. replace the bleed
(1) Pull links out of cylinder boots. screw if the screw threads are damaged, or the screw
(2) Remove piston boots. Use plastic or wood tool is corroded, or distorted.
to either pry boots out or pull them out with needle- Inspect the wheel cylinder pistons. Replace the pis
nose pliers.
tons if worn, scored, corroded, or pitted. Do not sand
(3) Push pistons, cups and expander spring out one
end of cylinder bore (Fig. 12). the pistons in an attempt to restore the surface and
(4) Discard boots, piston cups and expander spring. reuse them. In most cases, if the pistons are dam
They are not reusable parts. aged, the cylinder bore will also be damaged requir
(5) Remove bleed screw from cylinder. ing complete replacement.
5 - 70 DRUM BRAKES - BR
The wheel cylinder connecting links can be cleaned CUPS

up with a wire brush if rusty or corroded. However,
be sure the link notches are in good condition and
will seat properly in the brakeshoes.
BLEED
SCREW
WHEEL PISTON
CYLINDER CUP
BOOT
PISTONS J9405-69
PISTON Fig. 13 Assembling Wheel Cylinder Pistons, Cups

COMPRESSION And Expander
SPRING AND
EXPANDERS J9405-6 BOOT
VISE
Fig. 12 Wheel Cylinder Components (All)
Wheel Cylinder Assembly
(1) Install bleed screw in cylinder. Finger tighten
cylinder only at this time.
(2) Coat cylinder bore, pistons and piston cups
with liberal quantity of fresh, clean brake fluid.
(3) Cylinder components can be installed two ways.
Either as an assembly (Fig. 13), or individually. Pro J9405-67
cedures are as follows:
(a) To install as assembly, assemble pistons, new Fig. 14 Seating Wheel Cylinder Dust Boots
cups and expander spring as shown (Fig. 13). Start
one piston and cup into bore. Then slide expander CYLINDER SUPPORT
MOUNTING PLATE
and remaining cup and piston into bore in one mo SURFACE
tion.
(b) To install parts individually, install first pis
ton cup in bore. Be sure open end of cup faces bore
interior and flat side of cup faces piston. Install
first piston in bore and seat it against piston cup.
Then insert expander spring and remaining piston
cup and piston.
(4) Start piston dust boots in each end of cylinder
bore by hand. Then seat boots in cylinder with a
bench vise (Fig. 14). Press boots into place until flush
with ends of cylinder.
(5) Apply light coat of silicone grease, or multi-pur
pose grease to wheel cylinder links. Then insert links J9405-70
into dust boots and seat them against pistons.
Fig. 15 Wheel Cylinder Mounting Surface (On
WHEEL CYLINDER INSTALLATION (ALL) Support Plate)
(1) Clean support plate and lubricate shoe contact (4) Mount wheel cylinder on support plate and in
pads with multi-mileage or silicone grease (Fig. 3). stall cylinder attaching screws. Tighten screws to 20
(2) Apply thin coat of Mopar silicone sealer to N-m (15 ft. lbs.) torque.
wheel cylinder mounting surface of support plate (5) Tighten brakeline fitting to 13 N-m (115 in.
(Fig. 15). Sealer prevents road splash from entering lbs.) torque.
brake drum past cylinder. (6) Install brakeshoe components.
(3) Start brakeline in cylinder inlet by hand. Do (7) Adjust brakeshoes to drum using brake gauge.
not tighten fitting at this time. (8) Install brake drum.
(9) Fill and bleed brake system. BRAKE SHOES

(10) Install wheel and tire assemblies and lower
vehicle.
DRUM BRAKE ADJUSTMENT
The rear drum brakes are equipped with a self-ad
justing mechanism. Under normal circumstances, the
only time adjustment is required is when the shoes
are replaced, removed for access to other parts, or
when one or both drums are replaced.
Adjustment can be made with a standard brake
gauge. Adjustment is performed with the complete
brake assembly in place on the support plate. Proce
dure is as follows:
A D J U S T M E N T P R O C E D U R E (WITH BRAKE
GAUGE) Fig. 17 Adjusting Brakeshoes To Gauge
(1) Be sure parking brakes are fully released. (10) Make final adjustment as follows:
(2) Raise rear of vehicle and remove wheels and (a) Drive vehicle and make one forward stop fol
brake drums. lowed by one reverse stop.
(3) Verify that left and right automatic adjuster le (b) Repeat procedure 8-10 times to operate auto
vers and cables are properly connected. matic adjusters and equalize adjustment.
(4) Insert brake gauge in drum. Expand gauge un (c) Bring vehicle to complete standstill at
til gauge inner legs contact drum braking surface. each stop. Incomplete, rolling stops will not
Then lock gauge in position (Fig. 16). activate automatic adjusters.
BRAKE SUPPORT PLATE REMOVAL

(2) Remove brake drums
(3) Remove axle shaft and retainer. Refer to Group
3 for procedures.
(4) Remove primary brakeshoe for access to park
ing brake cable.
(5) Compress parking brake cable retainer tabs
with a hose clamp (Fig. 18). Then push retainer and
cable through and out of support plate.
(6) Disconnect brake line at wheel cylinder.
(7) Remove wheel cylinder and secondary brake-
shoe from support plate.
(8) On models with full float rear axle, remove axle
shaft. Then remove hub and bearing assembly.
Fig. 16 Setting Gauge To Brake Drum Diameter (9) Remove bolts attaching support plate to axle
(5) Reverse gauge and install it on brakeshoes and remove support plate.
(Fig. 17). Position gauge legs at shoe centers as
shown. If gauge does not fit (too loose/too tight), ad BRAKE SUPPORT PLATE INSTALLATION
just shoes. • (1) Apply thin bead of Mopar silicone sealer
(6) Pull shoe adjuster screw star wheel away from around wheel cylinder mounting surface. Then trans
adjuster lever. fer wheel cylinder to new support plate.
(7) Turn adjuster screw star wheel (by hand) to ex (2) Apply thin bead of Mopar silicone sealer
pand or retract brakeshoes. Continue adjustment un around axle mounting surface of support plate.
til gauge outside legs are light drag-fit on shoes (Fig. (3) Install support plate on axle flange. Tighten at
17). taching bolts to 47-68 N-m (35-50 ft. lbs.).
(8) Repeat adjustment at opposite brakeshoe as (4) Install parking brake cable in support plate.
sembly. (5) Install axle shaft and retainer.
(9) Install brake drums and wheels and lower ve
hicle.
AIRCRAFT TYPE
HOSE CLAMP RB763 KHHr
Fig. 18 Compressing Parking Brake Cabie Retainer
m a m
Tabs
(6) On models with full float axle, install bearing
hub and axle shaft.
(7) Start brakeline in wheel cylinder and install — " RB762A
cylinder on support plate. Tighten brakeline fitting
Fig. 19 Typical Location Of Drum Maximum
after cylinder installation.
Diameter
(8) Connect parking brake cable to lever on second
ary shoe and install brakeshoes on support plate. ment involves mounting the drum in a brake lathe
(9) Adjust brakeshoes to dram with brake gauge. and checking variation and runout with a dial indi
(10) Install brake drams. cator.
(11) Fill and bleed brake system. Variations in dram diameter should not exceed
(12) Install wheel and tire assemblies and lower 0.076 mm (0.003 in). Drum runout should not exceed
vehicle. 0.20 mm (0.008 in.) out of round. Refinish the drum
if runout or variation exceed these values. Replace
BRAKE DRUM SERVICE ' the drum if refinishing would cause the drum to ex
ceed maximum allowable diameter.
B R A K S®mj>oa REFINISHING
The brake drums can be resurfaced, on a drum WHEEL NUT TIGHTENING
lathe when necessary. Initial machining cuts should
The wheel attaching nuts should be properly tight
be no more than 0.12 mm (0.005 in.) as heavier feed
rates can produce taper and surface variation. Final ened to ensure efficient brake operation. Overtighten
finish cuts of 0.025 mm (0.001 in.) are recommended ing the nuts or tightening them in the wrong
and will generally provide the best surface finish. sequence could cause distortion of the brake rotors
Be sure the drum is securely mounted in the lathe and drums.
before machining operations. A damper strap should Impact wrenches are not the best tools for tighten
always be used around the drum to reduce vibration ing wheel nuts. A torque wrench should be used for
and avoid chatter marks. this purpose at all times.
The correct tightening sequence is important in
S - ^ K i l ttaKGC 13LIMNISH LIMITS avoiding rotor and drum distortion. The correct se
The maximum allowable diameter of the drum quence is in a diagonal crossing pattern.
braking surface is stamped or cast into the drum Seat the wheel and install the wheel nuts finger
outer edge (Fig. 19). Generally, a drum can be ma tight. Tighten the nuts in the sequence to 1/2 re
chined to a maximum of 1.5 mm (0.060 in.) oversize. quired torque. Then repeat the tightening sequence
Always replace the drum if machining would cause to final specified torque.
drum diameter to exceed indicated size limit.
BRAKE DRUM RUNOUT
Measure drum diameter and runout with an accu
rate gauge. The most accurate method of measure-
BR PARKING BRAKES 5 - 73
PARKING BRAKES
INDEX
page page
Front Cable Replacement 73 Parking Brake Pedal Assembly Replacement . . . . . 75

Parking Brake Cable Tensioner Adjustment 74 Rear Cable Replacement 73
FRONT CABLE REPLACEMENT

(1) Remove knee bolster.
(2) Release parking brake pedal completely.
(3) Raise vehicle.
(4) Loosen tensioner nut to create slack in front ca
ble and extension cable (Fig. 1).
EXTENSION
CABLE
FRONT
CABLE
TENSIONER GROMMET/SEAL J9405-171
Fig. 2 Front Cable Grommet (In Floorpan)
PEDAL
ASSEMBLY
CABLE
CONNECTORS J9405-169
Fig. 1 Extension-To-Front Cable Attachment

(5) Disengage front cable from extension cable con
nector (Fig. 1). Note that extension cable also be re
moved at this time if necessary.
(6) Lower vehicle.
(7) Roll back carpet and loosen cable grommet (Fig.
2). Then pull cable through floorpan grommet and re
move cable.
(8) Disengage front cable from arm on foot pedal
assembly (Fig. 3).
(9) Insert new cable through floorpan grommet FRONT
(Fig. 3). Then feed cable up to arm on pedal assembly CABLE
(Fig. 2).
(10) Hook cable T-connector in arm on pedal as J9405-170
sembly (Fig. 2).
(11) Secure floorpan grommet/seal. Fig. 3 Front Cable Attachment (At Foot Pedal)
(12) Realign floor carpet. (15) Adjust cable tensioner. Refer to procedure in
(13) Install knee bolster (if removed). this section.
(14) Engage front cable and extension cable in ca
ble connectors. Make sure right rear cable is secured REAR CABLE REPLACEMENT
in tensioner connector (Fig. 4). (1) Raise vehicle and remove necessary wheel and
brake drum.
(2) Remove secondary brakeshoe. Then disconnect
cable from parking lever attached to secondary shoe.
5 - 74 PARKING BRAKES — — ^ — ^ — • —- - - ——— — BR
R.R.
CABLE
FRONT
CABLE
J9505-117
F/g. 4 Cable Attachment At Tensioner

(3) Compress rear cable retainer with hose clamp R.R.
or pliers and pull cable out of support plate (Fig. 5). SPRING
REAR
CABLE
(LH. SHOWN)
REACTION
BRACKET REAR
CABLE
REACTION
BRACKET 10-16 Nm
(90-140 in. lbs.)
J9405-174
SUPPORT
PLATE Fig. 6 Rear Cable Reaction Bracket Location
J9405-172
(11) Seat cable in body clips, reaction bracket, and
Fig. 5 Rear Cable Routing frame bracket.
(4) Remove one (or both) cables as needed from re (12) Connect cable to tensioner.
action bracket on right rear fame rail (Fig. 6). (13) Adjust cable tensioner, Refer to procedure in
(5) Disengage rear cable from tensioner (Fig. 7). this section.
(6) Remove cable from bracket on frame (Fig. 7). (14) Install wheel and tire assemblies.
Compress cable retainer with hose clamp or pliers (15) Lower vehicle.
and slide cable out of bracket. (16) Verify parking brake operation.
(7) Remove cable.
(8) Route new cable to rear brake support plate. PARKING BRAKE CABLE TENSIONER ADJUSTMENT
(9) Insert cable through support plate, seat cable Tensioner adjustment is only necessary when
retainers and attach cable to parking brake lever on the tensioner, or a cable has been replaced or
secondary brakeshoe. disconnected for service. When adjustment is
(10) Install brakeshoes but do not install brake necessary, perform adjustment only as de
drum at this time. scribed in the following procedure. This is nec
essary to avoid faulty parking brake operation.
mm PARKING BRAKES I - 75
(10) Lower vehicle until rear wheels are 15-20 cm

(6-8 in.) off shop floor.
(11) Release parking brake foot pedal and verify
L.R. that rear wheels rotate freely without drag. Then
CABLE lower vehicle.
CABLE
CONNECTOR
EQUALIZER THREADED
ROD
(TO EQUALIZER)
TENSIONER
ROD
CABLE
BRACKET
R.R.
CABLE
CABLE
TENSIONER
J9405-173 PLACE
MARK
HERE
Fig, 7 Cabie And Tensioner Attachment
(1) Eaise vehicle.
(2) Back off cable tensioner adjusting nut to create
slack in cables. TENSIONER BRACKET
(3) Remove rear wheel/tire assemblies. Then re J9405-176
move brake drums.
(4) Check rear brakeshoe adjustment with stan Fig. 8 Placing Adjustment Mark On Cable Tensioner
dard brake gauge. Also check condition of brake parts Rod
as follows:
(a) Replace worn parts if necessary. Excessive PARKING BRAKE PEDAL ASSEMBLY
shoe-to-drum clearance, or worn components REPLACEMENT
will result in faulty parking brake adjustment (1) Release parking brakes.
and operation. (2) Raise vehicle.
(b) Verify that parking brake cables operate (3) Loosen cable tensioner nut at equalizer to cre
freely and are not binding, or seized. Replace faulty ate slack in front cable.
cables, before proceeding. (4) Lower vehicle.
(c) Adjust rear brakeshoes to drums. (5) Remove knee bolster.
(d) Install drums and verify that drums rotate (6) remove necessary dash trim, or ducting for bet
freely without drag. ter access to pedal assembly as needed.
(5) Reinstall wheel/tire assemblies after brakeshoe (7) Disconnect brakelight wire from switch on
adjustment is complete. pedal assembly.
(6) Lower vehicle enough for access to parking (8) Roll carpet back and loosen front cable grom-
brake foot pedal. Then fully apply parking met/seal from floorpan (Fig. 2).
brakes. Leave brakes applied until adjustment (9) Disengage cable end connector from arm on
is complete. pedal assembly (Fig. 3).
(7) Raise vehicle again. (10) Remove bolts/nuts attaching pedal assembly
(8) Mark tensioner rod 6.5 mm (1/4 in.) from edge to cowl, dash panels, and instrument panels (Fig. 9).
of tensioner bracket (Fig. 8). (11) Remove old pedal assembly.
(9) Tighten adjusting nut at equalizer u n t i l (12) Position replacement pedal assembly on dash
mark o n tensioner rod moves into alignment and cowl.
with tensioner bracket (Fig. 8). (13) Install and tighten pedal assembly bolts/nuts
to 21-34 N-m (200-300 in. lbs.) torque.
CAUTION: Do not loosen, or tighten the tensioner (14) Connect front cable to arm on pedal assembly.
adjusting nut for any reason after completing ad (15) Connect wires to brakelight switch on pedal
justment. assembly.
I - 76 PARKING BRAKES BR
PEDAL COWL DASH

(17) Raise vehicle.
ASSEMBLY (18) Adjust parking brake cable tensioner. Refer to
procedure in this section.
ITEM TORQUE
J9405-175 <s> A 21-34 N-m (200-300 in. lbs.)
Fig, 9 Parking Brake Pedal Mounting

(16) Install knee bolster and any trim removed for
pedal access..
BR — — — — • — — — — — — _ PARKING BRAKES 5 - 77
SPECIFICATIONS
BRAKE SIZE CHART
Disc Brake Caliper Type (All) Single Piston, Slider
Disc Brake Caliper Piston Diameter:

1/2 Ton Models .75 mm (2.95 in.)
3/4 Ton Models 80 mm (3.14 in.)
1 Ton Models . . 86 mm (3.38 in.)
Disc Brake Rotor Diameter x Thickness:

1/2 Ton Models . . . . . . . . . . . . .2.94x32 mm (11.57x1.26 in.)
3/4 Ton Models 317.5x38 mm (12.5x1.5 in.)
1 Ton Models 317.5x38 mm (12.5x1.5 in.)
Drum Brake Size:

1/2 Ton Models . 11x2 in. (279x51 mm)
3/4 Ton Models . 13x2.5 in. (330x63.5 mm)
1 Ton Models 13x3.5 in. (330x89 mm)
Drum Brake Type (All) Dual Shoe With Self-Adjusting Mechanism
Master Cylinder Bore Size:

1/2 Ton Models , 28.6 mm (1.125 in.)
3/4 Ton Models . . . . . . .31.8 mm (1.25 in.)
1 Ton Models 31.8 mm (1.25 in.)
Wheel Cylinder Bore Size:

1/2 Ton Models . 23.8 mm (0.937 in.)
3/4 Ton Models 23.8 mm (0.937 in.)
1 Ton Models ................... 27 mm (1.06 in.)
Recommended Brake Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MOPAR Brake Fluid or Equivalent Meeting

SAE Standard J1703 and
Federal Standard DOT 3
J9405-14
3R CLUTCH 6 -1
CLUTCH
CONTENTS
page page
CHECKING NV4500 CLUTCH HOUSING CLUTCH LINKAGE SERVICE 16

RUNOUT 19 CLUTCH PEDAL INSTALLATION 17
CLUTCH COMPONENT LUBRICATION . . . . . . . . . 3 CLUTCH PEDAL POSITION SWITCH 3
CLUTCH COMPONENTS 1 CLUTCH PEDAL REMOVAL 17
CLUTCH COVER AND DISC INSTALLATION . . . 1 2 CLUTCH PROBLEM CAUSES .. 4
CLUTCH COVER AND DISC REMOVAL . . . . . . . 12 FLYWHEEL SERVICE 18
CLUTCH COVER APPLICATION 2 GENERAL DIAGNOSIS INFORMATION .3
CLUTCH DISC APPLICATION 1 INSPECTION AND DIAGNOSIS CHARTS . . . . . . . 5
CLUTCH HOUSING REPLACEMENT (NV4500) . 14 PILOT BEARING REPLACEMENT 15
CLUTCH HYDRAULIC LINKAGE 3 RELEASE BEARING REPLACEMENT 15
CLUTCH LINKAGE FLUID 3
CLUTCH COMPONENTS master cylinder mounted on the dash panel. The cyl
The clutch mechanism in BR models with a gas or inder push rod is connected to the clutch pedal.
diesel engine consists of a single, dry-type clutch disc The clutch disc has damper springs in the disc hub.
and a diaphragm style clutch cover. A hydraulic linkage The clutch disc facing is riveted to the hub. The fac
is used to engage/disengage the clutch disc and cover. ing is made from a non-asbestos material. The clutch
The transmission input shaft is supported in the cover pressure plate is a diaphragm type with a one-
crankshaft by a bearing. A sleeve type release bear piece spring and multiple release fingers. The pres
ing is used to engage and disengage the clutch cover sure plate release fingers are preset during
pressure plate. manufacture and are not adjustable.
The release bearing is operated by a release fork in
the clutch housing. The fork pivots on a ball stud CLUTCH DISC APPLICATION
mounted inside the housing. The release fork is actu Two clutch disc diameters and four different thick
ated by a hydraulic slave cylinder mounted in the nesses are used.
housing. The slave cylinder is operated by a clutch A 281 mm (11 in.) diameter clutch disc is used with
a 3.9L, 5.2L, or 5.9L gas engines (Figs. 1 and 2).
FACING
FACING MATERIAL
MATERIAL
IHM J9406-7 HE] J9406-8
Fig. 1 dutch Disc (V6 Engine) Fig. 2 dutch Disc (V8 Engine)
6 -2 CLUTCH BR
A 312.5 mm (12.3 in.) diameter clutch disc is used CLUTCH COVER APPLICATION
with diesel and V10 engines (Figs. 3 and 4). Two clutch covers are used for all applications. The
All the discs have damper springs in the hub. The 281 mm cover (Fig. 5), is used for 3.9L, 5.2L and 5.9L
281 mm discs have four springs while the 312.5 mm gas engine applications.
disc has five springs. The damper springs provide The 312.5 mm cover (Fig. 6), is used for 5.9L diesel
smoother torque transfer and disc engagement. and VI0 gas engine applications.
COVER
DAMPER
SPRINGS (5)
312.5 mm
(12.3 in.)
[DIESEL/VIOl J9406-11
J9406-9
Lviol
Fig. 5 dutch Cover (WW/Diesel Engine)
Fig. 3 dutch Disc (WW Engine)
FACING COVER
MATERIAL
PRESSURE
PLATE
281 mm
LMESELj J9406-10 (11 in.) J9406-12
Fig. 4 dutch Disc (Diesei Engine) Fig. 6 Clutch Cover (W6/W8 Gas Engine)
BR CLUTCH 6-3
CLUTCH PEDAL POSITION SWITCH CLUTCH LINKAGE FLUID

All BR models are equipped with a clutch pedal po The clutch fluid reservoir, master cylinder, slave
sition switch (Fig. 7). The switch is in circuit with cylinder and fluid lines are prefilled with fluid at the
the starter relay and is mounted on the clutch mas factory during assembly operations.
ter cylinder push rod. The switch is actuated by The hydraulic system should not require additional
clutch pedal movement. The clutch pedal must be fluid under normal circumstances. In fact, the reser
fully depressed in order to start the engine. voir fluid level will actually increase as normal
The position switch is an integral part of the clutch clutch wear occurs. For this reason, it is important to
master cylinder push rod and is not serviced sepa avoid overfilling, or removing fluid from the reser
rately. voir.
Position switch circuitry is provided at the end of If inspection or diagnosis indicates additional fluid
this section (refer to Figure 10).
may be needed, use Mopar brake fluid, or an equiv
alent meeting SAE and DOT standards J1703 and
CLUTCH CLUTCH PEDAL
DOT 3. Do not use any other type of fluid.
CLUTCH COMPONENT LUBRICATION

Proper clutch component lubrication is important
to satisfactory operation. The correct lubricant and
not overlubricating are equally important. Apply rec
ommended lubricant sparingly to avoid disc and pres
sure plate contamination.
J9506-26 Clutch and transmission components requiring lu
brication are:
Fig. 7 Clutch Pedal Position (Interlock) Switch • pilot bearing
• release lever pivot ball stud
CLUTCH HYDRAULIC LINKAGE • release lever contact surfaces
The hydraulic linkage consists of a remote reser • clutch disc hub splines
voir, clutch master cylinder, clutch slave cylinder and • clutch pedal pivot shaft bore
interconnecting fluid lines (Fig. 8). ® clutch pedal bushings
The clutch master cylinder is connected to the • input shaft splines
clutch pedal and the slave cylinder is connected to » input shaft pilot hub
the clutch release fork. The master cylinder is o transmission front bearing retainer slide surface
3
mounted on the drivers side of the dash panel adja Do not apply grease to any part of the clutch
cent to the brake master cylinder. cover, disc, or release bearing.
DASH
OPENING Recommended Lubricants
Use Mopar multi-purpose grease for the clutch
pedal bushings and pivot shaft. Use Mopar high tem
perature grease (or equivalent) for all other lubrica
tion requirements. Apply recommended amounts and
do not overlubricate.
GENERAL DIAGNOSIS INFORMATION

Unless the cause of a clutch problem is obvious, a
road test and component inspection will be required
for accurate diagnosis.
A road test will help determine the type of fault
while component inspection will identify the problem
component.
During a road test, drive the vehicle at normal
speeds. Shift the transmission through all gear
ranges and observe clutch action.
If chatter, grab, slip, or improper release is experi
SLAVE BODY enced, remove and inspect the clutch components.
CYLINDER CLIP J9406-15 However, if the problem is noise or hard shifting, fur
ther diagnosis is needed. The transmission or an
Fig. 8 Clutch Hydraulic Linkage other driveline component may actually be at fault.
6-4 CLUTCH BR
Careful observation during a road test will help Very light scratches or surface roughness on the
narrow the problem area. flywheel face can be cleaned up by scuff sanding with
180 grit emery cloth. However, if the surface is
CLUTCH PROBLEM CAUSES warped or severely scored, replace the flywheel.
Clean the crankshaft flange before mounting the
CONTAMINATION flywheel. Dirt and grease on the flange surface may
Fluid contamination is one of the more common cock the flywheel causing runout.
causes of clutch malfunctions. Oil, water, or clutch Use new bolts when remounting a flywheel and se
fluid on the clutch contact surfaces will result in cure the bolts with Mopar Lock And Seal, or Loctite
faulty operation. The usual result is chatter, slip, or 242. Tighten flywheel bolts to specified torque only.
grab. Overtightening could distort the flywheel hub caus
During inspection, note if any components are con ing runout.
taminated with oil, hydraulic fluid, or water/road
Clutch Cover And Disc Runout
splash.
Oil contamination indicates a leak at either the Check the clutch disc before installation. Axial
rear main seal or transmission input shaft. (face) runout of a new disc should not exceed 0.5 mm
Oil leakage produces a residue of oil on the housing (0.020 in.). Measure runout about 6 mm (1/4 in.) from
the outer edge of the disc facing. Obtain another disc
interior and on the clutch cover and flywheel.
if runout is excessive.
Heat buildup caused by slippage between the cover, Check condition of the clutch before installation. A
disc and flywheel, can sometimes bake the oil residue warped cover or diaphragm spring will cause grab
onto the components. The glaze-like residue ranges and incomplete release or engagement.
in color from amber to black. Be careful when handling the cover and disc. Im
Road splash contamination means dirt and water pact can distort the cover, diaphragm spring, release
are entering the clutch housing due to loose bolts, fingers and the hub of the clutch disc.
housing cracks, vent openings, or through the slave Use an alignment tool when positioning the disc on
cylinder opening. Driving through deep water pud the flywheel. The tool prevents accidental misalign
dles can force water/road splash into the housing ment which could result in cover distortion and disc
through such openings. damage.
An additional problem caused by water contamina A frequent cause of clutch cover distortion (and
tion and especially by steam cleaning, involves clutch consequent misalignment) is improper bolt tighten
disc sticking and poor release. ing. To avoid warping the cover, tighten the bolts al
Water and steam vapors can be absorbed by the ternately (in a diagonal pattern) and evenly (2-3
clutch facing material. If the vehicle sits idle for long threads at a time) to specified torque.
periods after water contamination, the force exerted
by the pressure plate may cause the disc to bond it Clutch Housing Misalignment And Runout
self to the flywheel or pressure plate. Clutch housing alignment is important to proper
Frequently, the only remedy for the above condition operation. The housing bore maintains alignment be
is component replacement. To avoid this problem, a tween the crankshaft and transmission input shaft.
vehicle should be driven as soon as possible to heat Misalignment can cause noise, incomplete clutch
and dry the clutch components. release and chatter. It can also result in premature
Clutch fluid leaks are from a loose or damaged wear of the pilot bearing, cover release fingers and
slave cylinder line or connection. However, clutch clutch disc. In severe cases, misalignment can. also
fluid leaks will usually be noted and corrected before cause premature wear of the transmission input
severe contamination occurs. shaft and bearing.
Housing face misalignment is generally caused by
CLUTCH MISALIGNMENT incorrect seating on the engine or transmission, loose
Clutch components must be in proper alignment housing bolts, missing alignment dowels or housing
with the crankshaft and transmission input shaft. damage. Infrequently, misalignment may also be
Misalignment caused by excessive runout or warpage caused by housing mounting surfaces that are not
of any clutch component will cause grab, chatter and parallel.
improper clutch release. If housing misalignment is suspected, the housing
is probably not fully seated on either the engine,
Flywheel Runout alignment dowels, or transmission front face. Since
Common causes of runout are heat warping, im the NV3500 clutch housing is an integral part of the
proper machining, mounting the flywheel on a dirty transmission front case, it will be necessary to re
crankshaft flange, incorrect bolt tightening, or im move the transmission and housing as an assembly
proper seating on the crankshaft flange shoulder. to check seating. Housing bore and face runout can
BR CLUTCH 6 -5
only be checked in the vehicle on models with a The use of non-standard or low quality parts can
NV4500 transmission. The runout check procedure is also lead to problems and wear. Use the recom
described in detail in the Clutch Service section. mended factory quality parts to avoid comebacks.
INSTALLATION METHODS AND PARTS INSPECTION AND DIAGNOSIS CHARTS
USAGE The clutch inspection chart (Fig. 9) outlines items
Distortion of clutch components during installation
to be checked before and during clutch installation.
and the use of non-standard components are addi
tional causes of clutch malfunction. Use the chart as a check list to help avoid overlook-
Improper, clutch cover bolt tightening can distort lug potential problem sources during service opera
the cover. The usual result is clutch grab, chatter tions.
and rapid wear. Tighten the cover bolts as described The diagnosis charts describe common clutch prob
in the Clutch Service section. lems, causes and correction. Fault conditions are
Improperly seated flywheels and clutch housings listed at the top of each chart. Conditions, causes and
are other causes of clutch failure. Improper seating corrective action are outlined in the indicated col
will produce misalignment and subsequent clutch umns.
problems. The charts are provided as a convenient reference
Tighten the clutch housing bolts to proper torque when diagnosing faulty clutch operation.
before installing any struts. Also be sure the align
ment dowels are in place and seated in the block and
housing beforehand.
6-6 CLUTCH
9 Inspect release bearing slide surface of trans, front

bearing retainer. Surface should be smooth, free of
nicks, scores. Replace retainer if necessary.
Lubricate slide surface before installing release
bearing.
10 Do not replace release bearing unless actually

faulty. Replace bearina only if seized, noisy, or
damaged.
11 Check clutch cover diaphragm spring and release

fingers. Replace cover ir spring or fingers are bent,
warped, broken, cracked. Do not tamper with
factory spring setting as clutch problems will result.
12 Check condition of clutch cover. Replace clutch

cover if plate surface is deeply scored, warped,
worn, or cracked. Be sure cover is correct size and
properly aligned on disc and flywheel.
13 Inspect clutch housing. Be sure bolts are tight.

Replace housing if damaged.
14 Verify that housing alignment dowels are in position

before installing housing.
15 Clean engine block surface before installing clutch

housing. Dirt, grime can produce misalignment.
1 Check clutch housing bolts. Tighten if loose. Be sure 16 Make sure side of clutch disc marked "flywheel
housing is fully seated on engine block. side" is toward flywheel.
2 Check flywheel. Scuff sand face to remove glaze. 17 Check rear main seal if clutch disc and cover were
Clean surface with wax and grease remover. oil covered. Replace seal if necessary.
Replace flywheel if severely scored, worn or
cracked. Secure flywheel with new bolts (if 18 Check crankshaft flange (if flywheel is removed). Be
removed). Do not reuse old bolts. Use Mopar Lock sure flange is clean andflywneelbolt threads are in
N'Seal on bolts. good condition.
3 Tighten clutch cover bolts 2-3 threads at a time, 19 Check pilot bearing. Replace bearing if damaged.
Lube with Mopar high temp, bearing grease before
alternately and evenly (in a star pattern) to
installation.
specified torque. Failure to do so could warp the
cover.
20 Check transmission input shaft. Disc must slide freely
4 Check release fork. Replace fork if bent or worn. on shaft splines. Lightly grease splines before
Make sure pivot and bearing contact surfaces are installation. Replace shaft if splines or pilot bearing
lubricated. hub are damaged.
5 Check release fork pivot (in housing). Be sure pivot 21 Check flywheel bolt torque. If bolts are loose,
is secure and ball end is lubricated. replace them. Use Mopar Lock N'Seal to secure new
bolts.
6 Transmission input shaft bearina will cause noise,
chatter, or improper release ir damaged. Check 22 Check clutch disc facing. Replace disc if facing is
condition before installing transmission. charred, scored, flaking off, or worn. Also check
runout of new disc. Runout should not exceed 0.5
7 Check slave cylinder. Replace it if leaking. Be sure mm (0.02 in.).
cylinder is properly secured in housing and cylinder
piston is seated in release fork.
8 Check input shaft seal if clutch cover and disc were

oil covered. Replace seal if worn, or cut. J9506-2
Fig. 9 Clutch Inspection Points

BR CLUTCH 6-7
CONDITION POSSIBLE CAUSES CORRECTION
DISC FACING WORN OUT 1. Normal wear. Driver frequently 1. Replace clutch disc. Also replace cover
rides (slips) clutch. Results in rapid if spring is weak or pressure plate surface
wear overheating. Insufficient is damaged.
clutch cover diaphragm spring
tension.
CLUTCH DISC FACING 1. Leak at rear main seal or at 1. Replace leaking seals. Apply less grease
CONTAMINATED WITH transmission input shaft seal. to input shaft splines. Replace clutch disc
OIL, G R E A S E , OR Excessive amount of grease (do not clean and reuse). Clean clutch
CLUTCH FLUID applied to input shaft splines. cover and reuse only if cover is in good
Road splash, water entering condition. Replace slave cylinder if leaking.
housing. Slave cylinder leaking.
CLUTCH IS RUNNING 1. Release bearing sticking- 1. Verify that bearing is actually binding,
PARTIALLY DISENGAGED binding. Does not return to then replace bearing and transmission
normal running position. front bearing retainer if sleeve surface is
damaged.
FLYWHEEL HEIGHT 1. Flywheel surface improperly 1. Replace flywheel.

INCORRECT machined. Too much stock
removed or surface is tapered.
WRONG DISC OR P R E S 1. Incorrect parts order or model 1. Replace with correct parts. Compare
S U R E PLATE INSTALLED number. old and new parts before installation.
CLUTCH DISC, COVER 1. Rough handling (impact) bent 1. Install new disc or cover as needed.
AND/OR DIAPHRAGM cover, spring, or disc. Incorrect Follow installation/tightening instructions.
SPRING, WARPED, bolt tightening sequence and
DISTORTED method caused warped cover.
FACING ON FLYWHEEL 1. Flywheel surface scored and 1. Reduce scores and nicks by sanding or
SIDE OF DISC TORN, nicked. surface grinding. Replace flywheel if
GOUGED, WORN scores-nicks are deeper than .002-.004
inch.
CLUTCH DISC FACING 1. Frequent operation under high 1. Scuff sand flywheel. Replace clutch
BURNT (CHARRED). FLY loads or hard acceleration cover and disc. Alert driver to problem
W H E E L AND COVER conditions. Driver frequently cause.
P R E S S U R E PLATE rides (slips) clutch. Results in
SURFACES HEAVILY rapid wear and overheating of
GLAZED disc and cover.
J9506-18
6-8 CLUTCH
CLUTCH DISC WARPED 1. New disc not checked for axial 1. Replace disc. Be sure runout of new
runout before Installation. disc is less than .5 mm (.020 in.).
CLUTCH DISC BINDS ON 1. Clutch disc hub splines 1. Clean, smooth and lubricate disc and
INPUT SHAFT SPLINES damaged during installation. shaft splines. Replace disc and/or input
Input shaft splines rough, . shaft if splines are severely damaged.
damaged. Corrosion, rust
formations on splines of disc
and input shaft.
CLUTCH DISC RUSTED 1. Occurs in vehicles stored, 1. Remove clutch cover and disc. Sand
TO FLYWHEEL AND/OR or not driven for extended rusted surfaces clean with 180 grit paper.
P R E S S U R E PLATE periods of time. Also occurs Replace disc cover, and flywheel if
after steam cleaning if vehicle corrosion is severe.
is not used for extended period.
CLUTCH DISC FACING 1. Vacuum may form in pockets 1. Drill 1 /16 inch diameter hole through
STICKS TO FLYWHEEL over rivet heads in clutch disc. rivets and scuff sand disc facing with 180
Occurs as clutch cools down grit paper.
after use. •
CLUTCH DISC TOO THICK 1. Wrong disc installed. 1. Replace disc.
PILOT BEARING SEIZED, 1. Bearing cocked during 1. Lubricate and install new bearing.
LOOSE, OR ROLLERS installation. Bearing defective. Check and correct any misalignment.
ARE WORN Bearing not lubricated. Clutch
misalignment.
CLUTCH WILL NOT 1. Low clutch fluid level. 1. Top off reservoir and check for
DISENGAGE PROPERLY leaks.
2. Clutch cover loose. 2. Tighten bolts.
3. Wrong clutch disc. 3. Install correct disc.
4. Disc bent, distorted during 4. Replace disc.
installation.
5. Clutch cover diaphragm spring 5. Replace cover.
bent or warped during
transmission installation.
6. Clutch disc installed backwards. 6. Remove and reinstall disc correctly.
Be sure disc side marked "to flywheel" is
actually toward flywheel.
7. Release fork bent or fork pivot 7. Replace fork and pivot if worn or
is loose or damaged. damaged.
8. Clutch master or slave cylinder 8. Replace master and slave cylinder as
fault. assembly.
J9506-1
BR CLUTCH 6-9
CLUTCH DISC FACING 1. Oil leak at rear main or input 1. Correct leak and replace disc (do not
COVERED WITH OIL, shaft seal. clean and reuse the disc).
GREASE, OR CLUTCH 2. Too much grease applied to 2. Apply lighter grease coating to splines
FLUID splines or disc and input shaft. and replace disc (do not clean and reuse
the disc).
CLUTCH DISC AND/OR 1. Incorrect or substandard parts. 1. Replace disc and/or cover with correct
COVER WARPED, OR DISC parts.
FACINGS EXHIBIT
UNUSUAL WRONG TYPE
CLUTCH MASTER OR 1. Master or slave cylinder 1. Replace both cylinders as assembly

SLAVE CYLINDER PLUNGER components worn or corroded. (and reservoir).
DRAGG1NG-BINDING
NO FAULT FOUND WITH 1. Problem actually related to 1. Further diagnosis required. Check
CLUTCH COMPONENTS suspension or driveline engine/transmission mounts, propeller
component. shafts and U-joints, tires, suspension
attaching parts and other driveline
components as needed.
2. Engine related problem. 2. Check EFl and ignition systems.
PARTIAL ENGAGEMENT 1. Clutch pressure plate 1 . Replace clutch cover and disc.
OF CLUTCH DISC (ONE position setting incorrect or
SIDE WORN-OPPOSITE . modified.
SIDE GLAZED AND 2. Clutch cover, spring, or release 2. Replace clutch cover and disc.
LIGHTLY WORN) fingers bent, distorted (rough
handling, improper assembly).
3. Clutch disc damaged or 3. Replace disc.
distorted.
4. Clutch misalignment. 4. Check alignment and runout of flywheel,
disc, or cover and/or clutch housing.
J9506-20
6 -10 CLUTCH
CONDITION POSSIBLE CAUSE CORRECTION
Clutch components damaged 1. Incorrect or sub-standard 1. Replace with parts of correct type and
or worn out prematurely. clutch parts. quality.
Pilot bearing damaged. 1. Bearing cocked during 1. Replace bearing. Be sure it is properly
installation. Bearing not lubricated seated and lubricated before installing
prior to installation. Bearing defect. clutch.
2. Clutch misalignment. 2. Check and correct misalignment caused
by excessive runout of flywheel, disc,
cover or clutch housing. Replace input
shaft if bearing hub is damaged.
Loose components. 1. Attaching bolts loose at 1. Tighten bolts to specified torque.

flywheel, cover, or clutch housing. Replace any clutch bolts that are damaged.
Components appear overheated. 1. Frequent high load, full 1. Replace parts as needed. Alert driver
Hub of disc cracked or torsion throttle operation. to condition causes.
damper springs are distorted
or broken.
Contact surface of release 1. Clutch cover incorrect, or 1. Replace clutch cover and bearing.
bearing damaged. release fingers are bent or
distorted causing damage.
2. Release bearing defect. 2. Replace bearing.
3. Release bearing misaligned. 3. Check and correct runout of clutch
components. Check front bearing retainer
sleeve surface. Replace if damaged.
Release bearing is noisy. 1. Release bearing defect. 1. Replace bearing.
Clutch pedal squeak. 1. Pivot pin loose. Pedal bushings 1. Tighten pivot pin. Replace bushings if
worn out or cracked. worn or damaged. Lubricate pin and
bushings with silicone base lubricator
chassis grease.
J9506-21
BR CLUTCH 6 -11
TO FUEL
SHUT DOWN
RELAY
DISTRIBUTION
CENTER
A41
18YL
CLUTCH
PEDAL POSITION
TO IGNITION (SWITCH) MANUAL
SWITCH -A41 20YL (ON CLUTCH TRANSMISSION
CYLINDER
AUTOMATIC PUSH ROD)
TRANSMISSION
J9406-24
Fig. 10 Clutch Pedal Position Switch Circuitry

6 -12 CLUTCH BR
CLUTCH COVER AND DISC REMOVAL

(1) Raise vehicle.
(2) Remove transmission and transfer case if
equipped. Refer to Group 21 for procedures.
(3) > On models with NV4500 transmission, remove
clutch slave cylinder from clutch housing (Fig. 1).
Then remove transmission and clutch housing from
engine (Fig. 2).
MOUNTING
STUDS
19-26 N-m
(170-230 in. lbs.]
J9106-22
FLUID
LINE Fig. 3 Supporting Engine With Jack Stand And
Wood Block (Diesel Model Shown)
ALIGNMENT
CLUTCH MARKS
HOUSING FLYWHEEL (SCRIBE OR PAINT)
SLAVE
CYLINDER J9406-13
Fig. 1 Slave Cylinder Mounting

CLUTCH
HOUSING
NV4500
TRANSMISSION
CLUTCH
COVER J9406-17
Fig. 4 Marking Clutch Cover Position

J9406-16
CLUTCH COWER AND DISC INSTALLATION
Fig. 2 Transmission/Clutch Housing (With NV4500) (1) Check runout and free operation of new clutch
(4) Support engine with wood block and adjustable disc:
jack stand (Fig. 3). Supporting engine is necessary to (a) Install disc on transmission input shaft
avoid undue strain on engine mounts. splines and check fit. Disc should slide freely on
(5) If clutch cover will be reused, mark position of splines.
cover on flywheel with paint or scriber (Fig. 4). (b) Leave disc on shaft and check disc runout
(6) Insert clutch alignment tool in clutch disc and with dial indicator.
into pilot bushing. Tool will hold disc in place when (c) Position indicator plunger about 1/4 inch from
cover bolts are removed. outer edge of disc facing.
(7) If clutch cover will be reused, loosen cover bolts (d) Runout should not exceed 0.5 mm (0.020 in.).
evenly, only few threads at a time, and in a diagonal Obtain another clutch disc if runout exceeds this
pattern (Fig. 5). This relieves cover spring tension limit.
evenly to avoid warping. (2) Lubricate crankshaft pilot bearing with Mopar
(8) Remove cover bolts completely and remove high temperature bearing grease.
cover, disc and alignment tool. (3) Insert clutch alignment tool in clutch disc hub.
B R - CLUTCH 6 -13
CLUTCH COVER
AND DISC
CLUTCH DISC
ALIGNMENT TOOL
w
FLYWHEEL. _ ^±~Y J f 106-18
Fig. 7 Clutch Disc And Cover Alignment/Installation
CLUTCH
HOUSING
J9106-17
COAT
Fig. 5 dutch Cover Boit Loosening/Tightening RELEASE
FORK PIVOT
Pattern BALL STUD
(4) Verify that disc hub is positioned correctly. Side WITH
HIGH TEMP.
of hub marked "Flywheel Side" should face flywheel GREASE
(Fig. 6).
LUBE
CLUTCH POINTS
DISC (HIGH TEMP.
GREASE)
RELEASE GAS
FORK
(HIGH TEMP.
"FLYWHEEL SIDE" " GREASE)
STAMPED ON LUBE
THIS SURFACE POINTS
J9006-33
Fig. 6 Clutch Disc Position (Typical)

(5) Insert alignment tool in pilot bearing and posi
tion disc on flywheel surface (Fig. 7).
(6) Position clutch cover over disc and onto fly APPLY LIGHT COAT
wheel (Fig. 7). HIGH TEMP. GREASE
(7) Align and hold clutch cover in position and in TO RELEASE BEARING
stall cover bolts finger tight. BORE J9106-19
(8) Tighten cover bolts evenly and a few threads at
a time. Cover bolts must be tightened evenly Fig. 8 Clutch Release Component Lubrication
and to specified torque to avoid distorting Points
cover. contact surfaces and release lever pivot stud (Fig. 8).
• Tighten 5/16 in. diameter bolts to 23 N-m (17 ft. (10) Apply light coat of Mopar high temperature
lbs.) bearing grease to splines of transmission input shaft
• Tighten 3/8 in. diameter bolts to 41 N-m (30 ft. (or drive gear) and to release bearing slide surface of
lbs.). the transmission front bearing retainer (Fig. 9). Do
(9) Remove release lever and release bearing from not overlubricate shaft splines. This can result
clutch housing. Apply Mopar high temperature bear in grease contamination of disc.
ing grease to bore of release bearing, release lever
6 -14 CLUTCH BR
APPLY LIGHT COAT OF

HI-TEMP GREASE TO THESE
SURFACES BEFORE INSTALLATION J9106-15
Fig. 9 input Shaft Lubrication Points (Typical)

(11) Install release lever and bearing in clutch
housing. Be sure spring clips that retain fork on
pivot ball and release bearing on fork are properly
installed and (Fig. 10).
FORK
J9006-32
Fig. 11 Clutch Housing Installation (NV4500)
J9406-18
Fig. 10 Release Fork And Bearing Spring Clip

Position
(12) Install clutch housing (Figs. 11 and 12). Be
sure housing is properly seated on alignment dowels
before tightening housing bolts.
(13) Install transmission.
(14) Check fluid level in clutch master cylinder.
CLUTCH HOUSING REPLACEMENT (NV4500)

Only the NV4500 clutch housing is serviced sepa
rately. The NV3500 clutch housing is part of the
transmission front case and is therefore serviced only
as part of the case assembly.
(1) Raise vehicle and remove transmission and Fig. 12 Clutch Housing/Transmission Installation
transfer case if equipped. (Diesel Engine)
(2) Remove clutch housing bolts and remove hous (4) Verify that clutch housing alignment dowels are
ing from engine (Figs. 2 and 11). in good condition and properly seated.
(3) Clean housing mounting surface of engine block
with wax and grease remover.
BR CLUTCH 6-15
(5) Transfer slave cylinder, release fork and boot,

fork pivot stud and wire/hose brackets to new hous
ing.
(6) Lubricate release fork and pivot contact sur
faces with Mopar High Temperature wheel bearing
grease before installation.
(7) Align and install clutch housing on transmis
sion. Tighten housing bolts closest to alignment dow
els first and to torque values indicated (Figs. 2 and
11).
(8) Install transmission-to-engine strut after in
stalling clutch housing. Tighten bolt attaching strut
to clutch housing first and engine bolt last.
(9) Install transmission and transfer case if
equipped. Refer to procedure in Group 21.
Fig. 14 Clutch Release Fork And Bearing Installation
RELEASE BEARING REPLACEMENT
(1) Remove transmission. PILOT BEARING REPLACEMENT
(2) On models with gas engine and new style re (1) Remove transmission and clutch housing.
lease fork, remove clutch housing for access to re (2) Remove clutch cover and disc.
lease fork and release bearing retainer springs. (3) Remove pilot bearing. Use blind hole puller
(3) Disconnect release bearing from release fork tools such as those included in Snap-On set CG40CB
and remove bearing (Fig. 12). to remove bearing.
(4) Inspect bearing slide surface on transmission (4) Clean bearing bore with solvent and wipe dry
front bearing retainer. Replace retainer if slide sur with shop towel.
face is scored, worn or cracked. (5) Install new bearing with clutch alignment tool
(5) Inspect release lever and pivot stud. Be sure (Fig. 15). Keep bearing straight during installation.
stud is secure and in good condition. Be sure fork is Do not allow bearing to become cocked. Tap bearing
not distorted or worn. Replace fork spring clips if into place until flush with edge of bearing bore. Do
bent or damaged. not recess bearing.
(6) Lubricate crankshaft pilot bearing, input shaft
splines, bearing retainer slide surface, lever pivot
ball stud and release lever pivot surface with Mopar
high temperature bearing grease.
(7) Install release fork and release bearing (Fig.
14). Be sure fork and bearing are properly secured by
spring clips.
(8) Install clutch housing, if removed.
(9) Install transmission. Also install transfer case
on 4-wheel drive models.
BEARING SEAL
MUST FACE
J9206-8
Fig. 15 Typical Method Of Installing Pilot Bearing

RELEASE BEARING RELEASE
(6) Lubricate bearing with Mopar high tempera
AND SLEEVE FORK RN1232
ture grease, or an equivalent quality grease.
Fig. 13 Clutch Release Components (7) Install clutch cover and disc.
6-16 CLUTCH BR
(8) Install clutch housing, transmission and trans (12) Verify that cap on clutch master cylinder res
fer case on 4-wheel drive models. ervoir is tight. This will avoid spillage during re
moval.
CLUTCH LINKAGE SERVICE (13) Remove screws that attach clutch fluid reser
The clutch master cylinder, remote reservoir, voir to dash panel.
slave c y l i n d e r and connecting lines are all ser (14) Remove reservoir mounting bracket screws
viced as an assembly.. These components cannot and remove reservoir from dash panel.
be serviced separately. T h e l i n k a g e cylinders (15) Rotate clutch master cylinder 45° counter
a n d c o n n e c t i n g lines a r e sealed units. They are clockwise to unlock it. Then remove cylinder from
prefilled w i t h fluid during manufacture and dash panel.
m u s t n o t b e disassembled n o r disconnected. (16) Remove clutch master cylinder rubber seal
from dash panel (Fig. 16).
LINKAGE MEMOWAL (17) Remove clutch cylinders, reservoir and con
(1) Raise vehicle. necting lines from vehicle.
(2) On diesel models, remove slave cylinder shield
from clutch housing if equipped. LINKAGE INSTALLATION
(3) Remove nuts attaching slave cylinder to studs (1) Tighten cap on clutch fluid reservoir to avoid
on clutch housing. spillage during installation.
(4) Remove slave cylinder from clutch housing. (2) Position cylinders, connecting lines and reser
(5) Disengage slave cylinder fluid line from body voir in vehicle engine compartment.
retainer clips. (3) Lubricate cylinder seal with liquid dish soap to
(6) Lower vehicle. ease installation. Then seat seal in dash and around
(7) Disconnect clutch pedal interlock switch wires. cylinder.
(8) Remove locating clip from clutch master cylin (4) Insert clutch master cylinder in dash panel. Ro
der mounting bracket (Fig. 16). tate cylinder 45° clockwise to lock it in place.
(9) Remove retaining clip, flat washer and wave (5) If cylinder seal is hard to seat, unlock cylinder
washer that attach clutch master cylinder push rod and reseat seal if necessary. Then relock cylinder af
to clutch pedal (Fig. 17). terward.
(10) Slide clutch master cylinder push rod off pedal (6) Position clutch fluid reservoir on dash panel
pin. and install reservoir screws. Tighten screws to 5 N-m
(11) Inspect condition of bushing on clutch pedal (40 in. lbs.) torque.
pin (Fig. 17). Remove and replace bushing if worn or (7) Install reservoir mounting bracket on dash
damaged. panel, if removed.
CYLINDER
RESERVOIR DASH
LOCATING
PIN CLUTCH
PUSH
ROD
CLUTCH
MASTER
CYLINDER
SLAVE
CYLINDER J9506-25
Fig. 16 dutch Hydraulic Linkage

CLUTCH 6 -17
PIN
Fig. 18 Knee Bolster Removal
PEDAL PEDAL
PEDAL SUPPORT PSVOT
J9406-21
Fig. 17 Clutch Cylinder Push Rod Attachment

(8) Install replacement bushing on clutch pedal pin
if necessary.
(9) Install clutch master cylinder push rod on
clutch pedal pin. Secure rod with wave washer, flat
washer and retainer ring.
(10) Connect clutch pedal position (interlock)
switch wires.
(11) Install locating clip in clutch master cylinder
mounting bracket.
(12) Raise vehicle.
(13) Install slave cylinder. Be sure cap at end of
cylinder rod is seated in release lever. Check this be
fore installing cylinder attaching nuts.
(14) Install and tighten slave cylinder attaching
nuts to 23 N-m (200 in. lbs.) torque.
(15) Lower vehicle. J9406-22
(16) If new linkage has been installed, remove
plastic shipping stop from master cylinder push rod. * Fig. 19 Clutch/Brake Pedal Mounting
Do this after installing slave cylinder and before op (5) Push pedal pivot shaft toward driver side of
erating linkage. support only enough to remove clutch pedal. It is not
(17) Operate linkage several times to verify proper necessary to remove shaft from pedal support en
operation. tirely.
(6) Remove clutch pedal.
CLUTCH PEDAL REMOVAL
(1) Remove retaining ring, flat washer and wave CLUTCH PEDAL INSTALLATION
washer that secure brake and clutch pedals to push (1) Inspect bushings in clutch and brake pedals
rods (Fig. 17). (Fig. 20). Replace bushings if worn, cracked, or dis
(2) Remove knee bolster (Fig. 18) for access to torted.
pedal pivot shaft. (2) Lubricate pedal shaft, pedal shaft bore (Figs.
(3) Remove brakelight switch. Turn switch clock
19 and 20) and all bushings with Mopar Multi Mile
wise about 30° to release it then remove switch from
bracket. age, or high temperature bearing grease. -
(4) Remove retainer from passenger side of pedal
pivot shaft (Fig. 19).
§ -18 CLUTCH BR
Install new attaching bolts whenever the flywheel

is replaced and use Mopar Lock N' Seal, or Loctite
242 on replacement bolt threads.
Recommended flywheel bolt torques are:
• 75 N-m (55 ft. lbs.) for gas engine flywheels
• 137 N-m (101 ft. lbs.) for diesel flywheels
Inspect the teeth on the starter ring gear. If the
teeth are worn or damaged, the flywheel should
be replaced as an assembly. This is the recom
mended and preferred method of repair.
In cases where a new flywheel is not readily avail
able, a replacement ring gear can be installed. How
ever, the following precautions must be observed to
avoid damaging the flywheel and replacement gear.
Fig. 20 dutch/Brake Pedal Bushings (a) Mark position of the old gear for alignment
reference on the flywheel. Use a scriber for this
(3) Position clutch pedal in support. Align pedal
purpose.
with pivot shaft and slide shaft through pedal bush
(b) Wear protective goggles or approved safety
ings. Then repeat process for brake pedal.
glasses. Also wear heat resistent gloves when han
(4) Slide pedal shaft through support and install
dling a heated ring gear.
shaft retainer.
(c) Remove the old gear by cutting most of the
(5) Secure push rods to clutch and brake pedals.
way through it (at one point) with an abrasive cut
(6) Install brakelight switch in bracket. Rotate
off wheel. Then complete removal with a cold chisel
switch into place to lock it in bracket.
or punch.
(7) Install knee bolster.
(d) The ring gear is a shrink fit on the flywheel.
This means the gear must be expanded by heating
FLYWHEEL SERVICE
in order to install it. The method of heating and
Inspect the flywheel whenever the clutch disc, expanding the gear is extremely important.
cover and housing are removed for service. Check Every surface of the gear must be heated at the
condition of the flywheel face, hub, ring gear teeth, same time to produce uniform expansion. An oven
and flywheel bolts.
or similar enclosed heating device must be used.
Minor scratches, burrs, or glazing on the flywheel
Temperature required for uniform expansion is
face can be scuff sanded with 180 grit emery cloth.
However, the flywheel should be replaced if the disc 325-350° F.
contact surface is severely scored, heat checked, CAUTION: Never use an oxy/acetylene torch to re
cracked, or obviously worn. move the old gear, or to heat and expand a new
Cleanup of minor flywheel scoring should be per gear. The high temperature of the torch flame will
formed with surface grinding equipment. Remove cause localized heating and damage the flywheel. In
only enough material to reduce scoring (approximate
addition, using the torch to heat a replacement gear
ly 0.001 - 0.003 in.). Heavy stock removal is not rec
will cause uneven heating and expansion. The torch
ommended. Replace the flywheel if scoring is severe
flame will also anneal the gear teeth resulting in
and deeper than 0.076 mm (0.003 in.). Excessive
rapid wear and damage after installation.
stock removal can result in flywheel cracking or
warpage after installation; it can also weaken the fly
(e) The heated gear must be installed evenly to
wheel and interfere with proper clutch release.
Check flywheel runout if misalignment is sus avoid misalignment or distortion. A shop press and
pected. Runout should not exceed 0.08 mm (0.003 suitable press plates should be used to install the
in.). Measure runout at the outer edge of the fly gear if at all possible.
wheel face with a dial indicator. Mount the dial indi (f) Be sure to wear eye and hand protection.
cator on a stud installed in place of one of the Heat resistent gloves and safety goggles are needed
flywheel attaching bolts. for personal safety. Also use metal tongs, vise grips,
Clean the crankshaft flange before mounting the or similar tools to position the gear as necessary
flywheel. Dirt and grease on the flange surface may for installation.
cock the flywheel causing excessive runout. (g) Allow the flywheel and ring gear to cool down
Check condition of the flywheel hub and attaching before installation. Set the assembly on a work
bolts. Replace the flywheel if the hub exhibits cracks bench and let it cool in normal shop air.
in the area of the attaching bolt holes.
BR CLUTCH 6-19
CAUTION: .Never use water, or compressed air t© available to correct runout on diesel engines. If
cool the flywheel. The rapid cooling produced by bore runout exceeds the stated maximum on a
water or compressed air can distort, or crack the diesel engine, it may be necessary to replace ei
gear and flywheel. ther the clutch housing, or transmission
adapter plate.
CHECIili 114111 CLUTCH HOUSING RUNOUT CORRECTING CLUTCH HOUSING BORE
Only t h e NV4500 clutch housing c a n b e RUNOUT (NV4S00 GAS ENGINE ONLY)
checked using t h e following bore and. face On gas engine vehicles, clutch housing bore runout
runout procedures. The NV3500 clutch housing is corrected w i t h offset dowels. However, i f bore
is a n integral p a r t of t h e transmission front r u n o u t exceeds 0.015 i n . T I R on a diesel equipped
case a n d c a n only be checked off t h e v e h i c l e . model, t h e clutch housing, or transmission adapter
plate m a y have to be replaced. Offset dowels are not
MEASURING CLUTCH HOUSING BORE
available for diesel models.
RUNOUT (NV4S00 ONLY)
The dial indicator reads positive when the plunger
(1) Remove the clutch housing and strut.
moves i n w a r d (toward indicator) a n d negative when
(2) Remove the clutch cover and disc.
i t moves outward (away from indicator). As a result,
(3) Replace one o f t h e flywheel bolts w i t h a n ap
the lowest or most negative reading determines the
propriate size threaded rod t h a t is 10 i n . (25.4 cm)
long (Fig. 21). The rod w i l l be used to mount the dial direction of housing bore offset (runout).
indicator. I n t h e sample readings shown i n Figure 24 and i n
(4) Remove the release fork from the clutch hous step (7) above, t h e bore is offset toward t h e 0.010
ing. inch reading. To correct this, remove the housing and
(5) Reinstall the clutch housing. Tighten the hous original dowels. Then install the new offset dowels i n
i n g bolts nearest t h e alignment dowels first. the direction needed to center t h e bore w i t h t h e
(6) M o u n t the dial indicator on t h e threaded r o d crankshaft centerline.
and position the indicator plunger on t h e surface of I n t h e example, T I R was 0.012 inch. The dowels
the clutch housing bore (Fig. 22). needed for correction would have a n offset of 0.007
(7) Rotate the crankshaft u n t i l t h e indicator i n . (Fig. 24).
plunger is a t the top center of the housing bore. Zero I n s t a l l t h e dowels w i t h the slotted side facing out
the indicator at this point. so they can be t u r n e d w i t h a screwdriver. Then i n
(8) Rotate the crankshaft and record the indicator stall t h e housing, remount t h e dial indicator and
readings at eight points (45° apart) around t h e bore check bore r u n o u t again. Rotate the dowels u n t i l t h e
(Figs. 21-22). Repeat the measurement at least twice T I R is less t h a n 0.010 i n . i f necessary.
for accuracy. I f a T I R o f 0.053 i n . or greater is encountered, i t
(9) Subtract each reading from t h e one 180° oppo may be necessary to replace the clutch housing.
site to determine magnitude and direction of runout.
Refer to Figure 23 and following example. 7/16 - 20 THREAD NUT
Bore runout example:
0.000 - (-0.007) = 0.007 in.
+0.002 - (-0.010) = 0.012 in.
+0.004 - (-0.005) = 0.009 in.
-0.001 - (+0.001) = -0.002 in. (= 0.002 inch)
I n t h e above example, the largest difference is
0.012 i n . and is called the total indicator reading ^ 10 INCHES L O N G - •—^
(TIR). This means t h a t the housing bore is offset
from the crankshaft centerline by 0.006 i n . (which is
J9Q06-25
1/2 of 0.012 in.).
On gas engines, the acceptable m a x i m u m T I R for Fig. 21 Dial Indicator Mounting Stud Or Rod
housing bore runout is 0.010 inch. I f measured T I R is
more t h a n 0.010 i n . (as i n the example), bore r u n o u t MEASURING CLUTCH HOUSING FACE
w i l l have to be corrected w i t h offset dowels. Offset RUNOUT (NV4500)
dowels are available i n 0.007, 0.014 and 0.021 i n . (1) Reposition the dial indicator plunger on t h e
sizes for this purpose (Fig. 23). Refer to Correcting housing face (Fig. 25). Place the indicator plunger at
Housing Bore Runout for dowel installation. the r i m of the housing bore as shown.
On diesel engines, the acceptable maximum (2) Rotate the crankshaft u n t i l the indicator
TIR for housing bore runout is 0.015 inch. How plunger is a t the 10 O'clock position on the bore.
ever, unlike gas engines, offset dowels are not Then zero the dial indicator.
§ - 21 CLUTCH BR
MOUNTING STUD DIAL INDICATOR (4) Subtract the lowest reading from the highest to
OR ROD determine total runout. As an example, refer to the
sample readings shown in Figure 26. If the low read
ing was minus 0.004 in. and the highest reading was
INDICATOR
PLUNGER plus 0.009 in., total runout is actually 0.013 inch.
(5) Total allowable face runout is 0.010 inch. If
runout exceeds this figure, runout will have to be
corrected. Refer to Correcting Clutch Housing Face
Runout.
C O R R E C T I N G CLUTCH HOUSING FACE
RUNOUT (NW4500)
Housing face runout, on gas or diesel engines, can
CLUTCH
HOUSING be corrected by installing shims between the clutch
BORE J9006-26 housing and transmission (Fig. 27). The shims can be
made from shim stock or similar materials of the re
Fig. 22 Checking Clutch Housing Bom Runout quired thickness.
As an example, assume that face runout is the
.000 same as shown in Figure 26 and in step (4) above. In
+ .002 this case, three shims will be needed. Shim thick
nesses should be 0.009 in. (at the 0.000 corner), 0.012
in. (at the -0.003 corner) and 0.013 in. (at the -0.004
+ 004
corner).
After installing the clutch assembly and housing,
tighten the housing bolts nearest the alignment dow
-.001
els first.
Clutch housing preferred bolt torques are:
• 41 N-m (30 ft. lbs.) for 3/8 in. diameter bolts
CLUTCH » 68 N-m (50 ft. lbs.) for 7/16 in. diameter bolts
HOUSING
BORE
• 47 N-m (35 ft. lbs.) for V10 and diesel clutch hous
(SAMPLE READINGS) J9Q06-27
CIRCLE ing bolts
Fig. 23 Housing Bore Measurement Points And
Sample Readings
SLOT SHOWS DIRECTION OFFSET

OF OFFSET DOWEL
D O W E L SELECTION
TIR OPFSET D O W E L
VALUE KiWiHiD
0.011 -0.021 inch 0.007 inch
0.022 - 0.035 inch 0.014 inch
0.036 - 0.052 inch 0.021 inch
J9206-7
Fig. 24 Housing Bore Alignment Dowel Selection

(3) Measure and record face runout at four points
90° apart around the housing face (Fig. 26). Perform
the measurement at least twice for accuracy.
BR CLUTCH 6 - 21
During final transmission installation, install the CUT/DRILL

shims between the clutch housing and transmission iOLT
HOLE
at the appropriate bolt locations. TO SIZE
DIAL INDICATOR SHIM
INDICATOR
CLUTCH STOCK
PLUNGE! HOUSING
FACE
MAKE SHIM
1-INCH
DIAMETER J9006-31
Fig. 27 Housing Face Alignment Shims

INDICATOR MOUNTING
1
^
STUD OR ROD J90G6-29
Fig. 25 Measuring Clutch Housing Face Runout
(AT RIM
OF BORE) J9006-30
Fig. 26 Housing Face Measurement Points And

Sample Readings
BR COOLING SYSTEM 7-1
COOLING SYSTEM
CONTENTS
page page
AUTOMATIC TRANSMISSION OIL COOLERS .. 50 ENGINE BLOCK HEATERS 61

DIAGNOSIS 4 SERVICE PROCEDURES 18
ENGINE ACCESSORY DRIVE BELTS 54 SPECIFICATIONS 63
GENERAL INFORMATION • Thermal viscous fan drive

Throughout this group, references are made to par • Fan shroud
ticular vehicle models by alphabetical designation or © Radiator pressure cap
by the particular vehicle nameplate. A chart showing • Thermostat
a breakdown of alphabetical designations is included • Coolant reserve/overflow system
in the Introduction section at the beginning of this • Transmission oil cooler (automatic transmission)
manual. © Coolant
All vehicles are equipped with either a 3.9L V-6 en • Water pump (to circulate coolant)
gine, a 5.2L V-8 engine, two different 5.9L V-8 en © Hoses and hose clamps
gines, an 8.0L V-10 engine or a 5.9L Cummins in-line Typical coolant flow circuits for gas powered , en
6 cylinder diesel engine. gines are shown in figure 1.
The 3.9L V-6 and 5.2L V-8 engines will be referred
to in this Cooling group as: LDC (Light Duty Cycle) COOLING S f S T E i C01P01E1TS—DIESEL
engines. The 5.9L V-8 gas powered engine will be re ENGINE
ferred to as either: LDC (Light Duty Cycle) or HDC Coolant flow circuits for the 5.9L diesel engine are
(Heavy Duty Cycle) engine. The 8.0L V-10 engine will
shown in figure 2.
be referred to as: HDC (Heavy Duty Cycle) engine.
Either of the HDC gas powered engines can be eas The diesel cooling system consists of: a cross-flow
ily identified by the use of an engine mounted air in radiator, engine driven cooling fan, thermal viscous
jection pump. The 3.9L V-6, 5.2/5.9L V-8 LDC gas fan drive, fan shroud, radiator pressure cap, thermo
engines or the diesel engine will not use an air injec stat, a vertically mounted one-way check valve (jiggle
tion pump. pin) at cylinder head, a bypass hose at thermostat,
coolant reserve/overflow system, transmission oil
COOLING SYSTEM cooler (if equipped with an automatic transmission),
The cooling system regulates engine operating tem coolant, water pump, hoses and hose clamps.
perature. It allows the engine to reach normal oper Coolant is drawn from radiator into the water
ating temperature as quickly as possible. It also pump. Water pump output is directed to the engine
maintains normal operating temperature and pre oil cooler cavity of the cylinder block (Fig. 3).
vents overheating. From the oil cooler cavity, the coolant circulates
The cooling system also provides a means of heat around each cylinder. It then crosses to the transfer
ing the passenger compartment and cooling the auto (lift) pump side of the engine where it flows up into
matic transmission fluid (if equipped). The cooling the cylinder head through openings in top of the cyl
system is pressurized and uses a centrifugal water inder block (Fig. 3). Coolant flows past the valve
pump on all engines to circulate coolant throughout bridges (Fig. 4), to exhaust manifold side of engine
the system. and to thermostat. As coolant flows toward the ther
An optional factory installed maximum duty cool mostat, it provides cooling for the injector nozzle.
ing package is available for some engines on most Also refer to Thermostat Operation—5.9L Diesel
models. This package will provide additional cooling Engine. This can be found in the Thermostat section
capacity for vehicles used under extreme conditions of this group.
such as trailer towing in high ambient temperatures.
COOLING SYSTEM COMPONENTS—ALL EXCEPT
DIESEL ENGINE
The cooling system consists of:
• A cross-flow radiator
7 -2 COOLING S f S T E i — ~ — — — — BR
THERMOSTAT OPEN—LOW FLOW J9407-1

Fig. 1 Typical Cooling System Flow—Gas Powered Engines
Fig. 2 Typical Cooling System Flow—Diesel Powered Engine

BR COOLING SYSTEM 7-3
Fig. 3 Cylinder Block Coolant Routing—Diesel

Engine
7 -4 COOLING SYSTEM DIAGNOSIS mm
DIAGNOSIS
INDEX
page page
DRB Scan Tool 5 Preliminary Checks 5

On-Board Diagnostics (OBD) 4
ON-BOARD DIAGNOSTICS (OBD) It is possible that a DTC for a monitored circuit

may not be entered into memory even though a mal
FOR CERTAIN COOLING SYSTEM function has occurred. Refer to On-Board Diagnostics
COMPONENTS (OBD) in Group 14, Fuel Systems for additional in
The powertrain control module (PCM) has been formation.
programmed to monitor certain cooling system com
ponents on gasoline powered engines only: ACCESSING DIAGNOSTIC TROUBLE CODES
• If the engine has remained cool for too long a pe A stored Diagnostic Trouble Code (DTC) can be dis
riod, such as with a stuck open thermostat, a Diag played by cycling the ignition key On-Off-On-Off-On
nostic Trouble Code (DTC) number 17 can be within three seconds and observing the malfunction
observed at the malfunction indicator lamp. This indicator lamp. This lamp is displayed on the instru
lamp is displayed on the instrument panel as the ment panel as the CHECK ENGINE lamp (Fig. 5).
CHECK ENGINE lamp (Fig. 5). DTC number 17 is They can also be displayed through the use of the
not used with diesel powered engines. Diagnostic Readout Box (DRB) scan tool. The DRB
connects to the data link connector in the engine
compartment (Fig. 6). For operation of the DRB, refer
to the appropriate Powertrain Diagnostic Procedures
service manual.
Fig. 5 Check Engine Lamp Location

If the problem is sensed in a monitored circuit of POWERTRAIN CONTROL
ten enough to indicate an actual problem, a DTC is MODULE (PCM) J9414-11
stored. The DTC will be stored in the PCM memory
Fig. 6 PCM and Data Link Connector—Typical
for eventual display to the service technician. If the
problem is repaired or ceases to exist, the PCM can EXAMPLES:
cels the DTC after 51 engine starts. • If the lamp (Fig. 5) flashes 1 time, pauses and
Certain criteria must be met for a DTC to be en flashes 2 more times, a flashing Diagnostic Trouble
tered into PCM memory. The criteria may be a spe Code (DTC) number 12 is indicated. If this code is
cific range of engine rpm, engine temperature and/or observed, it is indicating that the battery has been
input voltage to the PCM. disconnected within the last 50 key-on cycles. It
A DTC indicates that the PCM has recognized an could also indicate that battery voltage has been dis
abnormal signal in a circuit or the system. A DTC connected to the PCM. In either case, other DTC's
may indicate the result of a failure, but never iden may have been erased.
tify the failed component directly.
BR COOLING SYSTEM DIAGNOSIS 7-5
• If the lamp flashes 1 time,, pauses and flashes 7 • Increasing engine speed for more air flow is recom
more times, a flashing Diagnostic Trouble Code mended.
(DTC) number 17 is indicated. 2. TRAILER TOWING:
After any stored DTC information has been ob Consult Trailer Towing section of owners manual.
served, the display will end with a flashing DTC Do not exceed limits.
number 55. This will indicate the end of all stored in 3." AIR CONDITIONING; ADD-ON OR AFTER
formation. MARKET:
A maximum cooling package should have been or
E R A S I N G TROUBLE CODES
dered with vehicle if add-on or after market A/C is
After the problem has been repaired, use the DRB
scan tool to erase a DTC. Refer to the appropriate installed. If not, maximum cooling system compo
Powertrain Diagnostic Procedures service manual for nents should be installed for model involved per
operation of the DRB scan tool. manufacturer's specifications.
4. RECENT SERVICE OR ACCIDENT REPAIR:
DRB SCAN TOOL Determine if any recent service has been performed
For operation of the DRB scan tool, refer to the ap on vehicle that may effect cooling system. This may
propriate Powertrain Diagnostic Procedures service be:
manual. • Engine adjustments (incorrect ignition timing)
• Slipping engine accessory drive belt(s)
PRELIMINARY CHECKS • Brakes (possibly dragging)
• Changed parts. Incorrect water pump or pump ro
E N G f f f E COOLING SYSTEM OVERHEATING tating in wrong direction due to belt not correctly
Establish what driving conditions caused the com routed
plaint. Abnormal loads on the cooling system such as • Reconditioned radiator or cooling system refilling
the following may be the cause: (possibly under filled or air trapped in system).
1. PROLONGED IDLE, VERY HIGH AMBIENT If investigation reveals none of the previous
TEMPERATURE, SLIGHT TAIL WIND AT IDLE, items as a cause for an engine overheating com
SLOW TRAFFIC, TRAFFIC JAMS, HIGH SPEED plaint, refer to following Cooling System Diag
OR STEEP GRADES. nosis charts.
Driving techniques that avoid overheating are:
These charts are to be used as a quick-reference
• Idle with A/C off when temperature gauge is at
end of normal range. only. Refer to the group text for information.
7-6 COOLING SYSTEM DIAGNOSIS BR
COOLING SYSTEM DIAGNOSIS—ALL EXCEPT DIESEL
TEMPERATURE GAUGE 1. Has a Diagnostic Trouble 1. Refer to On-Board Diagnostics in the

READS LOW Code (DTC) number 17 been service manual text. Replace thermostat
set indicating a stuck open if necessary. If a Diagnostic Trouble
engine thermostat? Code (DTC) number 17 has not been set,
the problem may be with the temperature
gauge.
2. Is the temperature gauge 2. Check the engine temperature sensor
(if equipped) connected to the connector in the engine compartment.
temperature gauge coolant Refer to Group 8E. Repair as necessary.
sensor on the engine?
3. Is the temperature gauge 3. Check gauge operation. Refer to
(if equipped) operating OK? Group 8E. Repair as necessary.
4. Coolant level low in cold 4. Check coolant level in the coolant
ambient temperatures reserve/overflow tank and the radiator.
accompanied with poor heater Inspect system for leaks. Repair leaks as
performance. necessary. Refer to the Coolant section
of the manual text for WARNINGS and
precautions before removing the radiator
cap.
5. Improper operation of internal 5. Inspect heater and repair as necessary.
heater doors or heater Refer to Group 24, Heating and Air
controls. Conditioning for procedures.
TEMPERATURE G A U G E 1. Trailer is being towed, a steep hill 1. This may be a temporary condition and
READS HIGH OR ENGINE is being climbed, vehicle is repair is not necessary. Turn off the air
COOLANT WARNING LAMP operated in slow moving traffic, conditioning and attempt to drive the vehicle
ILLUMINATES. COOLANT or engine is being idled with very without any of the previous conditions.
MAY OR MAY NOT B E high ambient (outside) Observe the temperature gauge. The gauge
LOST OR LEAKING FROM temperatures and the air should return to the normal range. If the
COOLING SYSTEM conditioning is on. Higher gauge does not return to normal range,
altitudes could aggravate these determine the cause for overheating and
conditions. repair. Refer to POSSIBLE CAUSES
(numbers 2 through 20).
2. Is temperature gauge 2. Check gauge. Refer to Group 8E. Repair as
(if equipped) reading correctly? necessary.
3. Is temperature warning lamp 3. Check warning lamp operation. Refer to
(if equipped) illuminating Group 8E. Repair as necessary.
unnecessarily? .
4. Coolant low in coolant 4. Check for coolant leaks and repair as
reserve/overflow tank and necessary. Refer to Testing Cooling System
radiator? For Leaks in this group.
5. Pressure cap not installed tightly. 5. Tighten cap.
If cap is loose, boiling point of
coolant will be lowered. Also refer
to the following step 6.
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.
J9507-41
BR COOLING SYSTEM DIAGNOSIS 7 -7
COOLING SYSTEM DIAGNOSIS—ALL EXCEPT DIESEL—CONTINUED
CONDITION POSSIBLE C A U S E S CORRECTION
T E M P E R A T U R E GAUGE 7. Coolant level low in radiator but 7. (a) Check condition of radiator cap and cap
READS HIGH OR ENGINE not in coolant reserve/overflow seals. Refer to Radiator Cap in this
COOLANT WARNING LAMP tank. This means the radiator is group. Replace cap if necessary.
ILLUMINATES. COOLANT not drawing coolant from the (b) Check condition of radiator filler neck. If
MAY OR MAY NOT B E LOST coolant reserve/overflow tank as neck is bent or damaged, replace
OR LEAKING FROM the engine cools. As the engine radiator.
COOLING S Y S T E M - CONT. cools, a vacuum is formed in the
cooling system of the engine and (c) Check the condition of the hose from the
radiator. If radiator cap seals are radiator to the coolant tank. It should fit
defective, or cooling system has tight at both ends without any kinks or
leaks, a vacuum can not be tears. Replace hose if necessary.
formed. (d) Check coolant reserve/overflow tank and
tank hoses for blockage. Repair as
necessary.
8. Freeze point of antifreeze not 8. Check antifreeze. Refer to Coolant section
correct. Mixture may be too rich. of this group. Adjust antifreeze-to-water
ratio as required.
9. Coolant not flowing through 9. Check for coolant flow at radiator filler neck
system. 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 10. Clean insects or debris. Refer to Radiator
are dirty or clogged. Cleaning in this group.
11. Radiator core is corroded or 11. Have radiator re-cored or replaced.
plugged.
12. Aftermarket A/C installed without 12. Install proper radiator.
proper radiator.
13. Fuel or ignition system problems. 13. 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.
14. Dragging brakes. 14. Check and correct as necessary. Refer to
Group 5, Brakes in the manual text.
15. Bug screen is being used 15. Remove bug screen.
reducing airflow.
16. Thermostat partially or completely 16. Check thermostat operation and replace
shut. This is more prevalent on as necessary. Refer to Thermostats in this
high mileage vehicles. group.
17. Thermal viscous fan drive not 17. Check fan drive operation and replace if
operating properly. necessary. Refer to Viscous Fan Drive in
this group.
18. Cylinder head gasket leaking. 18. Check for cylinder head gasket leaks.
Refer to Testing Cooling System For
Leaks in this group. For repair, refer to
Group 9, Engines.
19. Heater core leaking. 19. Check heater core for leaks. Refer to
Group 24, Heating and Air Conditioning.
Repair as necessary.
J9507-50
7 -8 COOLING SYSTEM DIAGNOSIS — —
TEMPERATURE GAUGE 1. During cold weather operation, 1. A normal condition. No correction is

READING IS INCONSISTENT with the heater blower in the high necessary.
(FLUCTUATES, CYCLES OR position, the gauge reading may
IS ERRATIC) drop slightly.
2. Temperature gauge or engine 2. Check operation of gauge and repair if
mounted gauge sensor defective necessary. Refer to Group 8E, Instrument
or shorted. Also, corroded or Panel And Gauges.
loose wiring in this circuit.
3. Gauge reading rises when vehicle 3. A normal condition. No correction is
is brought to a stop after heavy necessary. Gauge reading should return to
use (engine still running). normal range after vehicle is driven.
4. Gauge reading high after re 4. A normal condition. No correction is
starting a warmed-up (hot) necessary. The gauge should return to
engine. normal range after a few minutes of engine
operation.
5. Coolant level low in radiator (air 5. Check and correct coolant leaks. Refer to
will build up in the cooling system Testing Cooling System For Leaks in this
causing the thermostat to open group.
late).
6. Cylinder head gasket leaking 6. (a) Check for cylinder head gasket leaks
allowing exhaust gas to enter with a commercially available Block
cooling system causing Leak Tester. Repair as necessary.
thermostat to open late.
(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
7. Check water pump and replace as
shaft.
^ necessary. Refer to Water Pumps in this
group.
8. Loose accessory drive belt (water 8. Refer to Engine Accessory Drive Belts in
pump slipping). this group. Check and correct as
necessary.
9. Air leak on the suction side of 9. Locate leak and repair as necessary.
water pump allows air to build up
in cooling system causing
PRESSURE CAP IS 1. Pressure relief valve in radiator 1. Check condition of radiator cap and cap
BLOWING OFF STEAM cap is defective. seals. Refer to Radiator Caps in this
AND/OR COOLANT TO . group. Replace cap as necessary.
COOLANT TANK.
TEMPERATURE GAUGE
READING MAY BE ABOVE
NORMAL BUT NOT HIGH.
COOLANT LEVEL MAY BE
HIGH IN COOLANT
RESERVE/OVERFLOW TANK
COOLANT LOSS TO THE 1. Coolant leaks in radiator, 1. Pressure test and repair as necessary.
GROUND WITHOUT cooling system hoses, water Refer to Testing Cooling System For
PRESSURE CAP BLOWOFF. pump or engine. Leaks in this group.
GAUGE IS READING HIGH
OR HOT
J9507-51
BR — • COOLING SYSTEM DIAGNOSIS 7-9
DETONATION OR P R E - 1. Engine overheating. 1. Check reason for overheating and repair

IGN1T10N (NOT CAUSED BY as necessary.
IGNITION SYSTEM). GAUGE 2. Freeze point of antifreeze not 2. Check antifreeze. Refer to the Coolant I
MAYOR MAY NOT BE correct. Mixture is too rich or too section of this group. Adjust antifreeze-
READING HIGH lean. to-water ratio as required.
HOSE OR H O S E S 1. Vacuum created in cooling 1. (a) Radiator cap relief valve stuck. Refer
COLLAPSE W H E N ENGINE system on engine cool-down is to Radiator Cap in this group.
IS COOLING not being relieved through Replace if necessary.
coolant reserve/overflow (b) Hose between coolant
system. reserve/overflow tank and radiator is
kinked. Repair as necessary.
(c) Vent at coolant reserve/overflow tank
is plugged. Clean vent and repair as
necessary.
(d) Reserve/overflow tank is internally
blocked or plugged. Check for
blockage and repair as necessary.
NOISY FAN 1. Fan blades.loose. 1. Replace fan blade assembly. Refer to

Cooling System Fans in this group.
2. Fan blades striking a 2. Locate point of fan blade contact and
surrounding object. repair as necessary.
3. Air obstructions at radiator or air 3. Remove obstructions and/or clean debris
conditioning condenser. or insects from radiator or A/C
condenser.
4. Thermal viscous fan drive has 4. Replace fan drive. Bearing is not
defective bearing. serviceable. Refer to Viscous Fan Drive
in this group.
5. A certain amount of fan noise 5. Refer to Viscous Fan Drive in this group
(roaring) may be evident on for an explanation of normal fan noise.
models equipped with a thermal
viscous fan drive. Some of this
noise is normal.
INADEQUATE AIR 1. Radiator and/or A/C condenser is 1. Remove restriction and/or clean as
CONDITIONER restricted, obstructed or dirty necessary. Refer to Radiator Cleaning in
PERFORMANCE (COOLING (insects, leaves etc.). this group.
SYSTEM SUSPECTED) 2. Thermal viscous fan drive is free 2. Refer to Viscous Fan Drive for diagnosis.
wheeling. Repair as necessary.
3. Engine is overheating (heat may 3. Correct overheating condition. Refer to
be transferred from radiator to text in Group 7, Cooling.
A/C condenser. High underhood
temperatures due to engine
overheating may also transfer
heat to A/C components).
4. Some models with certain 4. Check for missing or damaged air seals
engines are equipped with air and repair as necessary.
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.
J9507-52
7 - 10 COOLING SYSTEM DIAGNOSIS BR
CONDITION POSSIBLE CAUSES ORRECTION
INADEQUATE HEATER 1. Has a diagnostic trouble code 1. Refer to On-Board Diagnostics in the
PERFORMANCE. (DTC) number 17 been set? manual text and replace thermostat if
THERMOSTAT FAILED IN necessary.
OPEN POSITION 2. Coolant level low. 2. Refer to Testing Cooling System For
Leaks in the manual text. Repair as
necessary.
3. Obstructions in heater hose 3. Remove heater hoses at both ends and
fittings at engine. check for obstructions. Repair as
necessary.
4. Heater hose kinked. 4. Locate kinked area and repair as
necessary.
5. Some models with certain 5. Refer to Group 24, Heating and Air
engines are equipped with a Conditioning for diagnosis. Repair as
water control valve located on necessary.
one of the heater hoses. This
valve may be defective.
6. Water pump is not pumping 6. Refer to Water Pumps in this group.
water to heater core. When the Repair as necessary. If a slipping belt is
engine is fully warmed up, both detected, refer to Engine Accessory Drive
heater hoses should be hot to Belts in this group. Repair as necessary.
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.
HEAT ODOR 1. Various heat shields are used at 1. Locate missing shields and replace or
certain drive line components. repair as necessary.
One or more of these shields
may be missing.
2. Is temperature gauge reading 2. Refer to the previous Temperature
above the normal range? Gauge Reads High in these Diagnosis
Charts. Repair as necessary.
3. Is cooling fan operating 3. Refer to Cooling System Fan in this
correctly? group for diagnosis. Repair as necessary.
4. Has undercoating been applied 4. Clean undercoating as necessary.
to any unnecessary component?
5. Engine may be running rich 5. Refer to the DRB scan tool and the
causing the catalytic converter appropriate Powertrain Diagnostic
to overheat. Procedures service manual. Repair as
necessary.
POOR DRIVEABILITY 1. For proper driveability, good 1. Refer to On-Board Diagnostics in this
(THERMOSTAT POSSIBLY vehicle emissions and for group. DTC's may also be checked using
STUCK OPEN). GAUGE preventing build-up of engine oil the DRB scan tool. Refer to the proper
MAY BE READING LOW sludge, the thermostat must be Powertrain Diagnostics Procedures
. operating properly. Has a service manual for checking the
diagnostic trouble code (DTC) thermostat using the DRB scan tool.
number 17 been set? Replace thermostat if necessary.
J9507-53
— — COOLING SYSTEM DIAGNOSIS 7-11
Condition Possible Causes Correction
STEAM IS COMING FROM 1. During wet weather, moisture 1. Occasional steam emitting from this
FRONT OF VEHICLE NEAR (snow, ice or rain condensation) area is normal. No repair is necessary.
GRILL AREA W H E N on the radiator will evaporate
WEATHER IS WET, ENGINE when the thermostat opens.
IS WARMED UP AND This opening allows heated
RUNNING, AND VEHICLE IS water into the radiator. When
STATIONARY. the moisture contacts the hot
TEMPERATURE GAUGE IS radiator, steam may be emitted.
IN NORMAL RANGE This usually occurs in cold
weather with no fan or airflow
to blow it away.
COOLANT COLOR 1. Coolant color is not necessarily 1. Refer to Coolant in this group for
an indication of adequate antifreeze tests. Adjust antifreeze-to-
corrosion or temperature water ratio as necessary.
protection. Do not rely on
coolant color for determining
condition of coolant.
COOLANT LEVEL CHANGES ' 1. Level changes are to be 1. A normal condition. No repair is
IN COOLANT RESERVE/ expected as coolant volume necessary.
OVERFLOW TANK. fluctuates with engine
TEMPERATURE GAUGE temperature. If the level in the
IS IN NORMAL RANGE tank was between the FULL
and ADD marks at normal
engine operating temperature,
the level should return to
within that range after operation I
at elevated temperatures.
J9507-55
7 -12 COOLING SYSTEM DIAGNOSIS • — -— BR
COOLING SYSTEM DIAGNOSIS—DIESEL ENGINE
TEMPERATURE GAUGE 1. Diesel engines, due to their 1. The low gauge reading may be normal.
READS LOW inherent efficiency are slower Refer to thermostats in the manual text
to warm up than gasoline for information. See Thermostat
powered engines, and will Diagnosis - Diesel Engine.
operate at lower temperatures
when the vehicle is unloaded.
2. Is the temperature gauge 2. Check the engine temperature sensor
connected to the temperature connector in the engine compartment.
gauge coolant sensor on the Refer to Group 8E. Repair as necessary.
engine?
3. Is the temperature gauge 3. Check gauge operation. Refer to
operating OK? Group 8E. Repair as necessary.
4. Coolant level low in cold 4. Check coolant level in the coolant
ambient temperatures reserve/overflow tank and the radiator.
accompanied with poor heater Inspect system for leaks. Repair leaks as
performance. necessary. Refer to the Coolant section
of the manual text for WARNINGS and
precautions before removing the radiator
cap.
5. Improper operation of internal 5. Inspect heater and repair as necessary.
heater doors or heater Refer to Group 24, Heating and Air
controls. Conditioning for procedures.
TEMPERATURE GAUGE 1. Trailer is being towed, a steep hill 1. This may be a temporary condition and
READS HIGH. COOLANT is being climbed, vehicle is repair is not necessary. Turn off the air
MAY OR MAY NOT B E operated in slow moving traffic, conditioning and attempt to drive the vehicle
LOST OR LEAKING FROM or engine is being idled with very without any of the previous conditions.
COOLING SYSTEM high ambient (outside) Observe the temperature gauge. The gauge
temperatures and the air should return to the normal range. If the
conditioning is on. Higher gauge does not return to normal range,
altitudes could aggravate these determine the cause for overheating and
conditions. repair. Refer to POSSIBLE CAUSES
(numbers 2 through 17).
2. Is temperature gauge 2. Check gauge. Refer to Group 8E. Repair as
reading correctly? necessary.
3. Coolant low in coolant 3. Check for coolant leaks and repair as
reserve/overflow tank and necessary. Refer to Testing Cooling System
radiator? For Leaks in this group.
4. Pressure cap not installed tightly. 4. Tighten cap.
If cap is loose, boiling point of
coolant will be lowered. Also refer
to the following step 5.
5. Poor seals at radiator cap. 5. (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.
J9507-57
BR COOLING SYSTEM DIAGNOSIS 7 -13
COOLING SYSTEM DIAGNOSIS—DIESEL ENGINE—CONTINUED
T E M P E R A T U R E GAUGE 6. Coolant level low in radiator but 6. (a) Check condition of radiator cap and cap
READS HIGH. COOLANT not in coolant reserve/overflow seals. Refer to Radiator Cap in this
MAY OR MAY NOT BE LOST tank. This means the radiator is group. Replace cap if necessary.
OR LEAKING FROM not drawing coolant from the (b) Check condition of radiator filler neck. If
COOLING S Y S T E M - CONT. coolant reserve/overflow tank as neck is bent or damaged, replace
the engine cools. As the engine radiator.
cools, a vacuum is formed in the
cooling system of the engine and (c) Check the condition of the hose from
radiator. If radiator cap seals are the radiator to the coolant tank. It should
defective, or cooling system has fit tight at both ends without any kinks or
leaks, a vacuum can not be tears. Replace hose if necessary.
formed. (d) Check coolant reserve/overflow tank
and tank hoses for blockage. Repair as
necessary.
7. Freeze point of antifreeze not * 7. Check antifreeze. Refer to Coolant section
correct. Mixture may be too rich. of this group. Adjust antifreeze-to-water
ratio as required.
8. Coolant not flowing through 8. Check for coolant flow at radiator filler neck
system. 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.
9. Radiator or A/C condenser fins 9. Clean insects or debris. Refer to Radiator

are dirty or clogged. Cleaning in this group.
10. Radiator core is corroded or 10. Have radiator re-cored or replaced.
plugged.
11. Aftermarket A/C installed without 11. Install proper radiator.
' proper radiator.
12. Dragging brakes. 12. Check and correct as necessary. Refer to
Group 5, Brakes in the manual text.
13. Bug screen is being used 13. Remove bug screen.
reducing airflow.
14. Thermostat partially or completely 14. Check thermostat operation and replace
shut. This is more prevalent on as necessary. Refer to Thermostats in this
high mileage vehicles. group.
15. Thermal viscous fan drive not 15. Check fan drive operation and replace if
operating properly. necessary. Refer to Viscous Fan Drive in
this group.
16. Cylinder head gasket leaking. 16. Check for cylinder head gasket leaks.
Refer to Testing Cooling System For
Leaks in this group. For repair, refer to
Group 9, Engines.
17. Heater core leaking. 17. Check heater core for leaks. Refer to
Group 24, Heating and Air Conditioning.
Repair as necessary.
J9507-58
7 -14 COOLING SYSTEM DIAGNOSIS BR
TEMPERATURE GAUGE 1. During cold weather operation, 1. A normal condition. No correction is

READING IS INCONSISTENT with the heater blower in the high necessary.
(FLUCTUATES, CYCLES OR position, the gauge reading may
IS ERRATIC) drop slightly. Fluctuation is also
influenced by loads, outside
temperature and extended idle
time with diesel engines.
2. Temperature gauge or engine 2. Check operation of gauge and repair if
mounted gauge sensor defective necessary. Refer to Group 8E, Instrument
or shorted. Also, corroded or Panel And Gauges.
loose wiring in this circuit.
3. Gauge reading rises when vehicle 3. A normal condition. No correction is
is brought to a stop after heavy necessary. Gauge reading should return to
use (engine still running). normal range after vehicle is driven.
4. Gauge reading high after re 4. A normal condition. No correction is
starting a warmed-up (hot) necessary. The gauge should return to
engine. normal range after a few minutes of engine
operation.
5. Coolant level low in radiator (air 5. Check and correct coolant leaks. Refer to
will build up in the cooling system Testing Cooling System For Leaks in this
causing the thermostat to open group.
late).
6. Cylinder head gasket leaking 6. (a) Check for cylinder head gasket leaks
allowing exhaust gas to enter with a commercially available Block
cooling system causing Leak Tester. Repair as necessary.
thermostat to open late. (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 7. Check water pump and replace as
shaft. necessary. Refer to Water Pumps in this
group.
8. Loose accessory drive belt (water 8. Refer to Engine Accessory Drive Belts in
pump slipping). this group. Check and correct as
necessary.
9. Air leak on the suction side of 9. Locate leak and repair as necessary.
water pump allows air to build up
in cooling system causing
PRESSURE CAP IS 1. Pressure relief valve in radiator 1. Check condition of radiator cap and cap
BLOWING OFF STEAM cap is defective. seals. Refer to Radiator Caps in this
AND/OR COOLANT TO group. Replace cap as necessary.
COOLANT TANK.
TEMPERATURE GAUGE
READING MAY BE ABOVE
NORMAL BUT NOT HIGH.
COOLANT LEVEL MAY BE
HIGH IN COOLANT
RESERVE/OVERFLOW TANK
COOLANT LOSS TO THE 1. Coolant leaks in radiator, 1. Pressure test and repair as necessary.
GROUND WITHOUT PRES cooling system hoses, water Refer to Testing Cooling System For
SURE CAP BLOWOFF. GAUGE pump or engine. Leaks in this group.
IS READING HIGH OR HOT
J9507-59
BR COOLING SYSTEM DIAGNOSIS 7 15
CONDITION P O S S I B L E CAUSES CORRECTION
HOSE OR HOSES 1. Vacuum created in cooling 1. (a) Radiator cap relief valve stuck. Refer
COLLAPSE WHEN ENGINE system on engine cool-down is to Radiator Cap in this group.
IS COOLING not being relieved through Replace if necessary.
coolant reserve/overflow (b) Hose between coolant
system. reserve/overflow tank and radiator _
kinked. Repair as necessary.
(c) Vent at coolant reserve/overflow tank
is plugged. Clean vent and repair as
necessary.
(d) Reserve/overflow tank is internally
blocked or plugged. Check for
blockage and repair as necessary.
NOISY FAN 1. Fan blades loose. 1. Replace fan blade assembly. Refer to
Cooling System Fans in this group.
2. Fan blades striking a 2. Locate point of fan blade contact and
surrounding object. repair as necessary.
3. Air obstructions at radiator or air 3. Remove obstructions and/or clean debris
conditioning condenser. or insects from radiator or A/C
condenser.
4. Thermal viscous fan drive has 4. Replace fan drive. Bearing is not
defective bearing. serviceable. Refer to Viscous Fan Drive
in this group.
5. A certain amount of fan noise 5. Refer to Viscous Fan Drive in this group
(roaring) may be evident on for an explanation of normal fan noise.
models equipped with a thermal
viscous fan drive. Some of this
noise is normal.
INADEQUATE AIR 1. Radiator and/or A/C condenser is 1. Remove restriction and/or clean as
CONDITIONER restricted, obstructed or dirty necessary. Refer to Radiator Cleaning in
PERFORMANCE (COOLING (insects, leaves etc.). this group.
SYSTEM SUSPECTED) 2. Thermal viscous fan drive is free 2. Refer to Viscous Fan Drive for diagnosis.
wheeling. Repair as necessary.
3. Engine is overheating (heat may 3. Correct overheating condition. Refer to
be transferred from radiator to text in Group 7, Cooling.
A/C condenser. High underhood
temperatures due to engine
overheating may also transfer
heat to A/C components).
4. Some models with certain 4. Check for missing or damaged air seals
engines are equipped with air and repair as necessary.
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.
J9507-60
7 -16 COOLING SYSTEM DIAGNOSIS — — — — BR
INADEQUATE HEATER 1. Diesel engines, due to their 1. The low gauge reading may be normal.
PERFORMANCE. MAY B E inherent efficiency are slower to Refer to Thermostats in the manual text
ACCOMPANIED B Y LOW warm up than gasoline powered for information. See Thermostat
GAUGE READING engines, and will operate at Diagnosis - Diesel Engine.
lower temperatures when the
vehicle is unloaded.
2. Coolant level low. 2. Refer to Testing Cooling System For
Leaks in the manual text. Repair as
necessary.
3. Obstructions in heater hose 3. Remove heater hoses at both ends and
fittings at engine. check for obstructions. Repair as
necessary.
4. Heater hose kinked. 4. Locate kinked area and repair as
necessary.
5. Water pump is not pumping 5. Refer to Water Pumps in this group.
water to heater core. When the Repair as necessary. If a slipping belt is
engine is fully warmed up, both detected, refer to Engine Accessory Drive
heater hoses should be hot to Belts in this group. Repair as necessary
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.
HEAT ODOR 1. Various heat shields are used at 1. Locate missing shields and replace or
certain drive line components. repair as necessary.
One or more of these shields
may be missing.
2. Is temperature gauge reading 2. Refer to the previous Temperature
above the normal range? Gauge Reads High in these Diagnosis
Charts. Repair as necessary.
3. Is cooling fan operating 3. Refer to Cooling System Fan in this
correctly? group for diagnosis. Repair as necessary
4. Has undercoating been applied 4. Clean undercoating as necessary.
to any unnecessary component?
J9507-61
COOLING SYSTEM DIAGNOSIS 7 -17
Condition Possible Causes Correction
STEAM IS COMING FROM 1. During wet weather, moisture 1. Occasional steam emitting from this
FRONT OF VEHICLE NEAR (snow, ice or rain condensation) area is normal. No repair is necessar
GRILL AREA WHEN on the radiator will evaporate
WEATHER IS WET, ENGINE when the thermostat opens.
IS WARMED UP AND This opening allows heated
RUNNING, AND VEHICLE IS water into the radiator. When
STATIONARY. the moisture contacts the hot
TEMPERATURE GAUGE IS radiator, steam may be emitted.
IN NORMAL RANGE This usually occurs in cold
weather with no fan or airflow
to blow it away.
COOLANT COLOR 1. Coolant color is not necessarily 1. Refer to Coolant in this group for
an indication of adequate antifreeze tests. Adjust antifreeze-to-
corrosion or temperature water ratio as necessary.
protection. Do not rely on
coolant color for determining
condition of coolant.
COOLANT LEVEL CHANGES 1. Level changes are to be 1. A normal condition. No repair is
IN COOLANT RESERVE/ expected as coolant volume necessary.
OVERFLOW TANK. fluctuates with engine
TEMPERATURE GAUGE temperature. If the level in the
IS IN NORMAL RANGE 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.
J9507-55
7 -18 COOLING SYSTEM SERVICE PROCEDURES BR
SERVICE PROCEDURES
INDEX
page page
Coolant 37 Refilling Cooling System 38

Coolant Reserve/Overflow System 41 Testing Cooling System for Leaks 40
Cooling System Cleaning/Reverse Flushing 39 Thermostat 30
Cooling System Fan—Diesel Engine 47 Viscous Fan Drive . . . . . . . . . . . . . . . . . . . . . . . . . 48
Cooling System Fan—Gas Engines . . . . . . . . . . . . 46 Water Pump Bypass Hose . . . . . . . . . . . . . . . . . . 26
Cooling System Hoses 45 Water Pump—5.9L Diesel 25
Draining Cooling System . 38 Water Pump—8.0L V-10 Engine . . . . . . . . . . . . . . 21
Radiator Pressure Cap . 42 Water Pumps—Except Diesel and 8.0L V-10
Radiators 43 Engine 18
WATER PUMPS—EXCEPT DIESEL AND 8.0L V-10 (3) Remove windshield washer reservoir tank from
ENGINE radiator fan shroud. Refer to Group 8K, Windshield
Wiper and Washer Systems.
A centrifugal water pump circulates coolant
(4) Disconnect the coolant reserve/overflow tank-to-
through the water jackets, passages, intake manifold, radiator hose at the tank.
radiator core, cooling system hoses and heater core. (5) Remove the four fan shroud mounting bolts at
The pump is driven from the engine crankshaft by a the radiator (Fig. 1). Do not attempt to remove
drive belt. shroud from vehicle at this time.
The water pump impeller is pressed onto the rear
of a shaft that rotates in a bearing pressed into the RADIATOR
water pump body. The body has a small hole for ven
tilation. The water pump seals are lubricated by an
tifreeze in the coolant mixture. Additional lubrication
is not necessary.
A quick test to determine if pump is working is to
check if heater warms properly. P. defective water
pump will not be able to circulate heated coolant
through the long heater hose to the heater core.
MEMOWAl
The water pump on all models can be removed
without discharging the air conditioning system (if
equipped).
The water pump on all gas powered engines is
bolted directly to the engine timing chain case/cover.
On all 3.9L/5.2L/5.9L gas powered engines, a gas
ket is used as a seal between the water pump and
timing chain case/cover.
If water pump is replaced because of bearing/shaft
damage or leaking shaft seal, the mechanical cooling FAN SHROUD MOUNTING BOLTS J9407-37
fan assembly should also be inspected. Inspect for fa
tigue cracks, loose blades or loose rivets that could Fig. 1 Typical Fan Shroud Mounting
have resulted from excessive vibration. Replace fan if W A R N I N G : CONSTANT T E N S I O N HOSE C L A M P S
any of these conditions are found. Also check condi ARE U S E D ON HOST C O O L I N G SYSTEM HOSES.
tion of the thermal viscous fan drive. Refer to Viscous W H E N R E M O V I N G OR I N S T A L L I N G , USE ONLY
Fan Drive in this group. T O O L S D E S I G N E D FOR S E R V I C I N G THIS T Y P E O F
(1) Disconnect negative battery cable from battery. CLAMP SUCH AS SPECIAL C L A M P TOOL (NUMBER
S
(2) Drain cooling system. Refer to Draining Cooling 6094) ( F I G . 2). S N A P - O N C L A M P TOOL ( N U M B E R
System in this group. H P C - 2 0 ) M A Y B E U S E D F O R L A R G E R CLAMPS. AL
Do not waste reusable coolant. If solution is clean, W A Y S W E A R S A F E T Y G L A S S E S WHEN SERVICING
drain coolant into a clean container for reuse. C O N S T A N T T E N S I O N CLAMPS.
BR COOLING SYSTEM SERWiCE PROCEDURES 7-19
CAUTION: A number or letter is stamped into the If water pump is being replaced, do not unbolt fan
tongue of constant tension clamps (Fig. 3). If re blade assembly (Fig. 4) from the thermal control fan
placement is necessary, use only an original equip drive.
ment clamp with a matching number or letter. (8) Remove fan blade/fan drive and fan shroud as
an assembly from vehicle.
(6) Remove upper radiator hose at radiator. After removing fan blade/fan drive assembly, do
not place the thermal viscous fan drive in the hori
HOSE CLAMP HOSE
TOOL 6094 zontal position. If stored horizontally, the silicone
CLAMP
fluid in the viscous drive could drain into its bearing
assembly and contaminate the bearing lubricant.
Do not remove the water pump pulley bolts at this
time.
FAN BLADE WATER WATER PUMP
ASSEMBLY PUMP
PULLEY
THREADED
NUT
J9207-36
Fig. 2 Hose Clamp Tool—Typical

TYPICAL
CONSTANT
TENSION HOSE
CLAMP
THREADED SHAFT CRANKSHAFT

(WATER PUMP HUB) PULLEY
VISCOUS FAN DRIVE

J9307-32
Fig. 4 Fan Blade and Viscous Fan Drive—Typical

(9) Remove accessory drive belt as follows: The
drive belt is equipped with a spring loaded automatic
tensioner (Figs. 5 or 6).
3.9L V-6 or 5.2/5.9L V-8 LDC-Gas Engines: Relax
the tension from the belt by rotating the tensioner
TYPICAL clockwise (as viewed from front) (Fig. 5). When all
HOSE
CLAMP
belt tension has been relaxed, remove accessory drive
NUMBER/LETTER belt.
LOCATION J9407-39 5.9L HDC-Gas Engine: Relax the tension from the
belt by rotating the tensioner counterclockwise (as
Fig. 3 Clamp Number/Letter Location viewed from front) (Fig. 6). When all belt tension has
(7) The thermal viscous fan drive is attached been relaxed, remove accessory drive belt.
(threaded) to the water pump hub shaft (Fig. 4). Re (10) Remove the four water pump pulley-to-water
move the fan/fan drive assembly from water pump by pump hub bolts (Fig. 4) and remove pulley from ve
turning the mounting nut counterclockwise (as hicle.
viewed from front). Threads on the fan drive are • (11) Remove the lower radiator hose and heater
RIGHT-HAND. A Snap-On 36 MM Fan • Wrench hose from water pump.
(number SP346 from Snap-On Cummins Diesel Tool (12) Loosen heater hose coolant return tube
Set number 2017DSP) can be used. Place a bar or mounting bolt (Figs. 7 or 8) and remove tube from
screwdriver between the water pump pulley bolts water pump. Discard the old tube o-ring.
(Fig. 4) to prevent the pulley from rotating. (13) Remove the seven water pump mounting bolts
(Fig. 9).
7 - 20 COOLING SYSTEM SERVICE PROCEDURES
Fig. 5 Beit Tensioner—3.9L V-6 or 5.2/5.9L V-8 Fig. 7 Coolant Return Tube—3.91 V-6 or 5.2/5.9L V-8
LDG-Gas Engines LBG-Gas Engines
Fig. 6 Belt Tensioner—5.9L HDC-Gas Engine Fig. 8 Coolant Return Tube—5.9L HDC-Gas Engine
(14) Loosen the clamp at the water pump end of INSPECTION
bypass hose (Fig. 4). Slip the bypass hose from the Replace water pump assembly if it has any of the
water pump while removing pump from vehicle. Do following conditions:
not remove the clamp from the bypass hose. • The body is cracked or damaged
(15) Discard old gasket. • Water leaks from the shaft seal. This is evident by
traces of coolant below the vent hole
CAUTION: Do not pry the water pump at timing • Loose or rough turning bearing. Also inspect ther
chain case/cover. The machined surfaces may be mal fan drive
damaged resulting in leaks. • Impeller rubs either the pump body or timing
chain case/cover
BR COOLING SYSTEM SERVICE PROCEDURES 7 - 21
Fig. 9 Water Pump Bolts—3.9L V-6 or 5.2/5.9L V-8

Gas Engines—Typical
INSTALLATION
(1) Clean gasket mating surfaces. *IF VEHICLE IS NOT EQUIPPED WITH POWER
(2) Using a new gasket, install water pump to en STEERING, THIS WILL BE AN IDLER PULLEY. J9307-26
gine as follows: Guide water pump nipple into bypass Fig. 10 Belt Routing—3.9L V-6 or 5.2/5.9L V-8
hose as pump is being installed. Install water pump LDC-Gas Engines
bolts (Fig. 9). Tighten water pump mounting bolts to
40 N-m (30 ft. lbs.) torque. AUTOMATIC
(3) Position bypass hose clamp to bypass hose. TENSIONER
(4) Spin water pump to be sure that pump impeller
does not rub against timing chain case/cover.
(5) Install a new o-ring to the heater hose coolant
return tube (Figs. 7 or 8). Coat the new o-ring with
antifreeze before installation.
(6) Install coolant return tube and its mounting
bolt to engine (Figs. 7 or 8). Be sure the slot in tube
bracket is bottomed to mounting bolt. This will prop
erly position return tube.
(7) Connect radiator lower hose to water pump.
(8) Connect heater hose and hose clamp to coolant
return tube.
(9) Install water pump pulley. Tighten bolts to 27
N-m (20 ft. lbs.) torque. Place a bar or screwdriver
between water pump pulley bolts (Fig. 4) to prevent
pulley from rotating.
(10) Relax tension from automatic belt tensioner
(Figs. 5 or 6). Install drive belt. J9307-55
CAUTION: When installing the serpentine accessory Fig. 11 Belt Routing—5.9L HDC-Gas Engine—With
drive belt, belt must be routed correctly. If not, en A/C
gine may overheat due to water pump rotating in (14) Fill cooling system. Refer to Refilling Cooling
wrong direction. Refer to (Figs. 10, 11 or 12) for cor System in this group.
rect belt routing. The correct belt with correct (15) Connect negative battery cable.
length must be used. (16) Start and warm the engine. Check for leaks.
(11) Position fan shroud and fan blade/viscous fan
WATER PUMP—8.0L V-10 ENGINE
drive assembly to vehicle as a complete unit.
(12) Install fan shroud. A centrifugal water pump circulates coolant
(13) Install fan blade/viscous fan drive assembly to through the water jackets, passages, intake manifold,
water pump shaft.
7 - 22 COOLING SYSTEM SERVICE PROCEDURES BR
AUTOMATIC (2) Drain cooling system. Refer to Draining Cooling

TENSIONER System in this group.
Do not waste reusable coolant. If solution is clean,
drain coolant into a clean container for reuse.
(3) Remove windshield washer reservoir tank from
radiator fan shroud. Refer to Group 8K, Windshield
Wiper and Washer Systems.
(4) Remove the four fan shroud mounting bolts at
the radiator (Fig. 13). Do not attempt to remove
shroud from vehicle at this time.
RADIATOR
J9307-56
Fig. 12 Belt Routing—5.9L HDC-Gas Engine—

Without A/C
radiator core, cooling system hoses and heater core.
The pump is driven from the engine crankshaft by a
drive belt.
The water pump impeller is pressed onto the rear
of a shaft that rotates in a bearing pressed into the
water pump body. The body has a small hole for ven
tilation. The water pump seals are lubricated by an
FAN SHROUD MOUNTING BOLTS J9407-37
tifreeze in the coolant mixture. Additional lubrication
is not necessary. Fig. 13 Typical Fan Shroud Mounting
A quick test to determine if pump is working is to
check if heater warms properly. A * defective water WARNING: CONSTANT TENSION HOSE CLAMPS
ARE USED ON MOST COOLING SYSTEM HOSES.
pump will not be able to circulate heated coolant
through the long heater hose to the heater core. WHEN REMOVING OR INSTALLING, USE ONLY
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
REMOWAL CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER
The water pump on all models can be removed 6094) (FIG. 14). SNAP-ON CLAMP TOOL (NUMBER
without discharging the air conditioning system (if HPC-20) MAY BE USED FOR LARGER CLAMPS. AL
equipped). WAYS WEAR SAFETY GLASSES WHEN SERVICING
The water pump on all gas powered engines is CONSTANT TENSION CLAMPS.
bolted directly to the engine timing chain case/cover.
On the 8.0L V-10 engine, a rubber o-ring (instead CAUTION: A number or letter is stamped into the
of a gasket) is used as a seal between the water tongue of constant tension clamps (Fig. 15). If re
pump and timing chain case/cover. placement is necessary, use only an original equip
If water pump is replaced because of bearing/shaft ment clamp with a matching number or letter.
damage or leaking shaft seal, the mechanical cooling
fan assembly should also be inspected. Inspect for fa (5) Remove upper radiator hose at radiator.
tigue cracks, loose blades or loose rivets that could (6) The thermal viscous fan drive is attached
have resulted from excessive vibration. Replace fan if (threaded) to the water pump hub shaft (Fig. 16). Re
any of these conditions are found. Also check condi move the fan/fan drive assembly from water pump by
tion of the thermal viscous fan drive. Refer to Viscous turning the mounting nut counterclockwise (as
Fan Drive in this group. viewed from front). Threads on the fan drive are
(1) Disconnect negative battery cable from battery. RIGHT-HAND. A Snap-On 36 MM Fan Wrench
(number SP346 from Snap-On Cummins Diesel Tool
HOSE CLAMP HOSE FAN BLADE WATER WATER PUMP
J9207-36

TYPICAL
CONSTANT
TENSION HOSE
CLAMP VISCOUS FAN DRIVE
J9307-32
Fig. 16 Fan Blade and Viscous Fan Drive—Typical

(8) Remove accessory drive belt as follows: The
drive belt is equipped with a spring loaded automatic
tensioner (Fig. 17).
Relax the tension from the belt by rotating the ten
sioner counterclockwise (as viewed from front) (Fig.
17). The threads on the pulley bolt are left-hand.
When all belt tension has been relaxed, remove ac
cessory drive belt.
TYPICAL
HOSE
CLAMP
NUMBER/LETTER
LOCATION J9407-39
Fig. 15 Clamp Number/Letter Location

Set number 2017DSP) can be used. Place a bar or
screwdriver between the water pump pulley bolts
(Fig. 16) to prevent the pulley from rotating.
If water pump is being replaced, do not unbolt fan
blade assembly (Fig. 16) from the thermal control fan
drive.
(7) Remove fan blade/fan drive and fan shroud as
an assembly from vehicle.
After removing fan blade/fan drive assembly, do
not place the thermal viscous fan drive in the hori
zontal position. If stored horizontally, the silicone
fluid in the viscous drive could drain into its bearing
assembly and contaminate the bearing lubricant.
Fig. 17 Belt Tensioner—8. OL V-10 Engine
Do not remove the water pump pulley bolts at this
time. (9) Remove the four water pump pulley-to-water
pump hub bolts (Fig. 16) and remove pulley from ve
hicle.
(10) Remove the lower radiator hose at water CAUTION: Do not pry the water pump at timing
pump. chain case/cover. The machined surfaces may be
(11) Remove heater hose at water pump fitting. damaged resulting in leaks.
(12) Remove the seven water pump mounting bolts
(Fig. 18).
(INSPECTION
Replace water pump assembly if it has any of the
following conditions:
• The body is cracked or damaged
• Water leaks from the shaft seal. This is evident by
traces of coolant below the vent hole
• Loose or rough turning bearing. Also inspect ther
mal fan drive
• Impeller rubs either the pump body or timing
chain case/cover
INSTALLATION
(1) If water pump is being replaced, install the
heater hose fitting to the pump. Tighten fitting to 16
N-m (144 in. lbs.) torque. After fitting has been
torqued, position fitting as shown in figure 20. When
positioning fitting, do not back off (rotate counter
clockwise). Use a sealant on the fitting such as Mo
par® Thread Sealant With Teflon. Refer to the
directions on the package.
J9407-19
CAUTION: This heater hose fitting must be installed
Fig. 18 Water Pump Bolts—8.0L V-10—Typical to pump before pump is installed to engine.
(13) Loosen the clamp at the water pump end of

bypass hose. Slip the bypass hose from the water
pump while removing pump from vehicle. Do not re
move the clamp from the bypass hose. HEATER
HOSE
(14) Discard the water pump-to-timing chain/case FITTING
cover o-ring seal (Fig. 19).
WATER PUMP
WATER
PUMP
<^ 1 FRONT
O-RING
SEAL
J9407-17
J9407-18
Fig. 20 Heater Hose Fitting Position—8.0L V-10
Fig. 19 Water Pump O-Ring Seal—8.0L V-10 (2) Clean the o-ring mating surfaces at rear of wa
(15) Remove the heater hose fitting from water ter pump and front of timing chain/case cover.
pump if pump replacement is necessary. Note posi (3) Apply a small amount of petroleum jelly to o-
tion (direction) of fitting before removal. Fitting must ring (Fig. 19). This will help retain o-ring to water
be re-installed to same position. pump.
en COOLING SYSTEM SERVICE PROCEDURES 7 - 25
(4) Install water pump to engine as follows: Guide AUTOMATIC

water pump fitting into bypass hose as pump is being TENSIONER
installed. Install water pump bolts (Fig. 18). Tighten
water pump mounting bolts to 40 N-m (30 ft. lbs.)
torque.
(5) Position bypass hose clamp to bypass hose.
(6) Spin water pump to be sure that pump impeller
does not rub against timing chain case/cover.
(7) Connect radiator lower hose to water pump.
(8) Connect heater hose and hose clamp to heater
hose fitting.
(9) Install water pump pulley. Tighten bolts to 22
N-m (16 ft. lbs.) torque. Place a bar or screwdriver
between water pump pulley bolts (Fig. 16) to prevent
pulley from rotating.
(10) Relax tension from automatic belt tensioner
(Fig. 17). Install drive belt.
CAUTION: When installing the serpentine accessory
drive belt, belt must be routed correctly. If not, en
J9307-56
gine may overheat due to water pump rotating in
wrong direction. Refer to (Figs. 21 or 22) for correct Fig. 22 Belt Routing—8.0L V-10 Engine—Without
belt routing. The correct belt with correct length A/C
must be used.
WATER PUMP—5.9L DIESEL
AUTOMATIC The diesel engine water pump draws coolant from
TENSIONER
radiator outlet and circulates it through engine,
heater core and back to radiator inlet. The crank
shaft pulley drives the water pump with a serpentine
drive belt (Fig. 23). An automatic belt tensioner (Fig.
23) is used to prevent the belt from slipping.
J9307-55
Fig. 21 Belt Routing—8.0L V-10 Engine—With A/C

Fig. 23 Water Pump—5.9L Diesel—Typical (non-A/C
drive assembly to vehicle as a complete unit.
shown)
(12) Install fan shroud to radiator. Tighten bolts to
6 N-m (50 in. lbs.) torque. MEMOWML
(13) Install fan blade/viscous fan drive assembly to (1) Disconnect the negative battery cables from
water pump shaft. both batteries.
(14) Fill cooling system. Refer to Refilling Cooling (2) Drain cooling system. Refer to Draining Cooling
System in this group. System in this section.
(15) Connect negative battery cable.
(16) Start and warm the engine. Check for leaks.
lit
(3) Remove the bolt retaining the wiring harness WATER PUMP BYPASS HOSE
near the top of water pump. Position wire harness to A water pump bypass hose (Fig. 26) is used be
the side. tween the intake manifold and water pump on all
(4) Remove the accessory drive belt. Refer to the gas powered engines. To test for leaks, refer to Test
Engine Accessory Drive Belt section of this group. ing Cooling System for Leaks in this group.
(5) Remove water pump mounting bolts (Fig. 24).
FAN BLADE WATER WATER PUMP
Fig, 24 Pump Removal/Installation—5.9L Diesel

(6) Clean water pump sealing surface on cylinder
block. VISCOUS FAN DRIVE
INSTALLATION J9307-32
(1) Install new o-ring seal in groove on water Fig. 26 Water Pump Bypass Hose—Typical
pump (Fig. 25).
REMOVAL—3.&L V*6 OR 5.2/5»BL ¥-8 ENGINES
WITHOUT AIR CONDITIONING
(1) Partially drain cooling system. Refer to Drain
ing Cooling System in this group.
Do not waste reusable coolant. If the solution is
clean, drain the coolant into a clean container for re
use.
WARNING: CONSTANT TENSION HOSE C L A M P S
A R E U S E D ON MOST COOLING S Y S T E M H O S E S .
W H E N REMOVING OR INSTALLING, U S E ONLY
TOOLS DESIGNED FOR SERVICING THIS T Y P E OF
CLAMP, SUCH A S S P E C I A L CLAMP TOOL (NUMBER
6094) (FIG. 27). SNAP-ON CLAMP TOOL (NUMBER
HPC-20) MAY B E U S E D FOR L A R G E R C L A M P S . AL
WAYS W E A R S A F E T Y G L A S S E S W H E N SERVICING
Fig. 25 Pump O-ring Seal—5.9L Diesel CONSTANT TENSION C L A M P S .
(2) Install water pump. Tighten mounting bolts to

24 N-m (18 ft. lbs.) torque. CAUTION: A number or letter is stamped into the
(3) Install accessory drive belt. Refer to the Engine tongue of constant tension clamps (Fig. 28). If re
Accessory Drive Belt section of this group. placement is necessary, use only an original equip
(4) Install the bolt retaining the wiring harness ment clamp with a matching number or letter.
near top of water pump.
(5) Fill cooling system. Refer to Refilling Cooling (2) Loosen both bypass hose clamps and position to
System in this section. the center of hose.
(6) Connect both battery cables. (3) Remove hose from vehicle.
(7) Start and warm the engine. Check for leaks.
BU COOLING S Y S I E 1 SERVICE PROCEDURES 7 - 27
HOSE CLAMP HOSE system is not necessary. Do not remove any refriger
ant lines from A/C compressor.
SUPPORT BRACKET (ROD)
J9207-36
GEN ERATOR/COMPRESSOR
MOUNTING BRACKET
J9307-66
Fig. 29 Generator—A/C Compressor Mounting

Bracket—Typical
WARNING: THE A/C SYSTEM IS UNDER P R E S S U R E
E V E N WITH THE ENGINE OFF. R E F E R TO R E F R I G
ERANT WARNINGS IN G R O U P 24 HEATING AND
?
AIR CONDITIONING. •
(1) Disconnect negative battery cable from battery.

(2) Partially drain cooling system. Refer to Drain
ing Cooling System in this group.
TYPICAL
HOSE Do not waste reusable coolant. If the solution is
CLAMP clean, drain the coolant into a clean container for re
NUMBER/LETTER use.
LOCATION J9407-39
(3) Remove upper radiator hose clamp at radiator.
Fig, 28 Clamp Number/Letter Location A special clamp tool (Fig. 27) must be used to remove
the constant tension clamps. Remove hose at radia
INSTALLATION tor.
(1) Position bypass hose clamps to the center of (4) Disconnect throttle cable from clip at radiator
hose. fan shroud.
(2) Install bypass hose to engine.* (5) Unplug wiring harness from A/C compressor.
(3) Secure both hose clamps. (6) Remove the air cleaner assembly.
(4) Fill cooling system. Refer to Refilling Cooling (7) Remove accessory drive belt. Refer to Belt Re
System in this group. moval/Installation in the Engine Accessory Drive Belt
(5) Start and warm the engine. Check for leaks. section of this group.
REMOVAL—3.BL W°6 OR 5.2/5*BL V-8 ENGINE—
(8) 3.9L V-6 or 5.2/5.9L V-8 LDC-6as: The drive
WITH AIR CONDITIONING
belt idler pulley must be removed to gain access to
If equipped with A/C, the generator and A/C com one of the A/C compressor/generator bracket mount
pressor along with their common mounting bracket ing bolts. Remove the idler pulley bolt and remove
(Fig. 29) must be partially removed. Removing the idler pulley (Fig. 30).
generator or A/C compressor from their mounting . 5.9L HDC-Gas: The automatic belt tensioner/pul-
bracket is not necessary. Also, discharging the A/C ley assembly must be removed to gain access to one
GENERATOR/COMPRESSOR (11) Remove heater hose coolant return tube

AND BRACKET mounting bolt (Figs. 32 or 33) and remove tube from
engine. Discard the old tube o-ring.
SUPPORT BRACKET
1 2
IDLER
PULLEY
AUTOMATIC
BELT
TENSIONER
J9307-33
IGNITION
COIL BRACKET
Fig. 30 idler Pulley—3.9L V-6 or 5.2/5.9L V-8

WATER
LDC-Gas Engines
PUMP J9307-34
of the A/C compressor/generator bracket mounting
bolts. Remove the tensioner mounting bolt (Fig. 31) Fig. 32 Coolant Return Tube—3.9L I ~6 or 5.2/5.9L
and remove tensioner. V-8 LDC-Gas Engines
COOLANT
PULLEY RETURN
BOLT TUBE
TENSIONER
MOUNTING
BOLT
TUBE
MOUNTING
BOLT
TENSIONER J9307-64 WATER PUMP J9307-61
Fig. 31 Belt Tensioner—5.9L HDC-Gas Engine Fig. 33 Coolant Return Tube—5.9L HDC-Gas Engine
(9) Remove the engine oil dipstick tube mounting (12) Remove bracket-to-intake manifold bolts
bolt at the side of the A/C-generator mounting (number 1 and 2 Fig. 29).
bracket. (13) Remove remaining bracket-to-engine bolts
(10) Disconnect throttle body control cables. Refer (Figs. 34 or 35).
to Accelerator Pedal and Throttle Cable in Group 14, (14) Lift and position generator and A/C compres
Fuel System. sor (along with their common mounting bracket) to
BR COOLING SYSTEM'SERVICE PROCEDURES 7 - 21
INSTALLATION
(1) Position bypass hose clamps to the center of
hose.
(2) Install bypass hose to engine.
(3) Secure both hose clamps.
(4) Install generator-A/C mounting bracket assem
bly to engine. Tighten bolt number 1 (Fig. 29) to 41
N-m (30 ft. lbs.) torque. Tighten bolt number 2 (Fig.
29) to 28 N-m (20 ft. lbs.) torque. Tighten bracket
mounting bolts (Figs. 34 or 35) to 40 N-m (30 ft. lbs.)
torque.
(5) Install a new o-ring to the heater hose coolant
return tube (Figs. 32 or 33). Coat the new o-ring with
antifreeze before installation.
(6) Install coolant return tube and its mounting
bolt to engine (Figs. 32 or 33).
(7) Connect throttle body control cables.
(8) Install oil dipstick mounting bolt.
(9) 3.9L V-6 or S.2/S.9L ¥-8 LDC-Gas Engines;
Install idler pulley. Tighten bolt to 41 N-m (30 ft.
lbs.) torque.
5.9L HDC-Gas: Install automatic belt tensioner
Fig. 34 Bracket Bolts—3.9L ¥-6 or 5.2/5.91 ¥-8 assembly to mounting bracket. A dowel pin is located
LDC-Gas Engines on back of tensioner (Fig. 36). Align this to dowel
hole (Fig. 37) in tensioner mounting bracket. Tighten
bolt to 41 N-m (30 ft. lbs.) torque.
" BELT TENSIONER
DOWEL PIN J9307-63
Fig. 36 Tensioner Dowel Pin—5.9L HDC-Gas Engine

(10) Install drive belt. Refer to Belt Removal/In
stallation in the Engine Accessory Drive Belt section
of this group.
Fig. 35 Bracket Bolts—SSL HDC-Gas Engine
gain access to bypass hose. A block of wood may be drive belt, the belt must be routed correctly. If not,
used to hold assembly in position. the engine may overheat due to the water pump ro
(15) Loosen and position both hose clamps to the tating in the wrong direction. Refer to Belt Schemat
center of bypass hose. A special clamp tool (Fig. 27) ics in the Engine Accessory Drive Belt section of
must be used to remove the constant tension clamps. this group for correct belt routing. The correct belt
Remove hose from vehicle. with the correct length must be used.
(11) Install air cleaner assembly.

(12) Install upper radiator hose to radiator.
7 - 30 COOLING SYSTEM SERVICE PROCEDURES — ~ — — — BR
TEMP. COOLANT
GAUGE TEMP.
SENDING SENSOR
UNIT (FOR PCM) HEATER
SUPPLY
FITTING
BOLTS (6)
HOUSING
GASKET
J9307-62
Fig, 37 Tensioner Mounting Bracket Dowel

Hole—SSL HDC-Gas Engine THERMOSTAT
(13) Connect throttle cable to clip at radiator fan
shroud.
(14) Connect wiring harness to A/C compressor.
(15) Fill cooling system. Refer to Refilling Cooling
System in this group.
- (16) Start and warm the engine. Check for leaks.
THERMOSTAT J9407-16
RUBBER LIP SEAL
GENERAL INFORMATION
Fig. 39 Thermostat—8.0L V-10 Engine
The thermostat on all gas powered engines is lo
cated beneath the thermostat housing at the front of The thermostat of the 5.9L diesel engine is located
the intake manifold (Figs. 38 or 39). in the thermostat housing (Fig. 40). The housing is
located behind the generator mounting bracket, at
front of cylinder head.
HOUSING HOSE LIFT
BRACKET
THERMOSTAT
HOUSING
GASKET
THERMOSTAT HOUSING OUTER THERMOSTAT

INNER
BOLTS SEAL SEAL J9507-22
INTAKE MACHINED GROOVE Fig. 40 Thermostat—5.9L Diesel—Typical

MANIFOLD
Gas powered engines: The thermostat is a wax pel
J9207-14 let driven, reverse poppet choke type (3.9L/5.2L/
5.9L), or moveable sleeve type (8.0L V-10). The wax
Fig. 38. Thermostat—8.9L V-6 or 5.2/5.9L V-8 Gas pellet is located in a sealed container at the spring
Powered Engines end of the thermostat. When heated, the pellet ex
pands, overcoming closing spring tension and water
COOLING SYSTEM SERVICE PROCEDURES 7 - 31
pump pressure to force the valve to open. Coolant Vehicles equipped with a 5.9L diesel engine
leakage into the pellet container will cause the ther do not have the DTC number 17 check engine
mostat to fail in the open position. Thermostats very lamp feature.
rarely stick. Do not attempt to free a thermostat with The DTC can also be accessed through the DRB
a prying device. scan tool. Refer to the appropriate Powertrain Diag
The same thermostat is used for winter and sum nostic Procedures manual for diagnostic information
mer seasons. An engine should not be operated with and operation of the DRB scan tool.
out a thermostat, except for servicing or testing.
Operating without a thermostat causes longer engine THERMOSTAT REMOVAL—3.9L V-6 OR
warmup time, unreliable warmup performance, in 5.2/5.9L V-8 GAS POWERED ENGINES
creased exhaust emissions and crankcase condensa
tion that can result in sludge formation. WARNING: DO NOT L O O S E N THE RADIATOR
DRAINCOCK WITH THE S Y S T E M HOT AND P R E S
CAUTION: Do not operate an engine without a ther SURIZED. S E R I O U S B U R N S FROM THE COOLANT
mostat, except for servicing or testing. CAN OCCUR.

THERMOSTAT OPERATION—EXCEPT DIESEL clean, drain the coolant into a clean container for re
The thermostat controls the operating temperature use.
of the engine by controlling the amount of coolant If the thermostat is being replaced, be sure that
flow to the radiator. The thermostat is closed below the replacement is the specified thermostat for the
88°C (192°F). When the coolant reaches this temper vehicle model and engine type.
ature, the thermostat begins to open, allowing cool Factory installed thermostat housings on 3.9L V-6
ant flow to the radiator. This provides quick engine or 5.2/5.9L V-8 engines are installed on a gasket with
warm-up and overall temperature control. The ther an anti-stick coating. This will aid in gasket removal
mostat is designed to provide a minimum engine op and clean-up.
erating temperature of 88 to 93°C (192 to 199°F). It (1) Disconnect negative battery cable at battery.
should be fully open for maximum coolant flow dur (2) Drain cooling system until coolant level is be
ing operation in hot ambient temperatures of approx low thermostat. Refer to Draining Cooling System in
imately 104°C (220°F). Above 104°C (220°F), coolant this group. If not equipped with air conditioning, pro
temperature is controlled by the radiator, fan and ceed to step number 4.
ambient temperature. (3) If equipped with air conditioning:
(a) Remove the support bracket (rod) located
CAUTION: Never operate the diesel engine without
near the rear of generator (Fig. 41).
a thermostat. Without a thermostat, coolant will not
flow to radiator causing engine overheating.
ON-BOARD DIAGNOSTICS
FOR CERTAIN COOLING SYSTEM COMPONENTS

All gasoline powered models are equipped with
On-Board Diagnostics for certain cooling system com
ponents. Refer to On-Board Diagnostics (OBD) in the
Diagnosis section of this group for additional infor
mation. If the powertrain control module (PCM) de
tects low engine coolant temperature, it will record a
Diagnostic Trouble Code (DTC) in the PCM memory.
The DTC number for low coolant temperature is 17.
Do not change a thermostat for lack of heat as indi
cated by the instrument panel gauge or by poor Fig. 41 Support Bracket—Generator Mounting
heater performance unless a DTC number 17 is Bracket-to-lntake Manifold—Typical
present. Refer to the Diagnosis section of this group (b) The drive belt must be removed. Refer to Belt
for other probable causes. For other DTC numbers, Removal/Installation in the Engine Accessory Drive
refer to On-Board Diagnostics in the General Diagno Belt section of this group.
sis section of Group 14, Fuel Systems. (c) The generator must be partially removed. Re
move the two generator mounting bolts. Do not re-
7 - 32 COOLIii SYSTE1 SERVICE PROCEDURES BR
move any wiring at generator. If equipped with
4WD, unplug the 4WD indicator lamp wiring har
ness (located near rear of generator).
(d) Remove generator. Position generator to gain
access for thermostat gasket removal.
A R E U S E D ON MOST COOLING S Y S T E M H O S E S .
CLAMP, S U C H A S S P E C I A L CLAMP TOOL ( N U M B E R
60§4) ( F I G . 42). SNAP-ON CLAMP TOOL ( N U M B E R
W A Y S W E A R S A F E T Y G L A S S E S W H E N SERVICING
CONSTANT TENSION C L A M P S .
CAUTION: A number or letter is stamped into the TYPICAL

tongue of constant tension clamps (Fig. 43). If re HOSE
placement is necessary, use only an original equip CLAMP
ment clamp with a matching number or letter. NUMBER/LETTER
LOCATION J9407-39
(4) Remove upper radiator hose clamp. Remove up
per radiator hose at thermostat housing. Fig. 43 Clamp Number/Letter Location
HOSE CLAMP HOSE
J9207-36 THERMOSTAT
(5) Position the wiring harness (behind the ther MACHINED GROOVE
mostat housing) to gain access to thermostat hous
ing.
(6) Remove thermostat housing mounting bolts, J9207-14
thermostat housing, gasket and thermostat (Fig. 44). Fig. 44 Thermostat—3.9L ¥-6 or 5.2/5.9L ¥-8 Gas
Discard old gasket.
Engines
INSTALLATION be placed towards the front of vehicle. The housing
(1) Clean mating areas of intake manifold and should be slightly angled forward after installation to
thermostat housing. intake manifold.
(2) Install thermostat (spring side down) into re (5) Install two housing-to-intake manifold bolts.
cessed machined groove on intake manifold (Fig. 44). Tighten bolts to 23 N-m (200 in. lbs.) torque.
(3) Install gasket on intake manifold and over
thermostat (Fig. 44).
(4) Position the thermostat housing to the intake
manifold. Note the word FRONT stamped on the
housing (Fig. 45). For adequate clearance, this must
B R COOLING SYSTEM SERVICE PROCEDURES 7 • 33

use.
If the thermostat is being replaced, be sure that
the replacement is the specified thermostat for the
vehicle model and engine type.
A rubber lip-type seal with a metal shoulder is
pressed into the intake manifold beneath the thermo
stat (Fig. 46).
Fig, 45 Thermostat Position—33L V-6 or 5.2/5.9L

V-8 Gas Engines
CAUTION; Housing must be tightened evenly and
thermostat must be centered into recessed groove Fig. 46 Thermostat Seal—8.01 V-10 Engine
in intake manifold. If not, it may result in a cracked
housing, damaged intake manifold threads or cool (1) Disconnect negative battery cable at battery.
ant leak. (2) Drain cooling system until coolant level is be
low thermostat. Refer to Draining Cooling System in
(6) Install upper radiator hose to thermostat hous this group.
ing. (3) Remove the two support rod mounting bolts
(7) Air conditioned vehicles: and remove support rod (intake manifold-to-genera
(a) Install generator. Tighten bolts to 41 N-m (30 tor mount) (Fig. 47).
ft. lbs.) torque.
(b) Install support bracket (generator mounting
bracket-to-intake manifold) (Fig. 41). Tighten bolts
drive belt, the belt must be routed correctly. If not,
the engine may overheat due to the water pump ro
tating in the wrong direction. Refer to Belt Schemat
ics in the Engine Accessory Drive Belt section of
this group for correct engine belt routing. The cor
rect belt with the correct length must be used.

(9) Connect negative battery cable to battery.
(10) Start and warm engine. Check for leaks.
Fig. 47 Support Rod—8.0L V-10 Engine
THERMOSTAT REMOVAL—8.0L V-10 ENGINE
WARNING: DO NOT L O O S E N THE RADIATOR

DRAINCOCK WITH THE S Y S T E M HOT AND PRES
SURIZED. S E R I O U S B U R N S FROM THE COOLANT
CAN OCCUR.
7 - 34 COOLING SYSTEM SERVICE PROCEDURES mm
WARNING: CONSTANT TENSION H O S E C L A M P S (2) Check the condition (for tears or cracks) of the
A R E U S E D ON MOST COOLING S Y S T E M H O S E S , rubber thermostat seal located in the intake manifold
W H E N REMOVING OR INSTALLING, U S E ONLY (Figs. 46 or 48). The thermostat should fit snugly
TOOLS DESIGNED FOR SERVICING THIS T Y P E O F into the rubber seal.
CLAMP, S U C H A S S P E C I A L CLAMP TOOL ( N U M B E R If seal replacement is necessary, coat the outer
6094) (FIG. 42) SNAP-ON CLAMP TOOL ( N U M B E R
B (metal) portion of the seal with Mopar® Gasket
HPC-20) MAY B E U S E D FOR L A R G E R C L A M P S . AL Maker. Install the seal into the manifold using Spe
WAYS W E A R S A F E T Y G L A S S E S W H E N SERVICING cial Seal Tool number C-3995-A with handle tool
CONSTANT TENSION C L A M P S . number C-4171.
(3) Install thermostat into recessed machined
groove on intake manifold (Fig. 48).
CAUTION: A number or letter is stamped into the
(4) Install gasket on intake manifold and over
tongue of constant tension clamps (Fig. 43). If re
thermostat (Fig. 48).
placement is necessary, use only an original equip
(5) Install housing-to-intake manifold bolts.
ment clamp with a matching number or letter.
Tighten bolts to 25 N-m (220 in. lbs.) torque.
(4) Remove upper radiator hose clamp. Remove up CAUTION: Housing bolts should be tightened
per radiator hose at thermostat housing. evenly to prevent damage to housing and to pre
(5) Disconnect the wiring connectors at both of the vent leaks.
sensors located on thermostat housing.
(6) Remove six thermostat housing mounting bolts, (6) Connect the wiring to both sensors.
thermostat housing, gasket and thermostat. Discard (7) Install the upper radiator hose and hose clamp
old gasket. to thermostat housing.
TEMP. COOLANT (8) Install support rod.
• (10) Connect negative battery cable to battery.
(11) Start and warm engine. Check for leaks.
THERMOSTAT OPERATION—5.9L DIESEL
ENGINE
The thermostat controls the operating temperature
of the engine by controlling the amount of coolant
flow to the radiator. When coolant temperature is be
low 83°C (181°F), the thermostat is closed (Fig. 49).
RUBBER LIP SEAL J9407-16
Fig. 49 Thermostat Operation—5.9L Diesel—Typical

Fig. 48 Thermostat—8.0L ¥-10 Engine
INSTALLATION
When coolant temperature reaches 83°C (181°F),
the thermostat begins to open allowing coolant flow
(1) Clean mating . areas of intake manifold and
to the radiator. This provides quick engine warm-up
thermostat housing. and overall temperature control. The thermostat is
designed to provide a minimum engine operating
temperature of 83°C (181°F) and to be fully open for stat is operating properly. This is because coolant
maximum coolant flow at approximately 95°C will be held in the engine until it reaches the ther
(203°F). Above 95°C (203°F), coolant temperature is mostat "set" temperature.
controlled by the radiator, fan and ambient tempera Diesel engines, due to their inherent efficiency are
ture. slower to warm up than gasoline powered engines,
The air bleeds (jiggle pins) that were used on the and will operate at lower temperatures when the ve
thermostats of diesel engines in previous years are hicle is unloaded. Because of this, lower temperature
no longer used. They have been replaced by a verti gauge readings for diesel versus gasoline engines
cally mounted one-way check valve (jiggle pin) and a may, at times be normal.
rubber bypass hose. The check valve is used as a ser Typically, complaints of low engine coolant temper
vicing feature and will vent air when the system is ature are observed as low heater output when com
being filled. It is also used to block the flow of cool bined with cool or cold outside temperatures.
ant during engine operation (all coolant will pass To help promote faster engine warm-up, the electric
through the thermostat). engine block heater must be used with cool or cold
Water pressure (or flow) will hold the pin closed. outside temperatures. This will help keep the engine
When the engine is off, the check valve will be in coolant warm when the vehicle is parked. Use the
the open position. When the engine is operating, the block heater if the outside temperature is below 4°C
check valve will be in the closed position. (40°F). Do not use the block heater if the out
The check valve is located inside of a brass fitting. side temperature is above 4°C (40°F) o
This fitting is threaded into the front of the cylinder A "Cold Weather Cover" is available from the parts
head (Fig. 50). It is connected to the thermostat department through the Mopar Accessories product
housing with a rubber hose and screw-type clamps line. This accessory cover is designed to block airflow
(Fig. 50). entering the radiator and engine compartment to
promote faster engine warm-up. It attaches to the
front of the vehicle at the grill opening. The cover is
to be used with cool or cold temperatures only.
If used with high outside temperatures, serious
engine damage could result. Refer to the litera
ture supplied with the cover for additional informa
tion.
TESTING:
The following test procedure is to be used for the
diesel engine only.
The DRB scan tool cannot be used to monitor
engine coolant temperature on the diesel en
gine.
(1) To determine if the thermostat is defective, it
must be removed from the vehicle. Refer to Thermo
stats for removal and installation procedures.
(2) After the thermostat has been removed, exam
ine the thermostat and inside of thermostat housing
for contaminants. If contaminants are found, the
thermostat may already be in a "stuck open" position.
Flush the cooling system before replacing thermostat.
Refer to Cooling System Cleaning/Reverse Flushing
in this group for additional information.
Fig. 50 One-Way Check Vaive (Jiggle Pin) Location
(3) Place the thermostat into a container filled
THERMOSTAT DIAGNOSIS—DIESEL ENGINE with water.
The cooling system used with the diesel engine pro (4) Place the container on a hot plate or other suit
vides the extra coolant capacity and extra cooling able heating device.
protection needed for higher GVWR (Gross Vehicle (5) Place a commercially available radiator ther
Weight Rating) and GCWR (Gross Combined Weight mometer into the water.
Rating) vehicles. (6) Apply heat to the water while observing the
This system capacity will not effect warm up or thermostat and thermometer.
cold weather operating characteristics if the thermo- (7) When the water temperature reaches 83°C
(181°F) the thermostat should start to open (valve
will start to move). If the valve starts to move before
7 - 36 COOLING SYSTEM SERVICE PROCEDURES B R
this temperature is reached, it is opening too early. HOUSING HOSE LIFT

Replace thermostat. The thermostat should be fully BRACKET
open (valve will stop moving) at 95°C (203°F).
If the valve is still moving when the water temper
ature reaches 203°, it is opening too late. Replace
thermostat.
If the valve refuses to move at any time, replace
thermostat.
THERMOSTAT REMOW&L—&IESEL ENGINE
WARNING: DO NOT LOOSEN THE RADIATOR

DRAINCOCK WITH THE SYSTEM HOT AND PRES
SURIZED, SERIOUS BURNS FROM THE COOLANT HOUSING OUTER THERMOSTAT
INNER
CAN OCCUR. BOLTS SEAL J9507-22
SEAL
Do not waste reusable coolant. If the solution is Fig. 51 Thermostat Removal—5.9L Diesel
use.
(1) Disconnect both negative battery cables from
both batteries.
(2) Remove accessory drive belt. Refer to Belt Re
moval/Installation in the Engine Accessory Drive Belt
section in this group.
(3) Drain cooling system until coolant level is be
low thermostat. Refer to Draining Cooling System in
this section.
WARNING: CONSTANT TENSION HOSE CLAMPS
A R E U S E D ON MOST COOLING SYSTEM HOSES.
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
CLAMP. SUCH A S SPECIAL CLAMP TOOL (NUMBER
6094) (FIG. 42). SNAP-ON CLAMP TOOL (NUMBER
HPC-20) MAY BE USED FOR LARGER CLAMPS. AL
WAYS W E A R SAFETY GLASSES W H E N SERVICING
CONSTANT TENSION CLAMPS.
J9407-13
tongue of constant tension clamps (Fig. 43). If re Fig. 52 Generator Mounting Bracket Bolts—Diesel
placement is necessary, use only an original equip (11) Remove the thermostat housing, thermostat,
ment clamp with a matching number or letter. inner and outer seals and lift bracket (Fig. 51).
(12) Clean the mating surfaces of the thermostat
(4) Remove radiator hose clamp and hose from housing and the cylinder head.
thermostat housing. A special clamp tool (Fig. 42)
must be used to remove the constant tension clamps. INSTALLATION
(5) Remove the hose clamp and check valve hose at (1) Install the outer seal (Figs. 51 or 53) into the
thermostat housing (Fig. 51). machined shoulder on the thermostat housing.
(6) Remove the two upper generator bracket (2) Install the thermostat into the machined shoul
mounting bolts (Fig. 52). der next to the outer seal. Note direction of thermo
(7) Remove the upper generator mounting bracket stat in figures 51 and 53.
(Fig. 52). (3) Position the inner thermostat seal with the
(8) Loosen but do not remove the generator lower shoulder towards the thermostat housing (Fig. 53).
pivot bolt. (4) Install thermostat, lift bracket, seals and hous
(9) Position the generator to gain access to thermo ing to the engine as an assembly. Install and tighten
stat housing and housing bolts. mounting bolts to 24 N-m (18 ft. lbs.) torque.
(10) Remove thermostat housing mounting bolts.
LIFT temperature is hot enough to melt plastic and soften

solder. The increased temperature can result in en
gine detonation. In addition, 100 percent ethylene-
glycol freezes at -22°C (-8°F).
50/50 Ethylene-Glycol and Water-Is the recom
mended mixture, it provides protection against freez
ing to -37°C (-35°F). The antifreeze concentration
must always be a minimum of 44 percent, year-
round in all climates. If percentage is lower, engine
parts may be eroded by cavitation. Maximum protec
tion against freezing is provided with a 68 percent
antifreeze concentration, which prevents freezing
down to -67.7°C (-90°F). A higher percentage will
OUTER freeze at a warmer temperature. Also, a higher per
SEAL SHOULDER J9507-23 centage of antifreeze can cause the engine to over
heat because specific heat of antifreeze is lower than
Fig. 53 Thermostat Seals—5.9L Diesel—Typical
that of water.
(5) Position- generator to thermostat housing. In
stall and tighten mounting bolt to 24 N-m torque. CAUTION: Richer antifreeze mixtures cannot be
Tighten pivot bolt to 43 N-m (32 ft. lbs.) torque. measured with normal field equipment and can
(6) Install the check valve hose and hose clamp at cause problems associated with 100 percent ethyl
thermostat housing (Fig. 51). ene-glycol.
(7) Install accessory drive belt. Refer to Belt Re
moval/Installation in the Engine Accessory Drive Belt
COOLANT SELECTION-ADDITIVES *
section of this group.
(8) Connect negative battery cables to both batter The presence of aluminum components in the cool
ies. ing system requires strict corrosion protection. Main
(9) Fill cooling system and check for leaks. Refer to tain coolant at specified level with a mixture of
Refilling' Cooling System in this group. ethylene-glycol based antifreeze and water. Only use
an antifreeze containing ALUGARD 340-2 ™ such as
COOLANT • Mopar Antifreeze. If coolant becomes contaminated
or looses color, drain and flush cooling system and fill
GENERAL INFORMATION with correctly mixed solution.
The cooling system is designed around the coolant.
CAUTION: Do not use coolant additives that are
Coolant flows through the engine water jacket ab
claimed to improve engine cooling.
sorbing heat produced during engine operation. The
coolant carries the heat to radiator and heater core.
Here it is transferred to the ambient air passing COOLANT SERVICE—EXCEPT DIESEL
through the radiator and heater core fins. The cool It is recommended that the cooling system be
ant also removes heat from the automatic transmis drained and flushed at 84,000 kilometers (52,500
sion fluid in vehicles equipped with an automatic miles) or 3 years, whichever occurs first. Then every
transmission. two years or 48,000 kilometers (30,000 miles), which
ever occurs first.
COOLANT PERFORMANCE
The required ethylene-glycol (antifreeze) and water COOLANT SERVICE—DIESEL ENGINE
mixture depends upon climate and vehicle operating It is recommended that the cooling system be
conditions. The coolant performance of various mix drained and flushed every 24 months or 38,600 kilo
tures follows: meters (24,000 miles), whichever occurs first.
Pure Water-Water can absorb more heat than a
mixture of water and ethylene-glycol. This is for pur COOLANT LEVEL CHECK—ROUTINE
pose of heat transfer only. Water also freezes at a Do not remove radiator cap for routine cool
higher temperature and allows corrosion. ant level inspections. The coolant level can be
100% Ethylene-Glycol-The corrosion inhibiting checked at the coolant reserve/overflow tank.
additives in ethylene-glycol need the presence of wa The coolant reserve/overflow system provides a
ter to dissolve. Without water, additives form depos quick visual method for determining the coolant level
its in system. These act as insulation causing without removing the radiator pressure cap. With en
temperature to rise to as high as 149°C (300°F). This gine idling and at normal operating temperature, ob-
7 - 38 COOLING SYSTEM SERVICE PROCEDURES H R
serve coolant level in coolant reserve/overflow tank. the tank. When engine cools down the coolant, it will
The coolant level should be between the ADD and be drawn from reserve/overflow tank into radiator to
FULL marks. replace removed air.
ADDING ADDITIONAL COOLANT—ROUTINE DRAINING COOLING SYSTEM
Do not remove the radiator cap to a d d cool
ant to the system. When adding coolant to main WARNING: DO NOT REMOVE THE CYLINDER
tain the correct level, do so at the coolant reserve/ B L O C K DRAIN PLUGS OR L O O S E N THE RADIATOR
overflow tank with a 50/50 mixture of ethylene-glycol DRAIN P L U G WITH S Y S T E M HOT AND UNDER
antifreeze (containing Alugard 340-2 ™) and water. P R E S S U R E . S E R I O U S B U R N S FROM COOLANT
Remove the radiator cap only for testing or when re CAN OCCUR.
filling the system after service. Removing cap unnec
essarily can cause loss of coolant and allow air to DO NOT WASTE reusable coolant. If the solution
enter system. This produces corrosion. is clean, drain the coolant into a clean container for
reuse.
COOLANT LEVEL CHECK—SERVICE (1) Start the engine and place the heater control
The cooling system is closed and designed to main temperature selector in the Full-On position. Engine
tain coolant level to the top of the radiator. vacuum is needed to actuate the heater controls.
(2) Turn the ignition off.
WARNING: DO NOT O P E N RADIATOR DRAINCOCK (3) Do not remove radiator cap when draining cool
WITH ENGINE RUNNING OR WHILE ENGINE IS HOT ant from reserve/overflow tank. Open radiator drain
AND COOLING S Y S T E M IS UNDER P R E S S U R E . plug and when tank is empty, remove radiator cap. If
the coolant reserve/overflow tank does not drain, re
When vehicle servicing requires a coolant level fer to the Testing Cooling System for Leaks section in
check in the radiator, drain several ounces of coolant this group. The coolant need not be removed from
from the radiator drain cock. Do this while observing tank unless the system is being refilled with fresh
the coolant reserve/overflow system tank. The coolant mixture.
level in the reserve/overflow tank should drop (4) On vehicles equipped with gas powered en
slightly. If not, inspect for a leak between radiator gines, remove the cylinder block drain plugs. These
and coolant reserve/overflow system connection. Re are located on the sides of the block just above the oil
move radiator cap. The coolant level should be to the pan (Fig. 54).
top of the radiator. If not and if coolant level in re
serve/overflow tank is at the ADD mark, check for:
o An air leak in the coolant reserve/overflow tank
® An air leak in the radiator filler neck
• Leak in the pressure cap seal to the radiator filler
neck
LOW COOLANT LEVEL-AERATION

If the coolant level in the radiator drops below the
top of the radiator core tubes, air will enter the sys
tem.
Low coolant level can cause the thermostat pellet
to be suspended in air instead of coolant. This will
cause the thermostat to open later, which in turn
causes higher coolant temperature. Air trapped in
cooling system also reduces the amount of coolant
circulating in the heater core. This may result in low Fig. 54 Drain Plugs—Gas Powered Engines—Typical
heat output. (5) Remove radiator pressure cap.
DEAERATION REFILLING COOLING SYSTEM
As the engine operates, air trapped in the cooling Clean cooling system prior to refilling. Refer to
system gathers under the radiator cap. The next time Cooling' System Cleaning section of this group.
engine is operated, thermal expansion of coolant will (1) Install the cylinder block drain plugs (Fig. 54).
push trapped air past radiator cap into coolant re (2) Close radiator drain plug.
serve/overflow tank. Here it escapes to atmosphere in (3) Fill the cooling system with a 50/50 mixture of
water and antifreeze. 5.9L Diesel Engine Only: The
diesel engine is equipped with a one-way check valve REVERSE FLUSHING ENGINE—EXCEPT
(jiggle pin). The check valve is used as a servicing DIESEL
feature and will vent air when the system is being Drain cooling system. Remove thermostat housing
filled. Water pressure (or flow) will hold the valve and thermostat. Install thermostat housing. Discon
closed. D u e to the use of this valve, t h e engine nect radiator upper hose from radiator and attach
must not be operating when refilling the cool flushing gun to hose. Disconnect radiator lower hose
ing system. Refer to Thermostat Operation—5.9L from water pump and attach a lead-away hose to wa
Diesel Engine in the Thermostat section of this group ter pump inlet fitting.
for more information. Connect water supply hose and air supply hose to
(4) Fill coolant reserve/overflow tank to the FULL flushing gun. Allow engine to fill with water. When
mark. engine is filled, apply air in short blasts, allowing
(5) Start and operate engine until thermostat system to fill between air blasts. Continue until clean
opens. Upper radiator hose should be warm to touch. water flows through the lead away hose.
(6) If necessary, add 50/50 water and antifreeze Remove lead away hose, flushing gun, water supply
mixture to the coolant reserve/overflow tank to main hose and air supply hose. Remove thermostat hous
tain coolant level. This level should be between the ing and install thermostat. Install thermostat hous
ADD and FULL marks. The level in the reserve/over ing with a replacement gasket. Refer to Thermostat
flow tank may drop below the ADD mark after three Replacement. Connect radiator hoses. Refill cooling
or four warm-up and cool-down cycles. system with correct antifreeze/water mixture. Refer
to Refilling the Cooling System.
COOLING SYSTEM CLEANING/REVERSE FLUSHING
REVERSE FLUSHING ENGINE—DIESEL
CLEANING
(1) Drain the cooling system.
(2) Disconnect the upper hose from the radiator.
Drain cooling system and refill with water. Run en (3) Disconnect the radiator lower hose from the
gine with radiator cap installed until upper radiator water pump.
hose is hot. Stop engine and drain water from sys (4) Remove the heater core inlet hose from tube
tem. If water is dirty, fill system with water, run en (Fig. 55).
gine and drain system. Repeat until water drains
clean.
MEVE^SE FLUSHING
Reverse flushing of cooling system is the forcing of
water through the cooling system. This is done using
air pressure in the opposite direction of normal cool
ant flow. It is usually only necessary with very dirty
systems with evidence of partial plugging.
REVERSE FLUSHING RADIATOR
Disconnect radiator hoses from radiator inlet and
outlet. Attach a section of radiator hose to radiator
bottom outlet fitting and insert flushing gun. Con
nect a water supply hose and air supply hose to
flushing gun.
CAUTION: Internal radiator pressure must not ex Fig. 55 Typical Reverse-flushing—5.9L Diesel
ceed 138 kPa (20 psi) as damage to radiator may re (5) Attach water supply hose to heater tube.
sult. (6) Back-flush the engine until clean water exits
the water pump inlet.
Allow radiator to fill with water. When radiator is
filled, apply air in short blasts. Allow radiator to re CHEMICAL CLEANING
fill between blasts. Continue this reverse flushing In some instances, use a radiator cleaner (Mopar
until clean water flows out through rear of radiator Radiator Kleen or equivalent) before flushing. This
cooling tube passages. Have radiator cleaned more will soften scale and other deposits and aid flushing
extensively by a radiator repair shop. operation.
CAUTION: Follow manufacturers instructions when
using these products.
TESTING COOLING SYSTEM FOR LEAKS Inspect cams on outside of filler neck. If cams are
bent, seating of pressure cap valve and tester seal
ULTRAVIOLET LIGHT METHOD will be affected. Replace cap if cams are bent.
A leak detection additive is available through the Attach pressure tester (7700 or an equivalent) to
parts department that can be added to cooling sys radiator filler neck (Fig. 57).
tem. The additive is highly visible under ultraviolet
light (black light). Pour one ounce of additive into
cooling system. Place heater control unit in HEAT
position. Start and operate engine until radiator up
per hose is warm to touch. Aim the commercially
available black light tool at components to be
checked. If leaks are present, black light will cause
additive to glow a bright green color.
The black light can be used in conjunction with a
pressure tester to determine if any external leaks ex
ist (Fig. 56).
Fig. 57 Pressure Testing Cooling System—Typical

Operate tester pump to apply 103.4 kPa (15 psi)
pressure to system. If hoses enlarge excessively or
bulges while testing, replace as necessary. Observe
gauge pointer and determine condition of cooling sys
tem according to following criteria:
Holds Steady: If pointer remains steady for two
minutes, serious coolant leaks are not present in sys
tem. However, there could be an internal leak that
does not appear with normal system test pressure. If
it is certain that coolant is being lost and leaks can
not be detected, inspect for interior leakage or per
form Internal Leakage Test.
' Drops Slowly: Indicates a small leak or seepage is
occurring. Examine all connections for seepage or
slight leakage with a flashlight. Inspect radiator,
hoses, gasket edges and heater. Seal small leak holes
Fig. 56 Leak Detection Using Black Light—Typical with a sealer lubricant (or equivalent). Repair leak
PRESSURE TESTER METHOD holes and inspect system again with pressure ap
The engine should be at normal operating temper plied.
ature. Recheck the system cold if cause of coolant Drops Quickly: Indicates that serious leakage is
loss is not located during the warm engine examina occurring. Examine system for external leakage. If
tion. leaks are not visible, inspect for internal leakage.
Large radiator leak holes should be repaired by a
WARNING: HOT, PRESSURIZED COOLANT CAN reputable radiator repair shop.
C A U S E I N J U R Y B Y SCALDING.
INTERNAL LEAKAGE INSPECTION
Carefully remove radiator pressure cap from filler Remove engine oil pan drain plug and drain a
neck and check coolant level. Push down on cap to small amount of engine oil. If coolant is present in
disengage it from stop tabs. Wipe inside of filler neck the pan, it will drain first because it is heavier than
and examine lower inside sealing seat for nicks, oil. An alternative method is to operate engine for a
cracks, paint, dirt and solder residue. Inspect radia short period to churn the oil. After this is done, re
tor-to-reserve/overflow tank hose for internal obstruc move engine dipstick and inspect for water globules.
tions. Insert a wire through the hose to be sure it is Also inspect transmission dipstick for water globules
not obstructed. and transmission fluid cooler for leakage.
COOLING SYSTEM SERVICE PROCEDURES 7 - 41
WARNING: WITH COOLING S Y S T E M P R E S S U R E gases are leaking into cooling system, bubbles will
TESTER TOOL INSTALLED ON RADIATOR, DO NOT appear in coolant. If bubbles do not appear, internal
A L L O W P R E S S U R E TO E X C E E D 110 KPA (20 PSI). combustion gas leakage is not present.
P R E S S U R E W I L L BUILD UP QUICKLY IF A COM
BUSTION LEAK IS P R E S E N T TO RELEASE PRES COOLANT RESERVE/OVERFLOW SYSTEM
S U R E , ROCK T E S T E R FROM SIDE TO SIDE. W H E N The coolant reserve/overflow system works in con
REMOVING T E S T E R , DO NOT TURN T E S T E R MORE junction with the radiator pressure cap. It utilizes
THAN 1/2 TURN IF SYSTEM IS UNDER P R E S S U R E . thermal expansion and contraction of coolant to keep
coolant free of trapped air. It provides a volume for
Operate engine without pressure cap on radiator expansion and contraction of coolant. It also provides
until thermostat opens. Attach a pressure tester to a convenient and safe method for checking coolant
filler neck. If pressure builds up quickly it indicates a level and adjusting level at atmospheric pressure.
combustion leak exists. This is usually the result of a This is done without removing the radiator pressure
cylinder head gasket leak or crack in engine. Repair cap. The system also provides some reserve coolant
as necessary. to the radiator to cover minor leaks and evaporation
If there is not an immediate pressure increase, or boiling losses.
pump the pressure tester. Do this until indicated As the engine cools, a vacuum is formed in the
pressure is within system range of 110 kPa (16 psi). cooling system of both the radiator and engine. Cool
Fluctuation of gauge pointer indicates compression or ant will then be drawn from the coolant tank and re
combustion leakage into cooling system. turned to a proper level in the radiator.
Because the vehicle is equipped with a catalytic On 3.9L/5.2L/5.9L gas engines and the 5.9L diesel
converter, do not remove spark plug cables or short engine, the coolant reserve/overflow tank is mounted
out cylinders (non-diesel engines) to isolate compres to the side of the fan shroud (Fig. 58). On the 8.0L
sion leak. V-10 engine the tank is mounted to right inner
If the needle on dial of pressure tester does not fender (Fig. 59).
fluctuate, race engine a few times to check for an ab
normal amount of coolant or steam. This would be
emitting from exhaust pipe. Coolant or steam from
exhaust pipe may indicate a faulty cylinder head gas
ket, cracked engine cylinder block or cylinder head.
A convenient check for exhaust gas leakage into
cooling system is provided by a commercially avail
able Block Leak Check tool. Follow manufacturers in
structions when using this product.
COMBUSTION LEAKAGE TEST—WITHOUT
PRESSURE TESTER
DO NOT WASTE reusable coolant. If solution is
clean, drain coolant into a clean container for reuse.
WARNING: DO NOT REMOVE CYLINDER B L O C K
DRAIN P L U G S OR L O O S E N RADIATOR DRAIN-
COCK WITH S Y S T E M HOT A N D UNDER P R E S S U R E .
S E R I O U S B U R N S FROM COOLANT CAN OCCUR.
Drain sufficient coolant to allow thermostat re

moval. Refer to Thermostat Replacement. Disconnect
water pump drive belt.
Add coolant to radiator to bring level to within 6.3 Fig. 58 Coolant Reserve/Overflow Tank—All Except
mm (1/4 in) of top of thermostat housing. 8.0L V-10 Engine
Refer to Coolant Level Check—Service, Deaeration
CAUTION: Avoid overheating. Do not operate en
gine for an excessive period of time. Open drain-
and Radiator Pressure Cap sections in this group for
cock immediately after test to eliminate boil over.
coolant reserve/overflow system operation and ser
vice.
Start engine and accelerate rapidly three times, to Should the reserve/overflow tank become coated
approximately 3000 rpm (2000 rpm for diesel) while with corrosion, it can be cleaned with detergent and
observing coolant. If internal engine combustion
42 COOLING SYSTEM SERVICE PROCEDURES — — — — — BR
COOLANT
RESERVE/OVERFLOW
Fig. 60 Radiator Pressure Cap and Filler Neck-

BOLTS (2) J948D-21 Typical
A vent valve in the center of cap allows a small
Fig. 59 Coolant Reserve/Overflow Tank—8.01 V-10 coolant flow through cap when coolant is below boil
Engine ing temperature. The valve is completely closed when
water. Rinse tank thoroughly before refilling cooling boiling point is reached. As the coolant cools, it con
system as described in the Coolant section of this tracts and creates a vacuum in the cooling system.
group. This causes the vacuum valve to open and coolant in
the reserve/overflow tank to be drawn through its
TANK MBm&WAl—ALl EXCEPT 8.0L ¥-10 connecting hose into radiator. If the vacuum valve is
ENGINE stuck shut, the radiator hoses will collapse on cool-
(1) Remove overflow hose from radiator. down. Clean the vent valve (Fig. 60).
(2) Unsnap the coolant reserve/overflow tank from A rubber gasket seals radiator filler neck to pre
fan shroud. Lift straight up. The fan shroud is vent leakage. This is done to keep system under
equipped with T-shaped slots (Fig. 58) to attach the
pressure. It also maintains vacuum during coolant
tank. An alignment pin is located on the side of tank.
cool-down allowing coolant to return from reserve/
INSTALLATION! overflow tank.
(1) Snap the tank into the two T-slots and the
alignment pin on fan shroud. RADIATOR CAP-TO-FILLER NECK SEAL-
(2) Connect overflow hose to radiator. PRESSURE RELIEF CHECK
The pressure cap upper gasket (seal) pressure re
TANK REMOVAL—8.0L V-1G ENGINE lief can be tested by removing overflow hose from ra
(1) Remove overflow hose from radiator. diator 'filler neck nipple. Attach hose of pressure
(2) Remove three tank mounting bolts (Fig. 59) tester tool 7700 (or equivalent) to nipple. It will be
and remove tank. necessary to disconnect hose from its adapter for
filler neck. Pump air into radiator. The pressure cap
INSTALLATION • upper gasket should relieve at 69-124 kPa (10-18 psi)
(1) Position tank to inner fender. and hold pressure at a minimum of 55 kPa (8 psi).
(2) Install bolts and tighten to 6 N-m (50 in. lbs.)
torque. WARNING: THE WARNING W O R D S —DO NOT
(3) Connect overflow hose to radiator. O P E N HOT-— ON RADIATOR P R E S S U R E CAP, A R E
A SAFETY PRECAUTION. W H E N HOT, P R E S S U R E
RADIATOR PRESSURE CAP
BUILDS U P IN COOLING S Y S T E M . TO P R E V E N T
Radiators are equipped with a pressure cap, which SCALDING OR INJURY, RADIATOR CAP SHOULD
releases pressure at some point within a range of 97- NOT B E REMOVED WHILE SYSTEM IS HOT AND/OR
124 kPa (14-18 psi). The pressure relief point (in UNDER P R E S S U R E .
pounds) is engraved on top of cap.
The cooling system will operate at pressures Do not remove radiator cap at any time except for
slightly above atmospheric pressure. This results in a the following purposes:
higher coolant boiling point allowing increased radi • Check and adjust antifreeze freeze point
ator cooling capacity. The cap (Fig. 60) contains a • Refill system with new antifreeze
spring-loaded pressure relief valve that opens when • Conducting service procedures
system pressure reaches release range of 97-124 kPa • Checking for vacuum leaks
(14-18 psi).
COOLING SYSTEI SERVICE PROCEDURES 7 - 43
WARNING: IF VEHICLE HAS B E E N RUN RECENTLY, CAUTION: Radiator pressure testing tools are very
WAIT AT L E A S T 15 MINUTES B E F O R E REMOVING sensitive to small air leaks, which will not cause
RADIATOR CAP, WITH A R A G , S Q U E E Z E RADIATOR cooling system problems. A pressure cap that does
U P P E R H O S E TO C H E C K IF S Y S T E M IS UNDER not have a history of coolant loss should not be re
P R E S S U R E . P L A C E A R A G OVER CAP AND WITH placed just because it leaks slowly when tested
OUT PUSHING CAP DOWN, ROTATE IT COUNTER with this tool. Add water to tool. Turn tool upside
C L O C K W I S E TO FIRST STOP. A L L O W FLUID TO down and recheck pressure cap to confirm that cap
E S C A P E THROUGH THE COOLANT R E S E R V E / needs replacement.
O V E R F L O W HOSE INTO R E S E R V E / O V E R F L O W
TANK. S Q U E E Z E RADIATOR U P P E R HOSE TO DE
INSPECTION
TERMINE W H E N P R E S S U R E HAS B E E N R E
L E A S E D . W H E N COOLANT AND STEAM STOP Hold cap at eye level, right side up. The vent valve
B E I N G P U S H E D INTO TANK AND S Y S T E M P R E S (Fig. 61) at bottom of cap should open. If rubber gas
S U R E D R O P S , R E M O V E RADIATOR CAP COM ket has swollen and prevents vent valve from open
PLETELY. ing, replace cap.
Hold cap at eye level, upside down. If any light can
be seen between vent valve and rubber gasket, re
PRESSURE TESTING SSADIATOR GAPS place cap. Do not use a replacement cap that has
Remove cap from radiator. Be sure that sealing a spring to hold vent shut. A replacement cap
surfaces are clean. Moisten rubber gasket with water must be the type designed for a coolant reserve/over
and install cap on pressure tester 7700 or an equiv flow system with a completely sealed diaphragm
alent (Fig. 61). spring and a rubber gasket. This gasket is used to
seal to radiator filler neck top surface. Use of proper
cap will allow coolant return to radiator.
RADIATORS
GENERAL INFORMATION
The radiator used on all engines (both gas powered
and diesel) are of a cross-flow design with horizontal
tubes through the radiator core and vertical side
tanks.
Aluminum cores with plastic side tanks are used
on all 3.9L V-6 and 5.2/5.9L V-8 engines. Copper-
brass cores are used with the 8.0L V-10 and diesel
engines.
The radiator supplies sufficient heat transfer to
cool the engine and automatic transmission (if
equipped).
RADIATOR COOLANT FLOW CHECK
Use the following procedure to determine if coolant
J9507-3 is flowing through the cooling system.
(1) Idle engine until operating temperature is
Fig. 61 Pressure Testing Radiator Cap—Typical
reached. If the upper radiator hose is warm to the
Tester
touch, the thermostat is opening and coolant is flow
Operate tester pump to bring pressure to 104 kPa ing to the radiator.
(15 psi) on gauge. If pressure cap fails to hold pres
sure of at least 97 kPa (14 psi) replace cap. Refer to WARNING: HOT, P R E S S U R I Z E D COOLANT CAN
CAUTION below. C A U S E INJURY B Y SCALDING. USING A R A G TO
The pressure cap may test properly while posi COVER THE RADIATOR P R E S S U R E CAP, O P E N RA
tioned on tool 7700 (or equivalent). It may not hold DIATOR CAP S L O W L Y TO THE FIRST STOP. THIS
pressure or vacuum when installed on radiator. If so, WILL A L L O W ANY BUILT-UP P R E S S U R E TO VENT
inspect radiator filler neck and cap's top gasket for TO THE R E S E R V E / O V E R F L O W TANK. AFTER P R E S
damage. Also inspect for dirt or distortion that may S U R E BUILD-UP HAS B E E N R E L E A S E D , REMOVE
prevent cap from sealing properly. CAP FROM F I L L E R NECK.
(2) Drain a small amount of coolant from the radi

ator until the ends of the radiator tubes are visible
through the filler neck. Idle the engine at normal op
erating temperature. If coolant is flowing past the ex
posed tubes, the coolant is circulating.
RADIATOR REMOVAL—ALL ENGINES
(1) All Engines Except Diesel: Disconnect nega
tive battery cable from battery.
Diesel engine: Disconnect both negative battery
cables at both batteries. Remove the nuts retaining
the positive cable to the top of radiator. Position pos
itive battery cable to rear of vehicle.
WARNING: DO NOT REMOVE THE CYLINDER
B L O C K DRAIN P L U G S OR L O O S E N THE RADIATOR
DRAINCOCK WITH THE S Y S T E M HOT AND UNDER
P R E S S U R E . S E R I O U S B U R N S FROM COOLANT TYPICAL
CAN OCCUR. HOSE
CLAMP
NUMBER/LETTER
(2) Drain the cooling system. Refer to Draining LOCATION J9407-39
Cooling System in this group.
(3) Disconnect throttle cable from clip at top of ra Fig. 63 Clamp Number/Letter Location
diator fan shroud.
(5) All engines: Remove coolant reserve/overflow
HOSE CLAMP HOSE tank hose from radiator filler neck nipple.
(6) All engines except 8.0L V-10: Remove the cool
ant reserve/overflow tank from the fan shroud (pull
straight up). The tank slips into T-slots on the fan
shroud.
(7) Disconnect electrical connectors at windshield
washer reservoir tank and remove tank. Refer to
Group 8K, Windshield Wiper and Washer Systems
for procedures.
(8) If equipped with an automatic transmission (all
engines except diesel), disconnect oil cooler lines
(hoses) at radiator tank. Refer to Group 21, Trans
missions for procedures.
J9207-36
(9) Diesel Engine Only: Remove the two metal
clips retaining the upper part of fan shroud to the
Fig. 62 Hose Clamp Tool—Typical top of radiator.
(10) Remove the four fan shroud mounting bolts
A R E U S E D ON MOST COOLING S Y S T E M H O S E S . (Fig. 64). Position shroud rearward over the fan
W H E N REMOVING OR INSTALLING, U S E ONLY blades towards engine.
TOOLS DESIGNED FOR SERVICING THIS T Y P E OF (11) All Engines Except 8.0L V-10 and Diesel: Re
CLAMP, S U C H A S S P E C I A L CLAMP TOOL (NUMBER move the plastic clips retaining the rubber shields to
6094) (FIG. 62). SNAP-ON CLAMP TOOL ( N U M B E R the sides of radiator. Position rubber shields to the
HPC-20) MAY B E U S E D FOR L A R G E R C L A M P S . AL side.
WAYS W E A R S A F E T Y G L A S S E S W H E N SERVICING (12) Remove the two radiator upper mounting
CONSTANT TENSION CLAMPS. bolts (Fig. 65).
(13) Lift radiator straight up and out of engine
compartment. The bottom of the radiator is equipped
CAUTION: A number or letter is stamped into the with two alignment dowels that fit into holes in the
tongue of constant tension clamps (Fig. 63). If re lower radiator support panel (Fig. 65). Rubber bis
placement is necessary, use only an original equip cuits (insulators) are installed to these dowels. Take
care not to damage cooling fins or tubes on the radi
(4) Remove hose clamps and hoses from radiator. ator and air conditioning condenser when removing.
RADIATOR (5) 3.9L ¥-6 or 5.2L/5.9L V-8 Engines: Position the

rubber shields to the sides of radiator. Install the
plastic clips retaining the rubber shields to the sides
of radiator.
(6) Connect both radiator hoses. Refer to previous
CAUTION and install hose clamps.
(7) If equipped, connect transmission oil cooler
lines to radiator tank. Refer to Group 21, Transmis
sions for procedures.
(8) Install windshield washer reservoir tank. Refer
to Group 8K.
(9) Position fan shroud to flanges on sides of radi
ator. Install fan shroud mounting bolts (Fig. 64).
(10) Diesel Engines: Install metal clips to top of
fan shroud.
(11) All engines: Install coolant reserve/overflow
tank hose to radiator filler neck nipple.
(12) All Engines Except 8.0L V-10: Install coolant
FAN SHROUD MOUNTING BOLTS J9407-37
reserve/overflow tank to fan shroud (fits into T-slots
on shroud).
Fig. 64 Typical Fan Shroud Mounting (13) Connect throttle cable to fan shroud.
(14) Install negative battery cable(s) to battery(s).
MOUNTING
BOLTS (15) Diesel Engine: Install positive battery cable to
top of radiator. Tighten radiator-to-battery cable
mounting nuts.
(16) Position heater controls to full heat position.
(17) Fill cooling system with coolant. Refer to Re
filling Cooling System in this group.
(18) Operate engine until it reaches normal tem
perature. Check cooling system and automatic trans
mission (if equipped) fluid levels.
RADIATOR CLEANING
The radiator and air conditioning fins should be
cleaned when an accumulation of bugs, leaves etc.
has occurred. Clean radiator fins are necessary for
good heat transfer. With the engine • cold, apply cold
water and compressed air to the back (engine side) of
the radiator to flush the radiator and/or A/C con
denser of debris.
ALIGNMENT
DOWELS (2) J9407-38 COOLING SYSTEM HOSES
Rubber hoses route coolant to and from the radia
Fig. 65 Typical Radiator Mounting tor, intake manifold and heater core. Radiator lower
RADIATOR INSTALLATION hoses are spring-reinforced to prevent collapse from
(1) Position fan shroud over the fan blades rear water pump suction at moderate and high engine
ward towards engine. speeds.
(2) Install rubber insulators to alignment dowels at Inspect the hoses at regular intervals. Replace
lower part of radiator. hoses that are cracked, feel brittle when squeezed or
(3) Lower the radiator into position while guiding swell excessively when system is pressurized. The
the two alignment dowels into lower radiator sup use of molded replacement hoses is recommended.
port. Different alignment holes are provided in the When performing a hose inspection, inspect radiator
lower radiator support for each engine application. lower hose for proper position and condition of
(4) Install two upper radiator mounting bolts. spring.
7 - 46 COOLING SYSTEM SERVICE PROCEDURES B R
WARNING: CONSTANT TENSION HOSE C L A M P S TYPICAL

A R E U S E D ON MOST COOLING S Y S T E M H O S E S . CONSTANT
TENSION HOSE
W H E N REMOVING OR INSTALLING, U S E ONLY CLAMP
CLAMP, SUCH A S S P E C I A L CLAMP TOOL ( N U M B E R
6094) (FIG. S i ) . SNAP-ON CLAMP TOOL ( N U M B E R
WAYS W E A R S A F E T Y G L A S S E S W H E N SERVICING
CONSTANT TENSION C L A M P S .

placement is necessary, use only an original equip
Ordinary worm gear type hose clamps (when

equipped) can be removed with a straight screw TYPICAL
HOSE
driver or a hex socket. To prevent damage to CLAMP
hoses or clamps, the hose clamps should be NUMBER/LETTER
tightened to 4 N-m (34 in. lbs.) torque. Do not LOCATION J9407-39
over tighten hose clamps.
For all vehicles: In areas where specific routing Fig. 67 Clamp Number/Letter Location
clamps are not provided, be sure that hoses are posi (4) The thermal viscous fan drive/fan blade assem
tioned with sufficient clearance. Check clearance bly is attached (threaded) to water pump hub shaft
from exhaust manifolds and pipe, fan blades, drive (Fig. 68). Remove fan blade/viscous fan drive assem
belts and sway bars. Improperly positioned hoses can bly from water pump by turning mounting nut coun
be damaged, resulting in coolant loss and engine terclockwise as viewed from front. Threads on
overheating. viscous fan drive are RIGHT-HAND. A Snap-On 36
HOSE CLAMP HOSE
MM Fan Wrench (number SP346 from Snap-On
Cummins Diesel Tool Set number 2017DSP) can be
used. Place a bar or screwdriver between water
pump pulley bolts (Fig. 68) to prevent pulley from ro
tating.
Do not attempt to remove fan/viscous fan drive as
sembly from vehicle at this time.
Do not unbolt fan blade assembly (Fig. 68) from
viscous fan drive at this time.
(5) Remove four fan shroud-to-radiator mounting
bolts.
(6) Remove fan shroud and fan blade/viscous fan
drive assembly as a complete unit from vehicle.
After removing fan blade/viscous fan drive assem
J9207-36 bly, do not place viscous fan drive in horizontal po
sition. If stored horizontally, silicone fluid in the
Fig. 66 Hose damp Tool—Typical viscous fan drive could drain into its bearing assem
bly and contaminate lubricant.
COOLING SYSTEM FIN—GAS ENGINES
Also refer to the proceeding Viscous Fan Drive sec CAUTION: Do not remove water pump pulley-to-wa
tion for additional information. ter pump bolts (Fig. 68). This pulley is under spring
tension.
REMOVAL
(1) Disconnect negative battery cable from battery. (7) Remove four bolts securing fan blade assembly
(2) Remove throttle cable at top of fan shroud. to viscous fan drive (Fig. 68).
(3) All Except 8.0L V-10 Engine: Unsnap coolant
reserve/overflow tank from fan shroud and lay aside. INSPECTION
The tank is held to shroud with T-shaped slots. Do The fan cannot be repaired. If fan is damaged, it
not disconnect hose or drain coolant from tank. must be replaced. Inspect fan as follows:
BR COOLING SYSTEM SERVICE PROCEDURES 7 47
FAN BLADE WATER WATER PUMP (4) Install fan blade/viscous fan drive assembly to
PUMP water pump shaft (Fig. 68).
ASSEMBLY PULLEY PULLEY
BOLTS (5) Except 8.0L V-10 Engine: Install coolant re
THREADED
NUT serve/overflow tank to fan shroud. Snaps into posi
tion.
(6) Install throttle cable to fan shroud.
(7) Connect negative battery cable.
COOLING SYSTEM FAN—DIESEL ENGINE

Also refer to the proceeding Viscous Fan Drive sec
tion for additional information.
REMOVAL
(1) Disconnect both negative battery cables at both
batteries.
(2) Remove the fan shroud mounting bolts. Posi
tion fan shroud towards engine.
THREADED SHAFT CRANKSHAFT
(WATER PUMP HUB) PULLEY CAUTION: Do not remove the fan pulley bolts. This
VISCOUS FAN DRIVE pulley is under spring tension.
J9307-32
(3) The thermal viscous fan drive/fan blade assem
Fig. 68 Fan Blade/Viscous Fan Drive—Gas bly is attached (threaded) to the fan hub shaft (Fig.
Engines—Typical 69). Remove the fan blade/fan drive assembly from
(1) Remove fan blade and viscous fan drive as an fan pulley by turning the mounting nut clockwise (as
assembly from the engine. Refer to preceding Re viewed from front). Threads on the viscous fan drive
moval procedure. are LEFT-HAND. A Snap-On 36 MM Fan Wrench
(2) Remove fan blade assembly from viscous fan (number SP346 from Snap-On Cummins Diesel Tool
drive unit (four bolts). Set number 2017DSP) can be used. Place a bar or
(3) Lay fan on a flat surface with leading edge fac screwdriver between the fan pulley bolts to prevent
ing down. With tip of blade touching flat surface, re pulley from rotating.
place fan if clearance between opposite blade and
surface is greater than 2.0 mm (.090 inch). Rocking THREADED
SHAFT
motion of opposite blades should not exceed 2.0 mm FAN
(.090 inch). Test all blades in this manner. BLADE
ASSEMBLY
WARNING;, DO NOT ATTEMPT TO B E N D OR
STRAIGHTEN FAN B L A D E S IF NOT WITHIN S P E C I
FICATIONS.
(4) Inspect fan assembly for cracks, bends, loose

rivets or broken welds. Replace fan if any damage is
found. THREADED
NUT
CAUTION: If fan blade assembly is replaced be
cause of mechanical damage, water pump and vis
cous fan drive should also be inspected. These
components could have been damaged due to ex
cessive vibration.
FAN BLADE
INSTALLATION BOLTS (4)
VISCOUS FAN DRIVE J9307-65
(1) Install fan blade assembly to viscous fan drive.
Tighten bolts (Fig. 68) to 23 N-m (17 ft. lbs.) torque. Fig. 69 Fan Blades/Viscous Fan Drive—5.9L Diesel
drive assembly to vehicle as a complete unit. (4) Remove the fan shroud and the fan blade/vis
(3) Install fan shroud. cous drive as an assembly from vehicle.
(5) Remove fan Hade-to-viscous fan drive mount A thermostatic bimetallic spring coil is located on
ing bolts. the front face of the viscous fan drive unit (a typical
Inspect the fan for cracks, loose rivets, loose or viscous unit is shown in figure 70). This spring coil
bent fan blades. reacts to the temperature of the radiator discharge
air. It engages the viscous fan drive for higher fan
INSPECTION speed if the air temperature from the radiator rises
The fan cannot be repaired. If the fan is damaged, above a certain point. Until additional engine cooling
it must be replaced. Inspect the fan as follows: is necessary, the fan will remain at a reduced rpm re
(1) Remove fan blade and thermal viscous fan gardless of engine speed.
drive assembly from engine. Refer to the preceding
MOUNTING NUT
Removal procedure. TO WATER PUMP
(2) Remove fan blade assembly from thermal vis
cous fan drive unit (four bolts).
(3) Lay fan on a flat surface with leading edge fac
ing down. With tip of blade touching flat surface, re
place fan if clearance between opposite blade and
surface is greater than 2.0 mm (.090 inch). Rocking
motion of opposite blades should not exceed 2.0 mm
(.090 inch). Test all blades in this manner.
WARNING: DO NOT ATTEMPT TO BEND OR
STRAIGHTEN FAN B L A D E S IF NOT WITHIN S P E C I
FICATIONS.
(4) Inspect fan assembly for cracks, bends, loose

rivets or broken welds. Replace fan if any damage is Fig. 70 Viscous Fan Drive—Typical
found.
Only when sufficient heat is present, will the vis
CAUTION: If the fan blade assembly is replaced be cous fan drive engage. This is when the air flowing
cause of mechanical damage, the fan pulley and through the radiator core causes a reaction to the bi
viscous fan drive should also be inspected. These metallic coil. It then increases fan speed to provide
components could have been damaged due to ex the necessary additional engine cooling.
cessive vibration. Once the engine has cooled, the radiator discharge
temperature will drop. The bimetallic coil again re
acts and the fan speed is reduced to the previous dis
INSTALLATION'
engaged speed.
(1) Install fan blade assembly to viscous fan drive.
Tighten mounting bolts to 23 N-m (17 ft. lbs.) torque. CAUTION: Some engines equipped with serpentine
(2) Position the fan shroud and fan blade/viscous drive belts have reverse rotating fans and viscous
fan drive to the vehicle as an assembly.
fan drives. They are marked with the word R E
(3) Install viscous fan drive assembly on fan hub
V E R S E to designate their usage. Installation of the
shaft. Tighten mounting nut to 57 N-m (42 ft. lbs.)
wrong fan or viscous fan drive can result in engine
torque.
overheating.
(4) Install fan shroud bolts.
(5) Install battery cables to batteries.
CAUTION: If the viscous fan drive is replaced be
VISCOUS FAN DRIVE cause of mechanical damage, the cooling fan
blades should also be inspected. Inspect for fatigue
OESCilPTIOl AID 0PERATI0I
cracks, loose blades, or loose rivets that could
Also refer to either of the previous Cooling System
have resulted from excessive vibration. Replace fan
Fan sections.
blade assembly if any of these conditions are
The thermal viscous fan drive (Figs. 68 or 69) is a
found. Also inspect water pump bearing and shaft
silicone-fluid-filled coupling used to connect the fan
blades to the water pump shaft. The coupling allows assembly for any related damage due to a viscous
the fan to be driven in a normal manner. This is fan drive malfunction.
done at low engine speeds while limiting the top
speed of the fan to a predetermined maximum level
at higher engine speeds.
NOISE (4) Block the air flow through the radiator. Secure
It is normal for fan noise to be louder (roar a sheet of plastic in front of the radiator (or air con
ing) when: ditioner condenser). Use tape at the top to secure the
• The underhood temperature is above the engage plastic and be sure that the air flow is blocked.
ment point for the viscous drive coupling. This may (5) Be sure that the air conditioner (if equipped) is
occur when ambient (outside air temperature) is very turned off.
high.
• Engine loads and temperatures are high such as WARNING: USE EXTREME CAUTION WHEN THE
when towing a trailer. ENGINE I S OPERATING. DO NOT STAND IN A DI
• Cool silicone fluid within the fan drive unit is be RECT LINE WITH THE FAN. DO NOT PUT YOUR
ing redistributed back to its normal disengaged HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
(warm) position. This can occur during the first 15 NOT WEAR LOOSE CLOTHING.
seconds to one minute after engine start-up on a cold
engine. (6) Start the engine and operate at 2400 rpm.
Within ten minutes the air temperature (indicated on
LEAIS the dial thermometer) should be up to 88° C (190° F).
Viscous fan drive operation is not affected by small Fan drive engagement should have started to occur
oil stains near the drive bearing. If leakage appears at between 74° to 82° C (165° to 180° F). Engage
excessive, replace the fan drive unit. ment is distinguishable by a definite increase in fan
flow noise (roaring). The timing light also will indi
TEST1NI
cate an increase in the speed of the fan (non-diesel
If the fan assembly free-wheels without drag (the only).
fan blades will revolve more than five turns when (7) When the air temperature reaches 88° C (190°
spun by hand), replace the fan drive. This spin test
F), remove the plastic sheet. Fan drive disengage
must be performed when the engine is cool.
For the following test, the cooling system must be ment should have started to occur at between 57° to
in good condition. It also will ensure against exces 79° C (135° to 175° F). A definite decrease of fan
sively high coolant temperature. flow noise (roaring) should be noticed. If not, replace
the defective viscous fan drive unit.
WARNING: BE SURE THAT THERE IS ADEQUATE
FAN BLADE CLEARANCE BEFORE DRILLING. VISCOUS FAN DRIVE REMOVAL/
INSTALLATION
(1) Drill a 3.18-mm (1/8-in) diameter hole in the For removal and installation procedures, refer to
top center of the fan shroud. either of the previous Cooling System Fan sections.
(2) Obtain a dial thermometer with an 8 inch stem Viscous Fan Drive Fluid Pump Out Require
(or equivalent). It should have a range of -18°-to- ment: After installing a new viscous fan drive, bring
105°C (0°-to-220° F). Insert thermometer through the the engine speed up to approximately 2000 rpm and
hole in the shroud. Be sure that there is adequate hold for approximately two minutes. This will ensure
clearance from the fan blades. proper fluid distribution within the drive.
(3) Connect a tachometer and an engine ignition
timing light. The timing light is to be used as a
strobe light. This step cannot be used on the diesel
engine.
7 - 50 AUTOMATIC TRANSMISSION OIL COOLERS BR
AUTOMATIC T R A N S M I S S I O N OIL COOLERS
INDE1
page page
Automatic Transmission Oil Coolers—Diesel
Engine 52 Automatic Transmission Oil Coolers—Except Diesel
Engines 50
AUTOMATIC TRANSMISSION OIL COOLERS- this' optional cooler is located between the radiator
EXCEPT DIESEL ENGINES and air conditioning condenser (Fig. 1).
8.0L V-10 Engine: The air-to-oil cooler is located
WATER-TO-OIL COOLER in front of and to the left side of the radiator (Fig. 2).
All gas powered models equipped with an auto This secondary cooler is supplied as standard equip
matic transmission are equipped with a transmission ment on models equipped with the 8.0L V-10 engine
oil cooler mounted internally within the radiator side and an automatic transmission.
tank. This internal cooler is supplied as standard UPPER RADIATOR TRANS. OIL
equipment on all gas powered models equipped with SUPPORT BRACKET COOLER
an automatic transmission. BOLT UPPER
RADIATOR MOUNTING
The internal radiator oil cooler is not used with BOLTS (2)
SUPPORT
the diesel engine. BRACKET
Transmission oil is cooled when it passes through TRANSMISSION
this separate cooler. In case of a leak in the internal OIL
radiator mounted transmission oil cooler, engine cool COOLER
ant may become mixed with transmission fluid or
transmission fluid may enter engine cooling system.
Both cooling system and transmission should be
drained and inspected if the internal radiator
mounted transmission cooler is leaking.
Also refer to the section on Transmission Air-to-Oil
Coolers. This heavy duty air-to-oil cooler is an option
on most engine packages. It is supplied as standard
equipment on both the 8.0L V-10 and 5.9L diesel en LOWER RADIATOR
gines. SUPPORT BRACKET TRANS. OIL
BOLTS (2) COOLER
LOWER
REPLACING WATER-TO-OIL COOLER i l RAiiATOR SIDE MOUNTING
TA1I BOLT J9407-40
The internal transmission oil cooler located within
the radiator is not serviceable. If it requires service, 1 Air-To-Oil Cooler—3.91 V-6 or 5.2/5.9L V-8
the radiator must be replaced. Engines
Once the repaired or replacement radiator has
The oil coolers on all gas powered engines operate
been installed, fill the cooling system and inspect for
leaks. Refer to the Refilling Cooling System and Test in conjunction with the internal radiator mounted
ing Cooling System For Leaks sections in this group. main oil cooler. The transmission oil is routed
If the transmission operates properly after repairing through the main cooler first, then the optional
the leak, drain the transmission and remove the cooler, before returning to the transmission.
transmission oil pan. Inspect for sludge and/or rust.
RE10¥AL—AIR-TO-OIL COOLER—3JL/I.2L/5JL ENGINES
Inspect for a dirty or plugged inlet filter. If none of
these conditions are found, the transmission and If a leak should occur in the internal radiator
torque convertor may not require reconditioning. Re mounted transmission air-to-oil cooler (gas engines
fer to Group 21 for automatic transmission servicing. only), engine coolant may become mixed with trans
mission fluid. Transmission fluid may also enter en
AIR-TO-OIL COOLER gine cooling system. Both cooling system and
5 2/5.9L V-8 Gas Powered Engines: An optional
0
transmission should be drained and inspected in case
air-to-oil transmission oil cooler is available with of oil cooler leakage.
most engine packages. On the 5.2/5.9L V-8 engines, (1) Disconnect negative battery cable at battery.
BR AUTOMATIC TRANSMISSION OIL COOLERS 7 - 51
RADIATOR MOUNTING
BOLTS
SUPPORT
TRANS.
OIL COOLER
TRANS. OIL
COOLER LINES
QUICK-CONNECT
FITTINGS
RADIATOR
(2)
OIL COOLER
MOUNTING ALIGNMENT
BOLTS (3) DOWELS (2) J9407-38
J9407-41
Fig. 2 Air-To-Oil Cooler—8.0L V-10 Engine Fig. 3 Radiator Mounting Bolts—Typical
(2) Drain cooling system. Refer to Draining Cooling INSTALLATION

System. (1) Install the oil cooler assembly to the A-shaped
(3) Place a drain pan under the oil cooler lines. radiator support bracket using the two upper mount
(4) Disconnect the two transmission oil cooler line ing bolts and mounting straps. Install the bolts but
quick-connect fittings at the radiator. Refer to Group do not tighten at this time.
21, Transmissions for procedures. Plug cooler lines to (2) Install the radiator support bracket and oil
prevent oil leakage. cooler (as an assembly) to the vehicle.
(5) Disconnect the oil cooler quick-connect fitting (3) Install the two lower radiator A-shaped support
at the transmission oil cooler line. Refer to Group 21, bracket bolts. Do not tighten bolts at this time.
Transmissions for procedures. (4) Slide and position the oil cooler on the
(6) Disconnect the windshield washer reservoir A-shaped bracket until its lower mounting hole lines
tank at the fan shroud. Refer to Group 8K, Wind up with the bolt hole on the vehicle body. Tighten the
shield Wiper and Washer Systems for procedures. oil cooler mounting strap bolts to 6 N-m (50 in. lbs.)
(7) Remove the rubber shield at right side of radi torque.
ator. The shield is held to vehicle body with plastic (5) Install the upper radiator A-shaped support
clips. bracket bolt. Tighten all three radiator support
(8) Remove the two radiator upper mounting bolts bracket mounting bolts to 11 N-m (95 in. lbs.) torque.
(Fig. 3). (6) Install the two radiator upper mounting bolts
(9) Position the upper part of radiator towards en (Fig. 1). Tighten bolts to 11 N-m (95 in. lbs.) torque.
gine. (7) Install windshield washer reservoir tank.
(10) Remove the oil cooler lower mounting bolt (oil (8) Install rubber shield to radiator.
cooler-to-vehicle body) (Fig. 1). (9) Install the quick-connect fittings on the two oil
(11) Remove three bolts (radiator support bracket- cooler lines to the radiator. Refer to Group 21, Trans
to-body) (Fig. 1). Remove this A-shaped support missions for procedures.
bracket and the transmission oil cooler as an assem (10) Fill cooling system. Refer to Refilling the Cool
bly from the vehicle. Take care not to damage the ra ing System in this group.
diator core or A/C condenser fins with the cooling (11) Connect negative battery cable to battery.
lines when removing. (12) Start the engine and check all fittings for
(12) Remove oil cooler from A-shaped support leaks.
bracket by removing two upper mounting strap bolts (13) Check the fluid level in the automatic trans
and mounting straps at support bracket (Fig. 1). mission. Refer to Group 21, Transmissions for proce
(13) Remove oil cooler from the A-shaped radiator dures.
support bracket.
7 - 52 AUTOMATIC TRANSMISSION OIL COOLERS BR
REMOVAL—Aii-TO-OiL COOLER—8.IL ¥-11 ENGINE
If a leak should occur in the internal radiator
mounted transmission oil cooler (gas engines only),
engine coolant may become mixed with transmission
fluid. Transmission fluid may also enter engine cool
ing system. Both cooling system and transmission
should be drained and inspected in case of oil cooler
leakage.
(1) Place a drain pan under the oil cooler lines.
(2) Disconnect the two transmission oil cooler line
quick-connect fittings from the transmission oil
cooler lines (Fig. 2). Refer to Group 21, Transmis
sions for procedures. Plug cooler lines to prevent oil
leakage.
(3) Remove three oil cooler-to-radiator support
mounting bolts (Fig. 2).
(4) Remove the oil cooler and line assembly from
the vehicle.
INSTALLATION
(1) Install the oil cooler and cooler line assembly to
the vehicle.
(2) Install three mounting bolts and tighten to 6
N-m (50 in. lbs.) torque.
(3) Connect the quick-connect fittings. Refer to
Group 21, Transmissions for procedures.
(4) Start the engine and check all fittings for leaks.
(5) Check the fluid level in the automatic trans
mission. Refer to Group 21, Transmissions for proce
dures.
AUTOMATIC TRANSMISSION OIL COOLERS-

DIESEL ENGINE
All diesel models equipped with an automatic
transmission are equipped with both a main water-
to-oil cooler and a separate air-to-oil cooler. Both cool
ers are supplied as standard equipment on diesel I QUICK-
engine powered models when equipped with an auto MOUNTING CONNECT
matic transmission. NUTS (2) FITTINGS (2) ' J9407-42
Transmission oil is cooled when it passes through
these coolers. Fig. 5 Air-To-Oil Cooler—Diesel Engine
The main water-to-oil transmission oil cooler is (1) Disconnect both negative battery cables at bat
mounted to a bracket on the turbocharger side of the teries.
engine (Fig. 4). (2) Remove air cleaner assembly and air cleaner
The air-to-oil cooler is located in front of and to the intake hoses. Refer to Group 14, Fuel System for pro
left side of the radiator (Fig. 5). cedures.
The diesel engine is not equipped with an internal (3) Drain cooling system. Refer to Draining Cooling
radiator mounted oil cooler. System.
(4) Disconnect coolant lines from cooler.
REMOVAL—WATER-TO-OIL COOLER—5.&L (5) Disconnect transmission oil lines from cooler.
DIESEL ENGINE Plug cooler lines to prevent oil leakage.
If a leak should occur in the water-to-oil cooler (6) Remove oil cooler mounting straps.
mounted to the side of the engine block, engine cool (7) Lift oil cooler off of mounting bracket.
ant may become mixed with transmission fluid.
Transmission fluid may also enter engine cooling sys INSTALLATION
tem. Both cooling system and transmission should be (1) Position oil cooler on bracket.
drained and inspected in case of oil cooler leakage. (2) Install mounting straps.
IR AUTOMATIC TRANSMISSION OIL COOLERS 7 - 53
(3) Connect transmission oil lines to cooler. (5) Remove the charge air cooler-to-oil cooler bolt
(4) Connect coolant hoses to cooler. (Fig. 5).
(5) Connect negative battery cables to both batter (6) Remove two mounting nuts.
ies. (7) Remove the oil cooler and line assembly to
(6) F i l l cooling system. Refer to Refilling Cooling wards the front of vehicle. Cooler must be rotated
System i n this section. and tilted into position while removing.
(7) Check transmission oil level and f i l l as neces
sary. INSTALLATION
(8) I n s t a l l air cleaner assembly and air cleaner i n (1) Carefully position the oil cooler assembly to the
take hoses. Refer to Group 14, Fuel System for pro vehicle.
cedures. (2) Install two nuts and one bolt. Tighten to 11
N-m (95 i n . lbs.) torque.
REMOVAL—AIR-TO-OIL COOLER—5.9L DIESEL
(3) Connect the quick-connect fittings to the trans
ENGINE
mission cooler lines. Refer to Group 2 1 , Transmis
(1) Remove front bumper. Refer to Group 23, Body.
sions for procedures.
(2) Place a drain pan under the oil cooler.
(4) Install front bumper. Refer to Group 23, Body.
(3) Raise the vehicle.
(5) Start the engine and check all fittings for leaks.
(4) Disconnect the oil cooler quick-connect fittings
from the transmission lines. These are located near (6) Check the f l u i d level i n the automatic trans
the power steering gearbox. Refer to Group 2 1 , mission. Refer to Group 2 1 , Transmissions for proce
Transmissions for procedures. dures.
7 - 54 ENGINE ACCESSORY DRIVE BELTS BR
NGINE ACCESSORY DRIVE BELTS
INDEX
page page
Automatic Belt Tensioner 58 Belt Schematics . 54

Belt Diagnosis 54 Belt Tension 54
Belt Removal/Installation 54 General Information 54
GENERAL INFORMATION
All vehicles are available with either a 3.9L V-6, a
5.2L V-8, two different 5.9L V-8 engines, an 8.0L V-10
or a 5.9L in-line 6 cylinder diesel engine.
The accessory drive components are operated by a
single, crankshaft driven, serpentine drive belt on all
engines. An automatic belt tensioner is also used to
NORMAL CRACKS
maintain correct belt tension at all times. This is BELT OK
used on all engines. Refer to Automatic Belt Ten
sioner proceeding in this group.
BELT DiAiNOSiS
SERPENTINE DRIVE BELT DIAGNOSIS—ALL
ENGINES
When diagnosing serpentine drive belts, small
cracks that run across ribbed surface of belt from rib
to rib (Fig. 1), are considered normal. These are not a
reason to replace belt. However, cracks running along
a rib (not across) are not normal. Any belt with NOT NORMAL CRACKS
cracks running along a rib must be replaced (Fig. 1). REPLACE BELT J9007-44
Also replace belt if it has excessive wear, frayed cords Fig, 1 Serpentine Accessory Drive Belt Wear
or severe glazing. Patterns
Refer to the Serpentine Drive Belt Diagnosis chart
for further belt diagnosis. Also refer to Automatic gine. All engines are equipped with an automatic belt
Belt Tensioner proceeding in this group. tensioner. The tensioner maintains correct belt ten
sion at all times. For other tensioner information and
BELT SCHEMATICS removal/installation procedures, refer to Automatic
Refer to figures 2, 3, 4, 5 or 6 for belt routing. The Belt Tensioner proceeding in this group. Due to use
belt routing schematics are published from the latest of this belt tensioner, do not attempt to use a belt
information available at the time of publication. If tension gauge on any engine.
anything differs between these schematics and
the Belt Routing Label, use the schematics on BELT REMOVAL/INSTALLATION
Belt Routing Label. This label is located in the en
gine compartment. Caution: Do not attempt to check belt tension with
a belt tension gauge on vehicles equipped with an
BELT TENSION automatic belt tensioner. Refer to Automatic Belt
Tensioner in this group.
ALL ENGINES
Correct accessory drive belt tension is required to
be sure of optimum performance of belt driven engine 3.9L V-6 OR 5.2/5.9L V-8 LDC-GAS ENGINES
accessories. If specific tension is not maintained, belt
slippage may cause; engine overheating, lack of REiOWAl
power steering assist, loss of air conditioning capac Drive belts on these engines are equipped with a
ity, reduced generator output rate and greatly re spring loaded automatic belt tensioner (Fig. 7). This
duced belt life. belt tensioner will be used on all belt configurations,
It is not necessary to adjust belt tension on any en- such as with or without power steering or air condi-
BR ENGINE ACCESSORY DRIVE BELTS 7 - 55
SERPENTINE DRIVE BELT DIAGNOSIS

RIB CHUNKING (ONE 1. Foreign objects imbedded in 1. Remove foreign objects from pulley
OR MORE R i B S HAS pulley grooves. grooves. Replace belt. \
SEPARATED FROM 2. Installation damage. 2. Replace belt.
BELT BODY
RIB OR BELT W E A R 1. Pulley(s) misaligned. 1. Align pulley(s).

2. Abrasive environment. 2. Clean pulley(s). Replace belt if necessary.
3. Rusted pulley(s). 3. Clean rust from pulley(s).
4. Sharp or jagged pulley 4. Replace pulley.
groove tips.
5. Rubber deteriorated. 5. Replace belt.
LONGITUDINAL BELT 1. Belt has mistracked from 1. Replace belt.

CRACKING (CRACKS pulley groove.
B E T W E E N TWO RIBS) 2. Pulley groove tip has worn 2. Replace belt.
away rubber to tensile i
member.
BELT S L I P S 1. Belt slipping because of 1. Replace automatic belt tensioner.

insufficient tension.
2. Incorrect belt. 2. Replace belt.
3. Belt or pulley subjected to 3. Replace belt and clean pulleys.
substance (belt dressing, oil,
ethylene glycol) that has
reduced friction.
4. Driven component bearing 4. Replace faulty component bearing.
failure.
5. Belt glazed and hardened 5. Replace belt.
from heat and excessive
slippage.
"GROOVE JUMPING 55
1. Belt tension either too high or 1. Replace automatic belt tensioner.
(BELT DOES NOT too low.
MAINTAIN CORRECT 2. Incorrect belt. 2. Replace belt.
POSITION ON PULLEY)
3. Pulley(s) not within design 3. Replace pulley(s).
tolerance.
4. Foreign object(s) in grooves. 4. Remove foreign objects from grooves.
4. Pulley misalignment. 4. Check and replace.
5. Belt cordline is broken. 5. Replace belt.
BELT BROKEN 1. Excessive tension. 1. Replace belt and automatic belt tensioner.
(NOTE; IDENTIFY AND 2. Incorrect belt. 2. Replace belt.
CORRECT P R O B L E M
B E F O R E N E W BELT 3. Tensile member damaged 3. Replace belt.
during belt installation.
IS INSTALLED)
4. Severe misalignment. 4. Check and replace.
5. Bracket, pulley, or bearing 5. Replace defective component and belt.
failure.
NOISE (OBJECTIONAL 1. Belt slippage. 1. Replace belt or automatic belt tensioner.

SQUEAL, SQUEAK, OR 2. Bearing noise. 2. Locate and repair.
R U M B L E IS HEARD OR
3. Belt misalignment. 3. Replace belt.
FELT WHILE DRIVE
BELT IS IN OPERATION) 4. Belt-to-pulley mismatch. 4. Install correct belt.
J9507-27
AUTOMATIC
TENSIONER
*IF VEHICLE IS NOT EQUIPPED WITH POWER

STEERING, THIS WILL BE AN IDLER PULLEY. J9307-26 J9307-56
Fig. 2 Belt Routing—3.9L V-6 or 5.2/5,91 V-8 Fig. 4 Belt Routing—5.9L HDC-Gas Engine and 8.0 L
LDC-Gas Engines ¥-10—Without A/C
AUTOMATIC •POWER STEERING PUMP IS NOT BELT DRIVEN

TENSIONER
39307-55
Fig. 3 Belt Routing—5.9L HDC-Gas Engine and 8.0 L

Fig. 5 Belt Routing—5.9L Diesel Engine—With A/C
W'10—With A/C
INSTALLATlOi
tioning. For more information, refer to Automatic
Belt Tensioner, proceeding in this group. CAUTION: When installing serpentine accessory
(1) Attach a socket/wrench to pulley mounting bolt drive belt, belt must be routed correctly. If not, en
of automatic tensioner (Fig. 7). gine may overheat due to water pump rotating in
(2) Rotate tensioner assembly clockwise (as viewed wrong direction. Refer to (Fig. 2) for correct engine
from front) until tension has been relieved from belt. belt routing. The correct belt with. correct length
(3) Remove belt from idler pulley first. must be used.
(4) Remove belt from vehicle.
BR ENGINE ACCESSORY DRIVE BELTS 7 - 57
POWER STEERING PUMP

(4) Check belt indexing marks. Refer to the pro
IS NOT BELT DRIVEN ceeding Automatic Belt Tensioner for more belt infor
mation.
5,BL HDC-GAS AND 8.0L V-10 ENGINES
iEiOWAL
Drive belts are equipped with a spring loaded au
tomatic belt tensioner (Fig. 8). This belt tensioner
will be used on all belt configurations, such as with
or without power steering or air conditioning. For
more information, refer to Automatic Belt Tensioner,
proceeding in this group.
PULLEY IDLER
BOLT AlUik PULLEY
AUTOMATIC
TENSIONER
TENSIONER
MOUNTING
BOLT
J9307-58
Fig. 6 Belt Routing—5.9L Diesel Engine—Without

A/C
IDLER \JJ
TENSIONER J9307-64
Fig. 8 Belt Tensioner—5.9L HDC-Gas and 8.0L V-10

Engines—Typical
(1) Attach a socket/wrench to pulley mounting bolt
of automatic tensioner (Fig. 8). The threads on the
pulley mounting bolt are left- hand.
(2) Relax the tension from the belt by rotating the
tensioner counterclockwise (as viewed from front)
(Fig. 8). When all belt tension has been relaxed, re
move belt from tensioner pulley first and other pul
leys last.
Fig. 7 Belt Tensioner—3.9L V-6 or 5.2/5.9L V-8 INSTALLATION

LDC-Gas Engines
CAUTION: When installing serpentine accessory
(1) Position drive belt over all pulleys except idler drive belt, belt must be routed correctly. If not, en
pulley. This pulley is located between generator and gine may overheat due to water pump rotating in
A/C compressor. wrong direction. Refer to (Figs. 3 or 4) for correct
(2) Attach a socket/wrench to pulley mounting bolt engine belt routing. The correct belt with correct
of automatic tensioner (Fig. 7). length must be used.
(3) Rotate socket/wrench clockwise. Place belt over
idler pulley. Let tensioner rotate back into place. Re
move wrench. Be sure belt is properly seated on all CAUTION: If the pulley is to be removed from the
pulleys. tensioner, its mounting bolt has left-hand threads.
7 - 58 ENGINE ACCESSORY DRIVE BELTS B R
(1) Position drive belt over all pulleys except ten (1) Position drive belt over all pulleys except wa
sioner pulley. ter pump pulley.
(2) Attach a socket/wrench to pulley mounting bolt (2) Attach a 3/8 inch ratchet to tensioner.
of automatic tensioner (Fig. 8). (3) Rotate ratchet and belt tensioner counterclock
(3) Rotate socket/wrench counterclockwise. Install wise. Place belt over water pump pulley. Let ten
belt over tensioner pulley. Let tensioner rotate back sioner rotate back into place. Remove ratchet. Be
into place. Remove wrench. Be sure belt is properly sure belt is properly seated on all pulleys.
seated on all pulleys.
AUTOMATIC BELT TENSIONER
5.9L DIESEL ENGINE Drive belts on all engines are equipped with a
spring loaded automatic belt tensioner (Figs. 10, 11
REMOWAL or 12). This belt tensioner will be used with all belt
Drive belts on diesel engines are equipped with a configurations, such as with or without power steer
spring loaded automatic belt tensioner (Fig. 9). Fig ing or air conditioning.
u r e i displays the tensioner for vehicles with
out air conditioning. Caution: Do not attempt to check belt tension with
This belt tensioner will be used on all belt configu a belt tension gauge on vehicles equipped with an
rations, such as with or without air conditioning. For automatic belt tensioner.
more information, refer to Automatic Belt Tensioner,
proceeding in this group.
Fig. 9 Beit Tensioner—5.91 Diesel—Typical (non-A/C

shown)
(1) A 3/8 inch square hole is provided in the auto
matic belt tensioner (Fig. 9). Attach a 3/8 inch drive- Fig. 10 Beit Tensioner—3.9L V-6 or 5.2/5.9L V-8
long handle ratchet to this hole. LDC-Gas Engines
(2) Rotate ratchet and tensioner assembly counter On 3.9L V-6 or 5.2/5.9L V-8 LDC-gas engines, the
clockwise (as viewed from front) until tension has tensioner is equipped with an indexing arrow (Fig.
been relieved from belt. 13) on back of tensioner and an indexing mark on
(3) Remove belt from water pump pulley first. tensioner housing. If a new belt is being installed, ar
(4) * Remove belt from vehicle. row must be within approximately 3 mm (1/8 in.) of
indexing mark (point B-figure 13). Belt is considered
INSTALLATION new if it has been used 15 minutes or less. If this
specification cannot be met, check for:
CAUTION: When installing serpentine accessory • The wrong belt being installed (incorrect length/
drive belt, belt must be routed correctly. If not, en width)
gine may overheat due to water pump rotating in ® Worn bearings on an engine accessory (A/C com
wrong direction. Refer to (Figs. 5 or 6) for correct pressor, power steering pump, water pump, idler pul
engine belt routing. The correct belt with correct ley or generator)
length must be used. © A pulley on an engine accessory being loose
© Misalignment of an engine accessory
B R ENGINE ACCESSORY DRIVE BELTS 7 - 59
TENSIONER
ASSEMBLY
INDEXING
ARROW
Fig, If Belt Tensioner—5.9L HDC-Gas and 8.0L ¥-10

Engines
Fig. 13 Indexing Marks—3.9L V-6 or 5.2/5.9L V-8

LDC-Gas Engines
(3) Remove ignition coil from coil mounting bracket
(two bolts). Do not remove coil mounting bracket
from cylinder head.
(4) Remove tensioner assembly from mounting
bracket (one nut) (Fig. 13).
WARNING: BECAUSE O F HIGH SPRING P R E S
SURE, DO NOT ATTEMPT TO D I S A S S E M B L E AUTO
MATIC TENSIONER. UNIT IS S E R V I C E D A S AN
A S S E M B L Y ( E X C E P T FOR P U L L E Y ) .
Fig. 12 Belt Tensioner—6.91 Diesel—Typical
(non-A/C shown) (5) Remove pulley bolt. Remove pulley from ten
sioner.
• Belt incorrectly routed. Refer to figures 2, 3, 4, 5
or 6 liSTALLATIOI
On 3.9L V-6 or 5.2/5.9L V-8 LDC-gas engines, a (1) Install pulley and pulley bolt to tensioner.
used belt should be replaced if tensioner indexing ar Tighten bolt to 61 N-m (45 ft. lbs.) torque.
row has moved to point-A (Fig. 13). Tensioner travel (2) Install tensioner assembly to mounting bracket.
stops at point-A. An indexing tab is located on back of tensioner. Align
3 . 9 L V-6 OR 5.2/5.9L V-8 LDC-GAS ENGINES
this tab to slot in mounting bracket. Tighten nut to
iEiOWAL (3) Connect all wiring to ignition coil.
(1) Remove accessory drive belt. Refer to Belt Re (4) Install coil to coil bracket. If nuts and bolts are
moval/Installation in this group. used to secure coil to coil bracket, tighten to 11 N-m
(2) Disconnect wiring and secondary cable from ig (100 in. lbs.) torque. If coil mounting bracket has
nition coil. been tapped for coil mounting bolts, tighten bolts to 5
CAUTION: To prevent damage to coll case, coil
BELT TENSIONER
mounting bolts must be torqued.
(5) Install drive belt. Refer to Belt Removal/Instal

lation in this group.
(6) Check belt indexing marks (Fig. 13).
S.BL HDC-GAS AMD 8.0L ¥-10 ENGINES
IEiOWAL
(1) Remove accessory drive belt. Refer to Belt Re
moval/Installation in this group.
(2) Remove tensioner mounting bolt (Fig. 11) and
remove tensioner.
CAUTION: If the pulley is to be removed from the DOWEL PIN J9307-<
tensioner, its mounting bolt has left-hand threads.
Fig. 14 Tensioner Dowel Pin—5.9L HDC-Gas and
8.0L V-10 Engines
WARNING: B E C A U S E OF HIGH S P R I N G P R E S
S U R E , DO NOT ATTEMPT TO D I S A S S E M B L E AUTO
MATIC TENSIONER. UNIT IS SERVICED AS AN
INSTALLATION
(1) Install pulley and pulley bolt to tensioner (ob
serve the previous CAUTION). Tighten bolt to 88
(2) Install tensioner assembly to mounting bracket.
A dowel pin is located on back of tensioner (Fig. 14).
Align this to dowel hole (Fig. 15) in tensioner mount
ing bracket. Tighten bolt to 41 N-m (30 ft. lbs.)
torque.
(3) Install drive belt. Refer to Belt Removal/Instal
lation in this group.
Fig. 15 Tensioner Dowel Hole—5.9L HDC-Gas and
5.9L DIESEL ENGINE 8.0L V-10 Engines
iEiOWAL INSTALLATION
(1) Remove accessory drive belt. Refer to Belt Re (1) Install pulley to tensioner.
moval/Installation in this group. (2) Install tensioner assembly to mounting bracket.
(2) Remove tensioner mounting bolt (Fig. 12) and A dowel is located on back of tensioner. Align this
remove tensioner. dowel to hole in tensioner mounting bracket. Tighten
bolt to 41 N-m (30 ft. lbs.) torque.
WARNING: B E C A U S E OF HIGH S P R I N G P R E S (3) Install drive belt. Refer to Belt Removal/Instal
S U R E , DO NOT ATTEMPT TO D I S A S S E M B L E AUTO lation in this group.
MATIC TENSIONER. UNIT IS S E R V I C E D AS AM
BR ENGINE BLOCI HEATERS 7 - 81
ENGINE BLOCK HEATERS
DESCRIPTION AND OPERATION

An optional engine Mock heater is available with
for all models. The heater is equipped with a power
cord. The cord is attached to an engine compartment
component with tie-straps. The heater warms the en
gine providing easier engine starting and faster
warm-up in low temperatures. The heater is mounted
in a core hole of the engine cylinder block (in place of
a freeze plug) with the heating element immersed in
engine coolant. Connect the power cord to a grounded
110-120 volt AC electrical outlet with a grounded,
three wire extension cord.
WARNING: DO NOT OPERATE ENGINE U N L E S S
B L O C K HEATER CORD HAS B E E N DISCONNECTED
FROM P O W E R S O U R C E AND S E C U R E D IN P L A C E .
THE P O W E R CORD MUST B E S E C U R E D IN ITS R E
TAINING C L I P S AND ROUTED AWAY FROM E X
HAUST MANIFOLDS AND MOVING PARTS.
The 3.9L/5.2L/5.9L gas powered engine has the HEATER J9407-43

block heater located on the right side of engine next
to the oil filter (Fig. 1). Fig. 2 Engine Block Heater—8.0L V-10 Engine
The 8.0L V-10 engine has the block heater located
on the right side of engine next to the engine oil dip
stick tube (Fig. 2).
The 5.9L diesel engine has the block heater located
on the right side of the engine below the exhaust
manifold (Fig. 3).
Fig. 3 Engine Block Heater—5.9L Diesel Engine

REMOVAL
(1) Disconnect negative battery cable(s) from bat-
teryGs).
(2) Drain coolant from radiator and cylinder block.
(3) Remove power cord from heater by unplugging
(Figs. 1 or 2). On the diesel engine, the cord is con
nected to the heater with a knurled cap. Unscrew
this cap for cord removal.
(4) Loosen (but do not completely remove) the
screw at center of block heater (Fig. 1 or 2). On the
diesel engine, an alien headed screw is used.
Fig. 1 Engine Block Heater—3.9U5.2U5.9L Gas (5) Remove block heater from engine by carefully
Powered Engine prying from side-to-side. When removing block
7 - 62 ENGINE BLOCK HEATERS _—. . _ — _ _ — BR
heater, note direction of heating element coil (up or (3) Insert block heater into cylinder block.
down). Element coil must be installed correctly to (4) With heater fully seated, tighten center screw.
prevent damage. (5) Fill cooling system with recommended coolant.
Refer to Refilling Cooling System section in this
INSTALLATION group.
(1) Thoroughly clean the cylinder block freeze plug (6) Start and warm the engine.
hole and block heater seat. (7) Check block heater for leaks.
(2) Install new o-ring seal(s) to heater.
BR COOLING SYSTEM SPECIFICATIONS 7 - 63
SPECIFICATIONS
GENERAL INFORMATION COOLANT CAPACITIES

The following specifications are published from the
latest information available at the time of publica
tion. If anything differs between t h e specifica
tions found on t h e Vehicle Emission Control
3.9L/5.2L/5.9L 19 Liters
Information (VECI) label a n d t h e following
Gas Engines . (20 Qts. or 5.0 Gals.)
specifications? use specifications on VECI label.
The VECI label is located in the engine compart 8.0L Engine 25 Liters
ment. (26 Qts. or 6.5 Gals.)
DRIVE BELT TENSION 5.9L Diesel Engine 23 Liters

All engines are equipped with a spring loaded au (24 Qts. or 6.0 Gals.)
tomatic belt tensioner. Do not attempt to check belt * Nominal refill capacities are shown. A variation
tension with a belt tension gauge on vehicles may be observed from vehicle to vehicle due to
equipped with an automatic belt tensioner. Refer to manufacturing tolerances and refill procedures.
Automatic Belt Tensioner in this group.
* Capacities shown include vehicles with air
conditioning and or heavy-duty cooling
systems.
J9407-21
TORQUE
Description _ j •••cription Torque) ^"""1
Automatic Belt Tensioner Pulley Bolt — Radiator Mounting Bolts . . . . . . . . 11 N*m(95 in. lbs.)
3.9L/5.2L/5.9L LDC Gas Engine . . . 61 N©m (45 ft. lbs.) Thermal Viscous Fan-to-Hub-Does®I
Automatic Belt Tensioner Pulley Bolt — Engine . 57N*itt(42 ft. lbs.)
5.9L HDC Gets and S.OL Thermostat Housing Bolts —
V-10 Engine 88 N*m (65 ft. lbs.) 23 N*m (200 in. lbs.)
All Gas Engines Except 8.0L V-10 .
Automatic Belt Tensioner-to-Mounting
Thermostat Housing Bolts—
Bracket-3.9L/5.2L/5.9l LDC
8.0LV-10. 25N«m(220 in. lbs.)
Gas Engine 67N®m (50 ft. lbs.)
Thermostat Housing Bolts —
Automatic Belt Tensioner-to-Mounting
Diesel Engine 24N*m(18ft. lbs.)
Bracket —5.9L HDC Gas and S.OL
V-10 Engines . 41 N®m (30 ft lbs.) Water Pump Mounting Bolts—
All Gas Engines 4 0 N # m ( 3 0 ft. lbs.)
Fan Shroud-to-Radiator Mounting
Bolts . 6 N*m (50 in. lbs.) Water Pump Pulley Bolts —
All Gas Engines 22N«m(16ft. lbs.)
Heater Hose Fitting at Water Pump —
Water Pump Mounting Bolts —
8.0L V-10 Engine . . . . . . . . . . . . . . 16 N»m {1441n. lbs.) Diesel Engine 24 N<»m (18 ft. lbs.)
Hose Clamps 4 N»m (34 in. lbs.)
Idler Pulley Mounting Bolt —
All Gas Engines . 61 N«m (45 ft. lbs.) J9407-20
BR ELECTRICAL 8A 1
ELECTRICAL
GROUP INDEX
group group
AUDIO SYSTEMS . . . 8F POWER LOCKS 8P

BATTERY/STARTER/GENERATOR SERVICE . . . . 8B POWER MIRRORS . . . . 8T
BATTERY/STARTING/CHARGING SYSTEMS POWER SEATS . . . . 8R
DIAGNOSTICS . . . 8A POWER WINDOWS 8S
CHIME/BUZZER WARNING SYSTEMS . . . 8U RESTRAINT SYSTEMS 8M
HORNS . . . 8G TURN SIGNAL AND HAZARD WARNING
IGNITION SYSTEMS . . . 8D SYSTEMS . . 8J
INSTRUMENT PANEL AND GAUGES . . . 8E VEHICLE SPEED CONTROL SYSTEM . . . . 8H
LAMPS . . . 8L WIPER AND WASHER SYSTEMS . « . . 8K
OVERHEAD CONSOLE . . . 8C WIRING DIAGRAMS . . . 8W
I
BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS
CONTENTS
page page
BATTERY .... 2 SPECiFlClTiOlS ...23

CHARGING SYSTEM ...18 STARTING SYSTE1 ...11
IGNITION-OFF DRAW . . . 10 USING ON-BOARD DIAGNOSTIC SYSTEM . . . 22
GENERAL INFORMATION
The battery, starting, and charging systems operate IGNITION SWITCH
with one another; therefore, they must be tested as a
complete system. In order for the vehicle to start and r
CLUTCH PEDAL 1
^ POSITION SWITCH |
charge properly, all of the components involved in
these systems must perform within specifications. ''^PARK/NEUTRAL P O S I T I O N ^
Group 8A covers battery, starting (Fig. 1) and SWITCH |
. .^.^.J
charging (Fig. 2) system diagnostic procedures. These
procedures include the most basic conventional diag
STARTER RELAY
nostic methods, to On-Board Diagnostics (OBD) built
into the Powertrain Control Module (PCM). Use of an
induction milliamp ammeter, volt/ohmmeter, battery
charger, carbon pile rheostat (load tester), and 12- J958A-13
volt test lamp will be required.
All OBD-sensed systems are monitored by the Fig. 1 Starting System Components - Typical
PCM. Each monitored circuit is assigned a Diagnos
tic Trouble Code (DTC). The PCM will store a DTC in ing On-Board Diagnostic System in this group for
electronic memory for any failure it detects. See Us- more information.
BATTERY
GENERAL INFORMATION electrons produces a flow of electrical current through

The storage battery is a device used to store electrical the load device attached to the battery terminals.
energy potential in a chemical form. When an electrical As the plate materials become more * similar chem
load 'is applied to the battery terminals, an electrochem ically, and the electrolyte becomes less acid, the volt
ical reaction occurs within the battery. This reaction age potential of each cell is reduced. However, by
causes the battery to discharge electrical current. charging the battery with a voltage higher than that
The battery is made up of 6 individual cells that of the battery, the process is reversed.
are connected in series. Each cell contains positively Charging the battery gradually changes the sulfated
charged plate groups made of lead oxide, and nega lead plates back into sponge lead and lead oxide, and
tively charged plate groups made of sponge lead. the water back into sulfuric acid. This action restores
These dissimilar metal plates are submerged in a the difference in electron charges deposited on the
sulfuric acid and water solution called electrolyte. plates, and the voltage potential of the battery cells.
As the battery discharges, a .gradual chemical For a battery to remain useful, it must be able to
change takes place within each cell. The sulfuric acid produce high-amperage current over an extended pe
in the electrolyte combines with the plate materials, riod. A battery must also be able to accept a charge,
causing both plates to change to lead sulfate. At the so that its voltage potential may be restored.
same time, oxygen from the positive plate material In addition to producing and storing electrical en
combines with hydrogen from the sulfuric acid, caus ergy, the battery serves as a capacitor or voltage sta
ing the electrolyte to become mainly water. bilizer for the vehicle electrical system. It absorbs
The chemical changes within the battery are caused abnormal or transient voltages caused by switching
by movement of excess or free electrons between the of any of the vehicle's electrical components.
positive and negative plate groups. This movement of
mm BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 8A - 3
The battery is vented to release excess gas that is air heater. The primary battery on the driver's
created when the battery is being charged or dis side is dedicated to all other vehicle electrical
charged. However, even with these vents, hydrogen requirements. In order to ensure accurate diag
gas can collect in or around the battery. If hydrogen nostic results, these batteries MUST be discon
gm is exposed to flame or sparks, it can ignite. nected from each other as well as from the
If the electrolyte level is low, the battery could arc in vehicle electrical system when being tested.
ternally and explode. If the battery is equipped with re The condition of a battery is determined by two cri
movable cell caps, add distilled water whenever the teria:
electrolyte level is below the top of the plates. If the bat (1) State-Of-Charge - This can be determined by
tery cell caps cannot be removed, the battery must be viewing the built-in test indicator, by checking spe
replaced when the electrolyte level is low. cific gravity of the electrolyte (hydrometer test), or by
checking battery voltage (open circuit voltage test).
WARNING: DO NOT ATTEMPT TO A S S I S T BOOST, (2) Cranking Capacity - This can be determined by
CHARGE, OR T E S T BATTERY W H E N E L E C T R O performing a battery load test, which measures the abil
LYTE L E V E L IS B E L O W THE TOP OF THE P L A T E S . ity of the battery to supply high-amperage current.
P E R S O N A L INJURY MAY OCCUR. If the battery has a built-in test indicator, use this
test first. If it has no test indicator, but has remov
able cell caps, perform the hydrometer test first. If
.BATTERY RATINGS cell caps are not removable, or a hydrometer is not
Currently, there are 2 commonly accepted methods for available, perform the open circuit voltage test first.
rating and comparing battery performance. These rat The battery must be charged before proceeding
ings are called Cold Cranking Amperage (CCA), and Re with a load test if:
serve Capacity (RC). Be certain that a replacement • the built-in test indicator has a black or dark color
battery has CCA and RC ratings that equal or exceed visible
the original equipment specification for the vehicle be • the temperature corrected specific gravity is less
ing serviced. See Battery Classifications and Ratings than 1.235
charts in Specifications at the back of this group. • the open circuit voltage is less than 12.4 volts.
A battery that will not accept a charge is faulty
COLD CRANKING AMPERAGE and further testing is not required. A battery that is
The Cold Cranking Amperage (CCA) rating speci fully-charged, but does not pass the load test is
fies how much current (in amperes) the battery can faulty and must be replaced.
deliver for 30 seconds at -17.7°C (0°F). Terminal volt Completely discharged batteries may take
age must not fall below 7.2 volts during or after the several hours to accept a charge. See Charging
30 second discharge. The CCA required is generally Completely Discharged Battery.
higher as engine displacement increases, depending A battery is fully-charged when:
also upon the starter current draw requirements. • all cells are gassing freely during charging
• a green color is visible in the sight glass of the
RESERVE CAPACITY built-in test indicator
The Reserve Capacity (RC) rating specifies the • three corrected specific gravity tests, taken at 1-hour
time (in minutes) it takes for battery terminal volt intervals, indicate no increase in specific gravity
age to fall below 10.2 volts at a discharge rate of 25 • open circuit voltage is 12.4 volts or greater.
amps. RC is determined with the battery fully-
charged at 26.7°C (80°F). This rating estimates how ABNORMAL BATTERY DISCHARGING
long the battery might last after a charging system Any of the following conditions can result in abnor
failure, under minimum electrical load. mal battery discharging:
(1) Corroded battery posts and terminals.
DIAGNOSIS (2) Loose or worn generator drive belt.
The battery must be completely charged and the (3) Electrical loads that exceed the output of the
top, posts, and terminal clamps should be properly charging system, possibly due to equipment installed
cleaned before diagnostic procedures are performed. after manufacture or repeated short trip use.
Refer to Group 8B - Battery/Starter/Generator Ser (4) Slow driving speeds (heavy traffic conditions) or
vice for more information. prolonged idling with high-amperage draw systems in
Models equipped with the diesel engine op use.
tion are equipped with two 12-volt batteries (5) Faulty circuit or component causing excessive
connected in parallel (positive-to-positive/nega ignition-off draw. See Ignition-Off Draw in this group
tive-to-negative). The secondary battery on the for diagnosis.
passenger side is dedicated to providing cur (6) Faulty charging system.
rent for the operation of the intake manifold (7) Faulty or incorrect battery.
- 4 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS
BATTERY DIAGNOSIS
IS THIS THE CORRECT

BATTERY BATTERY FOR THIS REPLACE W I T H
SEEMS W E A K YES VEHICLE? REFER TO NO CORRECT
OR DEAD? SPECIFICATIONS, BATTERY.
IN THIS GROUP.
YES
ARE BATTERY
POSTS TIGHT A N D REPLACE
IS BATTERY CASE NO DAMAGED
FREE OF DAMAGE BATTERY.
OR LEAKS?
YES
ARE BATTERY
CLEAN A N D
CONNECTIONS NO TIGHTEN A S
CLEAN A N D
REQUIRED.
TIGHT
DONE
YES
IS BATTERY FULLY
CHARGED? REFER TO CHARGE BATTERY
TEST INDICATOR, DOES BATTERY ACCEPT REPLACE
HYDROMETER TEST, OR NO A CHARGE? REFER TO NO FAILED
O P E N CIRCUIT BATTERY C H A R G I N G , BATTERY.
VOLTAGE TEST, IN IN THIS GROUP.
THIS GROUP.
YES
WILL BATTERY
PASS A LOAD
TEST? REFER TO NO
LOAD TEST, IN
THIS GROUP.
YES
t
REFER TO
BATTERY STILL
ABNORMAL
S E E M S W E A K OR
NO BATTERY
DEAD W H E N
DISCHARGING,
STARTING?
IN THIS GROUP.
YES
REFER TO
STARTER
D I A G N O S I S , IN
THIS GROUP.
J958A-1
BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 8A - 5
BUILT-IN TEST INDICATOR may be caused by an over-charging condition. See

A test indicator (hydrometer) built into the top of Charging System in this group to diagnose an over
the battery case, provides visual information for bat charging condition.
tery testing (Fig. 3). It is important when using the
test indicator that the battery be level and have a WARNING: DO NOT ATTEMPT TO CHARGE, TEST,
clean sight glass to see correct indications. Additional OR A S S I S T BOOST BATTERY W H E N Y E L L O W OR
light may be required to view indicator. BRIGHT COLOR I S V I S I B L E IN SIGHT G L A S S OF
T E S T INDICATOR. LOW ELECTROLYTE L E V E L CAN
WARNING: DO NOT U S E OPEN FLASHE A S A A L L O W BATTERY TO ARC INTERNALLY AND EX
S O U R C E O F ADDITIONAL LIGHT FOR VIEWING PLODE. P E R S O N A L INJURY MAY OCCUR.
T E S T INDICATOR. E X P L O S I V E HYDROGEN G A S
MAY B E P R E S E N T IN THE A R E A SURROUNDING TEST INDIGATOR/STATE-OF-CHARGE
BATTERY. LOW
100% 75% O
ELECTROLYTE
liBii ilSl
Miisik y^/gfT tMSm&i
GREEN BLACK YELLOW

J958A-6
Fig. 4 Built-in Test Indicator Sight Glass

HYDROMETER TEST
The hydrometer test reveals the battery state-of-
Fig. 3 Built-in Test Indicator charge by measuring the specific gravity of the elec
Like a hydrometer, the built-in test indicator mea trolyte. This test cannot be performed on batteries
sures the specific gravity of the electrolyte. Specific with non-removable cell caps. If battery has non-re
gravity will indicate battery state-of-charge. How movable cell caps, see Built-in Test Indicator or Open
ever, the test indicator will not indicate cranking ca Circuit Voltage Test.
pacity of the battery. See Load Test in this group for Specific gravity is a comparison of the density of
more information. the electrolyte to the density of pure water. Pure wa
Look into the sight glass and note the color of the ter has a specific gravity of 1.000, and sulfuric acid
indicator (Fig. 4). See the following description, as has a specific gravity of 1.835. Sulfuric acid makes
the color indicates: up approximately 35% of the electrolyte by weight, or
• GREEN - indicates 75% to 100% state-of-charge. 24% by volume.
The battery is adequately charged for further test In a fully-charged battery the electrolyte will have
ing or return to use. If the vehicle will not crank for a temperature corrected specific gravity of 1.260 to
a minimum of 15 seconds with a fully-charged bat 1.290. However, a specific gravity of 1.235 or above is
tery, perform Load Test. satisfactory for battery load testing and/or return to
• BLACK OR DARK - indicates 0% to 75% state-of- service.
charge. Before testing, visually inspect battery for any
The battery is inadequately charged and must be damage (cracked case or cover, loose posts, etc.) that
charged until green indicator (Fig. 4) is visible in would cause the battery to be faulty. Then remove
sight glass (12.4 volts or more) before the battery is cell caps and check electrolyte level. Add distilled wa
tested further or returned to use. See Abnormal Bat ter if electrolyte level is below the top of the battery
tery Discharging in this group to diagnose cause of plates.
discharged condition. To use the hydrometer correctly, hold it with the
• YELLOW OR BRIGHT - indicates low electrolyte top surface of the electrolyte at eye level. Refer to the
level. hydrometer manufacturer's instructions for correct
The electrolyte level in the battery is below test in use of hydrometer. Remove only enough electrolyte
dicator. A maintenance-free battery with non-remov from the battery so the float is off the bottom of the
able cell caps must be replaced if electrolyte level is hydrometer barrel with pressure on the bulb re
low. Water can be added to a low-maintenance bat leased.
tery with removable cell caps. A low electrolyte level
8A - 6 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS
Exercise care when inserting the tip of the hydrom (1) Before measuring open circuit voltage the sur
eter into a cell to avoid damaging the plate separa face charge must be removed from the battery. Turn
tors. Damaged plate separators can cause premature headlamps on for 15 seconds, then allow up to 5 min
battery failure. utes for voltage to stabilize.
Hydrometer floats are generally calibrated to indi (2) Remove both battery cables, negative first. On
cate the specific gravity correctly only at 26.7°C diesel engine models with dual batteries, each bat
(80°F). When testing the specific gravity at any other tery must be disconnected and tested separately from
temperature, a correction factor is required. the other.
The correction factor is approximately a specific (3) Using a voltmeter connected to the battery
gravity value of 0.004, referred to as 4 points of spe posts (refer to instructions provided with voltmeter)
cific gravity. For each 5.5°C above 26.7°C (10°F above measure open circuit voltage (Fig. 5).
80°F), add 4 points. For each 5.5°C below 26.7°C See Open Circuit Voltage chart. This voltage read
(10°F below 80°F), subtract 4 points. Always correct ing will indicate state-of-charge, but will not reveal
the specific gravity for temperature variation. Test cranking capacity. If a battery has an open circuit
the specific gravity of the electrolyte in each battery voltage reading of 12.4 volts or greater, it may be
cell. load tested. A battery that will not endure a load test
Example: A battery is tested at -12.2°C (10°F) and is faulty and must be replaced.
has a specific gravity of 1.240. Determine the actual OPEN CIRCUIT VOLTAGE
specific gravity as follows:
(1) Determine the number of degrees above or be
low 26.7°C (80°F): Open Circuit ¥©its
26.6°C - -12.2°C = 38.8°C (80°F - 10°F = 70°F)
(2) Divide the result from step 1 by 5.5 (10): 11.7 volts or less 0%
38.8°C/5.5 = 7 (70°F/10 = 7)
12.0 25%
(3) Multiply the result from step 2 by the temper
ature correction factor (0.004): 12.2 50%
7 x 0.004 = 0.028 12.4 75%
(4) The temperature at testing was below 26.7°C 12.6 or more 100%
(80°F); therefore, the temperature correction is sub 928A-3
tracted:
1.240 - 0.028 = 1.212
The corrected specific gravity of the battery in this
example is 1.212.
If the specific gravity of all cells is above 1.235, but
variation between cells is more than 50 points
(0.050), the battery should be replaced.
If the specific gravity of one or more cells is less
than 1.235, charge the battery at a rate of approxi
mately 5 amperes. Continue charging until 3 consec
utive specific gravity tests, taken at 1-hour intervals,
are constant. If the cell specific gravity variation is
more than 50 points (0.050) at the end of the charge
period, replace the battery.
When the specific gravity of all cells is above 1.235, 898A-7
and cell variation is less than 50 points (0.050), the Fig. 5 Testing Open Circuit Voltage
battery may be load tested.
LOAD TEST
OPEN CIRCUIT VOLTAGE TEST A battery load test will verify battery cranking ca
A battery open circuit voltage (no load) test will pacity. The test is based on the Cold Cranking Am
show state-of-charge of a battery. This test can be perage (CCA) rating of the battery. See Battery
used in place of the hydrometer test if a hydrometer Classifications and Ratings chart in Specifications, at
is not available, or for maintenance-free batteries the back of this group.
with non-removable cell caps.
Before proceeding with this test or load test, WARNING; IF BATTERY S H O W S S I G N S OF F R E E Z
completely charge battery as described in Bat ING, LEAKING, L O O S E P O S T S , OR L O W E L E C T R O
tery Charging in this group. LYTE L E V E L , DO NOT LOAD TEST. P E R S O N A L
Test battery open circuit voltage as follows: INJURY AND/OR VEHICLE DAMAGE MAY RESULT.
BR BATTERY/ST1RTING/CHARGING SYSTEMS DIAGNOSTICS 8A - 7
Before performing load test, the battery must

be FULLY-CHARGED. 20i.'jij!.j? 20 .„
(1) Remove both battery cables, negative first. Bat \l li i...iu
l
™ .Mi,..., C
10
O
tery top and posts should be clean.
(2) Connect a suitable volt-ammeter-load tester
(Fig. 6) to the battery posts (Fig. 7). Refer to operat
ing instructions provided with the tester being used.
Check the open circuit voltage (no load) of the bat
tery. Open circuit voltage must be 12.4 volts or
greater.
898A10
r i g , 3 R m n o m S m r m ® O h & i r g s f r o m Battery
us;
+ 1
t^K^^Ty^M^l:^: "" "._ . . . ^ ^ ' ' ^ 1 ^
VCMJ SELECTOR nan saa

j now
898A-8
Fig. 6 Volt-Amps-Load Tester - Typical
INDUCTION NEGATIVE
AMMETER CLAMP
CLAMP 898All
Fig. 9 Load 50% CCA Rating - Note Voltage

charged, boosted, or loaded a few minutes prior to
POSITIVE test, the battery will be somewhat warmer. See Load
CLAMP
Test Temperature chart for proper loaded voltage
reading.
(7) If the voltmeter reading falls below 9.6 volts, at
a minimum battery temperature of 21°C (70°F), re
place the battery.
J948A-13
LOAD TEST TEMPERATURE
Fig. 7 Volt-Ammeter-Load Tester Connections
Minimum Voltage
(3) Rotate the load control knob (carbon pile rheo P e
stat) to apply a 300 amp load for 15 seconds, then re
9.6 70 and above 21 and above
turn the control knob to OFF (Fig. 8). This will
remove the surface charge from the battery. 9.5 60 16
(4) Allow the battery to stabilize to open circuit 9.4 50 10

voltage. It may take up to 5 minutes for voltage to 9.3 40 4
stabilize. 9.1 30 -1
(5) Rotate the load control knob to maintain a load 8.9 20 ~7 1
equal to 50% of CCA rating (Fig. 9). After 15 seconds,
record the loaded voltage reading, then return the 8.7 10 -12
load control knob to OFF. 8.5 0 -18

(6) Voltage drop will vary with battery tempera J908A4
ture at the time of the load test. Battery temperature
can be estimated by the ambient temperature over
the past several hours. If the battery has been
81 - 8 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS
BATTERY CHARGING Some battery chargers are equipped with polarity

sensing circuitry. This circuitry protects the charger
A battery is fully-charged when:
and/or battery from being damaged if improperly con
© all cells are gassing freely during charging nected.
© a green color is visible in sight glass of built-in If the battery state-of-charge is too low for the po
test indicator larity sensing circuitry to detect, the charger will not
© three corrected specific gravity tests, taken at operate. This makes it appear that the battery will
1-hour intervals, indicate no increase in specific grav not accept charging current. Refer to instructions
ity provided with the battery charger being used to by
• open circuit voltage is 12.4 volts or above. pass the polarity sensing circuitry.
WARNING: DO NOT A S S I S T BOOST OR C H A R G E A BATTERY CHARGING TIME TABLE
BATTERY THAT HAS LOW ELECTROLYTE L E V E L
OR IS F R O Z E N . BATTERY MAY A R C INTERNALLY Charging Amperage 5 Amps 10 Amps 20 Amps
AND E X P L O D E , Open Circuit Voltage H@urs Charging at 21°C
12.25to12.39 6Hrs. 3Hrs. 1.5 Hr.
WARNING: E X P L O S I V E HYDROGEN G A S F O R M S IN 12.00 to 12.24 8Hrs. 4Hrs. 2Hrs.
AND AROUND BATTERY* DO NOT SMOKE, USE 11.95to12.09 12Hrs. 6Hrs. 3 Hrs. 1
FLAME, OR CREATE S P A R K S NEAR BATTERY. 10.00 to 11.95 14Hrs. 7Hrs. 3.5 H s. |

10.00to0 See Charging Completely
Discharged Battery
WARNING: POISONOUS AND CAUSTIC. BATTERY
CONTAINS S U L F U R I C ACID. AVOID CONTACT WITH 928A-19
SKIN, E Y E S , OR CLOTHING. IN EVENT OF CON After the battery has been charged to 12.4 volts or
TACT, F L U S H WITH WATER AND CALL PHYSICIAN greater, perform a load test to determine cranking
IMMEDIATELY. K E E P OUT OF REACH OF CHIL capacity. If the battery will endure a load test, return
DREN. the battery to use. If the battery will not endure a
load test, it must be replaced.
Clean and inspect battery holddowns, tray, termi
CAUTION: Always disconnect the battery negative
nals, posts, and top before completing service. Refer
cable before charging battery to avoid damage to
to Group 8B - Battery/Starter/Generator Service for
electrical system components. Do not exceed 16.0
more information.
volts while charging battery.
emMmmiNG t i m e REQUIRED
Models equipped with the diesel engine op The time required to charge a battery will vary, de
tion are equipped with two 12-volt batteries pending upon the following factors:
connected in parallel (positive-to-positive/nega (1) Battery Capacity - A completely discharged
tive-to-negative). The secondary battery on the heavy-duty battery requires twice the recharging
passenger side is dedicated to providing cur time of a small capacity battery.
rent for the operation of the intake manifold
air heater. The primary battery on the driver's WARNING: NEVER E X C E E D 20 A M P S W H E N
side is dedicated to all other vehicle electrical CHARGING A COLD (-1°C*30°F) BATTERY. PER
requirements. In order to ensure proper charg SONAL INJURY MM RESULT.
ing of each battery, these batteries MUST be
disconnected from each other as well as from (2) Temperature - A longer time will be needed to
the vehicle electrical system while being charge a battery at -18°C (0°F) than at 27°C (80°F).
charged. When a fast charger is connected to a cold battery,
current accepted by the battery will be very low at
Battery electrolyte will bubble inside battery case first. As the battery warms, it will accept a higher
during normal battery charging. If the electrolyte charging current rate.
boils, or is discharged from the vent holes while (3) Charger Capacity - A charger that supplies
charging, immediately reduce charging rate or turn only 5 amperes will require a longer charging time. A
OFF charger and evaluate battery condition. charger that supplies 20 amperes or more requires a
Battery should not be hot to the touch. If the shorter charging time.
battery feels hot to the touch, turn OFF (4) State-Of-Charge - A completely discharged
charger and let battery cool before continuing battery requires more charging time than a partially
charging operation. discharged battery. Electrolyte i s nearly pure water
in a completely discharged battery. At first, the
BR BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 8A- 9
charging current (amperage) will be low. As the bat

tery charges, the specific gravity of the electrolyte
will gradually rise.
CHARGING COMPLETELY DISCHARGED
BATTERY
The following procedure should be used to recharge
a completely discharged battery. Unless this proce
dure is properly followed, a good battery may be
needlessly replaced.
(1) Measure voltage at battery posts with a voltme
ter, accurate to 1/10 (0.10) volt (Fig. 10). If the read
ing is below 10 volts, the charge current will be low.
It could take some time before the battery accepts a 898A12
current greater than a few milliamperes. Such low
current may not be detectable on ammeters built into Fig. 10 Voltmeter Accurate to 1/10 Volt Connected
many chargers. charge current is measurable during charging time,
(2) Disconnect battery negative cable. Connect the battery may be good and charging should be com
charger leads. Some battery chargers are equipped pleted in the normal manner.
with polarity sensing circuitry. This circuitry protects
the charger and/or battery from being damaged if im CHARGE RATE
properly connected. If the battery state-of-charge is
too low for the polarity sensing circuitry to detect,
the charger will not operate. This makes it appear Voltage Hours
that the battery will not accept charging current. Re
fer to the instructions provided with the battery
charger to bypass the polarity sensing circuitry. 16.0 volts maximum up to 4 hrs.
(3) Battery chargers vary in the amount of voltage
14.0 to 15.9 volts up to 8 hrs.
and current they provide. The amount of time re
quired for a battery to accept measurable charger
13.9 volts or less up to 16 hrs.
current at various voltages is shown in Charge Rate
chart. If charge current is still not measurable at end J928A-6
of charging times, the battery should be replaced.' If
8A -10 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS
IGNITIONOFF DRAW
GENERAL INFORMATION battery negative terminal. Make sure that the doors
Ignition-Off Draw (10D) refers to power being remain closed so that illuminated entry is not acti
drained from the battery with the ignition switch vated.
turned OFF. A normal vehicle electrical system will The test lamp may light brightly for up to 3 min
draw from 5 to 20 milliamps (0.005 - 0.020 amps). utes, or may not light at all, depending upon the ve
This is with the ignition switch in the OFF position, hicle's electrical equipment. The term brightly, as
and all non-ignition controlled circuits in proper used throughout the following tests, implies the
working order. The 20 milliamps are needed to sup brightness of the test lamp will be * the same as if it
ply PCM memory, digital clock memory, and electron were connected across the battery.
ically-tuned radio memory. The test lamp must be securely clamped to the neg
A vehicle that has not been operated for approxi ative cable clamp and battery negative terminal. If
mately 20 days, may discharge the battery to an in the test lamp becomes disconnected during any part
adequate level. When a vehicle will not be used for of the IOD test, the electronic timer function will be
20 days or more (stored), remove the IOD fuse in the activated and all tests must be repeated.
Power Distribution Center (PDC). This will reduce (5) After 3 minutes the test lamp should turn off
battery discharging. or be dimly lit, depending upon the vehicle's electri
Excessive battery drain can be caused by: cal equipment. If the test lamp remains brightly lit,
• electrical items left on do not disconnect it. Remove each fuse or circuit
• faulty or improperly adjusted switches breaker (refer to Group 8W - Wiring Diagrams) until
• internally shorted generator test lamp is either off or dimly lit. This will isolate
• intermittent shorts in the wiring. each circuit and identify the source of the high-am
If the IOD is over 20 milliamps, the problem must
perage draw.
be found and corrected before replacing a battery. In
most cases, the battery can be charged and returned If the test lamp is still brightly lit after disconnect
to service. . ing each fuse and circuit breaker, disconnect the wir
ing harness from the generator. If test lamp now
DIAeiOSiS turns off or is dimly lit, see Charging System in this
Testing for high-amperage IOD must be per group to diagnose faulty generator. Do not disconnect
formed first to prevent damage to most milli- the test lamp.
amp meters. After high-amperage IOD has been corrected, low-
When testing a diesel engine-equipped vehicle amperage IOD may be checked. It is now safe to in
(dual batteries), do not check IOD between bat stall a milliamp meter to check for low- amperage
teries. One battery may be at a higher state-of- IOD.
charge than the other, which will cause a high (6) With test lamp still connected securely, clamp a
IOD between the batteries only. Remove nega milliamp meter between battery negative terminal
tive cable from passenger side battery negative and negative cable clamp.
post prior to performing the IOD diagnosis out Do not open any doors or turn on any electri
lined below. cal accessories with the test lamp disconnected
(1) Verify that all electrical accessories are off. or the milliamp meter may be damaged.
Turn off all lamps, remove ignition key, and close all (7) Disconnect test lamp. Observe milliamp meter.
doors. If the vehicle is equipped with illuminated en
The current draw should not exceed 0.020 amp. If
try or electronically-tuned radio, allow the systems to
automatically shut off (time out). This may take up draw exceeds 20 milliamps, isolate each circuit by re
to 3 minutes. moving circuit breakers and fuses. The milliamp
(2) Determine that the underhood lamp is operat meter reading will drop when the source of the draw
ing properly, then disconnect or remove bulb. is disconnected. Repair this circuit as necessary,
(3) Disconnect negative cable from battery. whether a wiring short, incorrect switch adjustment
(4) Connect a typical 12-volt test lamp (low-watt or a component failure is found.
age bulb) between the negative cable clamp and the
BR BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 8A -11
STARTING SYSTEM
GENERAL INFORMATION clutch pedal position switch. The clutch pedal posi
The starting system (Fig. 11) consists of: tion switch supplies battery voltage to the coil bat
• ignition switch tery terminal of the starter relay only if the clutch
• starter relay pedal is depressed while the ignition switch is turned
• park/neutral position switch (automatic transmis to the START position.
sion) If the vehicle is equipped with an automatic trans
® clutch pedal position switch (manual transmission) mission, the park/neutral position switch provides a
• wiring harness and connections ground path to the starter relay coil ground terminal.
• battery This switch provides ground only with the transmis
sion in NEUTRAL or PARK. If the vehicle is
• starter with an integral solenoid.
equipped with a manual transmission, the starter re
SOLENOID TERMINAL lay coil ground terminal is always grounded.
NEGATIVE With the starter relay coil now energized, the nor
mally open relay contacts close. The relay contacts
connect the relay common feed terminal to the relay
normally open terminal. The closed relay contacts en
ergize the starter solenoid coil windings.
The energized solenoid coils pull-in and hold-in the
solenoid plunger. The solenoid plunger pulls the shift
lever in the starter. This engages the starter overrun
ning clutch and pinion gear with the flywheel/drive
plate ring gear.
As the solenoid plunger reaches the end of its
travel, the solenoid contact disc completes the high-
IGNITION
amperage starter feed circuit. Current now flows be
SWITCH tween the solenoid battery terminal and the starter
CLUTCH PEDAL
POSITION SWITCH
motor, energizing the starter.
(MAN. TRANSMISSION ONLY) GROUND, Once the engine starts, the overrunning clutch pro
CIRCUIT tects the starter from damage by allowing the starter
PARK/NEUTRAL POSITION pinion gear to spin faster than the pinion shaft.
SWITCH (AUTO. When the driver releases the ignition switch to the
TRANS. ONLY) THIS CIRCUIT GROUNDED
AT ALL TIMES
ON position the starter relay coil is de-energized.
(MAN. TRANS. ONLY) This causes the relay contacts to open. When the re
lay contacts open, the starter solenoid coil is de-ener
gized.
958A-T When the solenoid coil is de-energized, the solenoid
plunger return spring returns the plunger to its re
Fig, 11 Starting System Components - Typical laxed position. This causes the contact disc to open
Following is a general description of the major the starter feed circuit, and the shift lever to disen
starting system components. Refer to Group 8W - gage the overrunning clutch and pinion gear from the
Wiring Diagrams for complete circuit descriptions ring gear.
and diagrams. The starter motor and solenoid are serviced only as
These components form 2 separate circuits. A high- a complete assembly. If either component fails, the
amperage feed circuit that feeds the starter up to entire assembly must be replaced.
300+ amps (700 amps-diesel engine), and a low-am DIAGNOSIS
perage control circuit that operates on less than 20 Before removing any unit from the starting system
amps. for repair, perform the following inspections:
If the vehicle is equipped with an automatic trans
mission, battery voltage is supplied through the low- INSPECTION
amperage control circuit to the coil battery terminal
of the starter relay when the ignition switch is BATTERY IlSPECTiOl
turned to the START position. If the vehicle is To determine condition of the battery, see Battery
equipped with a manual transmission, it also has a in this group.
81-12 BATTEif/STAiTIil/CHlRGiiG 8YSTE1S DIAGNOSTICS —- B R
WIRING INSPECTION SOLENOli, RELAY AND SWITCH I1SPECTI0NS

Inspect wiring for damage. Inspect all connections Inspect the solenoid, relay and ignition switch to
at: determine their condition. Also, if equipped with au
• starter solenoid tomatic transmission, inspect condition of the park/
• park/neutral position switch (automatic transmis neutral position switch. If equipped with manual
sion) transmission, inspect condition of the clutch pedal
• clutch pedal position switch (manual transmission) position switch. Testing information can be found in
• ignition switch the following pages.
• starter relay
• battery (including all ground connections).
Clean, tighten and repair all connections as re
quired.
- BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 8A - 13
STARTING SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAtJSIS COiRiCTION
STARTER FAILS 1 . Battery discharged or 1 . See Battery, in this group. Charge or

TO ENGAGE. faulty. replace battery, if required.
2. Starting circuit wiring 2. See Cold Cranking Test, in this group.
faulty. Test and repair feed and/or control
circuits, if required.
3. Starter relay faulty. 3. See Relay Test, in this group. Replace relay.
if required.
4. Ignition switch faulty. 4. Refer to Group 8D - Ignition Systems, for
testing and service information. Replace or
adjust switch, if required.
5. Park/Neutral position 5. Refer to Group 21 - Transmission and Transfer
switch (auto trans) Case, for testing and service information.
faulty or misadjusted. Replace switch, if required.
6. Clutch pedal position 6. Refer to Group 6 - Clutch, for testing and
switch (man trans) service information. Replace switch, if
faulty. required.
7. Starter solenoid 7 See Solenoid Test, in this group. Replace
faulty. starter assembly, if required.
8. Starter assembly 8 Refer to Group 8B - Battery/Starter/Generator
faulty. Service, for starter service procedures.
Replace starter assembly, if required.
STARTER 1. Battery discharged or 1. See Battery, in this group. Charge or
ENGAGES, faulty. replace battery, if required.
FAILS TO TURN 2. Starting circuit wiring 2. See Cold Cranking Test, in this group.
ENGINE. faulty. Test and repair feed and/or control
circuits, if required.
3. Starter assembly 3. Refer to Group 8B - Battery/Starter/Generator
4. Engine seized. 4. Refer to Group 9 - Engine, for diagnostic and
service procedures.
STARTER 1. Broken teeth on 1. Refer to Group 8B - Battery/Starter/Generator
ENGAGES, flywheel or drive plate Service, for starter removal procedures.
SPINS OUT BEFORE ring gear. Inspect ring gear and replace, if required.
ENGINE STARTS. 2. Starter assembly 2. Refer to Group 8B - Battery/Starter/Generator
STARTER DOES 1. Starter improperly 1. Refer to Group 8B - Battery/Starter/Generator
NOT DISENGAGE. installed. Service, for starter installation procedures.
2. Starter relay faulty. 2. See Relay Test, in this group. Replace
relay, if required.
3. Ignition switch faulty. 3. Refer to Group 8D - Ignition Systems, for
testing and service information. Replace or
adjust switch, if required.
4. Starter assembly 4. Refer to Group 8B - Battery/Starter/Generator
J958A-11
8A -14 BATTEiY/STARTIiG/CHARGiiG SYSTE1S DIAGNOSTICS BR
COLD CRANKING TEST (6) Rotate and hold the ignition switch in the
(1) Battery must be fully-charged and load tested START position. Note cranking voltage and amper
before proceeding. See Battery, in this group. age.
(2) Connect a suitable volt-ampere tester to the (a) If voltage reads above 9.6 volts and amperage
battery terminals (Fig. 12). Refer to the operating in draw reads above specifications, see Feed Circuit
structions provided with the tester being used. Tests.
(b) If voltage reads 12.5 volts or greater and am
perage reads below specifications, see Control Cir
cuit Tests.
A cold engine will increase starter current
and reduce battery voltage.
FEED CIRCUIT TESTS
The starter feed circuit tests (voltage drop method)
will determine if there is excessive resistance in the
high-amperage circuit. When performing these tests,
it is important that the voltmeter be connected prop
erly. Connect voltmeter leads to the terminals that
the cable connectors or clamps are attached to, not to
the cable connectors or clamps. For example: When
testing between the battery and solenoid, touch the
Fig. 12 Volt-Amps Tester Connections - Typical voltmeter leads to the battery post and the solenoid
(3) Fully engage parking brake. Place manual threaded stud.
transmission in NEUTRAL and fully depress clutch The following operation will require a voltmeter ac
pedal. Place automatic transmission in PARK. curate to 1/10 (0.10) volt. Before performing the tests,
(4) Verify that all lamps and accessories are OFF. be certain the following procedures are accomplished:
(5) To prevent engine from starting, unplug Auto • unplug Auto Shut-Down (ASD) relay from Power
Shut-Down (ASD) relay from Power Distribution Distribution Center (PDC) on gas engine models to
Center (PDC) on gas engine models, or disconnect prevent engine from starting
fuel shutdown solenoid connector (Fig. 13) on diesel • disconnect the fuel shutdown solenoid connector on
engine models. Relay location is shown on underside diesel engine models to prevent engine from starting
of PDC cover. • place transmission in NEUTRAL (manual trans
mission) or PARK (automatic transmission)
FRONT OF ENGINE AIR TEMPERATURE SENSOR • install a jumper wire between two clutch pedal po
sition switch connectors (manual transmission)
• parking brake is applied
• battery is fully-charged (see Battery, in this
group).
(1) Connect positive lead of voltmeter to battery
negative post. Connect negative lead of voltmeter to
battery negative cable clamp (Fig. 14). Rotate and
hold ignition switch in the START position. Observe
voltmeter. If voltage is detected, correct poor contact
between cable clamp and post.
(2) Connect positive lead of voltmeter to battery
positive post. Connect negative lead of voltmeter to
battery positive cable clamp (Fig. 14). Rotate and
hold ignition switch in the START position. Observe
voltmeter. If voltage is detected, correct poor contact
between cable clamp and post.
(3) Connect voltmeter to measure between the bat
tery positive post and the starter solenoid battery
SOLENOID ELECTRICAL J9414-93
J y 4 l 4 V J
stud (Fig. 15). Rotate and hold ignition switch in the
CONNECTOR
START position. Observe voltmeter. If voltage reads
Fig. 13 Fuel Shutdown Solenoid - Diesel Engine
above 0.2 volt, correct poor contact at battery cable to
solenoid connection. Repeat test. If reading is still
above 0.2 volt, replace battery positive cable.
B R BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS SA -15
VOLTMETER
(5) Connect positive lead of voltmeter to starter
housing. Connect negative lead of voltmeter to bat
tery negative terminal (Fig. 17). Rotate and hold ig
nition -switch in the START position. Observe
voltmeter. If voltage reads above 0.2 volt, correct poor
starter to engine ground.
STARTER BATTERY
MOTOR
BATTERY
898A-17
VOLTMETER
Fig. 14 Test Battery Connection Resistance
BATTERY
898A-26
Fig. 17 Test Starter Ground - Typical

If resistance tests detect no feed circuit problems,
remove the starter and see Solenoid Test in this
group.
CONTROL CIRCUIT TESTS
The starter control circuit consists of:
STARTER
MOTOR VOLTMETER 898A-20 • starter solenoid
• starter relay
Fig, 15 Test Battery Positive Cable Resistance - © ignition switch
Typical • park/neutral position switch (automatic transmis
(4) Connect voltmeter to measure between the bat sion)
tery negative post and a good clean ground on the © clutch pedal position switch (manual transmission)
engine block (Fig, 16), Rotate and hold ignition • wiring harness and connections.
switch in the START position. Observe voltmeter. If Test procedures for these components are as fol
voltage reads above 0.2 volt, correct poor contact at lows, and should be followed in the order described.
battery negative cable attaching point. Repeat test. If
CAUTION: Before performing any test, unplug Auto
reading is still above 0.2 volt, replace battery nega
Shut-Down (ASD) relay from Power Distribution
tive cable.
Center (PDC)(gas engine) or unplug fuel shutdown
VOLTMETER solenoid connector (diesel engine) to prevent en
gine from starting.
SOLENOii TEST
Refer to Group 8B - Battery/Starter/Generator Ser
vice for starter removal procedures.
(1) Disconnect solenoid field coil wire from field
coil terminal.
(2) Check for continuity between solenoid terminal
and field coil terminal with a continuity tester. There
should be continuity (Fig. 18).
ENGINE v (3) Check for continuity between solenoid terminal
GROUNDX BATTERY 898A-18
and solenoid case. There should be continuity (Fig.
Fig, W Test Ground Circuit Resistance 19).
8A- 16 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS
FIELD COIL POWER

TERMINAL DISTRIBUTION
CENTER
(PDC)
RR8BD32
Fig. 18 Continuity Test Between Solenoid Terminal

and Field Coil Terminal
SOLENOID
J9414-10
Fig. 20 Power Distribution Center

RR8BD33 STARTER RELAY CONNECTIONS
Fig. 19 Continuity Test Between Solenoid Terminal RELAY TERMINALS RELAY CAVITIES
and Solenoid Case
87A
(4) If there is continuity, solenoid is good. If there
is no continuity in either test, solenoid has an open
circuit and is faulty. Replace starter assembly. 85 f&TAT] 86
(5) Connect solenoid field coil wire to field coil ter
minal. 30
(6) Install starter as described in Group 8B - Bat
tery/ Starter/Generator Service.
J958A-2
TERMINAL LEGEND
iELAY TEST NUMBER IDENTIFICATION
The starter relay is in the Power Distribution Cen 30
85
COMMON FEED
COIL GROUND
ter (PDCXFig. 20). Refer to the underside of the PDC 86 COIL BATTERY
87 NORMALLY OPEN
cover for relay location. 87A NORMALLY CLOSED
. Remove starter relay from PDC to perform the fol
lowing tests: (2) The normally closed terminal (87A) is con
(1) A relay in the de-energized position should nected to terminal 30 in the de-energized position,
have continuity between terminals 87A and 30, and but is not used for this application. Go to next step.
no continuity between terminals 87 and 30. If OK, go (3) The normally open terminal (87) is connected to
to next step. If not OK, replace faulty relay. the battery terminal (30) in the energized position.
(2) Resistance between terminals 85 and 86 (elec This terminal supplies battery voltage to the starter
tromagnet) should be 75±5 ohms. If OK, go to next solenoid field coils. There should be continuity be
step. If not OK, replace faulty relay. tween cavity for relay terminal 87 and the starter so
(3) Connect a battery to terminals 85 and 86. lenoid terminal at all times. If OK, go to next step. If
There should now be continuity between terminals not OK, repair circuit to solenoid as required.
30 and 87, and no continuity between terminals 87A (4) The coil battery terminal (86) is connected to
and 30. If OK, go to Relay Circuit Test. If not OK, the electromagnet in the relay. It is energized when
replace faulty relay. the ignition switch is in the START position. Check
for battery voltage at cavity for relay terminal 86
iELAY CIRCUIT TEST with ignition switch in the START position. If OK, go
(1) The common feed terminal (30) is connected to to next step. If not OK and vehicle has automatic
battery voltage and should be hot at all times. If OK, transmission, refer to Group 8D - Ignition Systems
go to next step. If not OK, check circuit to fuse F12 for testing and service of the ignition switch. If not
in Power Distribution Center (PDC). Repair as re OK and vehicle has manual transmission, refer to
quired. Group 6 - Clutch for testing and service of the clutch
pedal position switch.
BR BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 8A -17
(5) The coil ground terminal (85) is connected to PARK/NEUTRAL POSITION SWITCH TEST
the electromagnet in the relay. On vehicles with an Refer to Group 21 - Transmission and Transfer
automatic transmission, it is grounded through the Case for testing and service of this component.
park/neutral position switch. On vehicles with a
manual transmission, it is grounded at all times. CLUTCH PEiAL POSITION SWITCH TEST
Check for continuity to ground at cavity for relay ter Refer to Group 6 - Clutch for testing and service of
minal 85. If not OK and vehicle has manual trans this component.
mission, repair circuit as required. If not OK and
vehicle has automatic transmission, refer to Group
21 - Transmission and Transfer Case for testing and
service of the park/neutral position switch.
IGNITION SWITCH TEST
Refer to Group 8D - Ignition Systems for testing
and service of this component.
8A -18 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS
CHARGING SYSTEM
GENERAL INFORMATION
The charging system consists of:
• generator
@ voltage regulator circuitry (within PCM)
• ignition switch
• battery
• voltmeter
• wiring harness and connections.
Following is a general description of the major
charging system components. Refer to Group 8 W -
Wiring Diagrams for complete circuit descriptions
and diagrams.
The charging system is turned on and off with the
ignition switch. When the ignition switch is turned to
the ON position, battery voltage is applied to the
generator rotor through one of the two field termi
nals to produce a magnetic field. The generator is
driven by the engine through a serpentine belt and
pulley arrangement.
As the energized rotor begins to rotate within the
generator, the spinning magnetic field induces a cur
rent into the windings of the stator coil. Once the
generator begins producing sufficient current, it also
provides the current needed to energize the rotor.
The wye (Y) type stator winding connections de
liver the induced AC current to 3 positive and 3 neg
ative diodes for rectification. From the diodes,
rectified DC current is delivered to the vehicle elec
trical system through the generator battery and Fig. 21 Charging System Components - Typical
ground terminals.
The amount of DC current produced by the gener DIAGNOSIS
ator is controlled by the generator voltage regulator When the ignition switch is turned to the ON posi
(field control) circuitry, contained within the Power- tion, battery potential will register on the voltmeter.
train Control Module (PCM)(Fig. 21). This circuitry is During engine cranking a lower voltage will appear
connected in series with the second rotor field termi on the meter. With the engine running, a voltage
nal and ground. reading higher than the first reading (ignition in ON)
Voltage is regulated by cycling the ground path to should register.
control the strength of the rotor magnetic field. The The following procedures may be used to diagnose
generator voltage regulator circuitry monitors system the charging system if:
line voltage and ambient temperature. It then com • the voltmeter does not operate properly
pensates and regulates generator current output ac • an undercharged or overcharged battery condition
cordingly. occurs.
The generator is serviced only as a complete as Remember that an undercharged battery is often
sembly. If the generator fails for any reason, the en caused by:
tire assembly must be replaced. The generator • accessories being left on with the engine not run
voltage regulator (field control) circuitry can be ser ning
viced only by replacing the entire PCM. • a faulty or improperly adjusted switch that allows
All vehicles are equipped with On-Board Diagnos a lamp to stay on (see Ignition-Off Draw in this
tics (OBD). All OBD-sensed systems, including the group).
generator voltage regulator (field control) circuitry,
are monitored by the PCM. Each monitored circuit is INSPECTION
assigned a Diagnostic Trouble Code (DTC). The PCM (1) Inspect condition of battery cable terminals,
will store a DTC in electronic memory for any failure battery posts, connections at engine block, starter so
it detects. See Using On-Board Diagnostic System in lenoid and relay. They should be clean and tight. Re
this group for more information. pair as required.
BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 8A -19
(2) Inspect all fuses in the fuseblock module and (6) Inspect connections at generator field, battery
Power Distribution Center (PDC) for tightness in re output, and ground terminals. Also check ground con
ceptacles. They should be properly installed and nection at engine. They should all be clean and tight.
tight. Repair or replace as required. Repair as required.
(3) Inspect the electrolyte level in the battery. If
cell caps are removable, add water if required. If cell OUTPUT WIRE RESISTANCE TEST
caps are not removable, replace battery if electrolyte This test will show the amount of voltage drop
level is low. across the generator output wire, from the generator
(4) Inspect generator mounting bolts for tightness. battery terminal to the battery positive post.
Replace or tighten bolts, if required. Refer to Group
8B - Battery/Starter/Generator Service for torque PREPARATION
specifications. (1) Before starting test make sure vehicle has a
(5) Inspect generator drive belt condition and ten fully-charged battery. See Battery in this group for
sion. Tighten or replace belt as required. Refer to more information.
Belt Tension Specifications in Group 7 - Cooling Sys (2) Turn ignition switch to OFF.
tem. (3) Disconnect negative cable from battery.
(4) Disconnect generator output wire from genera
tor battery output terminal.
CHARGING SYSTEM DIAGNOSIS
LOW OR 1. Battery discharged 1. See Battery, in this group. Charge or

UNSTEADY or faulty. replace battery, if required.
CHARGING. 2. Loose or faulty 2. Refer to Group 7 - Cooling System, for belt
generator drive inspection and tightening procedures. Replace
belt. or tighten belt, if required.
3. Loose generator 3. Refer to Group 8B - Battery/Starter/Generator
mounting. Service, for generator service procedures.
Tighten generator mounting, if required.
4. Loose or corroded 4. Inspect all charging circuit connections,
charging circuit including grounds and fuses. Clean or tighten,
wiring connections. if required.
5. High resistance in 5. See Ouput Wire Resistance Test, in this
generator output group. Test and repair, if required.
wire.
6. Generator assembly 6. See Current Output Test, in this group.
faulty. Test and replace, if required.
7. Faulty generator 7. See Using On-Board Diagnostic System,
field control in this group. Diagnose and repair, if
circuit. required.
OVER 1. Short in generator 1. See Using On-Board Diagnostic System,
CHARGING. field control in this group. Diagnose and repair, if
circuit. required.
2 Generator assembly 2. See Current Output Test, in this group.
faulty. Test and replace, if required.
GENERATOR 1. Loose, worn, or 1. Refer to Group 7 - Cooling System, for
NOISY. damaged drive belt. diagnosis and repair of drive belt problems
2. Drive belt 2. Refer to Group 7 - Cooling System, for
pulleys misaligned. diagnosis and repair of pulley misalignment.
3. Generator assembly 3. Refer to Group 8B - Batttery/Starter/Generator
faulty. Service, for generator service procedures.
J958A-12
8A - 2 0 BITTEiY/STARTiiG/CHARGili SYSTEMS DIAGNOSTICS BR
(5) Connect a 0-150 ampere scale DC ammeter (2) Adjust engine speed and carbon pile to main
(Fig. 22). Install in series between generator battery tain 20 amperes flowing in circuit. Observe voltmeter
output terminal and disconnected generator output reading. Voltmeter reading should not exceed 0.5
wire. Connect positive lead to generator battery out volts.
put terminal and negative lead to disconnected gen
erator output wire. RESULTS
(6) Connect positive lead of a test voltmeter (range If a higher voltage drop is indicated, inspect, clean
0-18 volts minimum) to disconnected generator out and tighten all connections. This includes any con
put wire. Connect negative lead of test voltmeter to nection between generator battery output terminal
battery positive cable at positive post. and battery positive post. A voltage drop test may be
(7) Connect one end of a jumper wire to ground performed at each connection to locate the connection
and with other end probe green K20 field wire at with excessive resistance. If resistance tests satisfac
back of generator (Fig. 22). This will generate a DTC. torily, reduce engine speed, turn OFF carbon pile and
turn OFF ignition switch.
CAUTION: Do not connect green/orange A142 field (1) Disconnect negative cable from battery.
wire to ground. Refer to Group 8 W - Wiring Dia (2) Remove test ammeter, voltmeter, carbon pile,
grams for more information. and tachometer.
(3) Remove jumper wire.
(8) Connect an engine tachometer, then connect (4) Connect generator output wire to generator
battery negative cable to battery. battery output terminal. Tighten nut to 8.5±1.5 N-m
(9) Connect a variable carbon pile rheostat be (75±15 in. lbs.).
tween battery terminals. Be sure carbon pile is in (5) Connect negative cable to battery.
OPEN or OFF position before connecting leads. See (6) Use DRB scan tool to erase DTC.
Load Test in this group for instructions.
CURRENT OUTPUT TEST
TEST The generator current output test determines
(1) Start engine. Immediately after starting, re whether generator can deliver its rated current out
duce engine speed to idle. put.
FIELD
TERMINALS 0 AMP FUSE
GROUND
Fig. 22 Generator Output Wire Resistance Test - Typical

BR BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 3A - 21
PREPARATION TEST
(1) Before starting test make sure vehicle has a (1) Start engine. Immediately after starting, re
fully-charged battery. See Battery in this group for duce engine speed to idle.
more information. (2) Adjust carbon pile and engine speed in incre
(2) Disconnect negative cable from battery. ments until a speed of 1250 rpm and voltmeter read
(3) Disconnect generator output wire at the gener ing of 15 volts is obtained.
ator battery output terminal.
(4) Connect a 0-150 ampere scale DC ammeter CAUTION: Do not allow voltage meter to read above
(Fig. 23). Install in series between generator battery 16 volts.
output terminal and disconnected generator output
wire. Connect positive lead to generator battery out (3) The ammeter reading must be within limits
put terminal and negative lead to disconnected gen shown in Generator Output Voltage Specifications.
erator output wire.
RESULTS
(5) Connect positive lead of a test voltmeter (range
0-18 volts minimum) to generator battery output ter (1) If reading is less than specified and generator
minal. output wire resistance is not excessive, generator
(6) Connect negative lead of test voltmeter to a should be replaced. Refer to Group 8B - Battery/
good ground. Starter/Generator Service.
(7) Connect an engine tachometer, then connect (2) After current output test is completed, reduce
battery negative cable to battery. engine speed, turn OFF carbon pile and turn OFF ig
(8) Connect a variable carbon pile rheostat be nition switch. * •
tween battery terminals. Be sure carbon pile is in (3) Disconnect negative cable from battery.
OPEN or OFF position before connecting leads. See (4) Remove test ammeter, voltmeter, tachometer
Load Test in this group for instructions. and carbon pile.
(9) Connect one end of a jumper wire to ground (5) Remove jumper wire (Fig. 23).
and with other end probe green K20 field wire at (6) Connect generator output wire to generator
back of generator (Fig. 23). This will generate a DTC. battery output terminal. Tighten nut to 8.5±1.5 N-m
(75±15 in. lbs.).
CAUTION: Do not connect green/orange A142 field (7) Connect negative cable to battery.
wire to ground. Refer to Group 8W - Wiring Dia- (8) Use DRB scan tool to erase DTC.
grams for more information. TO POWERTRAIN 10 AMP FUSE
BATTERY CONTROL MODULE
CASE GROUND
VOLTAGE
TERMINAL — 3^ IGNITION SWITCH
51 30 AMP FUSE
A142 4 ACC • OFF
AUTO frtTART%UNl
SHUTDOWN
RELAY
POWER
DISTRIBUTION a 1
^5FF
CENTER Bl
Ik^N
DISCONNECTED
GROUND GENERATOR
POWERTRAIN GROUND
CONTROL MODULE
BATTERY / q ]
CARBON PILE
IE CHASSIS '
RHEOSTAT GROUND
J948A-18
Fig. 23 Generator Current Output Test - Typical

8A - 22 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS
USING ON-BOARD DIAGNOSTIC SYSTEM
GENERAL INFORMATION to be set. Therefore, it is important that the test pro

The Powertrain Control Module (PCM) monitors cedures be followed in sequence, to understand what
critical input and output circuits of the charging sys caused a DTC to be set.
tem, making sure they are operational. A Diagnostic See Generator Diagnostic Trouble Code chart for
Trouble Code (DTC) is assigned to each input and DTC's which apply to the charging system. Refer to
output circuit monitored by the OBD system. Some the Powertrain Diagnostic Procedures manual to di
circuits are checked continuously and some are agnose an on-board diagnostic system trouble code.
checked only under certain conditions.
If the OBD system senses that a monitored circuit RETRIEVING DIAGNOSTIC TROUBLE CODES
is bad, it will put a DTC into electronic memory. The To start this function, cycle the ignition switch ON-
DTC will stay in electronic memory as long as the OFF-ON-OFF-ON within 5 seconds. This will cause
circuit continues to be bad. The PCM is programmed any DTC stored in the PCM memory to be displayed.
to clear the memory after 50 engine starts, if the The malfunction indicator (Check Engine) lamp will
problem does not occur again. display a DTC by flashing on and off. There is a
short pause between flashes and a longer pause be
DIAGNOSTIC TROUBLE CODES tween digits. All DTC's displayed are two-digit num
Diagnostic Trouble Codes (DTC) are two-digit num bers, with a four-second pause between codes.
bers flashed on the malfunction indicator (Check En An example of a DTC is as follows:
gine) lamp that identify which circuit is bad. A DTC (1) Lamp on for 2 seconds, then turns off.
description can also be read using the DRB scan tool. (2) Lamp flashes 4 times pauses and then flashes 1
Refer to Group 14 - Fuel Systems for more informa time.
tion. (3) Lamp pauses for 4 seconds, flashes 4 times,
A DTC does not identify which component in a cir pauses, then flashes 7 times.
cuit is bad. Thus, a DTC should be treated as a The two DTC's are 41 and 47. Any number of
symptom, not as the cause for the problem. In some DTC's can be displayed, as long as they are in mem
cases, because of the design of the diagnostic test ory. The lamp will flash until all stored DTC's are
procedure, a DTC can be the reason for another DTC displayed (55 = end of test).
GENERATOR DIAGNOSTIC TROUBLE CODE
Diagnostic DRB Scan Tool

Trouble Display Description of Diagnostic Trouble Code
Code
12*. .. Battery Disconnect Direct battery input to PCM was disconnected within the last 50 key-on cycles.
41**............. Generator Field Not An open or shorted condition detected in the generator field control circuit.
Switching Properly
46** .. Charging System Battery voltage sense input above target charging voltage during engine operation.
Voltage Too High
47** .. Charging System Battery voltage sense input below target charging during engine operation.
Voltage Too Low Also, no significant change detected in battery voltage during active test of
generator output.
55* N/A Completion of fault code display on Check Engine lamp.
* Check Engine lamp will not illuminate at all times if this Diagnostic Trouble Code was recorded. Cycle ignition key as
described in manual and observe code flashed by Check Engine lamp.'
* * Check Engine lamp will illuminate during engine operation if this Diagnostic Trouble Code was recorded.
J958A-7
BR BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 8A - 23
SPECIFICATIONS
BATTERY SPECIFICATIONS
BATTERY CLASSIFICATIONS AND RATINGS
Load Test Cold Cranking Reserve

(Amps) Rating @ 0°F Capacity
300 Amp 600 Amp 120 Minutes
CRANKING R A T I N G is the c u r r e n t a battery can d e l i v e r for 3 0 s e c o n d s and m a i n t a i n a t e r m i n a l voltage of 7.2 volts or greater
at specified temperature.
R E S E R V E CAPACITY RATING is the length of time a battery can deliver 25 amps and maintain a minimum terminal voltage
of 10.5 volts at 27°C (80T).
J958A-14
STARTING SYSTEM SPECIFICATIONS V-10 ENGINE STARTER SPECIFICATIONS
V-6 AND V-8 ENGINE STARTER

Manufacturer Nippondens©
SPECIFICATIONS Engine Application 8.0L
Part Number and 56004757
Manufacturer Power Rating 1.4 kw
Nippondenso
Voltage 12
Engine Application 5.91, 5.2L & 3.9L
No. of Fields 4
Part Number and 53005984 No. of Poles 4
• Power Rating 1.4 Kw Brushes 4
Voltage 12 1 Drive Reduction
No. of Fields . 4 Gear Train
No. of Poles 4 Free Running Test

Voltage 11
Brushes 4 Amperage Draw 73 Amps
Minimum Speed rpm 3601 rpm
Drive Reduction
Solenoid Closing Voltage 7.5 Volts
Gear Train
Cranking Amperage Draw Test . . . . 125-250 Amps*
Free Running Test
Voltage 11 * Engine should be up to operating temperature. Extremely
heavy oil or tight engine will increase starter amperage draw.
Amperage Draw 73 Amps
Minimum Speed rpm 3601 rpm J948B-25
Cranking Amperage Draw Test . . . 125-250 Amps* j DIESEL ENGINE STARTER SPECIFICATIONS
* Engine should be up to operating temperature. Extremely heavy R E D U C T I O N G E A R STARTER

oil or tight engine will increase starter amperage draw.
Manufacturer Nippondenso
Engine Application 5.9L DIESEL
J948B-26 Power Rating 2.7 kw
Voltage 12
No. of Fields 4
No. of Poles 4
Brushes 4
Drive Conventional
G e a r Train
Free Running Test
Voltage 11
Amperage Draw 200 Amps M a x .
Minimum Speed rpm 3000 rpm Min.
Solenoid Closing Voltage 8 Volts
Cranking Amperage Draw Test . . . . 4 5 0 - 7 0 0 Amps*
* Engine should be up to operating temperature. Extremely

J948B-23
8A - 24 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS BR
CHARGING SYSTEM SPECIFICATIONS
GENERATOR SPECIFICATIONS
PART Numn PULLEY G R O O V E S ENGINE RATING
NIPPONDENSO 53008646 7 ALL GASOLINE 75 AMPS
NIPPONDENSO 56027221 8 DIESEL 120 AMPS
J948B-24
BR BATTERY/STARTER/GENERATOR SERVICE 8B - 1
BATTERY/STARTER/GENERATOR SERVICE
CONTENTS
page page
BATTERY 1 SPECiFiCITlOlS I
GENERATOR 8 ST1RTER Aii STARTER RELAY 5
GENERAL INFORMATION tery/Starting/Charging Systems Diagnostics. Refer to
Group 8B covers battery, starter and generator ser Group 8W - Wiring Diagrams for complete circuit de
vice procedures. For diagnosis of these components scriptions and diagrams.
and their related systems, refer to Group 8A - Bat-
BATTERY
SE1ERAL HFORiATIOl
This section covers battery service procedures only.
For battery maintenance procedures, refer to Group 0 -
Lubrication and Maintenance. While battery charging
can be considered a service or maintenance procedure,
this information is located in Group 8A - Battery/Start
ing/Charging Systems Diagnostics. This was done be
cause the battery must be fully charged before any
diagnosis can be performed.
It is important that the battery, starting, and
charging systems be thoroughly tested and inspected
any time a battery needs to be charged or replaced.
The cause of abnormal discharge, over-charging, or
premature failure of the battery must be diagnosed
and corrected before a battery is replaced or returned Fig. 1 Maintenance-Free Battery
to service. Refer to Group 8A - Battery/Starting/
Charging Systems Diagnostics. BATTERY R E i O f E/ilSTALL
The factory-installed maintenance-free battery (Fig. (1) Turn ignition switch to OFF position. Make
1) has non-removable battery vent caps. Water can sure all electrical accessories are off.
not be added to this battery. The chemical composi (2) Loosen the cable terminal clamps and remove
tion within the maintenance-free battery reduces both battery cables, negative cable first. If necessary,
battery gassing and water loss at normal charge and use a puller to remove terminal clamps from battery
discharge rates. Therefore, the battery should not re posts (Fig. 2).
quire additional water in normal service.
The factory-installed battery also has a built-in test
indicator (hydrometer). The color visible in the sight
glass of the indicator will reveal the battery condi
BATTERY
tion, as follows: ERMINAL
® Green - Battery is fully charged. PULLER
• Black or Dark - Battery is discharged.
© Yellow or Bright - Electrolyte level is low.
If battery electrolyte level becomes low, the battery BATTERY
must be replaced. However, low electrolyte can be
caused by an over-charging condition. Be certain to 898A4
diagnose charging system before returning vehicle to
service. Refer to Group 8A - Battery/Starting/Charg Fig. 2 Remove Battery Terminal Clamp
ing Systems Diagnostics for more information.
8B - 2 BATTERY/STARTER/GENERATOR SERVICE BR
(3) Inspect the cable terminals for corrosion and

damage. Remove corrosion using a wire brush or post
and terminal cleaning tool, and a sodium bicarbonate
(baking soda) and warm water cleaning solution (Fig.
3). Replace cables that have damaged or deformed
terminals.
Fig. 3 Clean Battery Cable Terminal Fig. 4 Left Battery Holddown

WARNING: W E A R A SUITABLE PAIR OF R U B B E R
G L O V E S (NOT THE HOUSEHOLD T Y P E ) W H E N R E
MOVING A BATTERY B Y HAND. S A F E T Y G L A S S E S
SHOULD ALSO B E W O R N . IF THE BATTERY IS
C R A C K E D OR LEAKING, THE ELECTROLYTE CAN
B U R N THE SKIN AND E Y E S .
(4) Remove battery holddowns (Figs. 4 or 5) and

remove battery from vehicle.
(5) Inspect battery tray (Figs. 6, 7, or 8) and hold-
downs for corrosion or damage. Remove corrosion us
ing a wire brush and a sodium bicarbonate (baking
soda) and warm water cleaning solution. Paint any
exposed bare metal and replace any damaged parts.
(6) Inspect the battery case for cracks or other
damage that could result in electrolyte leaks. Also
check battery terminal posts for looseness. Batteries
with damaged cases or loose posts must be replaced.
(7) Inspect battery built-in test indicator sight
glass for indication of battery condition. If electrolyte
level is low, battery must be replaced. If battery is
discharged, charge as required. Refer to Group 8A - Fig. 5 Right Battery Holddown - Diesel Engine
Battery/Starting/Charging Systems Diagnosis for
more information.
(8) If the battery is to be reinstalled, clean outside
of battery case and top cover with sodium bicarbon-
BR BAITERY/8IARIER/GE1ERAI0R SERVICE 8B - 3
BATTERY TRAY placed, see Specifications to confirm replacement has

correct classification and ratings for the vehicle.
CLEANING BRUSH
TEST
INDICATOR WARM WATER
AND BAKING
SODA SOLUTION
J948B-13
Fig. 6 Left Battery Tray - w/o Speed Control
BATTERY TRAY
BATTERY RK108
Fig. 9 Clean Battery

(9) Clean corrosion from battery posts (Fig. 10)
with a wire brush or post and terminal cleaner, and
sodium bicarbonate (baking soda) and warm water
cleaning solution.
SPEED
CONTROL
SERVO
J948M4 TERMINAL
BRUSH
Fig. 7 Left Battery Tray - with Speed Control
DIESEL RIGHT SIDE

BATTERY TRAY
J928B-30
J948B-12
Fig. 10 Clean Battery Post
Fig. 8 Right Battery Tray - Diesel Engine
(10) Position battery in tray. Ensure that positive
ate (baking soda) and warm water cleaning solution and negative posts are correctly positioned. The cable
(Fig. 9) to remove acid film. Flush with clean water. terminals must reach the correct battery post with
Ensure that cleaning solution does not enter cells out stretching (Fig. 11).
through the vent holes. If the battery is being re-
CAUTION: B e certain that battery cables are con

nected to the correct battery terminals. Reverse po
larity can damage electrical components.
(12) Place oiled felt washer on battery positive ter

minal post.
(13) Install and tighten battery positive cable ter
minal clamp. Then install and tighten negative cable
terminal clamp. Tighten cable clamp bolts to 8.5 N-m
(75 in. lbs.).
(14) Apply a thin coating of petroleum jelly or
chassis grease to cable terminals and battery posts.
Fig. 11 Battery Cabies
(11) Loosely install battery holddown hardware.
Ensure that battery base is correctly positioned in
tray, then tighten holddowns to 12 N-m (100 in. lbs.).
STARTER am® m&mmm mmim
GENERAL INFORMATION
This section covers starter and starter relay service
procedures only. For diagnostic procedures, refer to
Group 8A - Battery/Starting/Charging Systems Diag
nostics. Service procedures for other starting system
components can be found as follows;
• battery - see Battery, in this group
• ignition switch - refer to Group 8D - Ignition Sys
tems
• park/neutral position switch - refer to Group 21 -
Transmission and Transfer Case
• clutch pedal position switch - refer to Group 6 -
Clutch
® wiring harness and connectors - refer to Group 8W
- Wiring Diagrams.
STARTER
The starter motor incorporates several features to Fig. 12 Starter Terminal Connector - V-6/V-8 Engine
create a reliable, efficient, compact and lightweight
unit. A planetary gear system (intermediate trans
mission) is used between the electric motor and pin
ion gear. This feature makes it possible to reduce the
dimensions of the starter. At the same time, it allows
higher armature rotational speed and delivers in
creased torque through the pinion gear to the fly
wheel or drive plate ring gear.
The starter motors for all engines are activated by
a solenoid mounted to the overrunning clutch hous
ing. However, the starter motor/solenoid are serviced
only as a complete assembly. If either component
fails, the entire assembly must be replaced.
STARTER RELAY
The, starter relay is an International Standards Or HARNESS J948B-16
ganization (ISO) type relay. It is located in the Power
Distribution Center -(PDC). The PDC is attached to Fig. 13 Starter Remove/Install - V-10 Engine
the driver's side inner fender shield, next to the bat • starter mounting bolts to 68 N-m (50 ft. lbs.)
tery. Refer to underside of PDC cover for relay iden
• starter mounting nut - 27 N-m (20 ft. lbs.)
tification and location.
• battery lead terminal nut - 8-12.5 N-m (70-110 in.
STARTER REMOVE/INSTALL lbs.)
• solenoid lead terminal nut - 5-7 N-m (45-65 in.
GASOLINE ENGINE lbs.).
(1) Disconnect negative cable from battery. Raise
and support vehicle. DIESEL ENGINE
(2) Remove wire terminal connector from starter (1) Disconnect both battery negative cables. Raise
motor (Figs. 12 or 13). and support vehicle.
(3) Remove mounting hardware securing starter to (2) Remove battery lead from starter solenoid ter
bellhousing (Figs. 13 or 14). minal by pulling rubber boot up and removing nut
(4) Move starter forward to clear lower mounting (Fig. 16).
stud (V-6/V-8 engine) and starter gear housing nose. (3) Remove nut from solenoid lead terminal at
This allows starter to come down past the exhaust starter solenoid.
pipe (Figs. 13 or 15). (4) Remove starter motor mounting bolts (Figs. 16
(5) Reverse removal procedures to install. Tighten and 17).
starter hardware as follows: (5) Remove starter motor.
8B - 6 BATTERY/STARTER/G EN ERATO R SERVICE BR
Fig. 16 Starter Terminal Connections - Diesel

Engine
© starter mounting bolts - 48 N-m (32 ft. lbs.)
• solenoid lead nut - 6 N-m (55 in. lbs.)
• battery lead nut - 10 N-m (90 in. lbs.).
STARTER RELAY REMOVE/INSTALL

(1) Disconnect battery negative cable(s).
(2) Remove starter relay by unplugging unit from
Power Distribution Center (PDC) (Fig. 18). Refer to
underside of PDC cover for relay location.
(3) Install starter relay by aligning relay terminals
with cavities in PDC and plugging relay in.
(4) Connect negative cable(s) to battery.
(5) Test relay operation.
Fig. 15 Starter Remove/Install - V-6/V-8 Engine

(6) Reverse removal procedures to install. Tighten
starter hardware as follows:
BATTERY/STARTER/GENERATOR SERVICE 8B - 7
GENERAL INFORMATION
This section covers generator service procedures
only. For generator or charging system diagnosis, re
fer to Group 8A - Battery/Starting/Charging Systems
Diagnostics.
The generator is belt-driven by the engine. All en
gines use serpentine drive. The generator is serviced
only as a complete assembly. If the generator fails for
any reason, the' entire assembly must be replaced.
Three generator output ratings are available on
this vehicle, depending upon optional equipment. Be
certain that the replacement generator has the same
output rating as the original unit. Refer to Group 8A
- Battery/Starting/Charging Systems Diagnostics and
see Specifications.
The generator field control (voltage regulator) cir
Fig. 19 Remove/Install Generator
cuitry is internal to the Powertrain Control Module
(PCM). If faulty, the entire PCM must be replaced.
Refer to Group 14 - Fuel System for PCM service
procedure.
GENERATOR REMOVE/INSTALL
WARNING: DISCONNECT NEGATIVE C A B L E ( S )
FROM BATTERY(IES) B E F O R E REMOVING BAT
TERY OUTPUT W I R E FROM GENERATOR. FAILURE
TO DO S O CAN R E S U L T IN INJURY.
(1) Disconnect battery negative cable(s).

(2) Remove generator drive belt. Refer to Group 7 -
Cooling System for procedure.
(3) Remove the generator pivot and mounting bolts
(Fig. 19). Position generator for access to wire con
nectors.
(4) Remove nuts from harness holddown, battery
terminal, ground terminal and 2 field terminals (Fig.
20). Remove wire connectors.
(5) Remove the generator.
generator hardware as follows: Fig. 20 Remove/install Generator Connectors
• generator mounting bolts - 41 N-m (30 ft. lbs.)
CAUTION: When installing a serpentine accessory
• battery terminal nut - 8.5 N-m (75 in. lbs.)
• ground terminal nut - 8.5 N-m (75 in. lbs.). drive belt, the belt MUST be routed correctly. The
• harness holddown nut - 8.5 N-m (75 in. lbs.) water pump will be rotating in the wrong direction if
• field terminal nuts - 2.8 N-m (25 in. lbs.) the belt is installed incorrectly, causing the engine
to overheat. Refer to belt routing label in engine
CAUTION: Never force a belt over a pulley rim us compartment, or refer to Belt Schematics in Group
ing a screwdriver. The synthetic fiber of the belt can 7 - Cooling System.
be damaged.
SPECIFICATIONS
BATTERY SPECIFICATIONS
BATTERY CLASSIFICATIONS AND RATINGS
Load Test Cold Cranking Reserve

(Amps} Rating @ 0T Capacity
CRANKING RATING is the current a battery can deliver for 30 seconds and maintain a terminal voltage of 7.2 volts or greater
at specified temperature.
RESERVE CAPACITY RATING is the length of time a battery can deliver 25 amps and maintain a minimum terminal voltage
of 10.5 volts at 27°C (80T).
J958A-14
STARTING SYSTEM SPECIFICATIONS V-10 ENGINE STARTER SPECIFICATIONS
V-6 AND V-8 ENGINE STARTER

SPECIFICATIONS Engine Application 8.0L
Power Rating 1.4 kw
Voltage 12
Engine Application 5.9L, 5.2L & 3.9L
No. of Fields 4
Part Number and 53005984 No. of Poles 4
Power Rating 1.4 Kw
Brushes 4
Voltage 12 Drive Reduction
No. of Fields 4 Gear Train
No. of Poles 4 Free Running Test

Voltage 11
Brushes I Amperage D r a w . . . . . . . . . . . . . 73 Amps
Minimum Speed rpm 3601 rpm
Drive . Reduction
Gear Train
Cranking Amperage Draw Test . . . . 125-250 Amps*
Free Running Test
Voltage 11 * Engine should be up to operating temperature. Extremely
Amperage Draw 73 Amps
Minimum Speed rpm 3601 rpm J948B-25
Cranking Amperage Draw Test . . . 125-250 Amps* DIESEL ENGINE STARTER SPECIFICATIONS
* Engine should be up to operating temperature. Extremely heavy DEDUCTION GEAR STARTER

oil or tight engine will increase starter amperage draw.
Engine Application 5.9L DIESEL
J948B-26 Power Rating 2.7 kw
Voltage 12
No. of Fields 4
No. of Poles 4
Brushes 4
Drive. Conventional
Gear Train
Free Running Test
Voltage 11
Amperage Draw 200 Amps Max.
Minimum Speed rpm 3000 rpm Min.
Solenoid Closing Voltage 8 Volts
Cranking Amperage Draw Test . . . . 4 5 0 - 7 0 0 Amps*
* Engine should be up to operating temperature. Extremely

J948B-23
8B -10 BATTERY/STARTER/GENERATOR SERVICE BR
CHARGING SYSTEM SPECIFICATIONS
GENERATOR SPECIFICATIONS
TYW PART N U M B E R PULLEY G R O O V E S ENGINE RATING
NIPPONDENSO 56027221 8 DIESEL 120 AMPS
J948B-24
BR — — _ _ _ _ _ OVERHEAD CONSOLE 8C - 1
OVERHEAD CONSOLE
CONTENTS
page page

GENERAL INFORMATION 1
GENERAL INFORMATION
An overhead console featuring an electronic com The self-calibrating compass unit requires no ad
pass and thermometer is an available option for Ram justing in normal use. The only calibration that may
truck models. Following are general descriptions of prove necessary is to drive the vehicle in 3 complete
major components used in the overhead console. Re circles, on level ground, in not less than 48 seconds.
fer to Group 8W - Wiring Diagrams for complete cir This will reorient the unit to its vehicle.
cuit descriptions and diagrams. The unit also will compensate for magnetism the body
of the vehicle may acquire during normal use. However,
avoid placing anything magnetic directly on the roof of
the vehicle. Magnetic mounts for an antenna, a repair
order hat, or a funeral procession flag can exceed the
compensating ability of the compass unit if placed on
the roof panel. Magnetic bit drivers used on the fasten
ers that hold the assembly to the roof header can also
affect compass operation.
If the vehicle roof should become magnetized, the
demagnetizing and calibration procedures may be re
quired to restore proper operation.
THEilOiETER
The thermometer displays the outside ambient
temperature. The temperature displayed can be
changed from Fahrenheit to Celsius using the US/
METRIC button. The displayed temperature is not
an instant reading of conditions, but an average tem
perature. It may take the unit several minutes to re
act to a major temperature change such as driving
out of a heated garage into winter temperatures.
When the ignition switch is turned OFF, the last dis
played temperature reading stays in memory. When the
ignition switch is turned ON again, the thermometer
will display the memory temperature for one minute;
then update the display to the current average temper
ature reading within five minutes.
J948C-2
READING AND COURTESY LAMPS
COMPASS All reading and courtesy lamps in the overhead
The compass will display the direction in which the console are activated by the door jamb switches.
vehicle is pointed using the eight major compass When both doors are closed, the lamps can be indi
headings (Examples: north is N, northeast is NE). It vidually activated by depressing the corresponding
does not display the headings in actual degrees. The lens. When a door is open, depressing the lamp lens
display is turned on or off using the COMP/TEMP switches will not turn the lamps off. Refer to Group
button to the left of the display. 8L - Lamps, for diagnosis and service of these lamps.
80 - 2 OVERHEAD CONSOLE
DIAGNOSIS
COMPASS/THERMOMETER DIAGNOSIS
CONDITION POSSIBLE CAUSES
OVERHEAD CONSOLE 1. Display has been switched off. 1. Depress COMP/TEMP button to switch
DISPLAY COMPLETELY unit to compass or thermometer display
DARK option.
2. Faulty fuse or headlamp delay 2. Refer to Group 8L — Lamps, for
module. diagnosis and service of this circuit.
3. Faulty wiring. 3. Refer to Group 8W — Wiring Diagrams,
for circuit diagrams. Check and repair
wiring, if required.
4. Faulty compass/thermometer 4. Replace compass/thermometer display
display module. module, if required.
OVERHEAD CONSOLE 1. Faulty compass/thermometer 1. See Self-Diagnostic Test, in this group.

DISPLAY S E G M E N T S display module. Replace compass/thermometer display
MISSING module, if required.
ERRATIC C O M P A S S 1. Magnet or strong magnetic field 1. Remove magnet and perform

OPERATION near compass module. Demagnetizing Procedure, in this group.
2. Variance setting incorrect. 2. See Variation Adjustment Procedure in
3. Calibration incorrect. this group.
4. Faulty compass/thermometer 3. See Calibration Procedure, in this group.
display module. 4. Replace compass/thermometer display
module, if required.
ERRATIC T H E R M O M E T E R 1. Faulty sensor wiring. 1. See Sensor Circuit Test, in this group.
OPERATION Repair wiring, if required.
2. Faulty sensor. 2. See Sensor Test, in this group. Replace
sensor, if required.
3. Faulty compass/thermometer 3. Replace compass/thermometer display
display module. module, if required.
J958C-1
COMPASS/DISPLAY SELF-DIAGNOSTIC TEST • SE 55

This self-diagnostic test is used to determine that • E 66
the compass and all of its display segments are oper • NE 77
ating properly electrically. Initiate the self-diagnostic To repeat test, press the COMP/TEMP button.
tests as follows: Pressing the US/METRIC button will light every seg
(1) With the ignition switch in the OFF position, ment of the display for 2 seconds. To repeat test,
simultaneously press and hold the COMP/TEMP but press the COMP/TEMP button. To exit self-diagnos
ton and the US/METRIC button. tics mode, press the US/METRIC button. The module
(2) Turn ignition switch to ON position. will return to compass/thermometer mode.
(3) Continue to hold both buttons until segments If the compass functions, but accuracy is sus
on the display light. The module is now in self-diag- pect, it may be necessary to perform a variation
nostic test mode. adjustment. This procedure allows the unit to
The display will respond by cycling through the fol accommodate variations in the earth's mag
lowing characters: netic field strength based on geographic loca
© N 00 t i o n . See Compass Variation Adjustment, in this
• NW 11 group.
o W 22 If the compass display has blanked out and
® SW 33 only CAL appears, demagnetizing may be nec-
• S 44
BR OVERHEAD CONSOLE 8C - 3
essary to remove excessive residual magnetic SENSOR TEST

fields from the vehicle. See Compass Demagne (1) T u r n t h e ignition switch to OFF. U n p l u g sensor
tizing, in this group. connector.
(2) Measure resistance of sensor. A t -40°F the re
THERMOMETER DIAGNOSIS sistance is 336K ohms. A t 140°F the resistance is
The thermometer function is supported by a tem 2.488K ohms. Sensor resistance should read between
perature sensor, a w i r i n g circuit and a portion of the these t w o values. I f OK, go to Sensor Circuit Test. I f
overhead console display. The sensor is mounted to not OK, replace the sensor.
the radiator support on t h e driver's side j u s t behind SENSOR CIRCUIT TEST
the grille (Fig. 1). (1) T u r n ignition switch to OFF. U n p l u g sensor
connector.
AMBIENT
TEMPERATURE (2) Short the pins on t h e body h a l f of connector us
SENSOR i n g a j u m p e r wire.
(3) Remove the overhead console as described i n
Service Procedures.
(4) Check continuity between cavities 4 and 5 of
overhead console harness connector (Fig. 2). There
should be continuity. I f OK, go to next step. I f not
OK, repair open circuit as required.
GROUND
ELECTRICAL
C O N N E C T O R J948C-18
PANEL DIMMER
Fig. 1 Temperature Sensor
I f any portion of the circuit fails, i t w i l l self-diag
nose as an open or short circuit. The system w i l l dis
play SC (short circuit) when the sensor is exposed to HEADLAMPS ON/OFF
COURTESY INPUT
temperatures i n excess of 60°C (140°F) or i f the cir DOOR SWITCH
GROUND
cuit is shorted. I f the temperature is below -40°C
(-40°F) or an open circuit exists, the system w i l l dis
play OC (open circuit).
To diagnose t h e temperature sensor, perform the Fig. 2 Overhead Console Harness Connector
following procedures. I f t h e sensor and circuit are (5) Remove jumper wire from temperature sensor
OK, then the electronic module is faulty and should harness connector. Check continuity between cavities
be replaced. 4 and 5 of overhead console harness connector (Fig.
2) and a good ground. There should be no continuity.
I f OK, replace electronic module. I f not O K , repair
short circuit as required.
8C - 4 OVERHEAD CONSOLE BR
SERVICE PROCEDURES
COMPASS VARIATION ADJUSTMENT ity of the compass. DO NOT use magnetic tools
when servicing the overhead console.
Variance is the difference between magnetic north
and geographic north. In some areas, the difference The compass features a self-calibrating design,
between magnetic and geographic north is great which simplifies the calibration procedure. This fea
enough to cause the compass to give false readings. If ture automatically updates the compass calibration
this occurs, the variance must be set. while the vehicle is being driven. This takes into ac
To set the variance: count small changes in residual magnetism the vehi
(1) Using the map in Fig. 3, find your geographic cle may acquire during normal use. Do not attempt
location and note the zone number. to calibrate the compass near large metal objects
such as other vehicles, large buildings or bridges.
Whenever the compass is calibrated manually,
the variation number must also be reset. See
Variation Adjustment Procedure, in this group.
Calibrate the compass manually as follows:
(1) Start the engine.
(2) Depress both the US/METRIC and COMP/
TEMP buttons. Hold down until CAL is displayed.
This takes about 10 seconds and appears about 5 sec
onds after VAR is displayed.
(3) Release both buttons.
(4) Drive vehicle on a level surface that is away
from large metal objects through 3 or more complete
circles in not less than 48 seconds. The CAL message
will disappear to indicate that the compass is now
calibrated.
If CAL message remains in display, either
there is excessive magnetism near the compass
or the unit is faulty. Repeat the demagnetizing
and calibration procedures at least one more
time.
If the wrong direction is still indicated, the
area selected may be too close to a strong mag
netic field. Repeat the calibration procedure in
another location.
COMPASS DEMAGNETIZING
Fig. 3 Variance Settings
The tool used to degauss or demagnetize the roof
(2) Turn ignition switch to the ON position. panel is the Miller Tool 6029. Equivalent units must
(3) Depress both the US/METRIC and COMP/ be rated as continuous duty for 110/115 volts and
TEMP buttons. Hold down until VAR is displayed. 60Hz. They must also have a field strength of over
This takes about 5 seconds. 350 gauss at 1/4-inch beyond the tip of the probe.
(4) Release both buttons. The degaussing tool is used to demagnetize the roof
(5) Press the US/METRIC button to step through panel, as follows:
the numbers until the zone number for your area ap (1) Be sure the ignition switch is in the OFF posi
pears in the display. tion before you begin the demagnetizing procedure.
(6) Press the COMP/TEMP button to enter this (2) Place an 8-1/2 X 11 inch piece of paper, oriented
zone number into compass unit memory. lengthwise from front to rear, on the center line of
(7) Confirm correct directions are indicated. the roof at the windshield header (Fig. 4). The pur
pose of the paper is to protect the roof panel from
COiPASS CALIBRATION
scratches and define the area to be demagnetized.
CAUTION: D O NOT place any external magnets (3) Plug in the degaussing tool, while keeping the
such as magnetic roof mount antennas, in the vicin tool at least 2 feet away from the compass unit.
BR — OVERHEAD CONSOLE 8C - 5
PULL TIP OF D E G A U S S I N G TOOL A W A Y
c AT LEAST T W O FEST A N D
DISCONNECT
C 1/2"
C
C " W I N D S H I E L D EDGE
START
J948C-5
J908E-27
Fig. 5 Console Mounting Screws
Fig. 4 Roof Demagnetizing Pattern
(4) Slowly approach the center line of the roof

panel at the windshield header with the degaussing
tool plugged in.
(5) Contact the roof panel with the tip of the tool.
Be sure template is in place to avoid scratching the
roof panel. Using a slow, back and forth sweeping
motion and allowing 1/2-inch between passes (Fig. 4),
move the tool at least 4 inches either side of the roof
center line and 11 inches back from the windshield
header.
(6) With the degaussing tool still energized, slowly
back it away from the roof panel until the tip is at
least 2 feet from the roof. Then unplug the tool.
(7) Calibrate the compass and adjust variance as
described in this group.
COMPASS/TEMPERATURE
OVERHEAD CONSOLE REMOVE/INSTALL CONNECTOR
(1) Remove 2 console mounting screws (Fig. 5).
(2) Pull front of console down slightly then move it
rearward until mounting clips detach from roof panel
J948C-11
(Fig. 6).
(3) Disconnect wire harness from compass module. Fig. 6 Remove/Install Overhead Console
(4) Reverse removal procedures to install.
8C-6 OVERHEAD CONSOLE BR
COMPASS/THERMOMETER MODULE REMOVE/

INSTALL
(1) Remove overhead console and unplug wiring.
See Overhead Console Remove/Install.
(2) Remove 3 screws holding module to console
(Fig. 7).
Fig. 8 Lighting Harness Connector

(2) Remove bulb by pulling straight down.
(3) Install new bulb by pushing firmly into socket.
(4) Pivot lens up into position and snap into place.
Test by depressing lens to check for proper switching
and lighting.
Fig. 7 Compass/Thermometer Module Remove/
Install
(3) Unplug harness connector from lighting module
(Fig. 8).
(4) Remove compass module.
READING/COURTESY LAMPS
LENS OB BULB REMOVE/INSTALL

(1) Insert a long flat-bladed tool at the notch on
the curved edge of the lens. Carefully pry the lens
from the housing and pivot the lens down. It may be
necessary to move the tool along the edge to free the
lens.
IGNITION SYSTEMS 8D - 1
IGNITION SYSTEMS
CONTENTS
page page
COMPONENT IDENTIFICATION/SYSTEM DIAGNOSTICS/SERVICE PROCEDURES I

OPERATION 1 IGNITION SWITCH 33
COMPONENT REMOVAL/INSTALLATION 22 SPECIFICATIONS 36
COMPONENT IDENTIFICATION/SYSTEM OPERATION
INDEX
page page
Automatic Shutdown (ASD) Relay 2 General Information 1

Camshaft Position Sensor—3.9L V-6 or 5.2/5.9L V-8 Ignition Coil Packs—8.0L V-10 Engine 6
Engines 2 Ignition Coil—3.9L V-6 or 5.2/5.9L V-8 Engines .... 5
Camshaft Position Sensor—8.OL V-10 Engine 3 Ignition Control Module—8.0L V-10 Engine 7
Crankshaft Position Sensor—3.9L V-6 or 5.2/5.9L Intake Manifold Air Temperature Sensor 7
V-8 Engines 3 Manifold Absolute Pressure (MAP) Sensor 7
Crankshaft Position Sensor—8.0L V-10 Engine . . . . 4 Oxygen Sensor (02S) 8
Distributors—3.9L V-6 or 5.2/5.9L V-8 Engines 5 Powertrain Control Module (PCM) 7
Engine Coolant Temperature Sensor 7
GENERAL INFORMATION For diagnostic procedures and adjustments, refer to

Throughout this group, references are made to par the Diagnostics/Service Procedures section of this
ticular vehicle models by alphabetical designation or group.
by the particular vehicle nameplate. A chart showing For removal and installation of ignition system
a breakdown of alphabetical designations is included components, refer to the Component Removal/Instal
in the Introduction group at the beginning of this lation section of this group.
manual. For other useful information, refer to On-Board Di
All vehicles are equipped with either a 3.9L V-6 en agnostics in the General Diagnosis sections of Group
gine, a 5.2L V-8 engine, two different 5.9L V-8 en 14, Fuel System in this manual.
gines, an 8.0L V-10 engine or a 5.9L Cummins in-line For operation of the DRB Scan Tool, refer to the
6-cylinder diesel engine. Refer to Group 14, Fuel Sys appropriate Powertrain Diagnostic Procedures ser
tem for diesel fuel service procedures. vice manual.
The 3.9L V-6 and 5.2L V-8 engines will be referred An Ignition specifications section is included at the
to in this Ignition group as: Light Duty Cycle (LDC) end of this group. A general Maintenance Schedule
engines. The 5.9L V-8 gas powered engine will be re (mileage or time intervals) for ignition related items
ferred to as either: Light Duty Cycle (LDC) or Heavy can be found in Group 0, Lubrication and Mainte
Duty Cycle (HDC) engine. The 8.0L V-10 engine will nance. This schedule can also be found in the Owners
be referred to as: Heavy Duty Cycle (HDC) engine. Manual.
Either of the HDC gas powered engines can be eas
ily identified by the use of an engine mounted air in IGNITION SYSTEMS
jection pump. The 3.9L V-6 engine, the 5.2/5.9L V-8 The ignition systems used on the 3.9L V-6, 5.2L V-8
LDC gas engines or the diesel engine will not use an and both of the 5.9L V-8 engines are basically iden
air injection pump. tical with each engine using a mechanical distributor.
This section of the group, Component Identifica Similarities and differences between the systems will
tion/System Operation, will discuss ignition system be discussed.
operation and will identify ignition system compo
nents.
8D - 2 IGNITION SYSTEMS BR
The ignition system used on the 8.0L V-10 engine the location of this relay within the PDC, refer to
does not use a conventional mechanical distributor. It PDC cover.
will be referred to as a distributor-less ignition sys As one of its functions, the ASD relay will supply
tem. battery voltage to the ignition coil (or coil packs if
ignition timing Is not adjustable on any en equipped with a V-10 engine). The ground circuit for
gine. the ASD relay is controlled by the powertrain control
A sequential multi-port fuel injection system is module (PCM). The PCM regulates ASD relay opera
used on all 3.9L V-6 or 5.2/5.9L V-8 gas powered en tion by switching the ground circuit to the ASD relay
gines. On the 8.0L V-10 engine, a multi-port fuel in on-and-off.
jection system is also used, although the fuel
injectors are operated in pairs.
The ignition coils on the V-10 are individually fired,
but each coil is a dual output. Refer to Ignition Coil
Packs—8.OL V-10 Engine in this Ignition System
group for additional information. Also refer to Group
14, Fuel Systems for additional information.
The ignition system is controlled by the powertrain
control module (PCM) on all engines (Fig. 1). The
PCM was formerly referred to as the SBEC or engine
controller.
Fig. 2 Power Distribution Center (PDC) Location

CAMSHAFT POSITION SENSOR—3.9L V-6 OR
5.2/5.9L V-8 ENGINES
The camshaft position sensor is located in the dis
tributor (Fig. 3) on all 3.9L V-6 or 5.2/5.9L V-8 en
gines.
POWERTRAIN CONTROL
MODULE (PCM) J9414-11
Fig. 1 PCM Location—Typical
An additional ignition control module (ICM) is used
to partially control ignition coil operation on the 8.0L
V-10 engine only. Refer to Ignition Coil Packs—8.OL
V-10 Engine in this Ignition System group for addi
tional information.
The ignition system consists of:
® Spark Plugs
• Ignition Coil (multiple coils with the 8.0L V-10 en
gine)
• Secondary Ignition Cables
© Distributor. Contains rotor and camshaft position
sensor (3.9L V-6 or 5.2/5.9L V-8 engines only)
© Ignition Control Module (8.0L V-10 engine only) Fig. 3 Camshaft Position Sensor—3.9L V-6 or
• Powertrain Control Module (PCM) 5.2/5.9L V-8 Engines—Typical
• Crankshaft Position Sensor SENSOR OPERATION—3.9L V-6 OR 5.2/5.9L
• Camshaft Position Sensor V-8 ENGINES
The camshaft position sensor contains a hall effect
AUTOMATIC SHUTDOWN (ASD) RELAY device called a sync signal generator to generate a
The ASD relay is located in the power distribution fuel sync signal. This sync signal generator (Fig. 3)
center (PDC) near the vehicle battery (Fig. 2). For detects a rotating pulse ring (shutter) on the distrib-
utor shaft. The pulse ring rotates 180 degrees termine crankshaft position from both the camshaft
through the sync signal generator. Its signal is used position sensor and crankshaft position sensor.
in conjunction with the crankshaft position sensor to The camshaft position sensor detects notches in the
differentiate between fuel injection and spark events. upper camshaft drive gear (Fig. 5). The face of the
It is also used to synchronize the fuel injectors with sensor is positioned next to this gear with a small air
their respective cylinders. gap.
When the leading edge of the pulse ring (shutter)
enters the sync signal generator, the following occurs:
The interruption of magnetic field causes the voltage
to switch high resulting in a sync signal of approxi
mately 5 volts.
When the trailing edge of the pulse ring (shutter)
leaves the sync signal generator, the following occurs:
The change of the magnetic field causes the sync sig
nal voltage to switch low to 0 volts.
For component testing, refer to the Diagnostics/Ser
vice Procedures section of this group.
For removal and installation of this component, re
fer to the Component Removal/Installation section of
this group.
CAMSHAFT POSITION SENSOR—8.0L V-10
ENGINE Fig. 5 Sensor Operation—8.0L V-10 Engine
The camshaft position sensor is located in the tim When the gear is rotating, the sensor will detect
ing chain case/cover on the left-front side of the en one of these notches. Input voltage from the sensor to
gine (Fig. 4). A machined hole is provided in the the PCM will then switch from a low (approximately
timing chain cover to place the face of the sensor 0.3 volts) to a high (approximately 5 volts). As the
next to the upper camshaft drive gear. A slot and a notch moves away from the sensor, the input voltage
single bolt are provided on the sensor for depth ad switches back low to 0.3 volts.
justment (Fig. 4).
CRANKSHAFT POSITION SENSOR—3.9L V-6 OR
5 J / I J L V-8 ENGINES
The sensor is bolted to the top of cylinder block
near the rear of the right cylinder head (Fig. 6).
Engine speed and crankshaft position are provided
through the crankshaft position sensor. The sensor
generates pulses that are the input sent to the pow
ertrain control module (PCM). The PCM interprets
the sensor input to determine the crankshaft posi
tion. The PCM then uses this position, along with
other inputs, to determine injector sequence and ig
nition timing.
The sensor is a hall effect device combined with an
internal magnet. It is also sensitive to steel within a
certain distance from it.
Fig. 4 Camshaft Position Sensor—8.0L V-10 SENSOR OPERATION—3.9L V-6 ENGINE
Engine—Typical The flywheel/drive plate has groups of notches at
SENSOR OPERATION—8.0L V-10 ENGINE its outer edge. On 3.9L V-6 engines, there are three
The camshaft position sensor is used in conjunction sets of double notches and three sets of single
with the crankshaft position sensor to differentiate notches (Fig. 7).
between fuel injection and spark events. It is also The notches cause a pulse to be generated when
used to synchronize the fuel injectors with their re they pass under the sensor. The pulses are the input
spective cylinders. The sensor generates electrical to the PCM.
pulses. These pulses (signals) are sent to the power- The engine will not operate if the PCM does not re
train control module (PCM). The PCM will then de ceive a crankshaft position sensor input.
8D ~ 4 IGNITION SYSTEMS — — — — — — — BR
SPARK
CRANKSHAFT
PLUG
POSITION
CABLE
SENSOR
LOOM
FLYWHEEL
NOTCHES
WIRING
^ N
HARNESS EGR > TUBE MOUNTING
TUBE / f BOLTS (2)
I M 1
J 9 3 ]
V^\ CONNECTOR \ J9314-88
Fig. 6 Crankshaft Position Sensor—3.9L V-6 or
Fig. 8 Sensor Operation—5.2L/5.9L V-8 Engines
5.2/5.9L V-8 Engines—Typical
The notches cause a pulse to be generated when
CRANKSHAFT they pass under the sensor. The pulses are the input
POSITION to the PCM. For each engine revolution, there are 8
SENSOR
pulses generated on V-8 engines.
FLYWHEEL
The engine will not operate if the PCM does not re
ceive a crankshaft position sensor input.
NOTCHES' fer to the Component Removal/Installation section of
this group.
CRANKSHAFT POSITION SENSOR—8.0L V-10

ENGINE
The crankshaft position sensor is located on the
right-lower side of the cylinder block, forward of the
right engine mount, just above the oil pan rail (Fig.
9).
SENSOR OPERATION—8»m lf-10 ENGINE

The crankshaft position sensor detects notches ma
J9314-89 chined into the middle of the crankshaft (Fig. 10).
There are five sets of notches. Each set contains
Fig. 7 Sensor Operation—3.9L V-6 Engine two notches. Basic ignition timing is determined by
For component testing, refer to the Diagnostics/Ser the position of the last notch in each set of notches.
vice Procedures section of this group. Once the powertrain control module (PCM) senses
For removal and installation of this sensor, refer to the last notch, it will determine crankshaft position
the Component Removal/Installation section of this (which piston will next be at Top Dead Center). An
group. input from the camshaft position sensor is also
needed. It may take the module up to one complete
SENSOR OPERATION—^5.2i/5.9L ¥-8 ENGINES engine revolution to determine crankshaft position
On 5.2L and 5.9L V-8 engines, the flywheel/drive during engine cranking.
plate has 8 single notches, spaced every 45 degrees, The PCM uses the signal from the camshaft posi
at its outer edge (Fig. 8). tion sensor to determine fuel injector sequence. Once
BR IGNITION SYSTEMS 80 - 5
The distributor is held to the engine in the conven

tional method using a holddown clamp and bolt. Al
though the distributor can be rotated, it will
have no effect on ignition timing.
All distributors contain an internal oil seal that
prevents oil from entering the distributor housing.
The seal is not serviceable.
this group.
IGNITION COIL—3 J L V-6 OR 5.2/5.9L V-8

ENGINES
3*§L V-6 or 5.2/5.9L V-8 LDC-Gas Engines: The
coil is mounted' to a bracket that is bolted to the
Fig. 9 Crankshaft Position Sensor—8.01 V-10 front of the right engine cylinder head (Fig. 11). This
Engine—Typical bracket is mounted on top of the automatic belt ten
sioner bracket using common bolts.
5.9L V-8 HDC-Gas Engine: The coil is mounted to
a bracket that is bolted to the air injection pump
(AIR pump) mounting bracket (Fig. 12).
Fig. 10 Sensor Operation—S.OL V-10 Engine

crankshaft position has been determined, the PCM
begins energizing a ground circuit to each fuel injec
tor to provide injector operation. Fig. 11 Ignition Coii—3.9L V-6 or 5.2/5.9L V-8
LDC-Gas Engines
DISTRIBUTORS—3.9L V-6 OR 5.2/5.9L V-8
ENGINES
All 3.9L V-6 and 5.2L/5.9L V-8 engines are
equipped with a camshaft driven mechanical distrib
utor, containing a shaft driven distributor rotor. They
are equipped with an internal camshaft position (fuel
sync) sensor. This sensor provides fuel injection syn
chronization and cylinder identification.
Distributors do not have built in centrifugal or vac
uum assisted advance. Base ignition timing and all
timing advance is controlled by the powertrain con
trol module (PCM). Because ignition timing is con
trolled by the PCM, base ignition timing Is not
adjustable on any of these engines.
Fig. 12 Ignition Coil—5.9L V-8 HDC-Gas Engine
8D - 6 IGNITION SYSTEMS — ^ ^ — ^ — ^ _ B R
The ignition coil is not oil filled. The windings are

embedded in an epoxy compound. This provides heat
and vibration resistance that allows the ignition coil
to be mounted on the engine.
The automatic shutdown (ASD) relay, after receiv
ing signals from the crankshaft and camshaft posi
tion sensors, will supply battery voltage to the
ignition coil positive terminal. If these signals are not
received by the PCM after approximately one second
of engine cranking (start-up), the ASD relay will shut
off positive voltage to the coil. Coil operation (firing)
is then controlled by switching ground circuits (off-
and-on) through the PCM. The PCM will determine ENGINE
cylinder identification after receiving signals from -CYLINDER
the crankshaft and camshaft position sensors. NUMBER BOLTS (8) J948D-6
Base ignition timing is not adjustable on any
engine. By controlling the coil ground circuit, the Fig, 13 ignition Coil Packs—8.0 L ¥-10 Engine
PCM is able to set the base timing and adjust the ig REAR COIL PACK FRONT COIL PACK
nition timing advance. This is done to meet changing
engine operating conditions.
The PCM adjusts ignition timing based on inputs it
receives from:
® The engine coolant temperature sensor
@ The crankshaft position sensor (engine speed)
• The manifold absolute pressure (MAP) sensor
• The throttle position sensor
• Transmission gear selection
this group.
IGNITION COIL PACKS—8.0L V-10 ENGINE

The ignition system used on the 8.0L V-10 engine
does not use a conventional mechanical distributor. It
will be referred to as a distributor-less ignition sys
tem, ignition timing is n o t adjustable on any
8.0L V-10 engine.
Two separate coil packs containing a total of five
independent coils are attached to a common mount RIGHT LEFT
ing bracket located above the right engine valve BANK BANK
cover (Fig. 13). The coil packs are not oilfilled.The FIRING ORDER
front coil pack contains three independent epoxy 1-10-9-4-3-6-5-8-7-2 948D-12
filled coils. The rear coil pack contains two indepen
dent epoxy filled coils. Fig. 14 Spark Plug Cable Order—8. OL ¥-10 Engine
When one of the 5 independent coils discharges, it The ignition system is controlled by the powertrain
fires two paired cylinders at the same time (one cyl control module (PCM) on all engines (Fig. 15). The
inder on compression stroke and the other cylinder PCM was formerly referred to as the SBEC or engine
on exhaust stroke). controller.
Coil firing (Fig. 14) is paired together on cylinders: The automatic shutdown (ASD) relay, after receiv
® Number 5 and 10 ing signals from the crankshaft and camshaft posi
• Number 9 and 8 tion sensors, will supply battery voltage to all of the
• Number 1 and 6 ignition coil positive terminals. If these signals are
© Number 7 and 4 not received by the PCM after approximately one sec
• Number 3 and 2 ond of engine cranking (start-up), the ASD relay will
BR IGNITION SYSTEMS 80 • 7
The PCM adjusts ignition timing based on Inputs it

receives from:
• The engine coolant temperature sensor
• The crankshaft position sensor (engine speed)
• The manifold absolute pressure (MAP) sensor
• The throttle position sensor
• Transmission gear selection
For removal and installation of the coil packs, refer
to the Component Removal/Installation section of
this group.
IGNITION CONTROL MODULE—8.0L V-10 ENGINE

POWERTRAIN CONTROL
MODULE (PCM) J9414-11 MODULE OPERATION
Fig. 15 PCM Location—Typical For ignition control module (ICM) operation, refer
to the previous section on Ignition Coil Packs—-8.OL
shut off positive voltage to all of the coils. Coil oper V-10 Engine.
ation (firing) is then controlled by switching ground For ICM testing, refer to the appropriate Power-
circuits (off-and-on) through the PCM. The PCM will train Diagnostic Procedures manual for operation of
determine cylinder identification after receiving sig the DRB scan tool.
nals from the crankshaft and camshaft position sen For removal and installation of the ICM, refer to
sors. the Component Removal/Installation section of this
Ignition coil ground path circuits for paired cylin group.
ders number 1/6, 3/2 and 9/8 are operated by the
PCM only. ENGINE COOLANT TEMPERATURE SENSOR
A separate ignition control module (1CM), along For an operational description, diagnosis and re
with commands from the PCM, is used to control the moval and installation procedures, refer to Group 14,
ground path circuits for only two of the five paired Fuel System.
coil packs. This will be for paired cylinders number
4/7 and 5/10. The ICM is located in the engine com INTAKE MANIFOLD AIR TEMPERATURE SENSOR
partment. It is mounted to the right inner fender be For an operational description, diagnosis and re
hind the coolant reserve/overflow tank (Fig. 16). moval and installation procedures, refer to Group 14,
Fuel System.
COOLANT
RESERVE/OVERFLOW
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
For information, refer to Group 14, Fuel System.
POWERTRAIN CONTROL MODULE (PCM)
The powertrain control module (PCM) is located in
the right-rear side of the engine compartment (Fig.
15). The PCM was formerly referred to as the SBEC
or engine controller.
The ignition system is controlled by the PCM.
Base ignition timing (by rotation of distribu
tor) is not adjustable.
The PCM opens and closes the ignition coil ground
circuit to operate the ignition coil (or coils). This is
SOLTS (2) J948D-21
done to adjust ignition timing, both initial (base) and
advance, for changing engine operating conditions.
Fig. 16 ignition Control Module Location—S.OL V-10
The PCM adjusts ignition timing based on inputs it
Engine
receives from:
Base ignition timing is not adjustable on t h e • The engine coolant temperature sensor
8.0L ¥-1© engine. By controlling all of the coil © The crankshaft position sensor (engine speed)
ground circuits, the PCM is able to set the base tim • The manifold absolute pressure (MAP) sensor
ing and adjust the ignition timing advance. This is • The throttle position sensor
done to meet changing engine operating conditions. ® Transmission gear selection
For removal and installation of this component, re OXYGEN SENSOR (02S)
fer to the Component Removal/Installation section of For an operational description, diagnosis and re
this group. moval or Installation of the 0 2 S , refer to Group 14,
For diagnostics, refer to the appropriate Powertrain Fuel' Systems In this manual.
Diagnostic Procedures service manual for operation
of the DRB scan tool.
D I A G H O S T 1 C S / S E R V S C E PROCEDURES
INDEX
page page
Automatic Shutdown (ASD) Relay Test . . . . . . . . . . 9 Ignition Coil Pack Tests—8.0L V-10 Engine 12
Camshaft Position Sensor Test—3.9L V-6 or Ignition Coil Test—3.9L V-6 or 5.2/5.9L V-8
5.2/5.9L V-8 Engines 9 Engines 12
Camshaft Position Sensor Test—8.0L V-10 Engine . 10 Ignition Control Module Test—8.0L V-10 Engine . . . 13
Crankshaft Position Sensor Test—3.9L V-6 or Ignition Secondary Circuit Diagnosis . . . . . . . . . . . 15
5.2/5.9L V-8 Engines 10 Ignition Timing . 16
Crankshaft Position Sensor Test—8.0L V-10 Intake Manifold Air Temperature Sensor Test . . . . . 16
Engine 11 Manifold Absolute Pressure (MAP) Sensor Test . . . 16
Distributor Cap—3.9L V-6 or 5.2/5.9L V-8 Engines . 11 On-Board Diagnostics 20
Distributor Rotor—3.9L V-6 or 5.2/5.9L V-8
Oxygen Sensor (02S) Tests 20
Engines . 12
Powertrain Control Module (PCM) 16
DRB Scan Tool 12
Engine Coolant Temperature Sensor Test . 14 Spark Plug Secondary Cables 19
General Information . . . . . . . . . . . . . . . . . . . . . . . . 9 Spark Plugs 17
GENERAL INFORMATION CAMSHAFT

POSITION
This section of the group, Diagnostics/Service Pro SENSOR
cedures, will discuss basic ignition system diagnostics
and service adjustments. SYNC
For system operation and component identification, SIGNAL
refer to the Component Identification/System Opera GENERATOR
tion section of this group.
For removal or installation of ignition system com
ponents, refer to the Component Removal/Installa
For other useful information, refer to On-Board Di
agnostics in the General Diagnosis sections of Group
14, Fuel System in this manual.
DISTRIBUTOR
For operation of the DRB Scan Tool, refer to the ASSEMBLY
appropriate Powertrain Diagnostic Procedures ser J9314-82
vice manual.
Fig. 1 Camshaft Position Sensor—3.9L V-6 or
AUTOMATIC SHUTDOWN (ASD) RELAY TEST 5.2/5.9L V-8 Engines—Typical
To perform a complete test of this relay and its cir insert them into the backside of the distributor wire
cuitry, refer to the DRB scan tool. Also refer to the harness connector to make contact with the termi
appropriate Powertrain Diagnostics Procedures man nals. Be sure that the connector is not damaged
ual. To test the relay only, refer to Relays—Opera when inserting the paper clips. Attach voltmeter
tion/Testing in the Group 14, Fuel System section of leads to these paper clips.
this service manual.
(1) Connect the positive (+) voltmeter lead into the
CAMSHAFT POSITION SENSOR TEST—3.9L V-6 sensor output wire. This is at done the distributor
OR 5.2/5.9L V-8 ENGINES wire harness connector. For wire identification, refer
The camshaft position sensor (Fig. 1) is located in to Group 8W, Wiring Diagrams.
the distributor on all 3.9L V-6 or 5.2L/5.9L V-8 en (2) Connect the negative (-) voltmeter lead into the
gines. ground wire. For wire identification, refer to Group
To perform a complete test of this sensor and its 8W, Wiring Diagrams.
circuitry, refer to the DRB scan tool. Also refer to the (3) Set the voltmeter to the 15 Volt DC scale.
appropriate Powertrain Diagnostics Procedures man (4) Remove distributor cap from distributor (two
ual. To test the sensor only, refer to the following: screws). Rotate (crank) the engine until the distribu
For this test, an analog (non-digital) voltme tor rotor is pointed towards the rear of vehicle. The
ter is needed. Do not remove the distributor connec movable pulse ring should now be within the sensor
tor from the distributor. Using small paper clips, pickup.
8D-10 IGNITION SYSTEMS BR
(5) Turn ignition key to ON position. Voltmeter
should read approximately 5.0 volts. CAMSHAFT \
(6) If voltage is not present, check the voltmeter
leads for a good connection.
(7) If voltage is still not present, check for voltage
at the supply wire. For wire identification, refer to
Group 8W, Wiring Diagrams.
(8) If voltage is not present at supply wire, check
for voltage at pin-7 of powertrain control module
(PCM) 60-way connector. Leave the PCM connector
connected for this test.
(9) If voltage is still not present, perform vehicle
test using the DRB scan tool.
(10) If voltage is present at pin-7, but not at the
supply wire;
(a) Check continuity between the supply wire.
This is checked between the distributor connector Fig. 2 Camshaft Position Sensor—8.0L V-10
and pin-7 at the PCM. If continuity is not present, Engine—Typical
repair the harness as necessary. scale for this test. The meter reading should be
(b) Check for continuity between the camshaft open (no resistance). Replace sensor if a low resis
position sensor output wire and pin-44 at the PCM. tance is indicated.
If continuity is not present, repair the harness as
necessary.
(c) Check for continuity between the ground cir
cuit wire at the distributor connector and ground.
If continuity is not present, repair the harness as
necessary.
(11) While observing the voltmeter, crank the en
gine with ignition switch. The voltmeter needle
should fluctuate between 0 and 5 volts while the en
gine is cranking. This verifies that the camshaft po
sition sensor in the distributor is operating properly
and a sync pulse signal is being generated.
If sync pulse signal is not present, replacement of VIEW LOOKING INTO
the camshaft position sensor is necessary. CONNECTOR ON SENSOR
For removal or installation of ignition system com PIGTAIL HARNESS J948D-20
ponents, refer to the Component Removal/Installa
Fig. 3 Typical Sensor Connector
For system operation and component identification, CRANKSHAFT POSITION SENSOR TEST—3.9L V-6
refer to the Component Identification/System Opera OR 5.2/5.9L V-8 ENGINES
tion section of this group. To perform a complete test of this sensor and its
circuitry, refer to the DRB scan tool. Also refer to the
CAMSHAFT POSITION SENSOR TEST—8.01 V-10 appropriate Powertrain Diagnostics Procedures man
ENGINE ual. To test the sensor only, refer to the following:
The camshaft position sensor is located in the tim The sensor is located on the top of cylinder block
ing chain case/cover on the left-front side of the en near the rear of right cylinder head (Fig. 4).
gine (Fig. 2). (1) Near the rear of intake manifold, disconnect
To perform a complete test of this sensor and its sensor pigtail harness connector from main wiring
circuitry, refer to the DRB scan tool. Also refer to the harness.
appropriate Powertrain Diagnostics Procedures man (2) Place an ohmmeter across terminals B and C
ual. To test the sensor only, refer to the following: (Fig. 3). Ohmmeter should be set to lK-to-lOK
(1) Disconnect the sensor pigtail harness from the scale for this test. The meter reading should be
main engine wiring harness connector. open (no resistance). Replace sensor if a low resis
(2) Place an ohmmeter across terminals B and C tance is indicated.
(Fig. 3). Ohmmeter should be set to lK-to-lOK
BR IGNITION SYSTEMS 8D -11
(3) Place an ohmmeter across terminals B and C

(Fig. 3). Ohmmeter should b e set to lK-to-lOK
scale for this test. The meter reading should be
open (no resistance). Replace sensor if a low resis
tance is Indicated.
DISTRIBUTOR CAP—3 J L V-6 OR 5.2/5 J L V-8

ENGINES
INSPECTION
Remove the distributor cap and wipe it clean with
a dry lint free cloth. Visually Inspect the cap for
cracks, carbon paths, broken towers, or damaged ro
tor button (Figs. 6 and 7). Also check for white depos
its on the Inside (caused by condensation entering
the cap through cracks). Replace any cap that dis
plays charred or eroded terminals. The inside flat
surface of a terminal end (faces toward rotor) will in
dicate some evidence of erosion from normal opera
tion. Examine the terminal ends for evidence of
mechanical interference with the rotor tip.
Fig. 4 Crankshaft Position Sensor—3.9L V-6 or
CRANKSHAFT POSITION SENSOR TEST—8.0L
V-10 ENGINE
5).
Fig. 6 Cap Inspection—External—Typical
Fig. 5 Crankshaft Position Sensor—8.0L ¥-10

Engine—Typical
To perform a complete test of this sensor and its
appropriate Powertrain Diagnostics Procedures man
ual. To test the sensor only, refer to the following:
(2) Disconnect the sensor pigtail harness from the
main engine wiring harness connector. Fig. 7 Cap Inspection—Internal—Typical
8D -12 IGNITION SYSTEMS
DISTRIBUTOR ROTOR—3.9L V-6 OR 5.2/5.9L V-8

ENGINES
Visually inspect the rotor (Fig. 8) for cracks, evi
dence of corrosion, or the effects of arcing on the
metal tip. Also check for evidence of mechanical in
terference with the cap. Some charring is normal on
the end of the metal tip. The silicone-dielectric-var
nish-compound applied to the rotor tip for radio in
terference noise suppression, will appear charred.
This is normal. Do not remove the charred com
pound. Test the spring for insufficient tension. Re
place a rotor that displays any of these adverse
conditions.
INSUFFICIENT
SPRING
TENSION Fig. 9 Ignition Coil—3.9L ¥-6 or 5.2/5.9L ¥-8
LDC-Gas Engines
EVIDENCE OF
PHYSICAL
CONTACT
WITH CAP J908D-48
Fig. 8 Rotor Inspection—Typical

Fig. 10 Ignition Coil—5.9L ¥-8 HDC-Gas Engine
DRB SCAN TOOL . Inspect the ignition coil for arcing. Test the coil ac
For operation of the DRB scan tool, refer to the ap cording to coil tester manufacturer's instructions.
propriate Powertrain Diagnostic Procedures service Test the coil primary and secondary resistance. Re
manual. place any coil that does not meet specifications. Refer
to the Ignition Coil Resistance chart.
IGNITION COIL TEST—3.9L V-6 OR 5.2/5.9L V-8 If the ignition coil is being replaced, the secondary
ENGINES spark plug cable must also be checked. Replace cable
To perform a complete test of the ignition coil and if it has been burned or damaged.
its circuitry, refer to the DRB scan tool. Also refer to Arcing at the tower will carbonize the cable boot,
the appropriate Powertrain Diagnostics Procedures which, if it is connected to a new ignition coil, will
manual. To test the coil only, refer to the following: cause the coil to fail.
The ignition coil is designed to operate without an If the secondary coil cable shows any signs of dam
external ballast resistor. age, it should be replaced with a new cable. Carbon
3.SL V-6 or 5.2/5.SL V-8 LDC-Gas Engines: The tracking on the old cable can cause arcing and the
coil is mounted to a bracket that is bolted to the failure of a new ignition coil.
front of the right engine cylinder head (Fig. 9). This
bracket is mounted on top of the automatic belt ten IGNITION COIL PACK TESTS—8.0L V-10 ENGINE
sioner bracket using common bolts. To perform a complete test of the ignition coil packs
5.9L V-8 HDC-Gas Engine: The coil is mounted to and their circuitry, refer to the DRB scan tool. Also
a bracket that is bolted to the air injection pump
(AIR pump) mounting bracket (Fig. 10).
BR IGNITION SYSTEMS 8D -13
IGNITION COIL RESISTANCE—EXCEPT 8.0L V-10 ENGINE
PRIMARY RESISTANCE S E C O N D A R Y RESISTANCE
COIL ( M A N U F A C T U R E ! ) 21-27°C (70-80°F) 21-27°C (7©-80°F)
Diamond 0.97- 1.18 Ohms 11,300- 15,300 Ohms
Toyodenso 0.95- 1.20 Ohms 11,300- 13,300 Ohms
J918D-2
refer to the appropriate Powertrain Diagnostics Pro and either the right (cylinders 9/8) or left (cylinders
cedures manual. To test the coil packs only, refer to 5/10) coil terminals (Fig. 15). Refer to figure 16 for
the following procedure: resistance specifications.
OHMMETER
independent coils are attached to a common mount
ing bracket located above the right engine valve
cover (Fig. 11). The coil packs are not oilfilled.The
front coil pack contains three independent epoxy MAKE OHMMETER
filled coils that will fire six cylinders. The rear coil CONNECTIONS AT
pack contains two independent epoxy filled coils that CORRESPONDING CYLINDERS
(1/6, 7/4 OR 3/2).
will fire four cylinders.
FRONT
OF
ENGINE
J948D-14
ENGINE COIL
5
CYLINDER^ "MOUNTING
NUMBER BOLTS (8) Fig. 12 Checking Coil Secondary Resistance—Front
J948D-6
Coils—8.0L V-10 Engine
Fig. 11 Ignition Coil Packs—8.0L V-10 Engine IGNITION CONTROL MODULE TEST—8.0L V-10
To test the secondary resistance of each individual ENGINE
paired coil, attach an ohmmeter across the coil tow The ICM is located in the engine compartment. It
ers (Figs. 12 or 13). This must be done between cor is mounted to the right inner fender behind the cool
responding cylinders number 3/2, 7/4, 1/6, 9/8 or 5/10 ant reserve/overflow tank.
(Fig. 11). Refer to figure 16 for resistance specifica Ignition coil ground path circuits for paired cylin
tions. ders number 1/6, 3/2 and 9/8 are operated by the
To test the primary resistance of the front coil PCM only.
pack, attach an ohmmeter between the B+ coil termi A separate ignition control module (ICM) (Fig. 17),
nal and either the right (cylinders 3/2), center (cylin along with commands from the PCM, is used to con
ders 7/4) or left coil (cylinders 1/6) terminals (Fig. trol the ground path circuits for only two of the five
14). Refer to figure 16 for resistance specifications. paired coil packs. This will be for paired cylinders
To test the primary resistance of the rear coil pack, number 4/7 and 5/10.
attach an ohmmeter between the B+ coil terminal For ICM testing, refer to the appropriate Power-
train Diagnostic Procedures manual for operation of
the DRB scan tool.
80 -14 IGNITION SYSTEMS BH
OHMMETER TO LEFT TO RIGHT

COIL COIL
MAKE OHMMETER
CONNECTIONS AT
CORRESPONDING CYLINDERS
(5/10 OR 9/8). FRONT
OF
ENGINE
FRONT
OF 1+
ENGINE TERMINAL J948D-17
Fig. 15 Checking Coil Primary Resistance—Rear

Coils—8.0L ¥-10 Engine
* Primary Resistance: 0.53 to 0.65 ohms

J948D-15 * * Secondary Resistance: 10.9 to 14.7 K ohms
Fig. 13 Checking Coil Secondary Resistance—Rear * Test across the primary connector.
Coils—8.0L ¥-10 Engine Refer to text for test procedures.
* * Test across the individual coil towers.
B+ TERMINAL
Refer to text for test procedures.
J948D-13
Fig. 16 Ignition Coil Resistance Specifications—8.0L

¥-10 Engine
FRONT
OF COOLANT
ENGINE RESERVE/OVERFLOW
TANK
IGNITION CONTROL
MODULE (ICM)
TO
CENTER
COIL J948D-16
Fig. 14 Checking Coil Primary Resistance—Front

Coils—8.0L ¥-10 Engine TANK
For removal and installation of the ICM, refer to MOUNTING
BOLTS (3)
the Component Removal/Installation section of this ICM MOUNTING
group. BOLTS (2) J948D-21
ENGINE COOLANT TEMPERATURE SENSOR TEST Fig. 17 Ignition Control Module Location—8.0L ¥-10
For an operational description, diagnosis and re Engine
moval and installation procedures, refer to Group 14,
Fuel System.
BR IGNITION SYSTEMS 80-15
IGNITION SECONDARY CIRCUIT DIAGNOSIS Also inspect the distributor cap and rotor for cracks
or burn marks. Repair as necessary. If steady arcing
CHECKING FOR SPARK—EXCEPT 8.0L If-fO occurs, connect ignition coil cable to the distributor
ENGINE cap.
(3) Remove a cable from one spark plug.
CAUTION: When disconnecting a high voltage cable (4) Using insulated pliers, hold the cable terminal
from a spark plug or from the distributor cap, twist approximately 12 mm (1/2 in.) from the engine cylin
the rubber boot slightly (1/2 turn) to break it loose der head or block while rotating the engine with the
(Fig. 18). Grasp the boot (not the cable) and pull it starter motor. Observe the spark plug cable terminal
off with a steady, even force. for an arc. If steady arcing occurs, it can be expected
that the ignition secondary system is operating cor
SPARK PLUG BOOT« rectly, (note that if the ignition coil cable is re
PULLER
moved for this test, instead of a spark plug
cable, the spark intensity will be much higher.)
SPARK PLUG
CABLE A N D
If steady arcing occurs at the spark plug cables, but
BOOT the engine will not start, connect the DRB scan tool.
Refer to the Powertrain Diagnostic Procedures ser
vice manual.
FAILURE TO START TEST—EXCEPT 8.0L V-fO

ENGINE
TWIST AND PULL

To prevent unnecessary diagnostic time and wrong
test results, the previous Checking For Spark test
should be performed prior to this test.
SPARK PLUG
958D-9
WARNING: S E T PARKING B R A K E OR B L O C K THE
Fig. 18 Cable Removal DRIVE W H E E L S B E F O R E PROCEEDING WITH THIS
TEST.
(1) Disconnect the ignition coil secondary cable
from center tower of the distributor cap. Hold the ca (1) Unplug the ignition coil harness connector at
ble terminal approximately 12 mm (1/2 in.) from a the coil (Figs. 20 or 21).
good engine ground (Fig. 19).
• O
o
O
CHECK HERE IGNITION

FOR SPARK c o , L
918D-18 -«* COL
ffCONNECTOR J°214-7
Fig. 19 Checking for Spark—Typical
Fig. 20 Coil Harness Connector—3.9L V-6 or
WARNING: B E V E R Y C A R E F U L W H E N THE ENGINE 5.2/5.9L LDC-Gas Engines
IS CRANKING. DO NOT PUT YOUR HANDS N E A R
THE P U L L E Y S , B E L T S OR THE FAN. DO NOT W E A R (2) Connect a set of small jumper wires (18 gauge
L O O S E FITTING CLOTHING. or smaller) between the disconnected harness termi
nals and the ignition coil terminals. To determine po
(2) Rotate (crank) the engine with the starter mo larity at connector and coil, refer to the Wiring
tor and observe the cable terminal for a steady arc. If Diagrams section.
steady arcing does not occur, inspect the secondary (3) Attach one lead of a voltmeter to the positive
coil cable. Refer to Spark Plug Cables in this group. (12 volt) jumper wire. Attach the negative side of
8D -16 IGNITION SYSTEMS
CAPACITOR CONNECT THIS

CLIP TO COIL
r
-7 - . 7 ALLIGATOR
GROUND -g&Z'^ CLIP
.33 MF
THIS /MOMENTARILY
J
CLIP - GROUND THIS
CLIP TO COII
NEGATIVE
ALLIGATOR CLIP RB1003
Fig. 23 Special Jumper Ground-to-Coil Negative

Terminal
(7) If spark is generated, replace the powertrain
COIL "\ control module (PCM).
CONNECTOR J9314-160
(8) If spark is not seen, use the special jumper to
ground the coil negative terminal directly.
Fig. 21 Coil Harness Connector—5*91 V-8 HDC-Gas
(9) If spark is produced, repair wiring harness for
Engine
an open condition.
voltmeter to a good ground. Determine that sufficient (10) If spark is not produced, replace the ignition
battery voltage (12.4 volts) is present for the starting coil.
and ignition systems.
(4) Crank the engine for 5 seconds while monitor IGNITION TIMING
ing the voltage at the coil positive terminal: Base (initial) ignition timing is NOT adjust
• If the voltage remains at zero during the entire pe able on any engine. On a 3.9L V-6 or a 5.2/5.9L
riod of cranking, refer to On-Board Diagnostics in V-8 engine, do not attempt to adjust ignition
Group 14, Fuel Systems. Check the powertrain con timing by rotating the distributor. The rota
trol module and auto shutdown relay. tional position of the distributor is determining
• If voltage is at or near battery voltage and drops fuel synchronization only.
to zero after 1-2 seconds of cranking, check the pow All ignition timing functions are controlled by the
ertrain control module circuit. Refer to On-Board Di powertrain control module (PCM). Refer to On-Board
agnostics in Group 14, Fuel Systems. Diagnostics in the Multi-Port Fuel Injection—Gen
© If voltage remains at or near battery voltage dur eral Diagnosis section of Group 14, Fuel Systems for
ing the entire 5 seconds, turn the key off. Remove more information. Also refer to the appropriate Pow
ertrain Diagnostics Procedures service manual for op
the 60-way connector (Fig. 22) from the powertrain
eration of the DRB Scan Tool.
control module (PCM). Check 60-way connector for
any spread terminals. INTAKE MANIFOLD AIR TEMPERATURE SENSOR
TEST
For an operational description, diagnosis and re
Fuel System.

CONNECTOR TEST
TERMINAL SIDE To perform a complete test of MAP sensor and its
SHOWN J908D-42
circuitry, refer to DRB scan tool and appropriate
Powertrain Diagnostics Procedures manual. To test
Fig. 22 PCM 60-Way Connector the MAP sensor only, refer to MAP Sensor in Group
(5) Remove test lead from the coil positive termi 14, Fuel System.
nal. Connect an 18 gauge jumper wire between the
battery positive terminal and the coil positive termi POWERTillN CONTiOL MODULE (PCM)
nal. The powertrain control module (PCM) is located in
(6) Make the special jumper shown in figure 23. the right-rear side of the engine compartment (Fig.
Using the jumper, momentarily ground terminal-19 24). The PCM was formerly referred to as the SBEC
of the 60-way connector. A spark should be generated or engine controller.
at the coil cable when the ground is removed. The ignition system is controlled by the PCM.
For removal and installation of this component, re-
BH IGNITION SYSTEMS 8D - 1 7
engine speeds. Faulty plugs can be identified in a

number of ways: poor fuel economy, power loss, de
crease in engine speed, hard starting and, in general,
poor engine performance.
Remove the spark plugs and examine them for
burned electrodes and fouled, cracked or broken por
celain insulators. Keep plugs arranged in the order
in which they were removed from the engine. An iso
lated plug displaying an abnormal condition indicates
that a problem exists in the corresponding cylinder.
Replace spark plugs at the intervals recommended in
the maintenance chart in Group 0, Lubrication and
Maintenance.
POWERTRAIN CONTROL Spark plugs that have low mileage may be cleaned
MODULE (PCM) J9414-11 and reused if not otherwise defective. Refer to the
following Spark Plug Condition section of this group.
fer to the Component Removal/Installation section of commoN
this group.
For diagnostics, refer to the appropriate Powertrain 10B1AL OPERATING
Diagnostic Procedures service manual for operation The few deposits present on the spark plug will
of the DRB scan tool. probably be light tan or slightly gray in color. This is
evident with most' grades of commercial gasoline
SPAFtI PLUGS (Fig. 26). There will not be evidence of electrode
For spark plug removal, cleaning, gap adjustment burning. Gap growth will not average more than ap
and installation, refer to the Component Removal/In proximately 0.025 mm (.001 in) per 1600 km (1000
stallation section of this group. miles) of operation. Spark plugs that have normal
On 3.9L V-6 or 5.2/5.9L V-8 engines, spark plug ca wear can usually be cleaned, have the electrodes
ble boot heat shields are pressed into the cylinder filed, have the gap set and then be installed.
head to surround each cable boot and spark plug NORMAL DRY BLACK COLD (CARBON) FOULING
(Fig. 25). These shields protect the spark plug boots \ DEPOSITS V \
from damage (due to engine heat generated by the
exhaust manifolds) and should not be removed. After
the spark plug cable has been installed, the lip of the
cable boot should have a small air gap to the top of
the heat shield (Fig. 25).
J908D-15
Fig. 26 Normal Operation and Cold (Carbon) Fouling

Some fuel refiners in several areas of the United
States have introduced a manganese additive (MMT)
for unleaded fuel. During combustion, fuel with MMT
causes the entire tip of the spark plug to be coated
with a rust colored deposit. This rust color can be
Fig. 25 Heat Shields—3.9L V-6 or 5.2J5.9L V-8 misdiagnosed as being caused by coolant in the com
Engines bustion chamber. Spark plug performance is not af
fected by MMT deposits.
Faulty carbon and/or gas fouled plugs generally
cause hard starting, but they will clean up at higher
8D -18 IGNITION SYSTEMS BR
COLD F0ULING/CARB01 FOULING This short circuits the electrodes. Spark plugs with
Cold fouling is sometimes referred to as carbon electrode gap bridging can be cleaned using standard
fouling. The deposits that cause cold fouling are ba procedures.
sically carbon (Fig. 26). A dry, black deposit on one or GROUND
two plugs in a set may be caused by sticking valves
or defective spark plug cables. Cold (carbon) fouling
of the entire set of spark plugs may be caused by a
clogged air cleaner element or repeated short operat
ing times (short trips).
WET FOULING OR G1S FOULING

A spark plug coated with excessive wet fuel or oil is
wet fouled. In older engines, worn piston rings, leak
ing valve guide seals or excessive cylinder wear can
cause wet fouling. In new or recently overhauled en
gines, wet fouling may occur before break-in (normal
oil control) is achieved. This condition can usually be
resolved by cleaning and reinstalling the fouled J908D-11
plugs.
Fig. 28 Electrode Gap Bridging
OIL O i ASH ENCRUSTED SCAfENGER DEPOSITS
If one or more spark plugs are oil or oil ash en Fuel scavenger deposits may be either white or yel
crusted (Fig. 27), evaluate engine condition for the low (Fig. 29). They may appear to be harmful, but
cause of oil entry into that particular combustion this is a normal condition caused by chemical addi
chamber. tives in certain fuels. These additives are designed to
change the chemical nature of deposits and decrease
spark plug misfire tendencies. Notice that accumula
tion on the ground electrode and shell area may be
heavy, but the deposits are easily removed. Spark
plugs with scavenger deposits can be considered nor
mal in condition and can be cleaned using standard
procedures.
GROUND
ELECTRODE
COVERED
^^^^SI^miKI PR1673
J908D-12
Fig. 27 Oil or Ash Encrusted
ELECTRODE GAP BRIDGING Fig. 29 Scavenger Deposits
Electrode gap bridging may be traced to loose de CHIPPED ELECTRODE INSULATOR
posits in the combustion chamber. These deposits ac A chipped electrode insulator usually results from
cumulate on the spark plugs during continuous stop- bending the center electrode while adjusting the
and-go driving. When the engine is suddenly spark plug electrode gap. Under certain conditions,
subjected to a high torque load, deposits partially liq severe detonation can also separate the insulator
uefy and bridge the gap between electrodes (Fig. 28). from the center electrode (Fig. 30). Spark plugs with
this condition must be replaced.
mm IGNITION SYSTEMS SD - I I
GROUND timing, detonation and cooling system malfunctions

ELECTRODE CENTER can also cause spark plug overheating.
ELECTRODE
BLISTERED
WHITE OR
GRAY
COLOiEP
INSULATOR
CHIPPED
INSULATOR
J908D-13
Fig. 30 Chipped Electrode insulator

J908D-16
PREIGNITION DAMAGE
Preignition damage is usually caused by excessive Fig. 32 Spark Plug Overheating
combustion chamber temperature. The center elec SPAM PLUI SECONDARY CABLES
trode dissolves first and the ground electrode dis
solves somewhat latter (Fig. 81). Insulators appear On 3.9L V-6 or 5.2/5.9L V-8 engines, spark plug
relatively deposit free. Determine if the spark plug heat shields are pressed into the cylinder head to
has the correct heat range rating for the engine. De surround each spark plug cable boot and spark plug
termine if ignition timing is over advanced, or if (Fig. 33). These shields protect the spark plug boots
other operating conditions are causing engine over from damage (due to engine heat generated by the
heating. (The heat range rating refers to the operat exhaust manifolds) and should not be removed. After
ing temperature of a. particular type spark plug. the spark plug cable has been installed, the lip of the
Spark plugs are designed to operate within specific cable boot should have a small air gap to the top of
temperature ranges. This depends upon the thick the heat shield (Fig. 33).
ness and length of the center electrodes porcelain in
sulator.)
GROUND
ELECTRODE
STARTING
TO DISSOLVE
CENTER
ELECTRODE
DISSOLVED
J9314-94
Fig. 33 Heat Shields—3.9L V-6 or 5.2/5.9L V-8

J908D-14 Engines
Fig. 31 Preignition Damage TESTING

Spark plug cables are sometimes referred to as sec
SPARK PLUG OVERHEATING
ondary ignition cables or secondary wires. The cables
Overheating is indicated by a white or gray center transfer electrical current from the distributor to in
electrode insulator that also appears blistered (Fig. dividual spark plugs at each cylinder. The spark plug
32). The increase in electrode gap will be consider cables are of nonmetallic construction and have a
ably in excess of 0.001 inch per 1000 miles of opera
built in resistance. The cables provide suppression of
tion. This suggests that a plug with a cooler heat
range rating should be used. Over advanced ignition radio frequency emissions from the ignition system.
Check the high-tension cable connections for good specifications as found in the Spark Plug Cable Re
contact at the ignition coil, distributor cap towers sistance chart, replace the cable. Test all spark plug
and spark plugs. Terminals should be fully seated. cables in this manner.
The terminals and spark plug covers should be in SHARK PLUG CABLE RESISTANCE
good condition. Terminals should fit tightly to the ig
nition coil, distributor cap and spark plugs. The
MINIMUM
spark plug cover (boot) of the cable should fit tight
around the spark plug insulator. Loose cable connec 250 Ohms Per Inch 1000 Ohms Per Inch
tions can cause corrosion and increase resistance, re 3000 Ohms Per Foot 12,000 Ohms Per Foot
sulting in shorter cable service life.
Clean the high tension cables with a cloth moist J908D-43
ened with a nonflammable solvent and wipe dry. To test ignition coil-to-distributor cap cable, do not
Check for brittle or cracked insulation. remove the cable from the cap. Connect ohmmeter to
When testing secondary cables for damage with an rotor button (center contact) of distributor cap and
oscilloscope, follow the instructions of the equipment terminal at ignition coil end of cable. If resistance is
manufacturer. Note that 8.0L V-10 engines equipped not within specifications as found in the Spark Plug
with distributor-less ignition will display opposite po Cable Resistance chart, remove the cable from the
larity spikes for paired cylinders. distributor cap. Connect the ohmmeter to the termi
If an oscilloscope is not available, spark plug cables nal ends of the cable. If resistance is not within spec
may be tested as follows: ifications as found in the Spark Plug Cable
Resistance chart, replace the cable. Inspect the igni
CAUTION: Do not leave any one spark plug cable tion coil tower for cracks, burns or corrosion.
disconnected for longer than necessary during test For removal and installation of spark plug cables,
ing. This may cause possible heat damage to the refer to Spark Plug Secondary Cables in the Compo
catalytic converter. Total test time must not exceed nent Removal/Installation section.
ten minutes.
OXYGEN SENSOR (02S) TESTS
With the engine running, remove spark plug cable
from spark plug (one at a time) and hold next to a
moval or installation of the 02S, refer to Group 14,
good engine ground. If the cable and spark plug are Fuel Systems in this manual.
in good condition, the engine rpm should drop and
the engine will run poorly. If engine rpm does not 0N-B0ARD DIAGNOSTICS
drop, the cable and/or spark plug may not be operat
ing properly and should be replaced. Also check en mm CERTAIN IGNITION SYSTEM
gine cylinder compression. COMPONENTS
With the engine not running, connect one end of a The powertrain control module (PCM) performs an
test probe to a good ground. Start the engine and run On-Board Diagnostic (OBD) check for certain ignition
the other end of the test probe along the entire system components on all vehicles. This is done by
length of all spark plug cables. If cables are cracked setting a diagnostic trouble code (DTC).
or punctured, there will be a noticeable spark jump A DTC can be obtained in two different ways. One
from the damaged area to the test probe. The cable of the ways is by connecting the DRB scan tool to the
running from the ignition coil to the distributor cap data link connector. This connector is located in the
can be checked in the same manner. Cracked, dam engine compartment (Fig. 34). Refer to the appropri
aged or faulty cables should be replaced with resis ate Powertrain Diagnostic Procedures service manual
tance type cable. This can be identified by the words for operation of the DRB scan tool. The other way is
ELECTRONIC SUPPRESSION printed on the cable to cycle the ignition key and observe the malfunction
jacket. indicator lamp (MIL). The MIL lamp is displayed on
3.9L/5.2L/5.9L Engines: Use an ohmmeter to test the instrument panel as the CHECK ENGINE lamp
for open circuits, excessive resistance or loose termi (Fig. 35). This lamp will flash a numeric code. If a
nals. Remove the distributor cap from the distributor. numeric code number 11 (for the crankshaft position
Do not remove cables from cap. Remove cable sensor), 42 (for the ASD relay), or 43 (for the ignition
from spark plug. Connect ohmmeter to spark plug coil, V-10 engine only) is observed, a problem has
terminal end of cable and to corresponding electrode been found in the ignition system.
in distributor cap. Resistance should be 250 to 1000 Note that the CHECK ENGINE lamp will illumi
Ohms per inch of cable. If not, remove cable from dis nate initially for approximately two seconds each
tributor cap tower and connect ohmmeter to the ter time the ignition key is turned to the ON position.
minal ends of cable. If resistance is not within This is done for a bulb test.
DATA LINK TACHOMETER

CONNECTOR
POWERTRAIN CONTROL
MODULE (PCM) J9414-11 J9414-62
Fig. 34 PCM and Data Link Connector—Typical Fig. 35 Check Engine Lamp—Typical Location
For a complete operational description of all code charts, refer to Diagnostic Trouble Code
DTC's, for accessing a DTC and for erasing a (DTC). This can also be found in the General
DTC, refer to On-Board Diagnostics. This can Diagnosis sections of Group 14, Fuel System.
be found in the General Diagnosis sections of
Group 14, Fuel System. For numeric flash lamp
COMPONENT REMOVAL/INSTALLATION
INDEX
page page
Automatic Shutdown (ASD) Relay . . . . . . . . . . . . . 22 Ignition Coil Packs—8.0L V-10 Engine 28

Camshaft Position Sensor—3.9L V-6 or 5.2/5.9L V-8 Ignition Coil—3.9L V-6 or 5.2/5.9L V-8 Engines . . . 28
Engines 22 Ignition Control Module—8.0L V-10 Engine 29
Camshaft Position Sensor—8.0L V-10 Engine . . . . 23 Intake Manifold Air Temperature Sensor 29
Crankshaft Position Sensor—3.9L V-6 or 5.2/5.9L Manifold Absolute Pressure (MAP) Sensor 29
V-8 Engines 24 Oxygen Sensor (02S) 29
Crankshaft Position Sensor—8.0L V-10 Engine . . . 25 Powertrain Control Module (PCM) 29
Distributor Service 26 Spark Plug Secondary Cables . . . . . . . . . . . . . . . . 31
Engine Coolant Temperature Sensor 26 Spark Plugs 30
General information . . 22
GENERAL INFORMATION INSTALLATION

This section of the group, Component Removal/In (1) Check the relay terminals in the PDC connec
stallation, will discuss the removal and installation tor for corrosion or damage before installing relay.
of ignition system components. Repair as necessary.
For basic ignition system diagnostics and service (2) Push the relay into the connector on the PDC.
adjustments, refer to the Diagnostics/Service Proce (3) Connect negative battery cable at battery.
dures section of this group.
For system operation and component identification, CAMSHAFT POSITION SENSOR—3 J L V-6 OR
refer to the Component Identification/System Opera 5.2/5 J L V-8 ENGINES
tion section of this group. The camshaft position sensor is located in the dis
tributor (Fig. 2).
AUTOMATIC SHUTDOWN (ASD) RELAY
The automatic shutdown (ASD) relay is located in REMOVAL
the power distribution center (PDC). The PDC is lo Distributor removal is not necessary to remove
cated next to the battery in the engine compartment camshaft position sensor.
(Fig. 1). For the location of the relay within the PDC,
refer to PDC cover.
Fig. 2 Camshaft Position Sensor—3.9L V-6 or

Fig. 1 Power Distribution Center (PDC) (1) Disconnect negative battery cable at battery.
REMOVAL (2) Remove the air cleaner assembly and connect
(1) Disconnect negative battery cable at battery. ing air tubes.
(2) Remove the cover at PDC. (3) Remove coil high-tension cable and all spark
(3) Remove the relay from the PDC by pulling plug cables at distributor cap. Note and mark posi
straight up. tion of cables before removal.
BR IGNITION SYSTEMS 8D - 23
(4) Remove distributor cap from distributor (two CAMSHAFT POSITION

screws), SENSOR
(5) Disconnect camshaft position sensor wiring
harness from main engine wiring harness.
(6) Remove distributor rotor from distributor shaft.
(7) Lift the camshaft position sensor assembly
from the distributor housing (Fig. 2).
INSTALLATION
(1) Install camshaft position sensor to distributor.
Align sensor into notch on distributor housing.
(2) Connect wiring harness connectors.
(3) Install rotor.
(4) Install distributor cap. Tighten mounting
screws. POSITIONING) J948D-11
(5) Install spark plug cables in correct firing order
to distributor cap. Refer to the Specifications section Fig. 4 Sensor Depth Positioning Rib—8.0L V-10
at the end of this group for spark plug cable order. Engine
Be sure all spark plug cables are firmly connected One of two different procedures must be followed
into distributor cap towers. for replacement of this sensor. Refer to the following:
(6) Install air cleaner assembly and connecting air Sensor Replacement—Old Sensor or Sensor Re
tubes. placement —New Sensor.
SENSOR REPLACEMENT—OLB SENSOR
CAMSHAFT POSITION SENSOR—8.0L V-10 If the original camshaft position sensor is to be re
ENGINE moved and installed, such as when servicing the tim
The camshaft position sensor is located in the tim ing chain, timing gears or timing chain cover, use
ing chain case/cover on the left-front side of the en this procedure.
gine (Fig. 3).
REMOWAL
(1) Disconnect the sensor harness connector from
the engine harness connector.
(2) Remove the sensor mounting bolt (Fig. 3).
(3) Carefully pry the sensor from the timing chain
case/cover in a rocking action with two small screw
drivers.
(4) Remove the sensor from vehicle.
(5) Check condition of sensor o-ring (Fig. 5).
SLOTTED MOUNTING ^ —^
BOLT HOLE ^ ^ ^ ^ ^ ^
/X SCRIBE ^llk
/ /\ LINE yfa
Fig. 3 Camshaft Position Sensor—S.OL V-10 Engine

CAMSHAFT POSITION
A thin plastic rib is molded into the face of the sen SENSOR O-RING
sor (Fig. 4) to position the depth of sensor to the up
per cam gear (sprocket). This rib can be found on
both the new replacement sensors and sensors that
were originally installed to the engine. The first time
the engine has been operated, part of this rib may be J948D-4
sheared (ground) off. Depending on parts tolerances,
some of the rib material may still be observed after Fig. 5 Camshaft Sensor O-Ring—8.0L V-10 Engine
removal.
80 - 24 SGilTlOl SYSTEMS BR
11STALLATI01 INSTALLATION
When installing a used camshaft position sensor, (1) Apply a small amount of engine oil to the sen
the sensor depth must be adjusted to prevent contact sor o-ring (Fig. 5).
with the camshaft gear (sprocket). (2) Install the sensor into the timing case/cover
(1) Observe the face of the sensor. If any of the with a slight rocking action. Do not twist the sensor
original rib material remains (Fig. 4), it must be cut into position as damage to the o-ring may result.
down flush to the face of the sensor with a razor Push the sensor all the way into the cover until the
knife. Remove only enough of the rib material until rib material on the sensor (Fig. 4) contacts the cam
the face of the sensor is flat/Do not remove more shaft gear.
material than necessary as damage to sensor may re (3) Install the mounting bolt and tighten to 6 N-m
sult. Due to a high magnetic field and possible elec (50 in.-lbs.) torque.
trical damage to the sensor, never use an electric (4) Connect sensor wiring harness to engine har
ness.
grinder to remove material from sensor.
(2) From the parts department, obtain a peel-and- CRANKSHAFT POSITION SENSOR—3.9L V-6 OR
stick paper spacer (Fig. 4). These special paper spac
5.2/5.9L V-8 ENGINES
ers are of a certain thickness and are to be used as a
tool to set sensor depth. REMOVAL
(3) Clean the face of sensor and apply paper spacer The sensor is bolted to the top of the cylinder block
(Fig. 4). near the rear of right cylinder head (Fig. 6).
(4) Apply a small amount of engine oil to the sen
sor o-ring (Fig. 5).
(5) Install the sensor into the timing case/cover
with a slight rocking action until the paper spacer
contacts the camshaft gear. Do not install the sensor
mounting bolt. Do not twist the sensor into position
as damage to the o-ring or tearing of the paper
spacer may result.
(6) Scratch a scribe line into the timing chain case/
cover to indicate depth of sensor (Fig. 5).
(7) Remove the sensor from timing chain case/
cover.
(8) Remove the paper spacer from the sensor. This
step must be followed to prevent the paper spacer
from getting into the engine lubrication system.
(9) Again, apply a small amount of engine oil to
sensor o-ring. ; , ,
(10) Again, install the sensor into the timing case/
cover with a slight rocking action until the sensor is
aligned to scribe line.
(11) Install sensor mounting bolt and tighten to 6
N*m (50 in. lbs.) torque.
(12) Connect engine wiring harness to sensor har Fig. 6 Crankshaft Position Sensor—3.9L V-6 or
ness. 5.2/5.9L V-8 Engines—Typical
(1) Remove the air cleaner assembly and its plastic
SENSOR REPLACEMENT—NEW SENSOR air intake tube. Refer to the Component Removal/In
If a new replacement camshaft position sensor is to stallation section for procedures.
be installed, use this procedure. (2) Remove the spark plug cable loom and spark
plug cables from valve cover mounting stud at rear of
iEiOWAL right valve cover (Fig. 6). Position spark plug cables
(1) Disconnect the sensor wiring harness connector to top of valve cover.
from the engine harness connector. (3) Disconnect 2 hoses at Exhaust Gas Recircula
(2) Remove the sensor mounting bolt (Fig. 3). tion (EGR) valve. Note position of hoses at EGR
(3) Carefully pry the sensor from the timing chain valve before removal.
case/cover in a rocking action with two small screw (4) Disconnect electrical connector and hoses at
drivers. electric EGR valve control. Note position of hoses be
(4) Remove the sensor from vehicle. fore removal.
BR _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ IGNITION SYSTEMS 8D - 25
(5) Remove 2 EGR valve mounting bolts and re thread sealant to get into the sending unit opening,
move EGR valve. Discard old EGR gasket. or the opening at the engine. Install sending unit to
(6) Disconnect electrical connector at engine oil engine and tighten to 14 N-m (130 in. lbs.) torque. In
pressure sending unit. stall electrical connector to sending unit.
(7) To prevent damage to oil pressure sending unit, (6) Clean the intake manifold and EGR valve of
a special tool, such as number 0-4597 must be used any old gasket material.
(Fig. 7). Remove sending unit from engine. (7) Install a new EGR valve gasket at intake man
SPECIAL TOOL
ifold.
C-4597 (8) Install EGR valve to intake manifold. Tighten 2
bolts to 23 N-m (200 in. lbs.) torque.
(9) Position EGR valve control and install its elec
trical connector. Connect hoses between EGR valve
and EGR valve control. Connect hose between main
vacuum harness and control valve.
(10) Install spark plug cable loom and spark plug
cables to valve cover mounting stud.
(11) Install the air cleaner housing and plastic air
intake tube.
CRANKSHAFT POSITION SENSOR—8.0L V-10

ENGINE
8).
OIL PRESSURE
SENDING UNIT
Fig. 7 Oil Pressure Sending Unit—Removal

Installation
(8) Loosen EGR tube mounting nut at intake man
ifold.
(9) Remove 2 EGR tube mounting bolts at exhaust
manifold (Fig. 6) and remove EGR tube. Discard old
gasket at exhaust manifold.
(10) Disconnect crankshaft position sensor pigtail
harness from main wiring harness.
(11) Remove 2 sensor (recessed hex head) mount
ing bolts (Fig. 6) and remove sensor.
J948D-1
INSTALLATION
(1) Position crankshaft position sensor to engine Fig. 8 Crankshaft Position Sensor—8.0L V-10
and install mounting bolts. Tighten bolts to 8 N-m Engine—Typical
(70 in. lbs.) torque. mmowAL
(2) Connect main harness electrical connector to
sensor.
(3) Clean the EGR tube and exhaust manifold (at (2) Disconnect the sensor harness connectors.
EGR tube mounting point) of any old gasket mate (3) Remove the sensor mounting bolt (Fig. 9).
rial. (4) Carefully pry the sensor from the cylinder block
(4) Install a new gasket to exhaust manifold end of in a rocking action with two small screwdrivers.
EGR tube and install EGR tube to both manifolds. (5) Remove the sensor from vehicle.
Tighten mounting nut at intake manifold. Tighten 2 (6) Check condition of sensor o-ring (Fig. 10).
mounting bolts at exhaust manifold to 23 N-m (204 INSTALLATION
in. lbs.) torque.
(1) Apply a small amount of engine oil to the sen
(5) Coat the threads of the oil pressure sending
unit with thread sealant. Do not allow any of the sor o-ring (Fig. 10).
8D - 26 IGNITION SYSTEMS mm
DISTRIBUTOR SERVICE
3.9L V-6 OR 5.2/5 J L V-8 ENGINES
REMOVAL
CAUTION: Base ignition timing is not adjustable on

any engine. Distributors do not have built in centrif
ugal or vacuum assisted advance. Base ignition
timing and timing advance are controlled by the
powertrain control module (PCM). Because a con
ventional timing light can not be used to adjust dis
tributor position after installation, note position of
SENSOR POSITIONED
distributor before removal.
FLUSH TO CYLINDER BLOCK J948D-2
(1) Disconnect negative battery cable at battery.
Fig. 9 Sensor Removal/Installation—8.0L V-10 (2) Remove air cleaner assembly and connecting
Engine tubes.
CRANKSHAFT
(3) Remove the spark plug cables and secondary
POSITION ignition coil cable at distributor cap. Mark position of
cables before removal. Position spark plug cables to
the side of engine.
(4) Remove distributor cap from distributor (two
screws).
(5) Mark the position of distributor housing in
relationship to engine or dash panel. This is done
to aid in installation.
Before distributor is removed, the number one cyl
inder must be brought to the top dead center (TDC)
firing position.
(6) Attach a socket to the Crankshaft Vibration
Damper mounting bolt.
(7) Slowly rotate engine clockwise, as viewed from
J948D-3 front, until indicating mark on crankshaft vibration
Fig. 10 Sensor O-Ring—8.0L V-10 Engine
damper is aligned to 0 degree (TDC) mark on timing
chain cover (Fig. 11).
(2) Install the sensor into the cylinder block with a
slight rocking action. Do not twist the sensor into po
sition as damage to the o-ring may result.
CAUTION; Before tightening the sensor mounting
bolt, be sure the sensor is completely flush to the
cylinder block (Fig. 9). If sensor Is not flush, dam
age to the sensor mounting tang may result.
(3) Install the mounting bolt and tighten to 8 N-m

(70 in. lbs.) torque.
(4) Connect sensor wiring harness and lower the
vehicle.
ENGINE COOLANT TEMPERATURE SENSOR

moval and installation procedures, refer to Group 14, Fig. 11 Damper-To-Cover Alignment Marks—Typical
Fuel System.
(8) The distributor rotor should now be aligned to
the CYL. NO. 1 alignment mark (stamped) into the
camshaft position sensor (Fig. 12). If not, rotate the
crankshaft through another complete 360 degree
turn. Note the position of the number one cylinder moved). Then continue to slowly rotate engine clock
spark plug cable (on the cap) in relation to rotor. Ro wise until indicating mark (Fig. 11) is aligned to 0
tor should now be aligned to this position. degree (TDC) mark on timing chain cover.
(1) Clean top of cylinder block for a good seal be
tween distributor base and block.
. (2) Lightly oil the rubber o-ring seal on the distrib
utor housing.
(3) Install rotor to distributor shaft.
(4) Position distributor into engine to its original
position. Engage tongue of distributor shaft with slot
in distributor oil pump drive gear. Position rotor to
the number one spark plug cable position.
(5) Install distributor holddown clamp and clamp
bolt. Do not tighten bolt at this time.
(6) Rotate the distributor housing until rotor is
aligned to CYL. NO. 1 alignment mark on the cam
shaft position sensor (Fig. 12).
DISTRIBUTOR J93I4-81 (7) Tighten clamp holddown bolt (Fig. 13) to 22.5
Fig. 12 Rotor Alignment Mark (8) Connect camshaft position sensor wiring har
(9) Disconnect camshaft position sensor wiring ness to main engine harness.
harness from main engine wiring harness. (9) Install distributor cap. Tighten mounting
(10) Remove distributor rotor from distributor screws.
shaft. (10) Install all spark plug cables in correct firing
(11) Remove distributor holddown clamp bolt and order to distributor cap. Refer to the Specifications
clamp (Fig. 13). Remove distributor from vehicle. section at the end of this group for spark plug cable
order. Be sure all spark plug cables are firmly con
nected into distributor cap towers.
(12) Install air cleaner assembly and connecting
tubes.
(14) Refer to the following, Checking Distributor
Position.
CHECKING ilSTRIBUTOR POSITION
To verify correct distributor rotational position,
connect the DRB scan tool to the data link connector.
The data link connector is located in the engine com
partment. Gain access to the SET SYNC screen on
the DRB.
WARNING: WHEN PERFORMING THE FOLLOWING
Fig. 13 Distributor Holddown Clamp TEST, T H E ENGINE WILL B E RUNNING. B E CARE
FUL NOT TO STAND IN LINE WITH THE FAN
CAUTION: Do not crank engine with distributor re
BLADES OR FAN BELT. DO NOT W E A R LOOSE
moved. Distributor/crankshaft relationship will be
CLOTHING.
lost.
Follow the directions on the DRB screen and start
INSTALLATION the engine. With the engine running, the words IN
If engine has been cranked while distributor is re RANGE should appear on the screen along with 0°.
moved, establish the relationship between distributor This indicates correct distributor position.
shaft and number one piston position as follows: If a plus (+) or a minus (-) is displayed next to the
Rotate crankshaft in a clockwise direction, as degree number, and/or the degree displayed is not
viewed from front, until number one cylinder piston zero, loosen but do not remove the distributor hold-
is at top of compression stroke (compression should down clamp bolt. Rotate the distributor until IN
be felt on finger with number one spark plug re RANGE appears on the screen. Continue to rotate
80 - 28 IGNITION SYSTEMS Hit
the distributor until achieving as close to 0° as pos

sible. After adjustment, tighten clamp bolt to 22.5
The degree scale on the SET SYNC screen of the
DRB is referring to fuel synchronization only. It is
not referring to ignition timing. Because of this,
do not attempt to adjust ignition timing using this
method. Rotating the distributor will have no effect
on ignition timing. All ignition timing values are con
trolled by the powertrain control module (PCM).
IGNITION COIL—3.9L V-6 OR 5.2/5.9L V-8

ENGINES
The ignition coil is an epoxy filled type. If the coil
is replaced, it must be replaced with the same type.
REMOVAL Fig. 15 Ignition Coil—5.9L V-8 HDC-Gas Engine
3.9L V-6 or 5.2/5.9L V-8 LDC-Gas Engines: The coil (3) Remove ignition coil from coil mounting bracket
is mounted to a bracket that is bolted to the front of (two bolts).
the right engine cylinder head (Fig. 14). This bracket
is mounted on top of the automatic belt tensioner INSTALLATION
bracket using common bolts. (1) Install the ignition coil to coil bracket. If nuts
5.9L V-8 HDC-Gas Engine: The coil is mounted to a and bolts are used to secure coil to coil bracket,
bracket that is bolted to the air injection pump (AIR tighten to 11 N-m (100 in. lbs.) torque. If the coil
pump) mounting bracket (Fig. 15).
mounting bracket has been tapped for coil mounting
bolts, tighten bolts to 5 N-m (50 in. lbs.) torque.
(2) Connect all wiring to ignition coil.
IGNITION COIL PICKS—8 J L ¥-11 ENGINE
REMOWAL
cover (Fig. 16). The front and rear coil packs can be
serviced separately.
Fig. 14 ignition Coil—3.9L V-6 or 5.2/5.91 V-8

LDC-Gas Engines
(1) Disconnect the primary wiring from the igni
tion coil (Figs. 14 or 15).
(2) Disconnect the secondary spark plug cable from
the ignition coil (Figs. 14 or 15).
WARNING: (3.9L V-6 OR 5.2/5.9L V-8 LDC-GAS E N
GINES) DO NOT REMOVE THE COIL MOUNTING
BRACKET-TO-CYLINDER HEAD MOUNTING B O L T S .
THE COIL MOUNTING B R A C K E T IS UNDER A C C E S
S O R Y DRIVE BELT TENSION. IF THIS B R A C K E T IS
TO B E REMOVED FOR ANY R E A S O N , A L L B E L T Fig. 16 Ignition Coil Packs—8.0L V-10 Engine
TENSION MUST FIRST B E R E L I E V E D . R E F E R TO (1) Remove the secondary spark plug cables from
THE B E L T SECTION OF G R O U P 7, COOLING S Y S the coil packs. Note position of cables before removal.
TEM.
(2) Disconnect the primary wiring harness connec (2) Remove the three bolts retaining the coolant re
tors at coil packs. serve/overflow tank to the inner fender (Fig. 18). Po
(3) Remove the four (4) coil pack-to-coil mounting sition the tank to the side. Do not drain coolant from
bracket bolts for the coil pack being serviced (Fig. tank.
16). (3) Disconnect the electrical connector at the ICM.
(4) Remove coil(s) from mounting bracket. (4) Remove the ICM from inner fender (two bolts)
(Fig. 18).
INSTALLATION
COOLANT
(1) Position coil packs to mounting bracket (prima RESERVE/OVERFLOW
ry wiring connectors face downward). IGNITION CONTROL
TANK
(2) install coil pack mounting bolts. MODULE (ICM)
(3) Install coil pack-to-engine mounting bracket (if
necessary).
(4) Connect primary wiring connectors to coil
packs (four wire connector to front coil pack and
three wire connector to rear coil pack).
(5) Connect secondary spark plug cables to coil
packs. Refer to, figure 17 for correct cable order.
TANK
REAR COIL PACK FRONT COIL PACK MOUNTING
BOLTS (3)
ICM MOUNTING
BOLTS (2) J948D-21
Fig. 18 Ignition Control Module Mounting—8.0L V-10

• Engine
INSTALLATION
(1) Position the ICM to the inner fender. Install
two mounting bolts.
(2) Connect the electrical connector to ICM.
(3) Position the coolant reserve/overflow tank to
the inner fender. Install and tighten three mounting
bolts.
(4) Connect the negative battery cable.
INTAKE MANIFOLD AIR TEMPERATURE SENSOR

Fuel System.
For removal and installation, refer to MAP Sensor
in Group 14, Fuel System.
RIGHT LEFT
HANK BANK
OXYGEN SENSOR (02S)
FIRING ORDER For an operational description, diagnosis and re
1-10-9-4-3-6-5-8-7-2 J948D-12
moval or installation of the 02S, refer to Group 14,
Fuel Systems in this manual.
Fig. 17 Spark Plug Cable Order—8.0L V-10 Engine*
IGNITION CONTROL MODULE—S.OL V-10 ENGINE POWERTRAIN CONTROL MODULE (PCM)

The ignition control module (ICM) is located in the REMOVAL
engine compartment. It is mounted to the right inner The powertrain control module (PCM) is located in
fender behind the coolant reserve/overflow tank. the right-rear side of the engine compartment (Fig.
REMOVAL
19). It is mounted the dash panel cowl with three
bolts (Fig. 20). The PCM was formerly referred to as
(1) Disconnect the negative battery cable at bat
the SBEC or engine controller.
tery.
(1) Disconnect negative battery cable at battery.
SPARK PLUGS '

On 3.9L V-6 or 5.2/5.9L V-8 engines, spark plug ca
ble heat shields are pressed into the cylinder head to
surround each cable boot and spark plug (Fig. 21).
These shields protect the spark plug boots from dam
age (due to engine heat generated by the exhaust
manifolds) and should not be removed. After the
spark plug cable has been installed, the lip of the ca
ble boot should have a small air gap to the top of the
heat shield (Fig. 21).
POWERTRAIN CONTROL
PCM
MOUNTING
Fig. 21 Heat Shields—3.9L V-6 or S.2/5.9L V-8

Engines
If removal of the heat shield(s) is necessary, remove
the spark plug cable and compress the sides of shield
for removal. Each shield is slotted to allow for com
pression and removal. To install the shields, align
shield to machined opening in cylinder head and tap
into place with a block of wood.
PCM CONNECTOR PLUG REMOVAL
CONNECTOR MOUNTING
BOLT m u .g
ALL ENGINES
Fig. 20 PCM Mounting (1) Always remove spark plug or ignition coil ca
bles by grasping at the cable boot. Turn the cable
(2) Remove 60-way electrical connector from PCM boot 1/2 turn and pull straight back in a steady mo
(one bolt) (Fig. 20). tion (Fig. 22). Never pull directly on the cable. Inter
(3) Remove the three PCM mounting bolts (Fig. nal damage to cable will result.
20). (2) Prior to removing the spark plug, spray com
(4) Remove PCM from vehicle. pressed air around the spark plug hole and the area
INSTALLATION
around the spark plug. This will help prevent foreign
(1) Check pins in PCM 60-way connector for dam material from entering the combustion chamber.
age. Repair as necessary. (3) Remove the spark plug using a quality socket
(2) Position PCM and install mounting bolts. with a rubber or foam insert.
Tighten bolts to 1 N-m (9 in. lbs.) torque. (4) Inspect the spark plug condition. Refer to
(3) Connect 60-way electrical connector to PCM. Spark Plugs in the Diagnostics/Service Procedures
Tighten bolt to 4 N-m (35 in. lbs.) torque. section of this group.
(4) Connect negative battery cable to battery. PLUG CLEANING
The plugs may be cleaned using commercially
available spark plug cleaning equipment. After clean-
B R IGNITION SYSTEMS 80 - 31
S P A R K PLUG G A P
3.9L E n g i n e ; .89 mm (.035 in)
5.2L/5.9L V-8 Engines: .89 mm (.035 in)
8.0L V-10 Engine: 1.14 mm (.045 in)
Also refer to the specifications section at the back
of this group for additional spark plug information.
PLUG INSTALLATION
Always tighten spark plugs to the specified torque.
Over tightening can cause distortion resulting in a
change in the spark plug gap or a cracked porcelain
insulator.
When replacing the spark plug and ignition coil ca
bles, route the cables correctly and secure them in
the appropriate retainers. Failure to route the cables
properly can cause the radio to reproduce ignition
Fig. 22 Cable Removal noise. It could cause cross ignition of the spark plugs,
ing, file the center electrode flat with a small point or short circuit the cables to ground.
file or jewelers file before adjusting gap. (1) Start the spark plug into the cylinder head by
hand to avoid cross threading.
CAUTION: Newer use a motorized wire wheel brush (2) Tighten spark plugs to 35-41 N-m (26-30 ft.
to clean the spark plugs. Metallic deposits will re lbs.) torque.
main on the spark plug insulator and will cause (3) Install spark plug cables over spark plugs.
plug misfire.
SPARK PLUG SECONDARY CABLES
PLUG GAP ADJUSTMENT CAUTION: When disconnecting a high voltage cable
Check the spark plug gap with a gap gauge tool. If from a spark plug, distributor cap or ignition coil,
the gap is not correct, adjust it by bending the twist the rubber boot slightly (1/2 turn) to break it
ground electrode (Fig. 23). N e v e r attempt to adjust loose (Fig. 22). Grasp the boot (not the cable) and
t h e gap b y b e n d i n g t h e center electrode. pull it off with a steady, even force.
Install cables into their proper order (Figs. 24, 25

or 26).
Fig. 24 Engine Firing Order—3.9L V-6 Engine
J908D-10
When replacing the spark plug and coil cables,
route the cables correctly and secure in the proper
Fig, 23 Setting Spark Plug Gap—Typical retainers. Failure to route the cables properly can
cause the radio to reproduce ignition noise. It could
also cause cross ignition of the plugs, or short circuit
the cables to ground.
8D • 32 IGNITION SYSTEMS BR
On 3.9L V-6 or 5.2/5.9L V-8 engines, spark plug ca

ble boot heat shields are pressed into the cylinder
head to surround each cable boot and spark plug
(Fig. 27). These shields protect the spark plug boots
from damage (due to engine heat generated by the
exhaust manifolds) and should not be removed. After
CLOCKWISE ROTATION
the spark plug cable has been installed, the lip of the
oFRONT
1-8-4-3-6-5-7-2
cable boot should have a small air gap to the top of
the heat shield (Fig. 27).
OF
ENGINE
J9314-79
Fig. 25 Engine Firing Order—5.2U5.9L ¥-8 Engines
REAR COIL PACK FRONT COIL PACK
J9314-94
Fig. 27 Heat Shields—3.9L ¥-6 or 5.2/5.9L ¥-8

Engines
RIGHT LEFT
BANK
BANK
FIRING ORDER
1-10-9-4-3-6-5-8-7-2 J948D-12
Fig. 26 Spark Plug Cable Order—8.0L ¥-10 Engine

When installing new cables, make sure a positive
connection is made. A snap should be felt when a
good connection is made between the plug cable and
the distributor cap tower.
IGNITION SYSTEMS 80 - 33
IGNITION SWITCH
IGNITION SWITCH AND KEY CYLINDER SERflCE

The ignition switch is located in the steering col
umn. The Key-In-Switch and Halo Light are integral
with the ignition switch. Refer to Group 8U for Key-
In-Switch and Halo Light diagnosis.
Refer to Group 8W, Wiring for ignition switch cir
cuits.
REMOVAL
(1) Disconnect negative battery cable(s) from bat-
tery(s).
(2) If vehicle has a tilt column, remove tilt lever by
turning it counterclockwise.
(3) Remove upper and lower covers from steering
column (Fig. 1).
STEERING TILT UPPER PANEL
Fig. 2 Ignition Switch Screw Removal
SHROUD NUT J928J-2
Fig. 1 Shroud Removal/Installation—Typical

(4) Remove ignition switch mounting screws. Use
tamper proof torx bit Snap-on TTXR20A2 or equiva
lent to remove the screws (Fig. 2 or 3).
(5) Gently pull switch away from column. Release
connector locks on 7-terminal wiring connector, then SWITCH 958D-61
remove connector from ignition switch.
(6) Release connector lock on 4-terminal connector, Fig. 3 Ignition Switch Screw Removal
then remove connector from ignition switch (Fig. 4). proximately 1/8 inch away from ignition switch
(7) To remove key cylinder from ignition switch: halo light ring. Do not attempt to remove key
(a) Insert key in ignition switch. Turn key to cylinder at this time.
LOCK position. Using a TTXR20A2 or equivalent (c) With key cylinder in unseated position, rotate
torx bit, remove key cylinder retaining screw and key counterclockwise to the lock position and re
bracket (Fig. 5 or 6). move key.
(b) Rotate key clockwise to the OFF position. (d) Remove key cylinder from ignition switch
Key cylinder will unseat from ignition switch (Fig. (Fig. 8).
7). When key cylinder is unseated, it will be ap-
80 - 34 IGNITION SYSTEMS B R
KEY-IN SWITCH & MULTI-FUNCTION BRACKET RETAINING

HALO LIGHT SWITCH SCREW
TURN S I G N A L
SWITCH & LEVER
IGNITION SPEED
SWITCH CONTROL J918J-2
Fig. 4 Key-In-Switch and Halo Lamp Connector
RETAINING 958D-63
BRACKET SCREW
Fig. 6 Key Cylinder Retaining Screw

KEY CYLINDER
BEZEL
958D-62
Fig. 5 Key Cylinder Retaining Screw

INSTALLATION
(1) Connect electrical connectors to ignition switch. j HALO LIGHT
RING 908D-16
Make sure that switch locking tabs are fully seated
in wiring connectors. Fig. 7 Unseated Key Cylinder
(2) Before attaching ignition switch to a tilt steer
ing column, the transmission shifter must be in Park (d) Apply a light coating of grease to column lock
position. The park lock dowel pin and column lock flag and park lock dowel pin.
flag must also be properly indexed before installing (3) Place ignition switch against lock housing open
switch (Fig. 9). ing on steering column. Ensure that ignition switch
(a) Place transmission shifter in PARK position. park lock dowel pin enters slot in park lock slider
(b) Place ignition switch in lock position. The linkage in steering column.
switch is in the lock position when column lock flag (4) Install retaining bracket and ignition switch
is parallel to ignition switch terminals (Fig. 9). mounting screws. Tighten screws to 3±.5 N-m (26±4
(c) Position ignition switch park lock dowel pin in. lbs.) torque.
so it will engage steering column park lock slider (5) Install ignition lock cylinder:
linkage (Fig. 10).
mm IGNITION SYSTEMS 30 - 35
Fig, 10 Ignition Switch Mounting Pad

(b) Insert ignition key into lock cylinder. While
gently pushing lock cylinder in toward ignition
switch, rotate ignition key to end of travel.
(6) Install retaining screw into bracket and lock
cylinder. Tighten screw to 3±.5 N-m (26±4 in. lbs.)
torque.
(7) Install steering column covers. Tighten screws
to 2 N-m (17 in. lbs.) torque.
(8) If vehicle is equipped with a tilt steering col
umn, install tilt lever.
(9) Connect negative cable to battery.
(10) Check for proper operation of halo light, shift
lock (if applicable), and column lock. Also check for
908D-18
proper operation of ignition switch accessory, lock,
Fig. 9 ignition Switch View From Column off, run, and start positions.
(a) With lock cylinder and ignition switch in
Lock position, insert lock cylinder into ignition
switch until it bottoms.
SPECIFICATIONS
GENERAL INFORMATION IGNITION THING

The following specifications are published from the Ignition timing is not adjustable on any engine. Re
latest information available at the time of publica fer to Ignition Timing in the Diagnostics/Service Pro
tion. If anything differs between the specifica cedures section of this group for more information.
tions found on the Vehicle Emission Control
Information (VECI) label and the following
specifications, use specifications on VECI label.
The VECI label is located in the engine compart
ment.
' IGHITION COIL RESISTANCE—EXCEPT 8.0L ENGINE
PRIMARY RESISTANCE S E C O N D A R Y RESISTANCE
COIL (MANUFiie?URER) 21-27°€ {7®-8®°¥)
Diamond 0.97- 1.18 Ohms 11,300- 15,300 Ohms
Toyodenso 0.95- 1.20 Ohms 11,300- 13,300 Ohms

J918D-2
SPARK PLUGS
Spark Plug
Engine Original Application Gap Tightening Size

Replacement
Equipment Torque
3.9L RC12YC RC12YC All .035" 41 N*m 14 mm Thread

V-6 {0.9 mm) (30 ft. lbs.) 3/4" Reach
5.2/5.9L RC12YC RC12YC All .035" 41 N t t i 14 mm Thread

V-8 (0.9 mm) (30 ft. lbs.) 3/4" Reach
8.0L RC9MC4 RC9MC4 Ail .045" 41 N*m 14 mm Thread

V-10 (30ft.lbs.) 3/4" Reach
(1.14 mm)
J948D-19
IGNITION COIL PACKS—8.0L V-10 ENGINE
* Primary Resistance: 0.53 to 0.65 ohms

* * Secondary Resistance: 10.9 to 14.7 K ohms SPARK PLUG CABLE RESISTANCE
* Test across the primary connector. MINIMUM

Refer to text for test procedures.
250 Ohms Per Inch 1000 Ohms Per Inch
* * Test across the individual coil towers.
Refer to text for test procedures. 3000 Ohms Per Foot 12,000 Ohms Per Foot
J948D-13 J908D-43
ENGINE FIRING ORDER—3.9L V-6 ENGINE ENGINE FIRING ORDER—S.2L/5.9L V-8

ENGINES
CLOCKWISE ROTATION
©'
FRONT 1-6-5-4-3-2 CLOCKWISE ROTATION
OF
ENGINE a
FRONT
1-8-4-3-6-5-7-2 '
OF
ENGINE
J9314-80
J9314-79
SPARK PLUG CABLE ORDER—8.0L V-10 TORQUE

ENGINE
Description Torque
REAR COIL PACK FRONT COIL PACK
Camshaft Position Sensor Bolt —
8.0L V-10 Engine 6 N » m ( 5 0 in. lbs.)
Crankshaft Position S e n s o r -
All Gas Powered Engines 8 N ^ m ( 7 0 in. lbs.)
Distributor Hold Down Bolt 23 N t * (17ft. lbs.)
Engine Coolant Temp. S e n s o r -
All Engines 7 N » m ( 6 2 in. lbs.)
Ignition Coil Mount. Bolts —
3.9L/5.2L/5.9L Engines
(nuts and bolts) 11 N*m (100 in. lbs.)
(bolts only 5 M*m (50 in. lbs.)
ignition Coil Mount. Bolts —
8.0L V-10 Engine 10N»m(90 in. lbs.)
Intake Manifold Air Temp. Sensor-
All Engines 13 N«m(10ft. lbs.)
MAP Sensor-To-Throttle Body
Mounting Bolts—
3.9L/5.2L/5.9L Engine 3 N * m ( 2 5 in. lbs.)
MAP Sensor-To-lnt. Man. Bolts-
8.0L V-10 Engine 2 N*m(20 in. lbs.)
PCM Mounting Screws 1 N«m(9 in. lbs.)
PCM 60-Way Elect. Connector. 4 N * m ( 3 5 in. lbs.)
Spark Plugs —All Engines . . . . 41 N*m (30 ft. lbs.)
RIGHT LEFT
J948D-18
HANK HANK
FIRING ORDER
1-10-9-4-3-6-5-8-7-2 J948D-12
BR —-——— — - INSTRUMENT PANEL AND GAUGES 8E - 1
INSTRUMENT PANEL AND GAUGES
CONTENTS
page page

GENERAL INFORMATION 1 SPECIFICATIONS 29
GENERAL INFORMATION
Following are general descriptions of major instru sembly allows access to the individual gauges, illumi
ment panel components. Refer to Group 8W - Wiring nation and indicator lamp bulbs, printed circuits, and
Diagrams for complete circuit descriptions and dia most wiring.
grams. Removal of the steering column cover/knee blocker
provides access to the steering column mounts, the
INSTRUMENT PANEL intermittent wipe module, the fuseblock module (re
Modular instrument panel construction allows all moval of a snap-fit cover on the left end of the instru
gauges and controls to be serviced from the front of ment panel allows access to the fuses and circuit
the panel. In addition, most instrument panel wiring breakers) and the gear selector (automatic transmis
or heater and air conditioning components can be ac sion) indicator cable.
cessed without complete instrument, panel removal. If
necessary, the instrument panel can be rolled-down NSTRUMENT CLUSTERS
and removed from the vehicle as an assembly. Two basic instrument cluster options are offered on
Removal of the instrument cluster bezel allows ac Ram truck models. One is referred to as a low line
cess to the cluster assembly, switches, the climate cluster (Fig. 1), and the other is referred to as a high
controls, and the radio. Removal of the cluster as line cluster (Fig. 2). Each cluster is served by a
printed circuit and two wiring connectors. Some vari-
J948E-43
Fig. 1 Low Line Cluster - Typical

8E - 2 INSTRUMENT PANEL AND GAUGES • — — — BR
£ BRAKE A
4WD «§») £ ™
J948E-25
. Pig. 2 High Line Cluster - Typical

ations of each cluster exist due to optional equipment MESSAGE CENTER
and regulatory requirements. In addition to the warning lamps found in the in
The standard cluster includes the following gauges: strument cluster, a message center area directly be
• coolant temperature gauge low the climate controls (Fig. 3) has a provision for
• fuel gauge up to 5 warning lamps. These lamps may or may not
• gear selector indicator (automatic transmission) be functional depending upon optional equipment
@ oil pressure gauge and regulatory requirements affecting the vehicle be-
• speedometer/odometer • ing serviced. The available lamps in the message cen
© trip odometer ter include:
• voltmeter. • hazard warning indicator (export)
The low line cluster includes provisions for the fol • master lighting indicator (export)
lowing indicator lamps: • transmission oil temperature warning (V-10 and
© airbag indicator lamp diesel engines with automatic transmission)
® anti-lock brake system lamp ® wait-to-start (diesel engine)
• brake warning lamp • water-in-fuel (diesel engine).
• four-wheel drive indicator lamp
• headlamp high beam indicator lamp GMJGES
© low oil pressure warning lamp With the ignition switch in the ON or START posi
• maintenance required indicator (heavy-duty cycle tion, voltage is supplied to all gauges through the in
emissions engines) strument cluster printed circuit. With the ignition
• malfunction indicator (Check Engine) lamp switch in the OFF position, voltage is not supplied to
• seat belt reminder lamp the gauges. A gauge pointer may remain within the
• turn signal indicator lamps gauge scale after the ignition switch is OFF. How-
• upshift indicator lamp. ' ever, the gauges do not accurately indicate any vehi
The high line cluster includes all of the gauges and cle condition unless the ignition switch is ON.
indicator lamps found in the low line cluster, but All gauges except the odometer are air core mag
adds a analog tachometer, low fuel warning lamp and netic units. Two fixed electromagnetic coils are lo
low washer fluid warning lamp. Some of the low line cated within the gauge. These coils are wrapped at
cluster gauges and indicator lamps have different po right angles to each other around a movable perma
sitions or sizes in the high line cluster to accommo nent magnet. The movable magnet is suspended
date the tachometer. within the coils on one end of a shaft. The gauge nee
dle is attached to the other end of the shaft.
BR — INSTRUMENT PANEL AND GAUGES 8E - 3
FUEL GAUGE
The fuel gauge gives an indication of the level of
fuel in the fuel tank. The fuel gauge sending unit has
a float attached to a swing-arm in the fuel tank. The
float moves up or down within the fuel tank as fuel
level changes. As the float moves, an electrical con
tact on the swing-arm wipes across a resistor coil,
which changes sending unit resistance. High sending
unit resistance causes low fuel level readings. Low
resistance causes high fuel level readings. Sending
unit resistance values are shown in a chart in Spec
ifications.
GEAR SELECTOR INDICATOR
The gear selector indicator is used on models with
an automatic transmission to show the position of
the transmission gear selector lever. The indicator is
mechanically actuated by a cable connected to the
PRNDL driver of the gear selector lever mechanism
on the steering column. Refer to Group 21 - Trans
mission and Transfer Case for diagnosis, service, and
adjustment of this component.
OIL PRESSURE GAUGE
TRANS
TEMP The oil pressure gauge gives an indication of en
gine oil pressure. The combination oil pressure send
J948E-37 ing unit contains a flexible diaphragm. The
diaphragm moves in response to changes in engine
oil pressure. As the diaphragm moves, resistance in
Fig. 3 Message Center
creases or decreases. High resistance on the gauge
One of the coils has a fixed current flowing through side of the sending unit causes low oil pressure read
it to maintain a constant magnetic field strength. ings. Low resistance causes high oil pressure read
Current flow through the second coil changes, which ings. Sending unit resistance values are shown in a
causes changes in its magnetic field strength. The chart in Specifications.
current flowing through the second coil can be
changed by: SPEEDOMETER/ODOMETER
• a variable resistor-type sending unit (fuel level, The speedometer/odometer gives an indication of
coolant temperature, or oil pressure) vehicle speed and travel distance. The speedometer
• changes in electrical system voltage (voltmeter) receives a vehicle speed pulse signal from the Vehicle
• electronic control circuitry (speedometer/odometer, Speed Sensor (VSS). An electronic integrated circuit
tachometer). contained within the speedometer reads and analyzes
the pulse signal. It then adjusts the ground path re
The gauge needle moves as the movable permanent
sistance of one electromagnet in the gauge to control
magnet aligns itself to the changing magnetic fields needle movement. It also sends signals to an electric
created around it by the electromagnets. stepper motor to control movement of the odometer
COOLANT TEMPERATURE GAUGE
number rolls. Frequency values for the pulse signal
are shown in a chart in Specifications.
The coolant temperature gauge gives an indication
The VSS is mounted to an adapter near the trans
of engine coolant temperature. The coolant tempera
mission (two-wheel drive) or transfer case (four-wheel
ture sending unit is a thermistor that changes elec drive) output shaft. The sensor is driven through the
trical resistance with changes in engine coolant adapter by a speedometer pinion gear. The adapter
temperature. Some gauge needle cycling, depending and pinion vary with transmission, transfer case,
upon vehicle load, is normal on models equipped with axle ratio and tire size. Refer to Group 21 - Trans
the diesel engine option. High sending unit resis mission and Transfer Case for more information.
tance causes low coolant temperature readings. Low
resistance causes high coolant temperature readings. TACHOMETER
Sending unit resistance values are shown in a chart The tachometer gives an indication of engine speed
in Specifications. in Revolutions-Per-Minute (RPM). With the engine
8E - 4 INSTRUMENT PANEL AND GAUGES
running, the tachometer receives an engine speed two halves of the split brake hydraulic system are
pulse signal from the Powertrain Control Module unequal. With the ignition switch turned ON, battery
(PCM). An electronic integrated circuit contained voltage is supplied to one side of the indicator bulb. A
within the tachometer reads and analyzes the pulse ground path for the bulb is provided by up to 5
signal. It then adjusts the ground path resistance of switches. The bulb will light when:
one electromagnet in the gauge to control needle • the brake warning switch is closed (indicating un
movement. Frequency values for the pulse signal are equal brake system hydraulic pressures possibly due
shown in a chart in Specifications. to brake fluid leakage)
• the ignition switch is in the START position (bulb
TRIP ODOMETER test)
The trip odometer is driven by the same electronic • the vacuum sensor (diesel engine) senses low sys
integrated circuit as the speedometer/odometer. How tem vacuum
ever, by depressing the trip odometer reset knob on o certain ABS or RWAL system faults are detected
the face of the speedometer, the trip odometer can be o the parking brake switch is closed (parking brake
reset to zero. The trip odometer is serviced only as a is applied).
part of the speedometer/odometer gauge assembly. Refer to Group 5 - Brakes for more information.
VOLTMETER FOUR-WHEEL DRIVE INDICATOR LAMP
The voltmeter is connected in parallel with the bat On vehicles with four-wheel drive, the indicator
tery. With the ignition switch ON, the voltmeter in lamp lights when the front axle disconnect is con
dicates battery or generator output voltage, nected in a 4WD operating mode. Voltage is supplied
whichever is greater. to one side of the indicator bulb. A switch in the front
axle disconnect housing is connected to the other side
INDICATOR LAMPS of the indicator bulb. When the switch is closed, a
Indicator lamps are located in several areas of the path to ground is provided and the indicator bulb
cluster and instrument panel, depending upon equip lights.
ment. Those lamps within the cluster area are served
by the cluster printed circuit and cluster connectors. HAZARD WARNING INDICATOR LAMP
AIRBAG INDICATOR LAMP
This lamp is used only on certain export models.
The airbag indicator lamp is switched to ground by The lamp in the message center is turned on by a
the Airbag Control Module (ACM). The lamp lights signal from the hazard warning (multi-function)
for 6 to 8 seconds each time the ignition switch is switch to indicate that the hazard warning lamp sys
turned to the ON position as a bulb test and to indi tem is activated.
cate a system self-test is in process. If the lamp re
HEADLAMP HIGH BEAM INDICATOR LAMP
mains on after the self-test or comes on while
driving, it may indicate that the ACM has detected a The high beam indicator lamp is controlled by the
system malfunction or that the system has become headlamp dimmer (multi-function) switch. One side
inoperative. Refer to Group 8M - Restraint Systems of the indicator bulb is grounded at all times. The
for more information. other side of the bulb receives battery feed through
the contacts of the dimmer switch when the multi
ANTI-LOCK BRAKE SYSTEM LAMP function switch stalk is actuated to turn the head
The Anti-Lock Brake System (ABS) or Rear Wheel lamp high beams on. Refer to Group 8L - Lamps for
Anti-Lock (RWAL) lamp is switched to ground by the more information.
ABS or RWAL module. The module lights the lamp
when the ignition switch is turned to the START po LOW FUEL WARNING LAMP
sition as a bulb test. The lamp will stay on for up to The low fuel warning lamp will light when the fuel
30 seconds after vehicle start-up to indicate a system level falls below approximately 4 gallons. One side of
self-test is in process. If the lamp remains on after the low fuel warning bulb is grounded at all times. A
start-up, or comes on and stays on while driving, it low fuel warning circuit attached to the rear of the
may indicate that the ABS or RWAL module has de gauge cluster provides battery voltage to the lamp
tected a system malfunction or that the system has when the fuel level is low. The low fuel warning mod
become inoperative. Refer to Group 5 - Brakes for ule monitors the signal from the fuel level sending
more information. unit. When the circuit senses approximately 65 ohms
or more from the fuel level sender for 10 to 20 con
BRAKE WARNING LM$P
tinuous seconds, the indicator will light. The indica
The brake warning lamp warns the driver that the
parking brake is applied or that the pressures in the tor will remain on until the circuit senses
BR INSTRUMENT PANEL AND GAUGES 8E - S
approximately 65 ohms or less from the fuel sender MASTER LIGHTING INDICATOR LAMP
for 10 to 20 continuous seconds. See chart in Specifi This lamp is used only on certain export models.
cations. The lamp in the message center is turned on by a
signal from the headlamp switch to indicate that the
LOW OIL PRESSURE WARNING LAMP exterior lamps are lighted.
The low oil pressure warning lamp lights with the
ignition switch in the ON position and the .engine not SEAT BELT REMINDER LAMP
running. The lamp should be off when the engine is The seat belt reminder lamp lights for 4 to 8 sec
running. Battery voltage is supplied to one side of onds after the ignition switch is turned to the ON po
the indicator bulb when the ignition switch is turned sition. A timer in the chime/buzzer module controls
ON. The warning lamp side of the combination oil ignition-switched battery feed to the lamp. Refer to
pressure sending unit is connected to the other side Group 8U - Chime/Buzzer Warning Systems for more
of the bulb. When normal engine oil pressure is ap information.
plied to the sending unit, resistance on the warning
lamp side is high and the lamp goes off. When engine TRANSMISSION OIL TEMPERATURE
oil pressure is too low, resistance on the warning WARNING LAMP
lamp side of the sending unit is low, which causes The transmission oil temperature warning lamp
the bulb to light. lights to indicate that the transmission oil is over
heating. One side of the lamp bulb receives battery
LOW WASHER FLUID WARNING LAMP voltage when the ignition switch is turned to the ON
The low washer fluid warning lamp indicates when position. The other side of the bulb is grounded by
the fluid level in the washer reservoir is too low. The the PCM when it senses transmission oil tempera
washer fluid level sensor uses a float in the reservoir ture is too high. A sensor mounted to the transmis
to monitor fluid level. The action of the float opens or sion cooler line sends a signal to the PCM indicating
closes the switch within the sensor that provides a transmission fluid temperature. This lamp is only
ground path to the lamp bulb. Refer to Group 8K - used on vehicles equipped with a diesel or V-10 en
Wiper and Washer Systems for more information. gine option and an automatic transmission. The lamp
is located in the message center.
MAINTENANCE REQUIRED INDICATOR
This lamp is used on vehicles equipped with the TURN SIGNAL INDICATOR LAMPS
heavy-duty cycle emissions package and a 5.9L V-8 or The left and right turn signal indicator lamps are
8.0L V-10 engine. This system is designed to act as a controlled by the turn signal and hazard warning
reminder that scheduled vehicle emissions mainte (multi-function) switches. One side of the bulb for
nance must be performed, as required by federal each lamp is grounded at all times. The other side of
emissions laws. It is not intended to indicate a warn the bulb receives battery feed through the contacts of
ing or that a state of emergency exists. However, the multi-function switch when the turn signal lever
when the lamp has been activated, the required ser (multi-function switch stalk) or hazard warning but
vice/maintenance must be performed before the lamp ton are actuated. Refer to Group 8J - Turn Signal
can be legally reset. For required service/mainte- and Hazard Warning Systems for more information.
nance, stated in time or mileage, refer to Group 0 -
Lubrication and Maintenance. Also refer to Group 25 UPSHIFT INDICATOR LAMP
- Emission Control System for more information. Vehicles equipped with manual transmissions have
an optional upshift indicator lamp. Ground feed for
MALFUNCTION INDICATOR LAMP the lamp is switched by the Powertrain Control Mod
The CHECK ENGINE or Malfunction Indicator ule (PCM). The lamp lights to indicate when the
Lamp (MIL) lights each time the ignition switch is driver should shift to the next highest gear for best
turned ON, and stays on for 3 seconds as a bulb test. fuel economy. The PCM will turn the lamp off after 3
If the Powertrain Control Module (PCM) receives an to 5 seconds if the upshift is not performed. The lamp
incorrect signal or no signal from certain fuel or will remain off until the vehicle stops accelerating
emission system related circuits or components, the and is brought back to the range of lamp operation,
lamp is turned on. This will indicate that the PCM or until the transmission is shifted into another gear.
has recorded a Diagnostic Trouble Code (DTC) in The indicator lamp is normally on when the igni
electronic memory for a circuit or component mal tion switch is turned ON and is turned off when the
function. Refer to Group 14 - Fuel System for more engine is started. The lamp will be turned on during
information. vehicle operation according to engine speed and load.
IE - i INSTRUMENT PANEL AND GAUGES
MMIT-TO-START LAMP turned on by the PCM to warn the driver when the
This lamp is used on diesel engine models only. water-in-fuel sensor signal indicates that excess wa
The wait-to-start lamp in the message center is ter has accumulated in the fuel filter. The lamp
turned on by the PCM after the ignition switch is should go off automatically when the excess water
turned to the ON position. It gives the driver an in has been drained. Refer to Group 14 - Fuel Systems
dication to wait until the intake manifold air heater for more information.
grid has had sufficient time to heat up the intake air
for a good quality start. The intake manifold preheat CLUSTER ILLUMINATION LAMPS
cycle is controlled by an electronic air heater control All cluster illumination lamps receive battery feed
module. The lamp will turn off if the driver turns the
from the instrument lamps fuse in the fuseblock
ignition switch to the START position before the
lamp times out on its own. Refer to Group 14 - Fuel module through the panel dimmer rheostat of the
Systems for more information. headlamp switch. When the park or headlamps are
on, the cluster illumination lamps light. Illumination
WATER-IN-FUEL LAMP brightness can be adjusted by rotating the headlamp
This lamp is used on diesel engine models only. switch knob (clockwise to dim, counterclockwise to
The water-in-fuel lamp in the message center is brighten).
OIAOHOSIS
GAUGES should be checked with a test gauge or thermometer

If an individual gauge is inoperative, see the diag and compared to gauge readings before you proceed
nostic procedure under the heading for that gauge. If with gauge diagnosis. Refer to Group 7 - Cooling Sys
more than one gauge is inoperative, perform the fol tem for more information.
lowing: (1) Turn ignition switch to ON. Disconnect coolant
(1) Check fuse 12 in the fuseblock module. If OK, temperature sending unit connector (Figs. 4, 5 or 6).
go to next step. If not OK, replace fuse. The gauge needle should move to low end of gauge
(2) Check for battery voltage at fuse 12 with igni scale. If OK, go to next step. If not OK, go to step 3.
tion switch in ON position. If OK, go to next step. If (2) Install a jumper wire from sending unit wiring
not OK, repair open in circuit from ignition switch
and/or refer to Group 8D - Ignition Systems for test
ing of ignition switch.
(3) Turn ignition switch to OFF. Disconnect battery
negative cable. Remove instrument cluster bezel and
cluster assembly. Unplug gauge cluster connector B
(black connector).
(4) Connect battery negative cable. Turn ignition
switch to ON. Check for battery voltage at cavity 8 of
cluster connector B. If OK, go to next step. If not OK,
repair open in circuit from fuse 12 as required.
negative cable. Unplug gauge cluster connector A
(white connector). Probe cavities 6 and 10 of cluster
connector A. Also probe cavity 9 of cluster connector
B. Check for continuity to a good ground. There
should be continuity. If OK, replace gauge cluster Fig. 4 Coolant Temperature Sending Unit - V-6/V-8
printed circuit. If not OK, repair open in circuit(s) to Engine
ground as required.
to ground. The gauge needle should move to high end
COOLANT TEMPERATURE GAUGE of gauge scale. If OK, replace sending unit. If not
The diagnosis found here addresses an inoperative OK, remove jumper wire and go to next step.
gauge condition. If the problem being diagnosed is re (3) Turn ignition switch to OFF. Disconnect battery
lated to gauge accuracy, be certain to confirm that negative cable. Remove instrument cluster bezel and
problem is with gauge and not with cooling system cluster assembly. Disconnect cluster connector A
performance. Actual engine coolant temperature (white connector).
BR INSTRUMENT PANEL AND GAUGES 8E - 7
TEMP. G A U G E \ | top of the fuel tank. The gauge needle should move
E N G I N E C O O L A N T TEMP. S E N S O R S E N S O R ( F O R T E M P . ~. *
GAUGE OPERATION)
to low end of gauge scale. If OK, go to next step. If
( F O R PCM O P E R A T I O N )
not OK, go to step 4.
(2) Connect a jumper wire between sending unit
ground cavity and fuel sensor input cavity in the
body half of the fuel gauge sending unit connector
(Fig. 7). The gauge needle should move to high end of
gauge scale. If OK, refer to Group 14 - Fuel System
for procedure to replace sending unit. If not OK, re
move jumper wire and go to next step.
FUEL PUMP SUPPLY
INPUT TO GAUGE
J948D-9
SENDING UNIT GROUND
Fig. 5 Coolant Temperature Sending Unit - V-10
Engine
1
FUEL PUMP GROUND
COOLANT J928E-49
TEMPERATURE
SENSOR
Fig. 7 Fuel Gauge Sending Unit Connector
negative cable. Check for continuity between sending
unit ground cavity in the. body half of fuel gauge
sending unit connector and a good ground. There
should be continuity. If OK, go to next step. If not
OK, repair circuit to ground as required.
(4) Remove instrument cluster bezel and cluster
assembly. Disconnect instrument cluster connector B
(black connector).
(5) Probe cavity 11 of cluster connector B. Check
J948E-58 for continuity to a good ground. There should be no
continuity. If OK, go to next step. If not OK, repair
Fig. 6 Coolant Temperature Sending Unit - Diesel short circuit as required.
Engine (6) Still probing cavity 11 of cluster connector B,
check for continuity to input to gauge cavity of send
(4) Probe cavity 7 of cluster connector A. Check for ing unit body half connector. There should be conti
continuity to a good ground. There should be no con nuity. If OK, replace gauge. If not OK, repair open
tinuity. If OK, go to next step. If not OK, repair short circuit as required.
in circuit as required.
(5) Still probing cavity 7 of cluster connector A, GEAR SELECTOR INDICATOR
check for continuity to sending unit wiring connector. Refer to Group 21 - Transmission and Transfer
There should be continuity. If OK, replace gauge. If Case for diagnosis, service, and adjustment of this
not OK, repair open in circuit as required. component.
FUEL GAUGE OIL PRESSURE GAUGE

The diagnosis found here addresses an inoperative The diagnosis found here addresses an inoperative
gauge condition. If the problem being diagnosed is re gauge condition. If the problem being diagnosed is re
lated to gauge accuracy, be certain to confirm that lated to gauge accuracy, be certain to confirm that
problem is with gauge and not with fuel tank. In problem is with gauge and not with engine oiling sys
spect fuel tank for signs of damage or distortion that tem performance. Actual engine oil pressure should
could affect sending unit performance before you pro be checked with a test gauge and compared to gauge
ceed with gauge diagnosis. Refer to Group 14 - Fuel readings before you proceed with gauge diagnosis.
System for more information. Refer to Group 9 - Engines for more information.
(1) Turn ignition switch to ON. Disconnect fuel (1) Turn ignition switch to ON. Disconnect oil pres
sure sending unit connector (Figs. 8, 9 or 10). The
gauge sending unit connector. Connector is located on
gauge needle should move to low end of gauge scale.
8E - 8 INSTRUMENT PANEL AND GAUGES BR
NO. IDENTIFICATION
1 SENSOR GAUGE OUTPUT
2 SENSOR LAMP OUTPUT
J958E-21
Fig. 11 Oii Pressure Sending Unit Connector

J948E-38 (5) Still probing cavity 10 of cluster connector B,
check for continuity to cavity 1 of sending unit wire
Fig. 9 Oii Pressure Switch/Sending Unit - V-10 connector (Fig. 11). There should be continuity. If
Engine OK, replace gauge. If not OK, repair open circuit as
(2) Install a jumper wire from cavity 1 of sending required.
unit connector (Fig. 11) to ground. The gauge needle
SPEEDOMETER/ODOMETER
should move to high end of gauge scale. If OK, re
place sending unit. If not OK, remove jumper wire The diagnosis found here addresses an inoperative
and go to next step. gauge condition. If the problem being diagnosed is re
(3) Turn ignition switch to OFF. Disconnect battery lated to gauge accuracy, be certain to confirm that
negative cable. Remove instrument cluster bezel and problem is with gauge and not with incorrect speed
cluster assembly. Disconnect instrument cluster con ometer pinion, axle ratio or tire size. Refer to Group
nector B (black connector). 21 - Transmission and Transfer Case for more infor
(4) Probe cavity 10 of cluster connector B and mation.
check for continuity to a good ground. There should
be no continuity. If OK, go to next step. If not OK,
repair short circuit as required.
(1) Perform vehicle speed sensor test as described TERMINAL END WIRE END
in the appropriate Powertrain Diagnostic Procedures
manual. If OK, go to next step. If not OK, replace ve
hicle speed sensor.
(2) Disconnect battery negative cable. Unplug vehi
cle speed sensor and PCM connectors. Remove in
strument cluster bezel and cluster assembly.
Disconnect instrument cluster connector A (white
connector).
(3) Probe cavity 11 of cluster connector A. Check
for continuity to a good ground. There should be no
continuity. If OK, go to next step. If not OK, repair
(4) Still probing cavity 11 of cluster connector A,
check for continuity to cavity 1 of vehicle speed sen
sor connector (Fig. 12). There should be continuity. If
OK, replace speedometer/odometer. If not OK, repair NO. IDENTIFICATION
open circuit as required. 32 MALFUNCTION INDICATOR LAMP
36 GENERATOR WARNING LAMP
43 TACHOMETER SIGNAL
54 UPSHIFT INDICATOR LAMP J958E-7
Fig. 13 Powertrain Control Module Connector

speedometer assembly. If speedometer/odometer func
tions are affected, see Speedometer/Odometer diagno
sis in this section.
WOLTMETER
3
(1) Turn ignition switch to ON. Voltmeter should
read battery voltage. If all gauges except voltmeter
NO. IDENTIFICATION are OK, go to next step. If other gauges are inopera
1 VSS SIGNAL
2 SENSOR GROUND
tive, see Gauges in this section for diagnosis.
3 SENSOR SUPPLY (2) Using an accurate test voltmeter, measure bat
J958E-6
tery voltage at battery. Compare this reading to in
strument cluster voltmeter reading. Now see
Fig. 12 Vehicle Speed Sensor Connector
Voltmeter Calibration chart in Specifications. If volt
TACHOMETER meter does not perform to specification, replace volt
(1) With engine running, check for tachometer sig meter.
nal at pin 43 of PCM connector (Fig. 13). See Ta
chometer Calibration chart in Specifications. If OK,
go to next step. If not OK, refer to appropriate Pow
ertrain Diagnostic Procedures manual to test PCM.
(2) Disconnect battery negative cable. Unplug PCM
connector. Remove instrument cluster bezel and clus
ter assembly. Disconnect instrument cluster connec
tor B (black connector).
(3) Probe cavity 3 of cluster connector B. Check for
continuity to a good ground. There should be no con
tinuity. If OK, go to next step. If not OK, repair short
circuit as required.
(4) Still probing cavity 3 of cluster connector B,
check for continuity to cavity 43 of PCM connector.
There should be continuity. If OK, replace tachome
ter. If not OK, repair open circuit as required.
TRIP ODOMETER
If the trip odometer is inoperative, but the speed
ometer/odometer functions are unaffected, replace
INSTRUMENT CLUSTER CONNECTIONS

BR INSTRUMENT PANEL AND GAUGES 8E - 1 1
INSTRUMENT CLUSTER PRINTED CIRCUIT BOARD

- HIGH LINE
SPEEDOMETER TACHOMETER
SCREWS
SCREWS
VOLTMETER
SCREWS
OIL PRESSURE
GAUGE SCREWS
COOLANT FUEL GAUGE

TEMPERATURE SCREWS
GAUGE
© AIR BAG
SCREWS
(D ILLUMINATION
(f) TURN SIGNAL INDICATORS
@ HIGH BEAM INDICATOR
© LOW FUEL
J948E-22
8E -12 INSTRUMENT PANEL AN I GAUGES BR
INSTRUMENT CLUSTER PRINTED CIRCUIT BOAR!

- LOW LINE
VOLTMETER SPEEDOMETER FUEL GAUGE
SCREWS SCREWS SCREWS
OIL PRESSURE
GAUGE SCREWS
COOLANT TEMPERATURE
GAUGE SCREWS
7. UPSHIFT INDICATOR
1. ILLUMINATION 8. SEAT BELT WARNING tAMP
2. TURN SIGNAL INDICATORS 9. MALFUNCTION INDICATOR
3. HIGH BEAM INDICATOR (CHECK ENGINE)
4.AIS 10. LOW OIL INDICATOR
5. MAINTENANCE INDICATOR 11. AIRBAG
6. BRAKE 12. 4WD INDICATOR J948E-45
BR- —— INSTRUMENT PANEL AND GAUGES SE -13
INDICATOR LAMPS
If an individual indicator lamp is inoperative, see
the diagnostic procedure under the heading for that
lamp. If more than one indicator lamp or a combina
tion of lamps and gauges in the instrument cluster is
inoperative, see Gauges in this section for diagnosis.
AIRBAG INDICATOR LAMP
(1) Disconnect battery negative cable. Remove in
strument cluster bezel and cluster assembly. Do not NO. IDENTIFICATION
unplug cluster connectors. 2 RWAL W A R N I N G LAMP OUTPUT
(2) Connect battery negative cable. Check for bat 5 PARKING BRAKE SWITCH S E N S E
tery voltage between bulb terminals on printed cir 6 BRAKE W A R N I N G LAMP SENSE i
cuit within 6 seconds after turning ignition switch to
J958E-25
ON position. If OK, replace faulty bulb. If not OK, go
to next step. Fig. 14 RWAL Control Module Connector
(3) Turn ignition switch to OFF position. Discon
nect battery negative cable. Check for continuity be
tween cavity 9 of cluster connector A (white) and
cavity 7 of airbag control module (ACM) connector 1.
There should be continuity. If OK, refer to Group 8M
- Restraint Systems for diagnosis of ACM. If not OK,
repair open circuit as required.
ANTI-LOCK BRAKE SYSTEM LAMP

The diagnosis found here addresses an inoperative
lamp condition. If the ABS lamp stays on with the ig
nition switch in the ON position, or comes on and
stays on while driving, refer to Group 5 - Brakes for NO. IDENTIFICATION !
diagnosis. If no ABS problem is found, the following 24 ABS W A R N I N G LAMP OUTPUT
procedure will help locate a short or open in the ABS 25 BRAKE W A R N I N G LAMP S E N S E J958E-24
lamp circuit.
(1) Disconnect battery negative cable. Remove in Fig. 15 ABS Control Module Connector
strument cluster bezel and cluster assembly. On mod BRAKE WARNING LAMP
els with ABS, remove ABS lamp relay from power
distribution center. Disconnect ABS/RWAL control
lamp condition. If the brake warning lamp stays on
module connector.
with the ignition switch in the ON position and the
(2) Install a jumper wire between cavity 14 of clus parking brake released, refer to Group 5 - Brakes for
ter connector B (black connector) and a good ground. diagnosis. If no service brake or parking brake prob
Connect battery negative cable and turn ignition lem is found, the following procedure will help locate
switch to ON. Lamp should light. If OK, remove a short circuit or faulty switch.
jumper wire and go to next step. If not OK, replace
(1) Turn ignition switch to START position. Lamp
bulb.
should light. Release ignition switch to ON position.
(3) Turn ignition switch to OFF. Disconnect battery Lamp should go OFF. If not OK, go to next step.
negative cable and unplug cluster connector B. Check
(2) Turn ignition switch to OFF position. Unplug
for continuity between cavity 14 of cluster connector
brake warning switch connector. Check for continuity
B and a good ground. There should be no continuity.
between switch terminal and a good ground. There
If OK, go to next step. If not OK, repair short circuit
should be no continuity. If OK, go to next step. If not
as required. ' -
OK, replace brake warning switch.
(4) Check continuity between cavity 14 of cluster
(3) Unplug parking brake switch connector. With
connector B and cavity 2 of RWAL control module
parking brake released, check for continuity between
connector (Fig. 14), or cavity 24 of ABS control mod
switch terminal and a good ground. There should be
ule connector (Fig. 15). There should be continuity. If
no continuity. Apply parking brake and check for con
OK, refer to Group 5 - Brakes for diagnosis of RWAL
tinuity between switch terminal and a good ground.
or ABS control module. If not OK, repair open circuit
as required.
8E -14 INSTRUMENT PANEL AND GAUGES — - ~ ———————— -—^— B R
There should be continuity. If OK, go to next step. If In each case there should be continuity. If not OK,
not OK, adjust or replace parking brake switch as re repair open circuit as required.
quired.
(4) Check for continuity between metal steering jFQ^Mmmt BMiwe INDICATOR LAMP
column jacket and a good ground. There should be (1) Turn ignition switch to ON position. Unplug
continuity. If OK, go to next step. If not OK, refer to 4WD switch connector at front axle disconnect hous
Group 19 - Steering to check steering column ground ing. Install a jumper wire between the two cavities of
clip installation. harness half of switch connector. Lamp should light.
(5) Disconnect battery negative cable. Unplug igni Remove jumper and lamp should go off. If OK, re
tion switch connector (Fig. 16). While holding igni place transfer case switch. If not OK, go to next step.
tion switch in START position, check for continuity (2) Turn ignition switch to OFF position. Check for
between ignition switch terminal 3 and a good continuity between cavity 2 (black wire) of transfer
ground. There should be continuity. Release ignition case switch connector and a good ground. There
switch to ON position and check for continuity again should be continuity. If OK, go to next step. If not
at switch terminal 3. There should be no continuity. OK, repair open circuit to ground as required.
If OK, go to next step, if not OK, repair ignition (3) Disconnect battery negative cable. Remove in
switch ground or replace faulty ignition switch as re strument cluster bezel and cluster assembly. Connect
quired. battery negative cable. Install a jumper wire between
cavity 13 of cluster connector B and a good ground.
Turn ignition switch to ON position. Lamp should
light. If OK, go to next step. If not OK, replace faulty
bulb.
(4) Turn ignition switch to OFF position. Discon
nect battery negative cable. Unplug cluster connector
B (black connector). Probe cavity 13 of cluster con
nector B. Check for continuity to a good ground.
NO. IDENTIFICATION There should be no continuity. If not OK, repair short
3 BRAKE WARNING LAMP OUTPUT circuit as required.
check for continuity to cavity 1 (black/gray wire) of
Fig. 16 Ignition Switch Connector
4WD switch connector. There should be continuity. If
(6) Remove instrument cluster bezel and cluster OK, go to next step. If not OK, repair open circuit as
assembly. Connect battery negative cable and igni required.
tion switch connector. Do not unplug cluster connec
tors. Install a jumper wire between cavity 5 of cluster HmmiAmp HIGH BEAM INDICATOR LAMP
connector A (white connector) and a good ground. (1) Check that headlamp high beams are func
Turn ignition switch to ON position. Lamp should tional. If OK, go to next step. If not OK, refer to
light. If OK, go to next step. If not OK, replace faulty Group 8L - Lamps for diagnosis of headlamp system.
bulb.
(2) Disconnect battery negative cable. Remove in
(7) Turn ignition switch to OFF and remove strument cluster bezel and cluster assembly. Unplug
jumper wire. Disconnect battery negative cable. Un
cluster connector A, (white connector). Connect bat
plug ignition switch, parking brake switch, vacuum
sensor (diesel engine only) and brake warning switch tery negative cable. Turn headlamps on and select
connectors. Unplug connector at RWAL or ABS con high beam. Check for battery voltage at cavity 13 of
trol module (Figs. 14 or 15), as equipped. Unplug cluster connector A. If OK, replace indicator bulb. If
cluster connector A. Check for continuity between not OK, repair circuit to headlamp dimmer (multi
cavity 5 of cluster connector A and a good ground. function) switch as required.
There should be no continuity. If OK, go to next step.
LOW F U E L WARNING LAMP
If not OK, repair short circuit as required.
(1) Check that fuel gauge is operating as designed.
(8) Check for continuity between cavity 5 of cluster
connector A and the following points: See Fuel Gauge Calibration chart in Specifications. If
• parking brake switch connector OK, go to next step. If not OK, see Fuel Gauge in
• brake warning switch connector this section for diagnosis.
• vacuum sensor connector (diesel engine only) (2) Disconnect battery negative cable. Unplug fuel
® ignition switch connector cavity 3 gauge sending unit connector. Remove instrument
© RWAL control module connector cavity 6 cluster bezel and instrument cluster. Replace low fuel
• ABS control module connector cavity 25. warning bulb with a known good unit. Connect bat-
tery negative cable and test operation. If OK, discard

faulty bulb. If not OK, replace faulty low fuel warn
ing printed circuit.
LOW OIL PRESSURE WARNING LAMP
lamp condition. If the problem being diagnosed is re
lated to lamp accuracy, be certain to confirm that
problem is with lamp and not with engine oiling sys
tem. Actual engine oil pressure should be checked
with a test gauge before you proceed with lamp diag
nosis. Refer to Group 9 - Engines for more informa
tion.
(1) Turn ignition switch to ON. Disconnect oil pres
sure sending unit connector (Figs. 17, 18 or 19). In
stall a jumper wire between cavity 2 of sending unit
connector (Fig. 20) and a good ground. The lamp
should light. Remove jumper wire and lamp should
go off. If OK, replace sending unit. If not OK, go to
next step.
Fig. 18 Oil Pressure Swiich/Senc

Engine
OIL PRESSURE -
SENDING UNIT J938E-35
Fig. 17 Oil Pressure Switch/Sending Unit •

Engine
negative cable. Remove instrument cluster bezel and
cluster assembly. Disconnect instrument cluster con
STEERING
nector B (black connector). ENGINE BLOCK
. PUMP Jf119-74
(3) Probe cavity 4 of cluster connector B and check
for continuity to a good ground. There should be no Fig. 19 Oil Pressure Switch/Sending Unit - Diesel
continuity. If OK, go to next step. If not OK, repair Engine
move jumper and lamp should go off. If OK, replace
check for continuity to cavity 2 of sending unit wire washer fluid level switch. If not OK, go to next step.
connector (Fig. 20). There should be continuity. If (2) Turn ignition switch to OFF position. Check for
OK, replace lamp bulb. If not OK, repair open circuit continuity between washer fluid level switch connec
as required. tor cavity 1 (black wire) and a good ground. There
should be continuity. If OK, go to next step. If not
LOW WASHER FLUID WARMING LAMP OK, repair open circuit to ground as required.
(1) Unplug washer fluid level switch connector. In (3) Disconnect battery negative cable. Remove ~ in
stall a jumper wire between two cavities of connector. strument cluster bezel and cluster assembly. Unplug
Turn ignition switch to ON. Lamp should light. Re- instrument cluster connector B (black connector).
8E-16 INSTRUMENT PANEL AND GAUGES — _ BR
TERMINAL END WIRE END
N O . IDENTIFICATION
1 SENSOR GAUGE OUTPUT
2 SENSOR LAMP OUTPUT J958E-21
Fig. 20 Oil Pressure Sending Unit Connector

(NO. IDENTIFICATION
Check for continuity between cavity 7 of cluster con 32 MALFUNCTION INDICATOR LAMP
nector B and a good ground. There should be no con 36 GENERATOR WARNING LAMP
tinuity. If OK, go to next step. If not OK, repair short 43 TACHOMETER SIGNAL
54 UPSHIFT INDICATOR LAMP
circuit as required. J958E-7
(4) Check for continuity between cavity 7 of cluster
connector B and cavity 2 (black and tan wire) of Fig. 21 Powertrain Control Module Connector
washer fluid level switch connector. There should be (4) Check continuity between cavity 6 of cluster
continuity. If OK, replace lamp bulb. If not OK, re connector B and cavity 32 of PCM connector. There
pair open circuit as required. should be continuity. If not OK, repair open circuit to
PCM as required.
MALFUNCTION INDICATOR LAMP
The diagnosis found here addresses an inoperative MAINTENANCE REQUIRED INDICATOR LAMP
lamp condition. If the lamp comes on and stays on (1) Disconnect battery negative cable. Unplug PCM
with engine running, refer to Group 14 - Fuel System connector. Remove instrument cluster bezel and clus
for diagnosis. If no fuel or emission system problem ter assembly. Do not unplug cluster connectors.
is found, the following procedure will help locate a (2) Install a jumper wire between cavity 5 of clus
short or open in the lamp circuit. ter connector B (black connector) and a good ground.
(1) Disconnect battery negative cable. Unplug PCM Connect battery negative cable. Turn ignition switch
connector. Install a jumper wire from cavity 32 of to ON position. Lamp should light. If OK, go to next
PCM connector (Fig. 21) to a good ground. Connect step. If not OK, replace faulty bulb.
battery negative cable. Turn ignition switch to ON. (3) Turn ignition switch to OFF position. Discon
Lamp should light. Remove jumper wire and lamp nect battery negative cable and unplug cluster con
should go OFF. If OK, refer to Powertrain Diagnostic nector B. Check for continuity between cavity 5 of
Procedures to check PCM. If not OK, go to next step. cluster connector B and a good ground. There should
(2) Turn ignition switch to OFF. Disconnect battery be no continuity. If OK, go to next step. If not OK,
negative cable. Remove instrument cluster bezel and repair short circuit as required.
cluster assembly. Install a jumper wire from cavity 6 (4) Still probing cavity 5 of cluster connector B,
of cluster connector B (black connector) to a good check for continuity to cavity 56 of PCM connector.
ground. Connect battery negative cable. Turn ignition There should be continuity. If OK, refer to Group 14 -
switch to ON. Lamp should light. If OK, go to next Fuel Systems for diagnosis of PCM. If not OK, repair
step. If not OK, replace faulty bulb. open circuit as required.
SEAT BELT REMUSSS&iS U*U*P
negative cable. Unplug cluster connector b. Check for
continuity between cavity 6 of cluster connector B (1) Refer to Group * 8U - Chime/Buzzer Warning
Systems to check chime/buzzer module operation. If
and a good ground. There should be no continuity. If
OK, go to next step. If not OK, replace chime/buzzer
OK, go to next step. If not OK, repair short circuit to module.
PCM as required. (2) Disconnect battery negative cable. Remove in
strument cluster bezel and cluster assembly. Unplug
cluster connector A (white connector). Check for con-
tinuity between cavity 10 of cluster connector A and nector and a good ground. Turn ignition switch to ON
a good ground. There should be continuity. If OK, position. Lamp should light. If OK, go to next step. If
plug cluster connector A back into cluster and go to not OK, replace faulty bulb.
next step. If not OK, repair open circuit to ground as (3) Turn ignition switch to OFF position. Discon
required. nect battery negative cable, message center connector
(3) Connect battery negative cable. Install a and PCM connector. Check for continuity between
jumper wire between a 12-volt battery feed and cav cavity 8 of message center connector and a good
ity 1 of cluster connector A. Lamp should light. If ground. There should be no continuity. If OK, go to
OK, go to next step. If not OK, replace bulb. next step. If not OK, repair short circuit as required.
(4) Disconnect battery negative cable. Unplug (4) Check for continuity between cavity 8 of mes
chime/buzzer module from fuseblock module. Unplug sage center connector and cavity 31 of PCM connec
cluster connector A. Check for continuity between tor. There should be continuity. If OK, refer to Group
cavity 1 of cluster connector A and a good ground. 21 - Transmission and Transfer Case to diagnose sen
There should be no continuity. If OK, go to next step. sor. If not OK, repair open circuit as required.
If not OK, repair short circuit to chime/buzzer mod
ule as required. TURN SIGNAL INDICATOR LAMPS
(5) Check continuity between cavity 1 of cluster (1) Disconnect battery negative cable. Remove in
connector A and cavity for terminal A3 of chime/ strument cluster bezel and cluster assembly. Probe
buzzer module (Fig. 22) in fuseblock module. There cavity 10 of cluster connector A (white connector).
should be continuity. If not OK, repair open circuit to Check for continuity to a good ground. There should
chime/buzzer module as required. be continuity. If OK, go to next step. If not OK, re
pair open circuit to ground.
(2) Connect battery negative cable. Install a
jumper wire from cavity 12 (left indicator) or cavity
14 (right indicator) of cluster connector A (white con
A4 f *| A3 f *] A2 A1 f nector) to a 12-volt battery feed. Lamp should light.
If OK, continue to next step. If not OK, replace bulb.
(3) Disconnect battery negative cable. Check for
continuity between cavity 12 (left indicator) or cavity
14 (right indicator) of cluster connector 1 and cavity
VIEWED FROM TERMINAL END
16 (left front turn signal) or cavity 11 (right front
turn signal) of multi-function switch connector. There
should be continuity. If OK, refer to Group 8J - Turn
Signals And Hazard Warning Flasher for further di
NO. IDENTIFICATION agnosis. If not OK, repair open circuit as required.
A3 SEAT BELT REMINDER LAMP
UPSHIFT INDICATOR LAMP
(1) Disconnect battery negative cable. Unplug PCM
Fig. 22 Chime/Buzzer IWoduie Receptacle connector. Connect battery negative cable. Turn igni
TRANSMISSION OIL TEMPERATURE tion switch to ON. Install a jumper wire from cavity
WARNING LAMP 54 of PCM connector (Fig. 21) to a good ground.
The diagnosis found here addresses an inoperative Lamp should light. Remove jumper from ground.
lamp condition. If the problem being diagnosed is re Lamp should go off. If OK, refer to Powertrain Diag
lated to lamp accuracy, be certain to confirm that nostic Procedures manual to diagnose PCM. If not
problem is with lamp and not with transmission oil OK, turn ignition switch to OFF and go to next step.
cooling system. Proper transmission oil flow and (2) Disconnect battery negative cable. Remove in
cooler operation should be checked before you pro strument cluster bezel and cluster assembly. Install a
ceed with lamp diagnosis. For diagnosis and service jumper wire from cavity 3 of cluster connector A
of the sensor and transmission oil cooling system, re (white connector) to a good ground. Connect battery
fer to Group 21 - Transmission and Transfer Case. negative cable. Turn ignition switch to ON. Lamp
(1) Disconnect battery negative cable. Remove in should light. If OK, go to next step. If not OK, re
strument cluster bezel and message center. Connect place bulb.
battery negative cable. Turn ignition switch to ON (3) Turn ignition switch to OFF. Disconnect battery
position. Check for battery voltage at cavity 3 of mes negative cable. Unplug cluster connector A. Check for
sage center connector. If OK, go to next step. If not continuity between cavity 3 of cluster connector A
OK, repair circuit to fuse 12 as required. and a good ground. There should be no continuity. If
(2) Turn ignition switch to OFF position. Install a OK, go to next step. If not OK, repair short circuit as
jumper wire between cavity 8 of message center con required.
8E -18 INSTRUMENT PANEL AND GAUGES — m m
(4) Check for continuity between cavity 3 of cluster OK, turn ignition switch to OFF, remove jumper wire
connector A and cavity 54 of PCM connector. There and go to next step. If not OK, replace faulty bulb.
should be continuity. If not OK, repair open circuit as (4) Disconnect battery negative cable. Unplug mes
required. sage center connector and PCM connector. Check for
continuity between cavity 2 of message center con
WAIT-TOSTART LAMP
nector and a good ground. There should be no conti
(1) Disconnect battery negative cable. Remove in nuity. If OK, go to next step. If not OK, repair short
strument cluster bezel and message center. Unplug
circuit as required.
message center connector.
(5) Still probing cavity 2 of message center connec
(2) Connect battery negative-cable. Turn ignition
switch to ON position. Check for battery voltage at tor, check for continuity to cavity 35 of PCM connec
cavity 3 of message center connector. If OK, turn ig tor. There should be continuity. If OK, refer to Group
nition switch to OFF position and go to next step. If 14 - Fuel Systems to diagnose PCM and its inputs. If
not OK, refer to Group 8W - Wiring Diagrams and not OK, repair open circuit to PCM connector as re
repair circuit to ignition feed as required. quired.
(3) Plug message center connector into message
center, install a jumper wire between cavity 4 - of CLUSTER ILLUMINATION LAMPS
message center connector and a good ground. Turn (1) Check fuse 13 in fuseblock module. If OK, go to
ignition switch to ON position. Bulb should light. If next step. If not OK, replace fuse.
OK, turn ignition switch to OFF, remove jumper wire (2) Turn park lamps on at headlamp switch. Rotate
and go to next step. If not OK, replace faulty bulb. headlamp switch knob counterclockwise to just before
(4) Disconnect battery negative cable. Unplug mes interior lamps detent. Check for battery voltage at
sage center connector and PCM connector. Check for fuse 13 in fuseblock module. Rotate headlamp switch
continuity between cavity 4 of message center con clockwise while observing test voltmeter. Reading
nector and a good ground. There should be no conti should go from battery voltage to zero volts. If OK,
nuity. If OK, go to next step, if not OK, repair short go to next step. If not OK, repair open circuit to
circuit as required. headlamp switch or refer to Group 8L - Lamps to di
(5) Still probing cavity 4 of message center connec agnose headlamp switch.
tor, check for continuity to cavity 36 of PCM connec (3) Disconnect battery negative cable. Remove in
tor. There should be continuity, if OK, refer to Group strument cluster bezel and cluster assembly. Unplug
14 - Fuel Systems to diagnose PCM and its inputs. If cluster connector B (black connector). Connect bat
not OK, repair open circuit as required. tery negative cable. Turn park lamps on at headlamp
switch. Rotate headlamp switch knob counterclock
WATER-IN-FUEL LAMP wise to just before interior lamps detent. Check for
(1) Disconnect battery negative cable. Remove in battery voltage at cavity 1 of cluster connector B. If
strument cluster bezel and message center. Unplug OK, go to next step. If not OK, repair open circuit to
message center connector. fuse as required.
(2) Connect battery, negative cable. Turn ignition (4) Turn park lamps off. Disconnect battery nega
switch to ON position. Check for battery voltage at tive cable. Remove fuse 13 from fuseblock module.
cavity 3 of message center connector. If OK, turn ig Probe cavity 1 of cluster connector B. Check for con
nition switch to OFF position and go to next step. If tinuity to a good ground. There should be no continu
not OK, refer to Group 8W - Wiring Diagrams - and ity. If OK, go to next step. If not OK, repair short
repair circuit to ignition feed as required. circuit as required.
(3) Plug message center connector into message (5) Probe cavity 1 of cluster connector B. Check for
center. Install a jumper wire between cavity 2 of continuity to output side of cavity for fuse 13. There
message center connector and a good ground. Turn should be continuity. If OK, replace illumination
ignition switch to ON position. Bulb should light. If bulb(s). If not OK, repair open circuit as required.
INSTRUMENT PANEL ANI IAUGES 8E - 1 1
SERVICE PROCEDURES
ASH RECEIVER REMOVE/INSTALL

(1) Remove ash receiver and remove 2 screws (Fig.
1) securing bracket to instrument panel.
J948E-9
Fig. 1 Ash Receiver Remove/install

(2) Remove ash receiver bracket assembly from in Fig. 3 Knee Blocker Remove/Install
strument panel.
CUP HOLDER REMOVE/INSTALL

(1) Open cup holder and remove 2 screws (Fig. 2)
securing assembly to instrument panel.
Fig. 2 Cup Holder Remove/install

(2) Remove cup holder assembly from instrument
panel.
Fig. 4 Fuseblock Module Remove/Install
KNEE BLOCKER REMOVE/INSTALL
(1) Remove 5 screws securing knee blocker (Fig. 3). INSIDE HOOD RELEASE REiOfE/INSTALL
(2) Remove knee blocker from lower instrument (1) Disengage cable from hood latch in engine com
panel. partment.
(3) Reverse removal procedures to install. - (2) Remove 2 screws holding handle assembly to
lower instrument panel support.
FUSEBLOCK MODULE REMOVE/INSTALL (3) Remove assembly by pulling cable rearward
(1) Disconnect battery negative cable. through dash panel grommet.
(2) Remove knee blocker as described in Knee (4) Reverse removal procedures to install.
Blocker Remove/Install.
(3) Remove 2 screws holding fuseblock module to CLUSTER BEZEL REMOVE/INSTALL
instrument panel (Fig. 4). (1) Disconnect battery negative cable.
(4) Pull fuseblock module back far enough to gain (2) Remove cup holder as described in Cup Holder
access to buzzer module. Remove/Install.
(3) Remove ash receiver as described in Ash Re (2) Remove cluster bezel as described in Cluster
ceiver Remove/Install. Bezel Remove/Install.
(4) Carefully pry bezel away from instrument (3) Remove knee blocker as described in Knee
panel to disengage clips (Fig. 5). Blocker Remove/Install.
(4) Pull PRND21 cable and twist to remove from
position arm (Fig. 7), if equipped.
PRNDL
CABLE
POSITION
ARM
STEERING
J948E-46 PUSH TAB COLUMN
UP
Fig. 5 Instrument Bezel Remove/Install J948E-4
(5) Unplug connector from cigar lighter. Fig. 7 PRND21 Cable Remove -
(6) Unplug connector from auxiliary power outlet.
(5) Push tab on bottom of cable retainer up then
squeeze sides to remove retainer from column.
CIGAR LIGHTER/POWER OUTLET REMOVE/ (6) Remove 4 screws that hold cluster (Fig. 8).
INSTALL
(1) Remove cluster bezel as described in Cluster
Bezel Remove/Install.
(2) Unscrew cigar lighter/power outlet housing
from rear of cluster bezel (Fig. 6).
ELECTRICAL
CONNECTOR
CLIPS
J948E-11
Fig. 8 Instrument Cluster Remove/Install

(7) Pull cluster rearward and unplug 2 electrical
connectors (Fig. 9).
(8) Remove cluster.
J948E-10
(9) Reverse removal procedures to install. Refer to
Group 21 - Transmission and Transfer Case for
Fig. 6 Cigar Lighter Remove/Install
PRND21 cable adjustment procedure.
(3) Remove cigar lighter/power outlet from front of
bezel. CLUSTER LENS AND MASK REMOVE/INSTALL
(4) Reverse removal procedures to install. (1) Remove cluster assembly as described in In
strument Cluster Remove/Install.
INSTRUMENT CLUSTER REMOVE/INSTALL (2) Remove 7 screws and lens (Fig. 10).
(1) Disconnect battery negative cable. (3) Remove gauge mask (Fig. 11).
(2) Remove required gauge screws from rear of

mounting bezel. Remove gauge from front.
PRND21 INDICATOR REMOVE/INSTALL
(1) Remove cluster assembly as described in In
strument Cluster Remove/Install.
. (2) Remove screws attaching PRND21 mechanism
to cluster housing (Fig. 12).
Fig. 9 Unplug Electrical Connectors

REMOVE SCREWS
Fig. 10 Cluster Lens Remove/Install
Fig. 12 PRND21 Housing Remove/Install

(3) Remove PRND21 mechanism from cluster.
(5) To adjust PRND21 indicator, place shift selector
in PARK position. Now adjust indicator by turning
recessed hex head screw (9/64-inch hex key wrench)
underneath cable retainer (Fig. 13).
J948E-14
Fig. 11 Instrument Cluster Assembly

CAUTION: Do not touch the face of a gauge or the
back of the lens with four finger. It will leave a per
manent finger print
Fig. 13 PRND21 Indicator Adjustment
(4) Reverse removal procedures to install. CLUSTER BUL1S REMOVE/INSTALL
(1) Remove instrument cluster as described in In
GAUGES REMOVE/INSTALL strument Cluster Remove/Install.
(1) Remove cluster lens and mask as described in (2) Twist lamp socket assembly and remove from
Cluster Lens and Mask Remove/Install. printed circuit board.
SE - 22 INSTRUMENT PANEL AND GAUGES BR
(3) Remove bulb from socket. (4) Pull flexible printed circuit back.
(4) Install correct replacement bulb Into socket. (5) Remove low fuel circuit.
(5) Reverse removal procedures to install. (6) Reverse removal procedures to install.
LOW FUEL CIRCUIT REMOVE/INSTALL PRINTED CIRCUIT REMOVE/INSTALL

(1) Remove cluster as described in Instrument (1) Remove instrument cluster as described in In
Cluster Remove/Install. strument Cluster Remove/Install
(2) Remove connector from cluster (Fig. 14). (2) Remove all lamp socket assemblies.
(3) If equipped, remove low fuel circuit as de
scribed in Low Fuel Circuit Remove/Install.
(4) Remove gauge mounting screws and remove
gauges.
(5) Remove printed circuit board from cluster hous
ing.
CAUTION: Do not overtighten mounting screws or
damage to circuit board and/or cluster housing will
occur.
OIL PRESSURE SENDING UNIT REMOVE/INSTALL

(1) Unplug connector from sending unit.
(2) Using oil pressure sending unit socket (Special
Fig, 14 Low Fuel Warning Connector Tool C-4597), remove the sender (Fig. 17).
(3) Remove left turn signal bulb and illumination
sending unit to 23 N-m (200 in. lbs.).
bulb.
Fig. 15 Cluster Printed Circuit - High Line and Diesei Engine

BR — — — INSTRUMENT PANEL AND GAUGES 8E - 23
VOLTMETER SPEEDOMETER FUEL GAUGE

SCREWS SCREWS
SCREWS
OIL PRESSURE
GAUGE SCREWS
7. UPSHIFT INDICATOR
1. ILLUMINATION 8. SEAT BELT WARNING LAMP
2. TURN SIGNAL INDICATORS 9. MALFUNCTION INDICATOR
3. HIGH BEAM INDICATOR (CHECK ENGINE)
4. ABS 10. LOW OIL INDICATOR
5. MAINTENANCE INDICATOR 11. AIRBAG
6 . BRAKE 12. 4WD INDICATOR J948E-45
Fig. 16 Cluster Printed Circuit - Low Line
SPECIAL TOOL (2) Remove sensor by loosening sensor coupling nut

C-4597 from the pinion gear adapter until sensor is free (Fig.
18).
coupling nut to 17 N-m (150 in. lbs.).
SPEEDOMETER
PINION GEAR
ELECTRICAL
CONNECTOR
O-RING
SENSOR
MOUNTING
BOLT
OIL PRESSURE
SENDING UNIT J9314-96
SPEEDOMETER PINION
Fig. 17 Oil Pressure Sending Unit Remove/Install GEAR ADAPTER
f EHICLE SPEED SENSOR REMOWE/INSTALL

VEHICLE
(1) Remove harness connector from sensor. Be sure O-RING
SPEED
weather seal stays on harness connector. SENSOR J9314-188
Fig. 18 Vehicle Speed Sensor Remove/Install

SE - 24 INSTRUMENT PANEL AND GAUGES B R
HEATER - A/C CONTROL/MESSAGE CENTER HEATER - A/C CONTROL/MESSAGE CENTER LAMP

REMOfE/INSTALL BULBS REMOVE/INSTALL
(1) Remove cluster bezel as described in Cluster (1) Remove heater - A/C control/message center as
Bezel Remove/Install. described in Heater - A/C Control/Message Center
(2) Remove 4 control attaching screws (Fig. 19). Remove/Install.
(2) Twist lamp socket assembly and remove from
printed circuit board.
(3) Remove bulb from socket.
(4) Install correct replacement bulb in socket.
HEADLAMP SWITCH REMOVE/INSTALL
WARNING: IF HEADLAMP SWITCH WAS ON, WAIT 5

MINUTES TO ALLOW THE CERAMIC DIMMER TO
COOL. IF THE CERAMIC DIMMER IS NOT ALLOWED
TO COOL YOU CAN BURN YOUR FINGERS.
(1) Remove cluster bezel as described in Cluster
Bezel Remove/Install.
(2) Remove 3 screws and headlamp switch from in
strument panel (Fig. 21).
Fig. 19 Heater - A/C Control/Message Center

Remove/install
(3) Pull control rearward.
(4) Unplug 2 wiring harness connectors (Fig. 20).
Fig. 21 Headlamp Switch and Bezel Remove/Install

(3) Unplug 2 electrical connectors (Fig. 22).
(4) Pull knob and stem assembly out to stop. De
press button on bottom of switch and remove knob
and stem from housing.
(5) Remove 2 screws and bezel from housing.
OVERDRIVE LOCKOUT/FOG LAMP SWITCH

Fig. 20 Heater - A/C Control/Message Center REMOVE/INSTALL
Connections (1) Remove cluster bezel as described in Cluster
(5) Push in on red cable connector to release. Re Bezel Remove/Install.
move cable end from control unit. (2) Remove 3 screws and remove switch and bezel
(6) Remove control. unit (Fig. 23).
(7) Reverse removal procedures to install. (3) From rear of switch and bezel unit, pull up on
retaining tab and unplug electrical connector.
(4) Release retaining tabs and remove switch from
rear of bezel.
BR INSTRUMENT PANEL ANi GAUGES 8E - 21
DOOR
STOP
GLOVE BOX DOOR

J948E-20
Fig. 22 Headlamp Switch Knob and Stem Remove/ Fig. 24 Glove Box Door Release
Install
• GLOVE BOX ™T^J/
OVERDRIVE LOCKOUT/FOG LAMP
SWITCH BEZEL
J948E-21
REMOVE SCREWS J958E-47
Fig. 25 Glove Box and Bin Remove/Install
Fig. 23 Overdrive Lockout/Fog Lamp Switch assembly are retained in mounting hole by a light
Remove/Install snap fit. To remove latch striker, remove 2 screws
(5) Reverse removal procedures to install. (Fig. 26).
GLOVE BOX REMOVE/INSTALL

REMOVE
(1) Open glove box door. Depress right side of bin SCREWS
enough to allow stop to clear opening (Fig. 24).
(2) From inside glove box, push on stem of button
holding strap at left end of door. Button will push out
allowing strap to be removed.
(3) The door and bin are removed by lifting door
off hinges (Fig. 25).
GLOVE BOX LAMP/SWITCH/LATCH STRIKER
REMOVE/INSTALL
(1) Open glove box until stops in bin rest against
instrument panel. J948E-18
(2) To remove lamp and switch, grasp switch by Fig. 26 Glove Box Lamp/Switch - Typical
plunger and pull firmly outward. Switch and lamp
(3) Disconnect wires to switch and lamp (Fig. 27).
(4) Remove bulb from socket.
j958e-48
REMOVE
CONNECTORS
GLOVE BOX
LAMP SWITCH
Fig. 28 Lower Instrument Panel Support
(6) Pull PRND21 cable and twist to remove from
position arm on steering column (Fig. 29).
J948E-19 PRNDL
CABLE
Fig. 27 Glove Box Lamp/Switch Connections - POSITION
Typical ARM
(5) Reverse removal procedures to install. Tuck
any wiring that was exposed by lamp removal back
into recess behind lamp. Do not leave wires exposed
in glove box latch area.
GLOVE BOX LATCH REMOVE/INSTALL

(1) Open glove box door.
(2) Remove latch retaining clip. STEERING
PUSH TAB COLUMN
(3) Remove latch. UP
(4) Reverse removal procedures to install. J948E-4
INSTRUMENT PANEL ASSEMBLY REMOWE/INSTALL Fig. 29 PRND21 Cable Removal

(7) Push tab on bottom of cable retainer up then
WARNING: THE A I R B A G S Y S T E M IS A SENSITIVE, squeeze sides to remove retainer from column.
ELECTRO-MECHANICAL UNIT. B E F O R E ATTEMPT (8) If equipped, remove tilt column lever.
ING TO REMOVE OR INSTALL THE A I R B A G S Y S (9) Remove upper and lower shrouds from column
TEM COMPONENTS YOU MUST FIRST (Fig. 30).
DISCONNECT AND ISOLATE THE BATTERY NEGA (10) Remove lower fixed column shroud.
TIVE (GROUND) C A B L E . A L L O W S Y S T E M CAPACI (11) Loosen multi-function switch connector screw.
TOR TO DISCHARGE FOR 2 MINUTES THEN B E G I N The screw will remain in the connector. Remove
A I R B A G REMOVAL. FAILURE TO DO S O COULD switch connectors (Figs. 31 and 32).
R E S U L T IN ACCIDENTAL DEPLOYMENT AND P O S (12) Remove airbag squib harness from wiring
S I B L E P E R S O N A L INJURY. trough.
(13) Remove wiring trough from steering column.
(1) Disconnect battery negative cable. (14) Remove 3 toe plate nuts and washers (Fig.
(2) Remove left and right cowl side panel trim. 33).
(3) Remove knee blocker as described in Knee (15) Remove 2 nuts and washers attaching steer
Blocker Remove/Install. ing column bracket to instrument panel steering col
(4) Remove 6 screws and lower instrument panel umn support bracket (Fig. 34).
support (Fig. 28).
(5) Unplug airbag squib connector at lower left cor
ner of instrument panel.
— INSTRUMENT PANEL AND GAUGES 8E - 27
STEERING TILT UPPER PANEL KEY-IN SWITCH & MULTI-FUNCTION

WHEEL LEVER SHROUD BRACKET
SWITCH CONTROL J918J-2
Fig. 32 Steering Column Connectors
SHROUD NUT J928J-2
Fig. 30 Steering Column Shrouds
Fig. 33 Steering Column Toe Plate
J918J-1 CONNECTOR
Fig. 31 Multi-Function Switch Connector
Fig. 34 Steering Column Mounting

SE - 28 INSTRUMENT PANEL AND GAUGES B R
(16) Lower column and allow it to rest on seat. (24) Remove lower center instrument panel mount
(17) Remove 2 screws from bottom of Airbag Con ing screw.
trol Module (ACM) cover (Fig. 35). (25) Loosen lower instrument panel pivot bolts.
(26) Roll instrument panel down.
(27) Using a screwdriver or pointed tool, push
through plastic flashing to release locking tab on
heater - A/C control cable (Fig. 37).
LOCKING
Fig, 35 Airbag Control Module Cower Screws

(18) Remove 4 screws holding ACM to transmis
sion tunnel (Fig. 36).
Fig. 37 Heater - A/C Cable Remove From Housing

(28)' Pull cable from top of heater core housing.
J948M-2 (29) Remove instrument panel from vehicle.
(30) Reverse removal procedures to install. Be cer
Fig. 36 Airbag Control Module Remove/Install tain that all wiring and hoses are not pinched. Refer
(19) Disconnect wiring at ACM. to Group 8M - Restraint Systems before connecting
(20) Disconnect left side wiring. battery negative cable. Tighten hardware as follows:
(21) Remove screw holding brake release to bottom • instrument panel upper mounting screws - 3 N-m
of instrument panel. (28 in. lbs.)
(22) Disconnect right side wiring. There are: • instrument panel pivot bolts - 12 N-m (110 in. lbs.)
© 2 connectors attached to the heater A/C housing © steering column shroud screws - 2 N-m (17 in. lbs.)
® courtesy lamp connector - © steering column bracket nuts - 12 N-m (110 in.
® antenna cable connector lbs.)
o 2 body harness connectors • toe plate nuts - 23 N-m (200 in. lbs.)
© vacuum harness for heater - A/C system. • multi-function switch connector screw - 2 N-m (17
(23) Remove 5 screws holding instrument panel to in. lbs.)
dash. • ACM mounting bolts - 11 N-m (105 in. lbs.)
SPECIFICATIONS
OIL PRESSURE GAUGE CALIBRATION VOLTMETER CALIBRATION

POINTER P O S I T I O N RESISTANCE VOLTAGE I N P U T ?®INTER P O S I T I O N
Low Normal ±3° 65 ohms Low Norma! 11.75 Grad. ±3°
High Normal ±4° 24.5 ohms High Normal 15.8 Grad. ±4°
TEMPERATURE GAUGE CALIBRATION TACHOMETER CALIBRATION

GASOLINE ENGINES
ENGINE INDICATION
POINTER POSITION RESISTANCE
V6
Low Normal ±3° 361.7 ohms V8 100 HZ 3000 RPM ± 200
Diesel
High Normal ±3° 77 ohms
V10 125 HZ 3000 RPM ±200
TEMPERATURE GAUGE CALIBRATION SPEEDOMETER CALIBRATION

DIESEL ENGINE
FREQUENCY INDICATION
POINTER POSITION BUSISTANgL! |
41.1 HZ 20 mph ±3.0
Low Normal ±3° 155 ohms
118.8 HZ 55 mph ±2.5
High Normal ±4° 80.9 ohms
163.2 HZ 75 mph ±2.5
FUEL GAUGE CALIBRATION LOW FUEL INDICATOR
POINTER POSITION RESISTANCE SENDER RESISTANCE (@htns) mm DELAY TIME

Empty Grad. ±2.5° 97 ohms O N or OFF 8 to 30
85.4 _ 5 Q
seconds
1/2 Full Grad. ±5° 32.5 ohms
Full Grad. ±2.5° 9 ohms
J948E-44
BR — AUDIO SYSTEMS 8F - 1
AUDIO SYSTEMS
CONTENTS
page page

GENERAL INFORMATION
Following are general descriptions of major compo door has two separate speakers, a woofer and a
nents used in Ram truck audio systems. Refer to tweeter. Each Infinity woofer features an integral
Group 8W - Wiring Diagrams for complete circuit de amplifier and frequency filter unit. The amplifier of
scriptions and diagrams. the radio is used to drive the tweeters at each
speaker location. The speaker-mounted amplifiers
RADIOS drive the woofers.
Radio options for the Ram track models include an
AM/FM, an AM/FM/cassette, an AM/FM/CD, or an FILTER CHOKE/SPEAKER RELAY
AM/FM/cassette with graphic equalizer. All receivers Models equipped with the Infinity premium speak
are stereo Electronically-Tuned Radios (ETR) and in ers use this choke/relay to control battery feed to the
clude a clock function. For more information on radio speaker-mounted amplifiers. The choke/relay is
features, setting procedures, and control functions re mounted to the center lower instrument panel brace
fer to the Sound System manual. The Sound System to the right of the knee blocker opening. The choke/
manual is included with the owner's manual in the relay should be checked if there is a lack of bass and
vehicle glove box. low frequency response noted at all speakers.
IGNITION-OFF DRAW FUSE ANTENNA
All vehicles are equipped with an Ignition-Off Draw All models use a fixed-length stainless steel rod-
(IOD) fuse that is removed when the vehicle is shipped type antenna mast, installed at the right front fender
from the factory. This fuse feeds various accessories that of the vehicle. The antenna mast is connected to the
require current when the ignition switch is in the OFF center wire of the coaxial antenna cable and is not
position, including the clock and radio station preset grounded to any part of the vehicle. The antenna ca
memory functions. The fuse is removed to prevent bat ble has an additional disconnect at the right end of
tery discharge during vehicle storage. the instrument panel near the cowl side panel to al
When installing or removing the IOD fuse, it is im low instrument panel installation and removal with
portant that the ignition switch be in the OFF posi out radio removal.
tion. Failure to place the ignition switch in the OFF To eliminate static, the antenna base must have a
position can cause the radio display to become scram good ground. The coaxial antenna cable shield (the
bled when the IOD fuse is removed. Replacing the outer wire mesh of the cable) is grounded to the an
IOD fuse will correct the scrambled display. . tenna base and the radio chassis.
The IOD fuse should be checked if the radio station The factory installed ETRs automatically compen
preset memory or clock functions are erratic or inoper sate for radio antenna trim. Therefore, no antenna
ative. The IOD fuse is located in the fuseblock module. trimmer adjustment is required or possible when re
placing the receiver or the antenna.
SPE1IEIS
Speaker system options include two or four speaker RADIO NOISE SUPPRESSION
locations. On two-speaker systems, one full range Radio Frequency Interference (RFI) and Electro-
speaker is located in each door. Four-speaker systems Magnetic Interference (EMI) noise suppression is ac
add one full range speaker in each B pillar. complished primarily through circuitry internal to
The premium speaker option upgrades the speak the radio receivers. These internal suppression de
ers in the above locations to Infinity models. The two vices are only serviced as a part of the radio receiver.
B pillar speakers are coaxial units and each front External suppression devices that are serviceable
8F • 2 AUDIO SYSTE1S BR
and should be checked in the case of RFI or EMI found in that circuit, repair as required before con
noise complaints include the following: sidering any component replacement.
• radio antenna base ground Fleet vehicles are available with an extra-cost RFI-
• engine-to-body ground strap suppressed Powertrain Control Module (PCM). This
• resistor-type spark plugs unit reduces interference generated by the PCM on
• radio suppression-type secondary ignition wiring. some radio frequencies used in two-way radio com
In addition, if the source of RFI or EMI noise is munications. However, this unit will not resolve com
identified as a component on the vehicle (i.e.:genera- plaints of RFI in the commercial AM or FM radio
tor, blower motor, etc.), the ground path for that com frequency ranges.
ponent should be checked. If excessive resistance is
DIAGNOSIS
RADIO (3) Check resistance between speaker feed and return

(1) Check fuses 7, 17 and 18 in fuseblock module cavities. Meter should read between 3 and 8 ohms
and fuses 1 and 2 in Power Distribution Center (speaker impedance). If OK with Infinity speakers, go to
(PDC). If OK, go to next step. If not OK, replace fuse. next step. If OK without Infinity speakers, see diagnosis
(2) Check for battery voltage at fuses 1 and 2 in for Radio. If not OK, go to step 5.
PDC. If OK, go to next step. If not OK, repair feed (4) Install a known good radio. Connect battery nega
circuit from battery to PDC as required. tive cable. Turn on radio and test speaker operation. If
(3) Turn ignition switch to ON position. Check for OK, see diagnosis for Radio. If not OK, disconnect battery
battery voltage at fuse 7 in fuseblock module. If OK, negative cable, remove test radio and go to next step.
go to next step. If not OK, repair circuit to ignition (5) Unplug speaker wiring connector. Check for
switch as required. continuity between speaker feed cavity at radio and
(4) Turn ignition switch to OFF position. Discon at speaker. Repeat check between speaker return
nect battery negative cable. Remove instrument clus cavity at radio and at speaker. There should be con
ter bezel. Remove radio, but do not unplug any tinuity. If OK with Infinity speakers, go to next step.
connections. Check for continuity between the radio If OK without Infinity speakers, replace speaker. If
chassis and a good ground. There should be continu not OK, repair wiring circuit as required.
ity. If OK, go to next step. If not OK, repair radio (6) Check for continuity between cavity 1 of
ground circuit as required. speaker connector and a good ground. There should
(5) Connect battery negative cable. Turn ignition be continuity. If OK, go to next step. If not OK, re
switch to ON position. See Radio and Speaker Con pair wiring circuit to ground as required.
nectors chart. Check for battery voltage at cavity 6 of (7) Install radio. Connect battery negative cable. Turn
left (gray) radio connector. If OK, go to next step. If radio on. Check for battery voltage at cavity 4 of
not OK, repair circuit to fuse 7 as required. speaker connector. If OK, replace speaker. If not OK, re
(6) Turn ignition switch to OFF position. Check for pair circuit to filter choke/speaker relay as required.
battery voltage at cavity 7 of left (gray) radio connec
tor. If OK, replace radio. If not OK, repair circuit to FILTER CHOKE/SPEAKER RELAY
fuse 17 in fuseblock module as required. The radio filter choke/speaker relay is used to switch
power to the individual speaker amplifiers used with
SPEAKERS the Infinity premium speaker package. The choke and
(1) Turn radio on and adjust balance and fader relay are serviced only as an assembly. If all speakers
controls to check performance of each individual operate, but have no bass or low frequency response,
speaker. Note the speaker locations that are not per the choke/relay is suspect. However, before replacement
forming correctly. Go to next step. make the following checks of the circuit:
If vehicle has Infinity premium speaker package (1) Check fuse 17 in fuseblock module. If OK, go to
and all speakers lack bass or low frequency re next step. If not OK, replace fuse.
sponse, see Filter Choke/Speaker Relay diagnosis. (2) Check for battery voltage at fuse 17 in fuse-
(2) Turn radio off. Disconnect battery negative ca block module. If OK, go to next step. If not OK, re
ble. Remove instrument cluster bezel and remove ra pair circuit to Power Distribution Center as required.
dio. See Radio and Speaker Connector chart. Check (3) Remove knee blocker and unplug choke/relay
both the speaker feed and return cavities at radio for connector. See Radio and Speaker Connectors chart.
continuity to a good ground. There should be no con Check for battery voltage at cavity 1 of choke/relay
tinuity. If OK, go to next step. If not OK, repair wir connector. If OK, go to next step. If not OK, repair
ing circuit as required. circuit to fuse 17 as required.
AUDIO SYSTEMS 8F - 3
RADIO DIAGNOSIS CHART
NO AUDIO 1. Fuse faulty. 1. Check radio fuses in fuseblock module. Replace fuses, if required.
2 . Radio connector faulty. 2 . Check for loose or corroded radio connector. Repair,
if required.
3. See Radio Connector illustration, in this group. Check for
3. Wiring faulty. battery voltage at radio feed cavities. Repair feed circuits,
if required.
4. Check for continuity between radio chassis and a known good
4. Ground faulty. ground. There should be continuity. Repair radio ground,
if required.
5. Exchange or replace radio, if required.
5 . Radio faulty.
6. See Speaker Diagnosis, in this group.
6. Speakers faulty.
NO DISPLAY 1. Fuse faulty. 1. Check radio and panel lamps fuses in fuseblock module.
Replace fuse, if required.
2 . Radio connector faulty. 2. Check for loose or corroded radio connector. Repair, j
if required.
3. Wiring faulty. 3. See Radio Connector illustration, in this group. Check for
battery voltage at radio feed cavities. Repair feed circuits,
if required.
4. Ground faulty. 4. Check for continuity between radio chassis and a known good
ground. There should be continuity. Repair radio ground,
if required.
5. Radio faulty. 5 . Exchange or replace radio, if required.
NO MEMORY 1. Fuse faulty. 1. Check ignition-off draw fuse. Replace fuse, if required.
2. Check for loose or corroded radio connector. Repair,
2. Radio connector faulty. if required.
3. See Radio Connector illustration, in this group. Check for
3. Wiring faulty. battery voltage at battery feed cavity. Repair circuit, if required.
4. Exchange or replace radio, if required.
4. Radio faulty.
POOR RADIO RECEPTION 1. Antenna faulty. 1. See Antenna Diagnosis, in this group. Repair or replace
antenna, if required.
2. Ground faulty. 2. Check for continuity between radio chassis and a known good
ground. There should be continuity. Repair radio ground,
if required.
3. Radio faulty. 3. Exchange or replace radio, if required.
NO/POOR TAPE OPERATION 1. Faulty tape 1. Insert known good tape and test operation.
2. Foreign objects behind tape door. 2. Remove foreign objects and test operation.
3. Faulty tape deck. 3. Exchange or replace radio, if required.
NO COMPACT DISC 1. Faulty CD. 1. Insert known good CD and test operation.
OPERATION 2. Foreign material on CD. 2. Clean CD and test operation.
3. Condensation on CD or optics. 3. Allow temperature of vehicle interior to stabilize and test
operation.
4. Faulty CD player. 4. Exchange or replace radio, if required.
J958F-2
4 AUDIO SYSTEMS
RADIO AND SPEAKER CONNECTORS
" Y j u u f l u u L - T ^ u u u f l u u L T "
• • • • • • • • • • • • • •
LEFT (GRAY) RADIO CONNECTOR RIGHT (BLACK) RADIO CONNECTOR
NO. IDENTIFICATION NO. IDENTIFICATION
1 BATTERY FEED (CLOCK/MEMORY) 1 RIGHT REAR SPEAKER RETURN (-)
2 IGNITION SWITCHED BATTERY FEED 2 LEFT REAR SPEAKER RETURN (-)
3 PANEL LAMPS (DIMMER) FEED 3 RIGHT FRONT SPEAKER FEED (+)
4 HEAD/PARK LAMPS — O N SENSE 4 LEFT FRONT SPEAKER FEED (+)
5 RIGHT FRONT SPEAKER RETURN (-) 5 RIGHT REAR SPEAKER FEED (+,
6 LEFT FRONT SPEAKER RETURN (-) 6 LEFT REAR SPEAKER FEED (+)
7 RADIO MUTE | 7 SWITCHED FEED (TO PWR AMP/ANT)
Z]
i )
SPEAKER CONNECTOR (STANDARD)
NO. IDENTIFICATION FRONT TWEETER CONNECTOR (STD)
1 SPEAKER RETURN (-) NO. IDENTIFICATION
2 SPEAKER FEED (+) 1 RIGHT/LEFT FRONT SPKR FEED (+)
2 RIGHT/LEFT FRONT SPKR RET (-)
FRONT WOOFER CONNECTOR (PREMIUM) REAR SPEAKER CONNECTOR (PREM)

NO. IDENTIFICATION NO. IDENTIFICATION
1 AMPLIFIER POWER FEED 1 AMPLIFIER GROUND
2 SPEAKER FEED (+) 2 RIGHT/LEFT REAR SPKR RET (-)
3 SPEAKER RETURN (-) 3 RIGHT/LEFT REAR SPKR FEED (+)
4 AMPLIFER GROUND 4 AMPLIFIER POWER FEED
r? ti
PERM SPEAKER RELAY CONNECTOR

NO. IDENTIFICATION
1 GROUND
2 SWITCHED FEED (FROM RADIO)
3 FEED (TO SPEAKER AMPLIFIERS)
4 AMPLIFIER POWER FEED
J958F-10
BR AUDIO SYSTEMS 8F - 5
(4) Probe cavity 4 of choke/relay connector. Check (2) Connect one ohmmeter lead to tip of antenna
for continuity to a good ground. There should be con mast and the other lead to the antenna base. Check
tinuity. If OK, go to next step. If not OK, repair open for continuity.
circuit to ground as required. (3) There should be no continuity. If continuity is
(5) Turn ignition switch to ON position and turn found, replace defective or damaged antenna base
radio on. Check for battery voltage at cavity 3 of and cable assembly.
choke/relay connector. If OK, go to next step. If not
OK, repair circuit to cavity 1 of right (black) radio TEST 2
connector as required. Test 2 checks the antenna for an open circuit as follows:
(6) Turn radio and ignition switches to OFF position. (1) Disconnect the antenna cable lead.
Connect choke/relay connector. Check voltage at cavity 2 (2) Connect one ohmmeter test lead to tip of an
of choke/relay connector. There should be zero volts. tenna mast. Connect remaining lead to tip of an
Turn ignition and radio switches to ON position. There tenna cable lead.
should now be battery voltage at cavity 2 of choke/relay (3) Continuity should exist (ohmmeter should only
connector. If OK, repair circuit from cavity 2 of choke/ register a fraction of an ohm). High or infinite resis
relay connector to speaker amplifiers as required. If not tance indicates damage to the base and cable assem
OK, replace choke/relay. bly. Replace if required.
TEST 3
ANTENNA Test 3 checks condition of the vehicle body ground
The following four tests are used to diagnose the connection as follows:
antenna with an ohmmeter: (1) Connect one ohmmeter test lead to the vehicle
• mast to ground test (Test 1) fender and the other lead to the battery negative post.
• tip-of-mast to tip-of-conductor test (Test 2) (2) Resistance should be less than one ohm.
• body ground to battery ground test (Test 3) (3) If resistance is more than one ohm, check the
• body ground to coaxial shield test (Test 4). braided ground strap connected to the engine and ve
Check two-piece antenna cable from connection un hicle body for being loose, corroded, or damaged. Re
der right end of instrument panel near right cowl pair as necessary.
side panel to antenna base, then from connection to
radio chassis connection. Ohmmeter test lead connec TEST 4
tions for each test are shown in Figure 1. Test 4 checks condition of the ground between the
antenna base and vehicle body as follows:
TEST I (1) Connect one ohmmeter test lead to the fender
Test 1 determines if the antenna mast is insulated and the other lead to the crimp on the coaxial an
from the base. Proceed as follows: tenna cable shield.
(1) Disconnect antenna cable lead and isolate. (2) Resistance should be less then one ohm.
(3) If resistance is more then one ohm, clean and/or
tighten antenna base to fender mounting hardware.
2 RADIO FREQUENCY INTERFERENCE

Inspect ground connections at:
• blower motor
• electric fuel pump
• generator
• ignition module
• wiper motor
3 • antenna coaxial ground
• radio ground
• body-to-engine ground strap (braided).
Clean, tighten or repair as required.
Also inspect the following secondary ignition sys
m tem components:
• spark plug wire routing and condition
• distributor cap and rotor
• ignition coil
4 • spark plugs.
o ©*
J898F-7 Reroute spark plug wires or replace components as re

Fig. 1 Antenna Tests quired.
8F - 6 AUDIO SYSTEMS BR
SERVICE PROCEDURES
RADIO REiOWE/liSTALL (5) Unplug connector from cigar lighter (Fig. 5).
(1) Disconnect battery negative cable. . fcLECTRICAL
(2) Remove 2 screws from cup holder (Fig. 2) and CONNECTOR j||f (II
remove assembly. CUPS
J948E-8
J948E-10
Fig. 2 Cup Holder Remove
(3) Remove 2 screws from ash receiver (Fig. 3) and Fig. 5 Cigar Lighter Remove
remove assembly.
(6) Unplug connector from auxiliary power outlet.
(7) Remove 2 mounting screws from front of radio
SJ (Fig. 6).
I . If . 11
i
- *cs
REMOVE- y x ©
SCREWS
J948E-9
Fig. 3 Ash Receiver Remove

(4) Carefully pry bezel away from instrument
panel to disengage clips (Fig. 4).
J948F-5
Fig. 6 Radio Mounting
J948E-46
Fig. 4 Instrument Bezel Remove/Install
BR AUDIO SYSTEMS 8F - 7
(8) Pull radio out of instrument panel and discon (3) Pull rear of switch up and away from door.
nect wiring and antenna cable (Fig. 7). (4) Unplug connectors from switch (Fig. 10).
ANTENNA
CONNECTOR
LOCKING SWITCH PANEL
J948F-6 TABS FRONT CLIP J948S-8
Fig. 7 Radio Connectors Fig. 10 Door Switch Connectors
(9) Remove screw from ground strap (Fig. 7) and (5) Pull power mirror switch control knob rearward
remove radio. to remove from switch (Fig. 11).
(10) Reverse removal procedures to install. DOOR TRIM
PANEL
SPEAKERS REMOVE/INSTALL
SWITCH CONTROL
FRONT DOOM KNOB
(1) Remove 2 screws and door pull cup (Fig. 8).
REMOVE 2 SCREWS
POWER MIRROR
- SWITCH —7 J948T-6
J948S-2 Fig. 11 Power Mirror Knob Remove/Install

(6) Remove switch retaining nut from switch (Fig.
Fig. 8 Door Pull Cup
12).
(2) Remove power window/lock switch by reaching To aid in removal of the trim panel, start at
through door pull cup opening and depressing rear the bottom of the panel.
switch retaining tab (Fig. 9). (7) Using a wide flat-bladed tool such as a trim
stick, pry trim panel away from door around perime
ter and remove trim panel.
SWITCH BEZEL
RETAINING TAB
J948S-3
Fig. 9 Switch Bezel Rear Retaining Tab

8F - 8 AUDIO SYSTEMS
Fig. 12 Power Mirror Switch Nut Fig. 14 B Pitiar Trim - Typicai

(8) Remove screws holding speaker (Fig. 13). (a) Gently unhook top 2 retainer clips by pulling
(9) Disconnect speaker wiring connector. inward and forward.
(10) Remove speaker. (b) Remove 2 plastic push-in fasteners from bot
tom of panel.
(c) Loosen rear screws of cowl/sill trim.
(d) Slide B pillar trim out from under cowl/sill
trim.
(4) Move trim panel far enough to access speaker
screws.
(5) Remove screws holding speaker.
(6) Pull speaker out and unplug wiring.
(7) Reverse removal procedures to install speaker.
FILTER CHOKE/SPEAKER RELAY REMOVE/INSTALL

(1) Remove knee blocker (Fig. 15).
J948F-4
Fig. 13 Door Mounted Speaker

REAR PILLAR
(1) Remove rear screw from sill trim.
(2) Remove 2 screws holding B pillar trim (Fig. Fig. 15 Knee Blocker Remove/Install
14).
(3) Remove B pillar trim as follows:
BR AUDIO SYSTEMS . 8F - 1
(2) Remove 2 screws holding bottom of RWAL-mod (4) Remove 2 screws and relay/choke assembly
ule bracket to instrument panel brace (Fig. 16). (Fig. 18).
Fig. 16 RWAL Module Lower Mounting

(3) Remove screw holding top of RWAL module
bracket to instrument panel (Fig. 17) and remove
module.
Fig. 18 Relay/Choke Assembly

ANTENNA REMOVE/INSTALL
(1) Disconnect battery negative cable.
(2) Remove 5 screws holding right side kick panel/
sill trim. Remove kick panel/sill trim.
(3) Remove antenna mast from antenna body (Fig.
19).
Fig. 17 RWAL Module Upper Mounting
Fig. 19 Antenna Mast Remove/install

SF - 1i AUiiO SYSTEMS H R
(4) Remove cap nut using antenna nut wrench ADAPTER AND GASKET CAP NUT
C-4816 (Fig. 20).
FRONT RIGHT FENDER
TOOL
ANTENNA
PR517 A
ADAPTER
ANTENNA BODY
Fig. 20 Cap Nut and Adapter AND CABLE ASSEMBLY RN1008
(5) Lower antenna assembly down far enough to Fig. 21 Antenna Mounting
gain access to antenna body (Fig. 21).
(6) Remove antenna lead and body by pulling an (7) To install, route antenna cable between fender
and cowl panel to A pillar area.
tenna cable out of cowl and through opening in cowl
(8) Reverse remaining removal procedures to in
reinforcement. stall.
HORNS 8G - 1
HORNS
CONTENTS
page page

GENERAL INFORMATION
Following are general descriptions of the major the battery. One side of the horn relay electromag
components in the Ram truck horn system. Refer to netic coil receives battery voltage at all times. When
Group 8W - Wiring Diagrams for complete circuit de a horn switch is depressed, the other side of the relay
scriptions and diagrams. coil is grounded. The energized relay coil causes the
normally open relay contacts to close, providing bat
HORN SWITCH . tery voltage to the horn.
Two horn switches are installed in the steering If a problem is encountered with a continuously
wheel, one on each side of the center-mounted driv sounding horn, it can usually be quickly resolved by
er's airbag module. When either switch is depressed removing the horn relay from the PDC until further
it completes a circuit to ground for the coil side of the diagnosis is completed.
horn relay. The steering wheel and steering column
must be properly grounded for the horn switches to HORN
function. The horn switches are only serviced as a set The single, lo-note, diaphragm-type horn is located
with their wiring. If either switch should fail, both on a bracket behind the left end of the front bumper.
switches must be replaced. It is grounded through its wiring connector and cir
cuit to the horn bracket mounting bolt and receives
HORN RELAY battery feed through the closed contacts of the horn
The horn relay is installed in the Power Distribu relay. The dual horn option adds a hi-note, dia
tion Center (PDC) in the engine compartment near phragm-type horn in the same location.
DIAGNOSIS
WARNING: B E F O R E BEGINNING ANY A I R B A G S Y S (2) Remove the horn relay from the PDC. See Horn
TEM COMPONENT REMOVAL OR INSTALLATION, Relay Connections (Fig. 1) and perform the following
REMOVE AND ISOLATE THE NEGATIVE (-) C A B L E tests:
FROM THE BATTERY. THIS IS THE ONLY S U R E (a) The common feed terminal (30) is connected
WAY TO D I S A B L E THE A I R B A G S Y S T E M . FAILURE to battery voltage and should be hot at all times. If
TO DO THIS COULD R E S U L T IN ACCIDENTAL AIR- battery voltage is not present at relay cavity 30,
B A G DEPLOYMENT AND P O S S I B L E INJURY. WAIT 2 check circuit to fuse B. Repair as required.
MINUTES FOR THE A I R B A G S Y S T E M CAPACITOR (b) The normally closed terminal (87A) is con
TO DISCHARGE B E F O R E REMOVING OR W O R K I N G nected to terminal 30 in the de-energized position,
ON ANY A I R B A G S Y S T E M COMPONENTS. but is not used for this application.
(c) The normally open terminal (87) is connected
to the common feed terminal (30) in the energized
HORN SYSTEM position. This terminal supplies battery voltage to
(1) Inspect fuses B and 1 in PDC. If OK, go to next the horn. There should be continuity between relay
step. If not OK, replace fuses as required. cavity 87 and the horn feed terminal at all times. If
not, repair wiring or connections as required.
8G - 2 HORNS BR
(d) The coil battery terminal (86) is connected to (4) Disconnect wiring at horn terminal. Depress
the electromagnet in the relay, and battery voltage horn switch. There should be battery voltage at the
should be present at all times. If battery voltage is dark green/red wire of the horn wiring connector. If
not present at relay cavity 86, check circuit to fuse OK, go to next step. If not OK, repair circuit to relay
B. Repair as required. as required.
(e) The coil ground terminal (85) is connected to (5) Measure the resistance between the black wire
of the horn wiring connector and a good chassis
the electromagnet in the relay. It is grounded when ground. The meter should read zero ohms. If OK, re
the horn switch is depressed. Check for continuity place faulty horn(s). If not OK, repair circuit to
to ground at relay cavity 85 with the horn switch ground as required.
depressed. If no continuity is found with hom
switch depressed, or if continuity is found with HORN SWITCH
horn switch released, repair horn switch or wiring
as required. See Horn Switch Remove/Install in WARNING: B E F O R E BEGINNING ANY A I R B A G S Y S
this group for service procedures. TEM COMPONENT REMOVAL OR INSTALLATION,
If all relay connections are OK, go to next step. R E M O V E AND ISOLATE THE NEGATIVE (-) C A B L E
FROM THE BATTERY. THIS IS THE ONLY S U R E
RELAY TERMINALS RELAY CAVITIES WAY TO D I S A B L E THE A I R B A G S Y S T E M . FAILURE
87A TO DO THIS COULD R E S U L T IN ACCIDENTAL AIR-
B A G DEPLOYMENT AND P O S S I B L E INJURY. WAIT 2
MINUTES FOR THE A I R B A G S Y S T E M CAPACITOR
TO DISCHARGE B E F O R E REMOVING OR WORKING
ON ANY A I R B A G S Y S T E M COMPONENTS.
(1) Disconnect battery negative cable. Remove

knee blocker. Check for continuity between metal
J958A-2 steering column jacket and a good ground. There
TERMINAL LEGEND should be continuity. If OK, go to next step. If not
NUMBER IDENTIFICATION
30 COMMON FEED
OK, refer to Group 19 - Steering and check for proper
85 COIL GROUND installation of steering column ground clip.
86 COIL BATTERY
87 NORMALLY OPEN
(2) Remove horn relay from fuseblock module. Ac
87A NORMALLY CLOSED cess horn switch wire connector as described in Horn
Switch Remove/Install. Unplug horn wire connector.
Fig. 1 Horn Relay Connections Check for continuity between steering column half of
(3) With the horn relay still removed, check the horn switch wire connector and a good ground. There
should be no continuity. If OK, go to next step. If not
horn relay by performing the following tests: OK, repair short circuit as required.
(a) A relay in the de-energized position should (3) Check for continuity between steering column
have continuity between terminal 87A and termi half of horn switch wire connector and horn relay
nal 30, and no continuity between terminal 87 and cavity 1. There should be continuity. If OK, go to
terminal 30. next step. If not OK, repair open circuit as required.
(b) Resistance value between terminals 85 and (4) Check for continuity between horn switch half
86 (electromagnet) is 75±5 ohms. of horn switch wire connector and a good ground.
(c) Connect a battery to terminals 85 and 86. There should be no continuity. If OK, go to next step.
There should now be continuity between terminal If not OK, replace faulty horn switches.
87 and terminal 30. (5) Depress one horn switch and check for continu
If relay fails any of the above tests, replace faulty ity between horn switch half of horn switch wire con
relay. If relay checks OK, reinstall and go to next nector and a good ground. There should be
continuity. Repeat test for other horn switch. If either
step.
switch is not OK, replace faulty horn switches.
HORNS 8G - 3
SERW1CE PROCEDURES
HORN SWITCH REMOVE/INSTALL (4) Using a small screwdriver remove right rear
steering wheel cover (Fig. 4).
WARNING: B E F O R E BEGINNING ANY A I R B A G S Y S
TEM COMPONENT REMOVAL OR INSTALLATION, RIGHT REAR
STEERING
REMOVE AND ISOLATE THE NEGATIVE (-) C A B L E ! WHEEL COVER
FROM THE BATTERY. THIS IS THE ONLY S U R E
WAY TO D I S A B L E THE A I R B A G S Y S T E M . FAILURE
TO DO THIS COULD R E S U L T IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND P O S S I B L E INJURY. WAIT 2
MINUTES FOR THE A I R B A G S Y S T E M CAPACITOR
TO DISCHARGE B E F O R E REMOVING OR W O R K I N G
ON ANY A I R B A G S Y S T E M COMPONENTS.

(2) From underside of steering wheel, remove speed
control switch or trim bar mounting screws (Fig. 2).
SPEED CONTROL
SWITCHES
J948G-1
Fig. 4 Right Rear Steering Wheel Cover Remove/

Install
(5) Remove 4 nuts attaching airbag module (Fig.
5).
IBf J948H-9
Fig. 2 Speed Control Switch/Trim Bar Remove/install
(3) Pull switch/trim bar from wheel and unplug
connector (Fig. 3).
J948G-2
SPiEP CONTROL
SWITCHES J94SH-8
Fig. 5 Airbag Module Remove/Install
Fig. 3 Speed Control Switch Connector Remove/install (6) Remove airbag module from steering wheel.
8G - 4 HORNS BR
(7) Using a small screwdriver pry horn button

from steering wheel (Fig. 6). There are 2 locking tabs
holding each horn button to steering wheel (Fig. 7).
HQftN
CIRCUIT ^
CONNECTORS J948G-5
Fig. 8 Horn Button Connectors

HORN REiOWE/iNSIlLl
The horn is mounted to a bracket located on the
driver's side bumper support (Fig. 9).
(1) Eaise and support vehicle.
(2) Disconnect horn(s) electrical connector(s).
(3) Remove bolt holding horn bracket to bumper
support and remove horn.
Fig. 6 Horn Button Remove
LOCKING
TABS
Fig. 9 Horn Remove/install

mounting bolt to 28 N-m (20 ft. lbs.).
J948G-4
Fig. 7 Horn Button Locking Tabs

(8) Unplug electrical connectors and remove horn
buttons from steering wheel (Fig. 8).
airbag module mounting nuts to 1.5 N-m (15 in. lbs.).
BR HORNS 8G - 5
HORN RELAY REMOVE/INSTALL

(2) The horn relay is located in the Power Distri
bution Center (PDC)(Fig. 10). Remove PDC cover.
(3) Refer to the label on the underside of PDC
cover for relay location and unplug relay from PDC
cavity.
(4) To install relay, align terminals with cavities in
PDC and push relay firmly into place.
(5) Connect battery negative cable and test relay
operation.
Fig. 10 Power Distribution Center

BR — • WEHICIE SPEED .CONTROL SYSTEM 8H - 1
VEHICLE SPEED CONTROL SYSTEM
CONTENTS
page page
DIAGNOSIS .................... 3 SERWiCE PROCEDURES. . ... 11

GENERAL INFORMATION
The vehicle speed control system (Fig. 1) is an SERVO CABLE

available option on Ram t r u c k models. The system is
The speed control servo cable is connected between
electronically controlled and vacuum operated. Fol
the speed control vacuum servo diaphragm and the
lowing are general descriptions of the major compo
throttle control linkage. This cable causes the throt
nents i n the speed control system. Refer to Group 8W
tle control linkage to open or close the throttle valve
- W i r i n g Diagrams for complete circuit descriptions
i n response to movement of the vacuum servo dia
and diagrams. phragm.
SPEED CONTROL SERVO POWERTRAIN CONTROL MODULE

The speed control servo is mounted to a bracket The speed control electronic control circuitry is i n
under the battery t r a y on the left side of the engine tegrated into the Powertrain Control Module (PCM).
compartment. The servo u n i t consists of a solenoid The P C M is located i n the engine compartment on
valve body, a vacuum servo and the mounting the right side dash panel. The P C M speed control
bracket. The P C M controls the solenoid valve body. functions are monitored by the On-Board Diagnostics
The solenoid valve body controls the application and (OBD). A l l OBD-sensed systems are monitored by the
release of vacuum to the diaphragm of the vacuum P C M . Each monitored circuit is assigned a Diagnos
servo. The servo u n i t cannot be repaired and is ser tic Trouble Code (DTC). The P C M w i l l store a DTC i n
viced only as a complete assembly. electronic memory for any failure i t detects. See Us
ing On-Board Diagnostic System i n this group for
SPEED CONTROL SWITCH more information. The P C M cannot be repaired and
The speed control switch module is mounted to the must be replaced i f faulty.
center of the steering wheel below the driver's airbag
module. The P C M monitors the state of the speed VACUUM RESERVOIR
control switches. The individual switches are labeled: The vacuum reservoir is mounted under the cowl
OFF, ON CRUISE," RESUME/ACCEL, SET/COAST. screen i n the r i g h t side cowl plenum. The reservoir
Refer to the owner's manual for more information on contains a one-way check valve to trap engine vac
speed control switch functions and setting proce u u m i n the reservoir. When engine vacuum drops, as
dures. The individual switches cannot be repaired. I f i n climbing a grade while driving, the reservoir sup
one switch fails, the entire switch module must be re plies the vacuum needed to m a i n t a i n proper speed
placed. control operation. Diesel engine models do not use a
vacuum reservoir. The vacuum reservoir cannot be
STOP LAMP SWITCH repaired and must be replaced i f faulty.
Vehicles w i t h the speed control option use a dual
function stop lamp switch. The switch is mounted i n
VEHICLE SPEED SENSOR
the same location as the conventional stop lamp The Vehicle Speed Sensor (VSS) is a pulse genera
switch, on the brake pedal mounting bracket under tor mounted to an adapter near the transmission
the instrument panel. The P C M monitors the state of (two-wheel drive) or transfer case (four-wheel drive)
the dual function stop lamp switch. Refer to Group 5 output shaft. The sensor is driven through the
adapter by a speedometer pinion gear. The VSS pulse
- Brakes for more information on stop lamp switch
signal to the speedometer/odometer is monitored by
service and adjustment procedures.
the P C M speed control circuitry to determine vehicle
8H - 2 VEHICLE SPEED CONTROL SYSTEM BR
Fig. 1 Vehicle Speed Control System - Typical

speed and to maintain speed control set speed. Refer CONDITIONS DO NOT PERMIT MAINTAINING A
to the Powertrain Diagnostic Procedures manual for CONSTANT S P E E D , SUCH A S IN HEAVY TRAFFIC
testing of this component. Refer to Group 14 - Fuel OR ON ROADS THAT A R E WINDING, ICY, SNOW
System for service of this component. COVERED, OR SLIPPERY.
WARNING: THE U S E O F VEHICLE S P E E D CON
TROL IS NOT RECOMMENDED W H E N DRIVING
BR VEHICLE SPEED CONTROL SYSTEM 8H - 3
DIAGNOSIS
ROAD TEST description can also be read using the DRB scan tool.
Before beginning diagnosis, perform a vehicle road Refer to Group 14 - Fuel Systems for more informa
test to verify reports of speed control system mal tion.
function. The road test should include attention to A DTC does not identify which component in a cir
the speedometer. Speedometer operation should be cuit is bad. Thus, a DTC should be treated as a
smooth and without flutter at all speeds. symptom, not as the cause for the problem. In some
Flutter in the speedometer indicates a problem cases, because of the design of the diagnostic test
which might cause surging in the speed control sys procedure, a DTC can be the reason for another DTC
tem. The cause of any speedometer problems should to be set. Therefore, it is important that the test pro
be corrected before proceeding. Refer to Group 8E - cedures be followed in sequence, to understand what
Instrument Panel and Gauges for speedometer diag caused a DTC to be set.
nosis. See Speed Control Diagnostic Trouble Code chart
for DTC's which apply to the speed control system.
INSPECTION Refer to the Powertrain Diagnostic Procedures man
If a road test verifies a system problem and the ual to diagnose an on-board diagnostic system trou
speedometer operates properly, check for: ble code.
(1) Loose or corroded electrical connections at the
servo. Corrosion should be removed from electrical RETRIEVING DIAGNOSTIC TROUBLE CODES
terminals and a light coating of Mopar Multipurpose To start this function, cycle the ignition switch ON-
Grease, or equivalent, applied. OFF-ON-OFF-ON within 5 seconds. This will cause
(2) Correct installation of the vacuum check valve any DTC stored in the PCM memory to be displayed.
in the hose from servo to vacuum source. The word The malfunction indicator (Check Engine) lamp will
VAC on the valve must point toward the vacuum display a DTC by flashing on and off. There is a
source. short pause between flashes and a longer pause be
(3) Loose or leaking vacuum hoses or connections. tween digits. All DTC's displayed are two-digit num
(4) Secure attachment of both ends of the speed bers, with a four-second pause between codes.
control servo cable. An example of a DTC is as follows:
(1) Lamp on for 2 seconds, then turns off.
C A U T I O N : When test probing for voltage or conti (2) Lamp flashes 1 time pauses and then flashes 5
nuity at electrical connectors, care must be taken times.
not to damage connector, terminals, or seals. If (3) Lamp pauses for 4 seconds, flashes 3 times,
these components are damaged, intermittent or pauses, then flashes 4 times.
complete system failure may occur. The two DTC's are 15 and 34. Any number of
DTC's can be displayed, as long as they are in mem
ory. The lamp will flash until all stored DTC's are
USING ON-BOARD DIAGNOSTIC SYSTEM displayed (55 = end of test).
The Powertrain Control Module (PCM) monitors If a DTC 15 is observed, see diagnosis for Vehicle
critical input and output circuits of the speed control Speed Sensor in this group. If a DTC 34 is observed,
system, making sure they are operational. A Diagnos see diagnosis for Speed Control Servo and Power-
tic Trouble Code (DTC) is assigned to each input and train Control Module in this group. If a DTC 11 is
output circuit monitored by the OBD system. Some observed (diesel engine only), refer to the Powertrain
circuits are checked continuously and some are Diagnostic Procedures manual and perform the test
checked only under certain conditions. for a faulty engine speed sensor. Correct any prob
If the OBD system senses that a monitored circuit lems found in your diagnosis, then recheck for DTC
is bad, it will put a DTC into electronic memory. The after corrections are completed.
DTC will stay in electronic memory as long as the
circuit continues to be bad. The PCM is programmed VEHICLE SPEED SENSOR
to clear the memory after 50 engine starts, if the For diagnosis of the VSS, refer to the Powertrain
problem does not occur again. Diagnostic Procedures manual.
DIAGNOSTIC TROUBLE CODES
Diagnostic Trouble Codes (DTC) are two-digit num
bers flashed on the malfunction indicator (Check En
gine) lamp that identify which circuit is bad. A DTC
SH - 4 VEHICLE SPEED CONTROL SYSTEM — BR
DIAGNOSIS CHART 1 - GAS ENGINE
W A R N I N G : T H E U S E OP TOE S P B D CONTROL
ITIR! ENGINE
is wet R M O M M E N M D W H E N awwfWG
CONDmONS TO NOT M R M I T MAmTAINNfG
a eoMMAm $ p » e mmi m w e a w
T R A F F I C OR ON § » H i « T H A T A K ¥VINDINO.
IC¥ SNOW COWBBO 0 1 S L I P P E R Y .
S SPKD CONTROL
ACCELERATE VEHICLE
ENGAGES WHEN
TO DESIRED SPEED
ENGINE IS STAOTED
PUSH ON BUTTON FAULTY

TO "ON" POSITION. ELECTRICAL CIRCUIT*
DEFECTIVE SERVO
SPEED CONTROL ENGAGES PUSH AND RELEASE
WITHOUT PUSHING THE "SET/COAST" BUTTON
"SET/COAST" BUTTON
±
FAULTY ELECTRICAL CIRCUIT* REMOVE FOOT FROM
:::::.i::z::z ACCELERATOR. SPEED
SHOULD BE CONTROLLED
DEFECTIVE SERVO
i
NO SPEED CONTROL WHEN i
T
HUNTING SURGI OR
l
excessiWiSAG SPem SETTING AFTER
SET/COAST BUTTON IS S P E E ® VARIATIONS O N MfUSOR LOCK-IN, TOO HIGH
PRESSED AND RELEASED AT LOWSPBDS IN TRANJER TOWING OR TOO IOW
-
f
f •
TORQUE CONVERTER ENGINE
FUSE BLOWN CLUTCH VACUUM LEAK
ROUGHNESS PERFmMANCE
f f f
AMPLIFICATION
NO VACUUM AT OF ENGINE VACUUM DEFECTIVE SERVO
SERVO SURGE LEAK
f t
SPEED CONTROL EXCESSIVE LOAD MAY
DEFECTIVE
THROTTLE CABLE DEFECTIVE SEftVO REQUIRE MANUAL
CABLE
DISCONNECTED ASSISTANCE ON HILLS . _. „
V>
DEFECTIVE DEFECTIVE VACUUM

IMPROPER STOP LAMP DEFECTIVE
CABLE RESERVOIR
SWITCH ADJUSTMENT VACUUM RESERVOIR
(CHECK VALVE)
f
DEFECTIVE
FAULTY ELECTRICAL POWERTRAIN
CIRCUIT* CONTROL MODULE
* H S t S A N D A U U S f l ^ l l A K MtCRMD
DEFECTIVE SERVO IN A P P i O P t f A f I SECTION OP MRVICE
MANUAL
DEFECTIVE VACUUM
RESERVOIR
J938H-8
VEHICLE SPEED CONTROL SYSTEM 8H -
DIAGNOSIS CHART 2 - GAS ENGINE
DRIVE VEHICLE OVER

ROUGH ROADS
UNIT DISENGAGES TAP BRAKE PEDAL

O N ROUGH ROADS LIGHTLY, SPEED
CONTROL SHOULD
I DISENGAGE
IMPROPER
ADJUSTMENT OF STOP
1 N O SYSTEM
DISENGAGEMENT
LAMP AND SPEED SPEED CONTROL W H E N itASCE P E D A L
CONTROL SWITCH * DIESENGAGES IS DEPRESSED
I
FAULTY
I
DEFECTIVE OR
IMPROPERLY ADJUSTED
ELECTRICAL STOP LAMP AND
CIRCUIT PUSH RESUME/ACCEL
SWITCH VEHICLE SPEED CONTROL
SHOULD RESUME SWITCH
PREVIOUSLY
I MEMORIZED SPEED
I
ENGINE DOES
N O T RETURN TO
NORMAL IDLE
I SPEED CONTROL
THROTTLE CABLE
KINKED OR DAMAGED
VEHICLE RESUMES
SPEED
i I
FAULTY ELECTRICAL
SPEED CONTROL
THROTTLE CABLE
KINKED OR DAMAGED
I
DEPRESS BRAKE
CIRCUIT*
PEDAL, SPEED
I
i CONTROL DEFECTIVE SERVO
STANDARD THROTTLE SHOULD DISENGAGE
LINKAGE FAULTS
SPEED CONTROL NO SYSTEM

1
RESUME SPEED
DISENGAGES DISENGAGE IS POSSIBLE
WHEN BRAKE PEDAL IS BELOW 20 M.P.H.
DEPRESSED
N O RESUME W H E N
BUTTON IS PRESSED
T T
DEFECTIVE VEHICLE
I DEFECTIVE BRAKE SPEED SENSOR
SWITCH
DEFECTIVE SWITCH
± t
I
FAULTY ELECTRICAL
I
JL.
f
SPEED CONTROL
FAULTY ELECTRICAL
CIRCUIT*
DEFECTIVE
ENGINE CONTROLLER
CIRCUIT* SYSTEM OK
DEFECTIVE POWERTRAIN
CONTROL MODULE J948H-21
8H - i VEHICLE SPEED COITiOL SYSTEM mm
DIAGNOSIS CHART 1 - DIESEL ENGINE
WARMNG: THE USE OF THE SPIED CONTROL

IS NOT RECOMMENDED WHEN DtfVlNG START m&IME
c w D n r m s m NOT permit mabNTAINIIG
A C O N I T M SPEED, SUCH AS H 1 A W
H A R K OR ON ROADS THAT ARE WINDING, SPEED CONTROL
ACCELERATE VEHICLE
ICY, SNOW COVERED OR SUPPEKY. ENGAGES WHEN
TO DESIRED SPEED ENGINE IS STARTED
PUSH ON/CRUISE
FAULTY
BUTTON TO "ON"
POSITION ELECTRICAL CIRCUfr
SPEED CONmOL DEFECTIVE SERVO

ENGAGES WITHOUT PUSH AND RELEASE
PUSHING TO! "SET/DECEL" BUTTON
"SET/DECEL" BUTTON
T
FAULTY ELECTRICAL CIRCUS
I
REMOVE FOOT FROM
ACCELERATOR. SPEED
SHOULD BE CONTROI1ED
DEFECTIVE SERVO
£
NO SPEED CONTROL HUNTING SURGE OR EXCESSIVE SAG SPEED SETTMG AFTER
WHEN SET/DECEL BUTTON SPEED VARIATIONS O N HILLS OR LO€K4N,TOOHK5H
IS PRESSED AND RELEASED AT LOW SPEEDS I N TRAILER TOWING OR TOO LOW
£
TORQUE CONVERTER ENGINE "INSUFFICIENT
FUSE BLOWN
CLUTCH ROUGHNESS PERFORMANCE VACUUM AT SERVO
"INSUFFICIENT AMPLIFICATION OF "INSUFFICIENT

DEFECTIVE SERVO
VACUUM AT SERVO ENGINE SURGE VACUUM AT SERVO
SPEED CONTROL
£ EXCESSIVE LOAD MAY
THROTTLE CABLE DEFECTIVE SERVO REQUIRE MANUAL DEFECTIVE CABLE
DISCONNECTED ASSISTANCE O N HILLS
t
IMPROPER STOP LAMP "REFER TO GROUP 5 - BRAKES
DEFECTIVE CABLE
SWITCH ADJUSTMENT FOR VACUUM PUMP DIAGNOSIS.
FAULTY ELECTRICAL DEFECTIVE

POWERTRAIN
TEST AND ADJUSTMENTS ARE DESCRIBED

DEFECTIVE SERVO IN APPROPRIATE SECTION OF SERVICE
MANUAL
DEFECTIVE ENGINE
SPEED SENSOR
J948H-28
IR VEHICLE SPEED C01TR0L SYSTE1 8H - 7
DIAGNOSIS CHART 2 - DIESEL ENGINE
DRIVE VEHICLE OVER

ROUGH ROAD
TAP BRAKE PEDAL

UNIT DISENGAGES LIGHTLY, SPEED
O N ROUGH ROAD CONTROL SHOULD
DISENGAGE
IMPROPER
ADJUSTMENT OF SPEED CONTROL NO SYSTEM
STOP LAMP SWITCH* DISENGAGES DtSBiGAGlliBfT
WHEN M A K E P D A L
IS!
FAULTY
ELECTRICAL
CIRCUIT
DEFECTIVE OR
IMPtOPERLY ADJUSTED
STOP LAMP SWITCH
PUSH RESUME/ACCEL
SWITCH VEHICLE
SHOULD RESUME
PREVIOUSLY SPEED CONTROL
MEMORIZED SPEED THROTTLE CABLE
ENGINE DOES
NOT RETURN TO KINKED OR DAMAGED
NORMAL IDLE
FAULTY ELECTRICAL
SPEED CONTROL CIRCUIT*
THROTTLE CABLE
KINKED OR DAMAGED
DEPRESS BRAKE
DEFECTIVE SERVO
STANDARD THROTTLE PEDAL, SPEED
LINKAGE FAULTS CONTROL
SHOULD DISENGAGE
SPEED CONTROL NO SYSTEM RESUME S P E ^

N O KSUfllE VfMEN
BUTTON IS PRESSED DISENGAGES DISENGAGE IS POSSIBLE
WHEN BRAKE PEDAL IS M O W 2 0 M.P.H.
DEPRESSED
DEFECTIVE DEFECTIVE VEHICLE

DEFECTIVE SWITCH
POWERTRAIN SPEED SENSOR
CONTROL MODULE
DEFECTIVE
FAULTY ELECTRICAL
POWERTRAIN
CIRCUIT* FAULTY ELECTRICAL
STICKY BRAKE SWITCH J948H-27

8H - 8 VEHICLE SPEED CONTROL SYSTEM BR
SPEED CONTROL DIAGNOSTIC TROUBLE COX
Diagnostic DRB Scon Tool

Trouble Display Description of Diagnostic Trouble Code
Code
IP No Crank Reference No crank reference signal detected during engine cranking.
Signal at PCM
15*V. No Vehicle Speed No vehicle distance (speed) sensor signal detected during road load conditions.
Sensor Signal
34* Speed Control An open or shorted condition detected in the Speed Control vacuum or vent solenoid
Solenoid Circuits circuits.
or
Speed Control Speed Control switch input below the minimum acceptable voltage.
Switch Always Low
or
Speed Control Speed Control switch input above the maximum acceptable voltage.
Switch Always High
55*......... N / A Completion of fault code display on Check Engine lamp.
* Check Engine Lamp will not illuminate at all times if this Diagnostic Trouble Code was recorded. Cycle Ignition key as described
in manualand observe code flashed by Check Engine Lamp.
*'Check Engine Lamp will illuminate during engine operation if this Diagnostic Trouble Code was recorded.
J948H-26
SPEED CONTROL SWITCH CONNECTOR TERMINAL END
WARNING: B E F O R E BEGINNING ANY A I R B A G S Y S

TEM COMPONENT REMOVAL OR INSTALLATION,
R E M O V E AND ISOLATE THE NEGATIVE (-) C A B L E
FROM THE BATTERY, THEN WAIT TWO MINUTES
FOR S Y S T E M CAPACITOR TO D I S C H A R G E B E
F O R E F U R T H E R S Y S T E M S E R V I C E . THIS IS THE
ONLY S U R E WAY TO D I S A B L E THE A I R B A G S Y S
T E M . FAILURE TO DO THIS COULD R E S U L T IN AC
CIDENTAL AIR B A G D E P L O Y M E N T AND P O S S I B L E
INJURY.
(1) Disconnect battery negative cable. Wait 2 min

utes for airbag system capacitor to discharge. Re SWITCH
move speed control switch from steering wheel.
(2) Check speed control switch continuity as shown
in chart (Fig. 2). If OK, reinstall switch. If not OK,
replace switch. © a f f i i i u i w wmwmm
OFF PIN 1 AND PIN 4
STOP LAMP SWITCH PIN 1 AND PIN 4
(1) Remove the stop lamp switch from the mount ON PIN 1 AND PIN 2
ing bracket. Refer to Group 5 - Brakes for procedure. ?y. Fr
(2) Disconnect switch from wiring harness. ON AND SET
(3) Using an ohmmeter, check switch continuity ON AND RESUME p:v : a k d PES: z
(Fig. 3) as follows: J948H-30
(a) With switch plunger released, there should be
continuity between pin 5 and pin 6. Fig. 2 Speed Control Switch Continuity
(b) With switch plunger depressed, there should
be continuity between pin 1 and pin 2. (4) If the switch fails the above continuity tests, it
(c) With switch plunger still depressed, there is faulty and must be replaced. If switch is OK, rein-
should be continuity between pin 3 and pin 4.
BR VEHICLE SPEED CONTROL SYSTEM 8H - 9
stall and check adjustment. Refer to Group 5

Brakes for installation and adjustment procedures.
PULL RUNGER
INDEX KEY 948H-6
Fig. 3 Stop Lamp Switch
VACUUM SUPPLY TEST

(1) Disconnect vacuum hose at the servo and in
stall a vacuum gauge in the hose.
(2) Start engine and observe gauge at idle. Vacuum
gauge should read at least ten inches of mercury. " SERVO BRACKET
(3) If vacuum does not meet this requirement, SCREWS (3)
check for vacuum leaks or poor engine performance. J948H-5
For diesel engine models, refer to Group 5 - Brakes
Fig. 4 Speed Control Servo
for vacuum pump diagnosis.
SPEED CONTROL SERVO
(1) Check fuse 10 in fuseblock module. If OK, go to PIN 3 PIN 2
next step. If not OK, replace fuse.
(2) Turn ignition switch to the ON position. Check
for battery voltage at fuse 10, If OK, go to next step.
PIN 4 PIN 1
If not OK, repair open circuit to ignition switch as re
quired.
(3) Connect the negative lead of a voltmeter to a
good chassis ground near the servo. Unplug the
4-way connector going to the servo (Fig. 4). Push the
speed control switch to the ON position. Check for CONNECTOR SHOWN
FROM TERMINAL END
battery voltage at servo harness connector cavity for
pin 2 (Fig. 5). If OK, go to next step. If not OK, see
diagnosis for Stop Lamp Switch.
(4) Connect a jumper wire between servo harness PIN 1 PIN 4
connector cavity for pin 2 and pin 2 of the servo. PIN 2 PIN 3
898H-5
Check for battery voltage at pins 1, 3 and 4 of the
servo. If OK, go to next step. If not OK, replace the Fig. 5 Servo Harness Connector
servo.
(5) Turn ignition switch to OFF position. Check for POWERTRAIN CONTROL MODULE
continuity between servo harness connector cavity for (1) Disconnect 60-way connector from the PCM, lo
pin 1 and a good ground. There should be continuity. cated on the right dash panel in the engine compart
If not OK, repair open circuit to ground as required. ment (Fig. 6).
(2) Connect negative lead of voltmeter to a good
body ground near the module.
8H-10 VEHICLE SPEED CONTROL SYSTEM BR
meter should read zero volts with the switch in the

OFF position, and battery voltage with the switch in
the ON position.
(5) Touch the positive lead of the voltmeter to the
terminal in cavity number 48. With the speed control
switch in the OFF position, the voltmeter should
read zero volts. With the switch in the ON position,
the voltmeter should read battery voltage. Pressing
the SET/COAST button should cause the voltmeter to
change from battery voltage to zero volts for as long
as the switch is held. If not, perform the Speed Con
trol Switch Test. If the switch is not at fault, then
check the main harness and repair as necessary.
(6) Touch the positive lead of the voltmeter to the
POWERTRAIN CONTROL
terminal in cavity number 50. The voltmeter should
MODULE (PCM) J9414-11 read zero volts with the speed control switch in ei
Fig. & Powertrain Control Module ther the OFF or ON position. With switch in either
RESUME or SET position, the voltmeter should read
(3) For the following tests, the ignition switch battery voltage. If not, perform the Speed Control
must be in the ON position. See Fig. 7 for controller Switch Test. If the switch is not at fault, then check
terminal locations. Touch the positive lead of the the main harness and repair as necessary.
voltmeter to the terminal in cavity number 33. With (7) Touch the positive lead of the voltmeter to the
the speed control switch in the OFF position, the terminal in cavity number 49. The voltmeter should
voltmeter should read zero volts. With the speed con read zero volts with the switch in the OFF position.
trol switch in the ON position, the voltmeter should With the switch in the ON position, the voltmeter
read battery voltage. If not, repair the main harness should read battery voltage. The voltmeter will con
as necessary. tinue to read battery voltage when either the SET or
RESUME switch is pressed. If not, perform the
Speed Control Switch Test. If the switch is not at
fault, then check the main harness and repair as nec
essary.
(8) Turn ignition switch OFF. Using an ohmmeter,
connect one lead to a good body ground and touch the
other lead to the terminal in cavity number 29. With
the brake pedal released, the meter should show con
tinuity. When the pedal is depressed, the meter
should show an open circuit.
Fig. 7 PCM 60-Way Connector - Terminal End
(9) The diesel engine PCM requires a signal from
(4) Touch the positive lead of the voltmeter to the the engine speed sensor to cavity number 24. To di
terminal in cavity number 53. As in step (3), the volt agnosis the engine speed sensor, refer to the Power-
train Diagnostic Procedures manual.
HR VEHICLE SPEED CONTROL SYSTEM 8H - 11
SERVICE PROCEDURES
SPEED CONTROL SERVO REMOVE/INSTALL V-IO AND DIESEL ENGINE

(1) Disconnect both battery cables, negative cable
V-0 AND V-8 ENGINE first.
(1) Disconnect vacuum hose at servo (Fig. 8). (2) Remove 2 bolts and battery holddown (Fig. 9).
(2) Disconnect electrical connector at servo.
Fig. 9 Battery Holddown

(3) If equipped, pull up on battery heat shield to
remove it (Fig. 10).
Fig. 8 Servo Mounting

(3) Remove 2 nuts from cable sleeve.
(4) Pull speed control cable away from servo to ex
pose cable hairpin clip.
(5) Remove hairpin clip attaching cable to servo.
(6) Pull servo away from mounting bracket.
(7) To install, insert servo studs through holes in
servo mounting bracket.
(8) With throttle blocked to full open position,
align hole in cable sleeve with hole in servo pin and
install hairpin clip.
(9) Insert servo studs through holes in cable
sleeve. Fig. 10 Battery Heat Shield
(10) Install 2 attaching nuts and tighten to 6 N-m (4) Remove battery from vehicle.
(50 in. lbs.). (5) From under left front wheel opening remove 2
(11) Connect vacuum hose to servo. forward battery tray nuts (Fig. 11).
(12) Connect electrical connector to servo termi (6) Remove 2 nuts and 2 bolts holding battery tray
nals. to vehicle (Fig. 12).
(7) Lift battery tray up far enough for access to
speed control servo electrical connector (Fig. 13).
8H -12 VEHICLE SPEED CONTROL SYSTEM BR
Fig. 14 Servo Cable Hairpin Clip

Fig. 12 Battery Tray Mounting (15) Insert servo studs through holes in cable
(8) Unplug electrical connector. sleeve.
(9) Remove 2 nuts from cable sleeve. (16) Install 2 attaching nuts and tighten to 6 N-m
(10) Pull speed control cable away from servo to (50 in. lbs.).
expose cable hairpin clip (Fig. 14). (17) Connect vacuum hose to servo.
(11) Remove hairpin clip attaching cable to servo. (18) Connect electrical connector to servo termi
(12) Pull servo away from mounting bracket. nals.
(13) To install, insert servo studs through holes in (19) Install battery tray. Tighten all battery tray
servo mounting bracket. mounting hardware to 16 N-m (140 in. lbs.).
(14) With throttle blocked to full open position, (20) Install battery in vehicle making sure that
align hole in cable sleeve with hole in servo pin and battery is properly positioned on battery tray.
install hairpin clip. (21) If equipped, install battery heat shield.
VEHICLE SPEED CONTROL SYSTEM 8H -13
SPEED CONTROL
SWITCHES
S P B D CONTROL
J948H-9 SWITCHES J948H-8
REMOVE 2 SCREWS j
Fig. 15 Speed Control Switch Remove/install Fig. 16 Switch Connector Remove/lnstail
(22) Install battery holddown clamp, making sure (1) Disconnect battery negative cable.
that it is properly positioned on battery. Tighten bolt (2) From underside of steering wheel, remove
to 4 N-m (35 in. lbs.). speed control switch mounting screws (Fig. 15).
(3) Pull switches from wheel and unplug connector
SPEED CONTROL SWITCH REMOVE/INSTALL (Fig. 16).
(4) Plug electrical connector into new switches.
WARNING: B E F O R E BEGINNING ANY A I R B A G S Y S (5) Install new switches with 2 screws.
TEM COMPONENT REMOVAL OR INSTALLATION,
REMOVE AND ISOLATE THE NEGATIVE (-) C A B L E SERVO CABLE REMOVE/INSTALL
FROM THE BATTERY. THEN WAIT TWO MINUTES (1) Remove air cleaner (except V-10 and diesel en
FOR S Y S T E M CAPACITOR TO DISCHARGE B E gine).
FORE FURTHER S Y S T E M S E R V I C E . THIS IS THE (2) Using finger pressure only, remove speed con
ONLY S U R E WAY TO DISABLE THE A I R B A G S Y S trol cable connector at bellcrank by pushing connec
TEM. FAILURE TO DO THIS COULD RESULT IN AC tor off the bellcrank (Fig. 17, 18 or 19). DO NOT try
CIDENTAL AIR B A G DEPLOYMENT AND P O S S I B L E to pull connector off perpendicular to the bellcrank.
INJURY.
SPEED CONTROL
SERVO CABLE
J948H-11
Fig. 17 Servo Cable - V-6/V-8 Engine

8H -14 VEHICLE SPEED CONTROL SYSTEM BR
(3) Squeeze tabs on speed control cable and push (5) Reverse removal procedures to install,
out of locking plate. ~~~~~ ~~
(4) Remove servo cable from servo as described in
Speed Control Servo Remove/Install.
Fig. 18 Servo Cable - V-10 Engine
Fig. 19 Servo Cable - Diesel Engine

— — VEHICLE SPEED CONTROL SYSTEM 8H -15
VACUUM RESERVOIR REMOVE/INSTALL

(1) Lift wiper arm to permit the latch (Fig. 20) to
be pulled out to the holding position. Remove arms
from pivots using a rocking motion.
CAUTION: The use of a screwdriver or other prying
tool to remove a wiper arm may distort it. This dis
tortion could allow the arm to come off the pivot
shaft, regardless of how carefully it is installed.
Fig. 20 Removing Wiper Arms

Fig. 22 Plastic Anchor Screws
(2) Remove weatherstrip along front edge of cowl
screen (Fig. 21).
Fig. 21 Cowl Screen Weatherstrip

(3) Release plastic anchor screws (Fig. 22).
(4) Move cowl screen aside far enough to access
Fig. 23 Vacuum Reservoir
reservoir in right cowl plenum area.
(5) Remove 2 push nuts and slide vacuum reser (7) Reverse removal procedures to install. Refer to
voir off studs (Fig. 23). Group 8K - Wiper and Washer Systems for correct in
(6) Disconnect all hoses. dexing of wiper arms.
BR — TURN SIGNAL AND HAZARD WARNING SYSTEMS 8J - 1
TURN SIGNAL AND HAZARD WARNING SYSTEMS
CONTENTS
page page

GENERAL INFORMATION
Following are general descriptions of the major The standard flasher is designed to handle the cur
components in the Ram truck turn signal and hazard rent flow requirements of the factory installed light
warning systems. Refer to Group 8W - Wiring Dia ing. If supplemental lighting is added to the turn
grams for complete circuit descriptions and diagrams. signal circuits such as when towing a trailer with
lights, the current flow through the flasher increases.
TURN SIGNAL SYSTEM This causes the flash rate to increase. It is recom
With the ignition switch in the ON or ACCESSORY mended that the standard flasher be replaced with a
position and the multi-function switch control lever heavy-duty (hazard warning) flasher when supple
moved up (right turn) or down (left turn), the turn mental lighting is added.
signal system is activated. However, when a turn signal bulb fails with a stan
dard flasher, the remaining bulbs in that circuit will
When the turn signal system is activated, the se
light, but not flash. This will give the driver an indi
lected (right or left) turn signal indicator lamp, front cation to check the turn signal bulbs. Because a
park/turn signal lamp and rear tail/stop/turn signal heavy-duty flasher has different internal circuitry, a
lamp bulb filaments will flash. failed bulb will not prevent the remaining bulbs in
the circuit from flashing. Therefore, it is recom
HAZARD WARNING SYSTEM mended that an occasional visual inspection of exte
The hazard warning is activated by a switch button rior turn signal lamp operation be performed when a
located on the top of the steering column between the heavy-duty flasher is installed.
steering wheel and the instrument panel. The hazard
warning flasher receives battery feed at all times,
and the system is functional regardless of ignition
switch position. The hazard warning switch button is
identified with a double triangle. Push the switch
button in to activate the hazard warning system, and
push in on the button again to turn the system off. BUZZER
MODULE*"
When the hazard warning system is activated, all
(right and left) turn signal indicator, front park/turn
signal lamp and rear tail/stop/turn signal lamp bulb
filaments will flash.
TURN SIGNAL FLASHER
The turn signal flasher is located in the fuseblock
module (Fig. 1). It contains one fixed contact point
and one contact point attached to a flexible bimetal
arm. The contact points are normally closed. When a
turn signal is activated, current flows through- the Fig, 1 Turn Signal and Hazard Warning Flashers
flasher. As the current flows through the bimetal arm HAZARD WARNING FLASHER
it heats and flexes to pull the contact points open, The hazard warning flasher is located in the fuse-
stopping current flow. As the bimetal arm cools it block module (Fig. 1). The hazard warning flasher
straightens, until the contact points close and the cy contains two normally open contact points mounted
cle repeats. to two flexible arms. A bimetal strip is attached be-
iJ - 2 TURN SIGNAL AND HAZARD WARNING SYSTEMS BR
tween the two arms. When the hazard warning is ac HAZARD WARNING
tivated, current flows through the flasher. As the
current flows through the bimetal strip it heats and
pulls the flexible arms together until the contact
points close, allowing current flow to the lamps. As
the bimetal strip cools, the contact points are pushed
open and the cycle repeats.
MULTIFUNCTION SWITCH
The multi-function switch assembly (Fig. 2) is
mounted to the left side of the steering column. This
switch contains electrical circuitry for the following
functions:
• turn signals
• hazard warning J938J-3
• headlamp beam selection
• headlamp optical horn Fig. 2 Multi-Function Switch
• windshield wipers
give the driver a visual indication that a turn signal
® windshield washers.
The information contained in this group addresses or the hazard warning circuit is operating. For diag
only the switch functions for the turn signal and haz nosis and service of this component, refer to Group
ard warning circuits. For information relative to 8E - Instrument Panel and Gauges.
other switch functions, refer to the appropriate
TURN SIGNAL LAMPS
group. However, the multi-function switch can not be
repaired. If any function of the switch is faulty, the The exterior lamps included in the turn signal and
entire switch assembly must be replaced. hazard warning circuits include: the front park/turn
TURN SIGNAL INDICATOR LAMPS signal, and the rear tail/stop/turn signal. For diagno
These lamps are located in the instrument cluster. sis and service of these lamps, refer to Group 8L -
They flash with the exterior turn signal lamps to Lamps.
DIAGNOSIS
When diagnosing the turn signal or hazard warn cuits to that lamp, as required. Test operation. If
ing circuits, remember that high generator output turn indicator does not light or still doesn't flash,
can burn out bulbs rapidly and repeatedly. If this is a continue to next step.
problem on the vehicle being diagnosed, refer to (2) Remove and inspect fuse 6 in fuseblock module.
Group 8A - Battery/Starting/Charging Systems Diag Replace fuse, if required.
nostics to test charging system. (3) With ignition switch in ON position, check for
battery voltage at fuse 6. If OK, go to next step. If
WARNING; ON V E H I C L E S E Q U I P P E D WITH AN AIR- not OK, repair circuit to ignition switch as required.
B A G , R E F E R TO G R O U P 8M - RESTRAINT S Y S (4) With ignition switch in ON position, place turn
T E M S B E F O R E ATTEMPTING S T E E R I N G W H E E L signal lever in neutral position. There should be bat
COMPONENT DIAGNOSIS OR S E R V I C E . FAILURE tery voltage at the fuse side of the turn signal flasher
TO TAKE P R O P E R PRECAUTIONS COULD R E S U L T (L5 circuit). If OK, go to next step. If not OK, repair
IN ACCIDENTAL A I R B A G DEPLOYMENT AND P O S circuit between fuse and turn signal flasher.
S I B L E P E R S O N A L INJURY. (5) Replace turn flasher with known good unit of
the same rating. The lamps should flash. If OK, dis
card faulty flasher. If not OK, re-install original
TURN SIGNAL flasher and go to next step. ' -*
(1) Turn ignition switch to ON position. Move turn (6) Locate the multi-function switch connector. See
signal lever down for left turn signal problem, or up diagnosis for Multi-Function Switch, in this group.
for right turn signal problem. Observe the turn indi Check for battery voltage at the multi-function
cator lamp in the instrument cluster. If the lamp switch connector cavity 17. If OK, replace multi-func
comes on but does not flash, check for a turn signal tion switch. If not OK, repair open circuit to flasher
bulb that is not lit. Replace that bulb or repair cir (L6 circuit).
BR TURN SIGNAL AND HAZARD WARNING SYSTEMS 8J - 3
VIEW FROM TERMINAL CASE
SWITCH POSITIONS
TURN SIGNAL HAZARD WARNING CONTINUITY BETWEEN
NEUTRAL OFF 12 AND 14 AND 15
LEFT OFF 15 AND 16 AND 17
LEFT OFF 12 AND 14
LEFT OFF 22 AND 23 WITH OPTIONAL CORNER LAMPS
RIGHT OFF 11 AND 12 AND 17
RIGHT OFF 14 AND 15
RIGHT OFF 23 AND 24 WITH OPTIONAL CORNER LAMPS
NEUTRAL ON 11 AND 12 AND 13 AND 15 AND 16
908J-4
Fig. 3 Multi-Functi Switch Continuity

HAZARD WARNING Check for battery voltage at the multi-function
(1) Check fuse C in power distribution center. If switch connector cavity 13. If OK, replace multi-func
OK, go to next step. If not OK, replace fuse. tion switch. If not OK, repair open circuit to flasher
(2) Check for battery voltage at the fuse side of the (L19 circuit).
hazard warning flasher (L9 circuit). If OK, go to next
step. If not OK, repair open circuit between fuse and MULTI-FUNCTION SWITCH
flasher. (1) Access multi-function switch connector and re
(3) Replace hazard flasher with known good unit of move. See service procedures for Multi-Function
the same rating. The lamps should flash. If OK, dis Switch, in this group.
card faulty flasher. If not OK, re-install original (2) Using an ohmmeter, perform switch continuity
flasher and go to next step. checks at the switch terminals as shown in the chart
(4) Locate the multi-function switch connector. See (Fig. 3).
diagnosis for Multi-Function Switch, in this group.
8J - 4 TURN SIGNAL AND HAZARD WARNING SYSTEMS BR
SERVICE PROCEDURES
WARNING: ON V E H I C L E S E Q U I P P E D WITH AN AIR- UPPER

B A G , R E F E R TO G R O U P 8M - RESTRAINT S Y S SHROUD
T E M S B E F O R E ATTEMPTING S T E E R I N G W H E E L
COMPONENT DIAGNOSIS OR S E R V I C E . FAILURE
TO TAKE P R O P E R PRECAUTIONS COULD R E S U L T
IN ACCIDENTAL A I R B A G DEPLOYMENT AND P O S
S I B L E P E R S O N A L INJURY.
MULTI-FUNCTION SWITCH REMOVE/INSTALL

(2) If equipped, remove tilt column lever.
(3) Remove both upper and lower shrouds from col
umn (Fig. 4).
(4) Remove multi-function switch tamper proof
mounting screws (tamper proof torx bit Snap On
TTXR20B2 or equivalent required).
(5) Gently pull switch away from column. Loosen
connector screw. The screw will remain in the con
nector. LOWER
(6) Remove wiring connector from multi-function SHROUD J9419-17
switch (Fig. 5).
(7) Reverse removal procedures to install. Tighten Fig. 4 Steering Column Shrouds Remove/Install
fasteners as follows:
• multi-function switch connector screw - 1.9 N-m
(17 in. lbs.)
© multi-function switch retaining screws - 1.9 N-m
(17 in. lbs.).
J918J-1 CONNECTOR
Fig. 5 Multi-Function Switch Connector

WIPER AND WASHER SYSTEMS 8K - 1
WIPER AND WASHER SYSTEMS
CONTEKTS
page page

GENERAL INFORMATION
Following are general descriptions of the major cloth and a mild detergent or non-abrasive cleaner. If
components in the Ram truck wiper and washer sys the squeegees continue to streak or smear, they
tems. Refer to Group 8W - Wiring Diagrams for com should be replaced.
plete circuit descriptions and diagrams. The blades are mounted to two spring-loaded wiper
arms. Spring tension of the wiper arms controls the
WINDSHIELD WIPER SYSTEM pressure applied to the blades on the windshield. The
An intermittent wiper system is standard equip wiper arms are attached by an integral latch to the
ment on all Ram truck models. This system allows two wiper pivots that protrude through the cowl
the driver to select from two wiper speeds or an in grille panel at the base of the windshield. The wiper
termittent wipe feature that allows a delay between arms and blades can not be adjusted or repaired. If
wipes of 2 to 15 seconds. Refer to the owner's manual faulty, they must be replaced.
for more information on wiper system controls and
operation. WIPER LINKAGE AND PIWOTS
The wipers will operate only when the ignition The wiper linkage, pivots, and motor are installed
switch is in the ACCESSORY or ON position. Fuse 8 and removed from the vehicle as a unit. These com
in the fuseblock module protects the circuitry of the ponents are all mounted to a bracket, which is bolted
wiper system. to another bracket in the cowl plenum area beneath
the cowl plenum screen. The linkage, pivots, and
WINDSHIELD WASHER SYSTEM bracket are serviced only as an assembly. The wiper
motor is available as a separate service item.
A electrically-operated windshield washer system is
standard equipment on all Ram truck models. The WIPER MOTOR
washers will operate only when the ignition switch is The two-speed permanent magnet wiper motor has
in the ACCESSORY or ON position. Fuse 8 in the an integral transmission and park switch. The motor
fuseblock module protects the circuitry of the washer is mounted to the wiper linkage module with 3
system. Refer to the owner's manual for more infor screws and a nut that secures the crank arm to the
mation on washer system controls and operation. motor output shaft.
Wiper speed is controlled by current flow to the ap
WIPER ARMS, BLADEBg AMD ELEMENTS propriate set of brushes. The wiper motor completes
All Ram truck models have two 20-inch wiper its wipe cycle when the switch is turned OFF, and
blades with replaceable rubber elements (squeegees). parks the blades in the lowest portion of the wipe
Caution should be exercised to protect the rubber pattern. The wiper motor assembly can not be re
squeegees from any petroleum-based cleaners or con paired. If faulty, the entire motor assembly must be
taminants, which will rapidly deteriorate the squee replaced. The crank arm, mounting bracket, pivots
gee rubber. If squeegees are damaged, worn or and other linkage are serviced only as an assembly.
contaminated they must be replaced.
Wiper squeegees exposed to the weather for a long WIPER/WASHER SWITCH
time tend to lose their wiping effectiveness. Periodic Controls for the windshield wiper and washer sys
cleaning of the squeegees is suggested to remove de tems are contained in the multi-function switch con
posits of salt and road film. The wiper blades, arms trol lever. The multi-function switch is mounted on
and windshield should be cleaned with a sponge or the left side of the steering column between the
steering wheel and the instrument panel. This switch
8K - 2 WIPER AND WASHER SYSTEMS — — mm
also controls many other functions. The multi-func the nozzles through hoses clipped to the underside of
tion switch can not be repaired. If any function of the the cowl grille panel. The nozzles can not be repaired
switch is faulty, the entire switch must be replaced. and, if faulty, should be replaced.
INTERMITTENT W I P E MODULE WASHER RESERVOIR
In addition to low and high speed, the intermittent The washer solvent reservoir is mounted to the left
wipe system has a delay mode. The delay mode has a side of the radiator fan shroud in the engine com
range of 2 to 15 seconds. The length of the delay is partment. It has a provision for a low washer fluid
selected with a variable resistor in the wiper switch level sensor. Refer to Group 8E - Instrument Panel
and is accomplished by electronic circuitry within the and Gauges for diagnosis and service of the sensor.
intermittent wipe module. If the washer knob is de The reservoir and filler cap are available for service.
pressed while the wiper switch is in the OFF posi
tion, the intermittent wipe module will operate the WASHER PUMP
wiper motor for approximately 2 wipes and automat The washer pump and motor are press-fit into a
ically turn the motor off. The intermittent wipe mod rubber grommet near the bottom of the washer res
ule is mounted to the lower instrument panel support ervoir. A permanently lubricated and sealed motor is
bracket, behind the knee blocker. The module can not
coupled to a rotor-type pump. Washer fluid is gravity
be repaired.
fed from the reservoir to the pump. The pump then
WASHER NOZZLES pressurizes the fluid and forces it through the plumb
The two fluidic washer nozzles are snap-fit into ing to the nozzles when the motor is energized. The
openings in the cowl grille panel below the wind pump and motor can not be repaired. If faulty, the
shield and are not adjustable. Washer fluid is fed to entire assembly must be replaced.
DIAGNOSIS
WIPER WIOTOB (2) Check motor operation in all wiper/washer

The following are wiper motor system problems, switch positions. If not OK and fuse blows, go to step
tests to be performed to locate the faulty part, and 5. If not OK and fuse is OK, go to next step.
the proper action to be taken. If the malfunction in (3) Place wiper/washer switch in LOW position and
volves only the delay mode, switch, or wiring, see the listen to motor. If you cannot hear it running, go to
diagnosis for Intermittent Wipe Module and Multi- next step. If motor is running, check motor output
Function Switch. shaft. If output shaft is not turning, replace motor
assembly. If it is turning, drive link to output shaft
or linkage is not properly connected. Replace worn
Motor will not run in any wiper/washer parts and/or properly connect drive link to the motor
switch position. output shaft.
PROCEDURE
(1) Check fuse 8 in the fuseblock module. If OK, go
to step 3. If not OK, replace fuse and go to next step.
BH WIPER AND WASHER SYSTEMS 8K - 3
WIPER/WASHER DIAGNOSIS
MOTOR WILL NOT RUN 1. Fuse faulty. 1. Check wiper fuse in fuseblock module.
Replace fuses, if required.
2. Switch faulty. 2. See diagnosis for Multi-Function Switch, in this
group. Replace, if required.
3. Wiring faulty. 3. See diagnosis for Wiper Motor, in this group.
Check wiring for continuity between motor and
switch. Repair, if required.
4. Ground faulty. 4. Check for continuity between wiper motor and
a known good ground. There should be
continuity. Repair motor ground, if required.
5. Motor faulty. 5. Replace motor, if required.
MOTOR RUNS — 1. Loose motor crank. 1. Tighten crank nut, if required.

BLADES DO NOT MOVE 2. Faulty linkage connection. 2. Re-install or replace linkage/bushings, if
required.
3. Faulty pivots. 3. Replace pivots, if required.
4. Faulty motor transmission. 4. Replace motor, if required.
BLADES DO NOT PARK 1. Blades improperly installed. 1. Re-install blades to specification, if required.
PROPERLY 2. Replace damaged or worn linkage/bushings, if
2. Faulty linkage. required.
3. Check wiring for continuity between motor and
3. Wiring faulty. switch. Repair wiring, if required.
4. See diagnosis for Multi-Function Switch, in this
4. Switch faulty. group. Replace, if required.
5. See diagnosis for Wiper Motor, in this group.
5. Motor faulty. Replace motor, if required.
W I P E R KNOCK NOISE 1. Blades improperly installed. 1. Re-install blades to specification, if required.

2. Faulty linkage. 2. Replace damaged or worn linkage/bushings, if
required.
3. Faulty motor. 3. Replace worn motor, if required.
BLADES CHATTER 1. Contaminated glass or blades. 1. Clean glass thoroughly and replace blade
2. Faulty wiper arm. elements, if required.
3. Faulty blade. 2. Twisted arm holds blade at wrong angle to
glass. Replace arm, if required.
3. Replace bent or damaged blade, if required.
W A S H E R S DO NOT 1. No fluid in reservoir. 1. Fill reservoir, if required.

OPERATE 2. Clear obstructed nozzle(s) and flush washer
2. Plugged nozzles. system, if required.
3. Re-route pinched hoses or replace leaking
3. Pinched or leaking plumbing. hoses and fittings, if required.
4. Check wiring for continuity between pump and
4. Faulty wiring. switch. Repair wiring, if required.
5. See diagnosis for Multi-Function Switch, in this
5. Switch faulty. group. Replace switch, if required.
6. Replace pump/motor, if required.
6. Pump/motor faulty.
J958K-1
8K - 4 WIPER AND WASHER SYSTEMS _
(4) Connect a voltmeter between motor terminal L

and ground strap (Fig. 1). If there is little or no volt
age (less than 1 volt), move negative test lead from
the ground strap to battery negative terminal. If an
increase in voltage is noticed, the problem is a bad
ground circuit. Make sure the motor mounting is free
of paint and that mounting fasteners are tight. If
there is still no indication of voltage, the problem is
an open in wiring or faulty wiper/washer switch. If a
small increase (greater than 3 volts) in voltage is ob
served, the problem is a faulty motor assembly.
VOLTMETER WIPER
Fig. 2 Ammeter Between Terminal L and Battery

(4) Set wiper/washer switch to HIGH position.
Move voltmeter (test lamp) lead from terminal H to
terminal L of the wiring harness. If voltage is
present, there is a short in the wiring or wiper/
washer switch.
CONDITION
Motor will run at high speed, but not at low
speed.
Motor will run at low speedy but not at high speed.
PROCEDURE
Fig. 1 Voltmeter Between Terminal L and Ground (1) If motor will not run on high speed, put wiper/
washer switch in HIGH position. Connect a test lamp
(5) Disconnect motor wiring connector and replace between motor terminal H and ground (Fig. 3). If mo
fuse. If fuse does not blow, motor is defective. If fuse tor will not run on low speed, put wiper/washer
blows, wiper/washer switch or wiring is at fault. switch in LOW position. Connect a test lamp between
motor terminal L and ground.
CONDITION
T E S T
Motor r u n s slowly at all speeds. TERMINAL
PROCEDURE
(1) Disconnect wiring harness connector at motor.
Remove wiper arms and blades. Connect an ammeter
between battery and terminal L on motor (Fig. 2). If
motor runs and average ammeter reading is more
than 6 amps, continue to next step. If motor runs
and average ammeter reading is less than 6 amps, go
to step 3.
(2) Check wiper linkage or pivots for binding or ob
struction. Disconnect drive link from motor. If motor
now runs and draws less than 3 amps, repair linkage
system. If motor continues to draw more than 3
amps, replace motor assembly. Fig. 3 Test Lamp Between Terminal H and Ground
(3) Check motor wiring harness for short between (2) If test lamp does not light at motor terminal,
high and low speed circuits. Connect a voltmeter or there is an open in wiring or wiper/washer switch. If
test lamp to motor ground strap. Set wiper/washer test lamp lights at motor terminal, replace motor as
switch to LOW position. Connect other lead of volt sembly.
meter (test lamp) to terminal H of the wiring har
ness. If voltage is present, there is a short in the CONDITION
wiring or wiper/washer switch. If no voltage is Motor will keep running with wiper/washer
present, go to next step. switch in OFF position.
BR - ^— WiPEi AND WASHEI SYSTEiS 81 - 1
OHAAMETER TERMINALS
(1) Disconnect wiring harness connector at motor.
Connect jumper from terminal P2 to terminal L of
wiper motor (Fig. 4).
_ TERMINALS
Fig. 5 Ohmmeter Between Terminal L and P2
J948K-26
I 17 16 15 1 4 / ^ \ 1 3 12 11 10 I
Fig. 4 One Jumper Wire Between Terminal P2 and L.
One Jumper Wire Between Terminal P1 and B+. 9 8 7 6 ^5^4 3 2 1 J
fcri o ezi e n a era a a czs a r s I
(2) Connect second jumper from terminal PI to
battery. If motor runs to park position and stops, MULTIFUNCTION SWITCH P I N S
wiper/washer switch is faulty. If motor keeps running SWITCH CONTINUITY
POSITION SETWEEN
and does not park, replace motor assembly.
OFF PIN 6 AND PIN 7
CONDITION PIN 8 AND PIN 9
PIN 2 AND PIN 4
Motor will stop wherever it is, when wiper/ DELAY PIN 1 AND PIN 2
washer switch is put in OFF position. (Wipers PIN 1 AND PIN 4
do not continue running to park position.) LOW PIN 4 AND PIN 6
HIGH P! v; 4 AND PIN 5
B
PROCEDURE WASH PIN 3 AND PIN 4

(1) Remove motor wiring connector and clean ter * RESISTANCE AT AAAXIMUM D E L A Y P O S I T I O N SHOULD BE
minals. Reconnect connector and test motor. If not BETWEEN 270,000 OHMS A N D 330,000 OHMS.
OK, go to step 2. •RESISTANCE A T MINIMUM DELAY POSITION SHOULD BE
Z E R O WT7H OHAAMETER SET ON HIGH OHM SCALE.
(2) Put wiper/washer switch in OFF position. Dis
connect motor wiring connector. Connect a voltmeter 918J-4
or test lamp to the motor ground strap. Connect the Fig. 6 Multi-Function Switch Continuity
other lead to terminal PI of wiring connector. If volt
age is not present, check for an open circuit in the INTERMITTENT WIPE MODULE
wiring harness or wiper/washer switch. If voltage is See Wiper Motor or Multi-Function Switch for di
present, go to next step. agnosis of system problems which do not involve the
(3) Connect an ohmmeter or continuity tester be DELAY function. If problem occurs only in the DE
tween terminals L and P2 (Fig. 5). If there is conti LAY mode, the following tests are to be performed.
nuity between these terminals, the problem is a These tests involve disconnecting the intermittent
defective motor. If there is no continuity, the problem wipe module, which can be found on a bracket lo
is an open in wiring or a faulty wiper/washer switch. cated behind the knee blocker (Fig. 7).
/IULTI-FUNCTION SWITCH CONDITION
Use an ohmmeter to test for continuity (no resis Excessive delay (more than 30 seconds) or in
tance) between the terminals of the switch as shown adequate variation in delay.
in the Multi-Function Switch Continuity chart (Fig. PROCEDURE
6). Variations in delay should be as follows:
...^ - ~ .•• •
81 - 1 WIPER AND WASHER SYSTEMS
PROCEDURE
Replace the intermittent wipe module.
CONDITIOM
Wipers start erratically during DELAY mode.
PROCEDURE
(1) Verify that the ground connection at the instru
ment panel is making good connection (free from
paint) and is tight.
(2) Verify that the motor ground strap is making
good contact and that the motor mounting bolts are
tight.
(3) Verify that the wiring ground connections for
the intermittent wipe module and the wiper/washer
switch are tight.
(4) If condition is not corrected, replace intermit
tent wipe module.
WASHER PUMP
(1) Check for continuity between black wire of
pump connector and a good ground. There should be
Pig. 7 intermittent Wipe Module continuity. If OK, go to next step. If not OK, repair
(1) Minimum delay (wiper/washer switch to ex ground circuit as required.
treme counter-clockwise position before LOW detent) (2) Turn ignition switch to ON position. Check for
1/2 to 2 seconds. battery voltage at brown wire of pump connector
(2) Maximum delay (wiper/washer switch to ex with washer switch depressed. If OK, replace pump.
treme clockwise position before OFF detent) 10 to 30 If not OK, see diagnosis for Multi-Function Switch in
seconds. this group. If switch tests OK, repair wiring between
(3) If there is excessive delay or no variations in switch and pump as required.
delay, see Multi-Function Switch.
CONDITION
In DELAY mode wipers run continually when
wash is operated, b u t do not provide a n extra
wipe when t h e washer switch is released.
BR WIPER AND WASHER SYSTEMS 8K - 7
WIPER BLADES REMOVE/INSTALL CLAW

(1) Turn wiper switch ON. Turn ignition switch
ON. When blades are in a convenient position turn
ignition OFF.
(2) Lift wiper arm to raise blade off glass.
(3) Remove blade assembly from arm by pushing
release tab under arm tip and slide blade away from
arm tip (Figs. 8 and 9).
Fig. 10 Wiper Blade Element Remove

(1) Lift the arm to permit the latch (Fig. 11) to be
pulled out to the holding position. Remove arm from
pivot using a rocking motion.
VERTABRA ELEMENT 938K-31
Fig. 8 Wiper Blade and Element - Typical
Fig. 11 Wiper Arm Remove/Install

(2) During blade installation, wiper motor must be
in PARK position. Position arms to pivot shafts.
(3) Rotate arm until tip of wiper blade is ±22MM
from upper edge of black out area at base of wind
Fig. 9 Wiper Blade Remove/Install
shield (Fig. 12).
(4) Gently place wiper arm tip on glass surface.
(5) Reverse removal procedures to install. When
complete turn ignition switch ON. Turn wiper switch
OFF allowing the wiper blades to PARK, then turn
ignition switch OFF.
WIPER ELEMENTS REMOVE/INSTALL

(1) Remove wiper blade assembly as described in
Wiper Blades Remove/Install.
(2) With blade removed, grasp end of element at TIP OF BLADE ± 22MM FROM EDGE OF BLACK OUT
locating claw and pull on element (Fig. 10). Remove
wiper element by sliding out of the claws.
Fig. 12 Adjust Wiper Arms
(4) Install arm onto pivot shaft.
WIPER ARM REMOVE/INSTALL (5) Grasp wiper arm with left hand and lift away
from windshield slightly to relieve spring tension on
CAUTION: The use of a screwdriver or other prying latch. Push latch toward front of vehicle.
tool to remove an arm may distort it. This distortion (6) Operate wipers with glass wet, then turn wip
could allow the arm to come off the pivot shaft, re ers off. Check for proper blade positioning and re-ad
gardless of how carefully it is installed. just if required.
8K - 3 WIPER AND WASHER SYSTEMS
WIPER MOTOR/LINKAGE REMOVE/INSTALL

(2) Remove wiper arms as described in Wiper Arms
Remove/Install.
(3) Remove weatherstrip along front edge of cowl
grille (Fig, 13).
Fig, 13 Cowl Grille Weatherstrip

(4) Release plastic anchor screws (Fig. 14).
Fig. 16 Linkage Mounting Bolts
Fig. 17 Wiper Motor Connectors

Fig. 14 Plastic Anchor Screws (11) Remove nut attaching crank arm to motor out
(5) Lift cowl grille from vehicle. put shaft.
(6) Remove washer hoses from supply hose at Y fit (12) Remove crank arm from motor.
ting (Fig. 15). Set cowl grille aside. (13) To install, position crank arm on motor drive
(7) Remove wiper linkage mounting bolts (Fig. 16). shaft making sure slot is indexed properly. Install
(8) Turn linkage/motor unit over. Unplug harness crank arm nut to output shaft and tighten to 14 N-m
and ground tab connectors from wiper motor (Fig. (11 ft. lbs.).
17). (14) Install crank arm pin in drive link retainer
(9) Remove crank arm from drive link by prying bushing by snapping together with channel lock pli
retainer bushing from crank arm pin with a suitable ers.
size screwdriver (Fig. 18). (15) Position motor on linkage bracket. Install mo
(10) Remove 3 screws securing motor to linkage tor mounting screws and tighten to 6 N-m (55 in.
bracket and remove motor. lbs.).
mm WIPER AND WASHER SYSTEMS 8K - 1
STEERING
REMOVE COLUMN
ASSY.
3 SCREWS
TURN SIGNAL
MULTI SWITCH AND
FUNCTION LEVER
SWITCH
J948K-17 J918J-1 CONNECTOR
Fig. 18 Wiper Motor/Linkage Remove/Install Fig. 20 Multifunction Switch Connector

(16) Reverse remaining removal procedures to com-' (7) Reverse removal procedures to install. Tighten
plete installation. fasteners as follows:
® multi-function switch connector screw - 1.9 N-m
MULTI-FUNCTION SWITCH REMOVE/INSTALL (17 in. lbs.)
(1) Disconnect battery negative cable. ® multi-function switch retaining screws - 1.9 N-m
(2) If equipped, remove tilt column lever. (17 in. lbs.).
(3) Remove both upper and lower shrouds from col
umn (Fig. 19). WASHER RESERVOIR REMOVE/INSTALL
UPPER WARNING: DO NOT LOOSEN THE RADIATOR
SHROUD
PANEL DRAINCOCK WITH THE SYSTEM HOT AND P R E S
TILT
LEVER BRACKET SURIZED. SERIOUS BURNS FROM THE COOLANT
STEERING CAN OCCUR.
WHEEL
WARNING: CONSTANT TENSION HOSE CLAMPS

ARE U S E D ON COOLING SYSTEM HOSES. WHEN
REMOVING OR INSTALLING THIS TYPE OF CLAMP,
ONLY USE TOOLS DESIGNED FOR SERVICING
THIS CLAMP SUCH AS SPECIAL CLAMP TOOL
NUT (NUMBER 6094) (FIG. 21). SNAP-ON CLAMP TOOL
(NUMBER HPC-20) MAY B E U S E D FOR L A R G E R
CLAMPS. ALWAYS WEAR SAFETY GLASSES W H E N
SERVICING CONSTANT TENSION C L A M P S .

LOWER placement is necessary, use only an original equip
SHROUD J9419-17 ment clamp with a matching number or letter.
Fig. 19 Steering Column Shrouds Remove/Install (1) Remove upper radiator hose at radiator (Fig.
(4) Remove multi-function switch tamper proof 23)
mounting screws (tamper proof torx bit Snap On (2) Pull hose off of pump and drain solvent into a
TTXR20B2 or equivalent required). clean container for re-use.
(5) Gently pull switch away from column. Loosen (3) Disconnect electrical leads from pump and level
connector screw. The screw will remain in the con sensor (if equipped).
nector. (4) Pull reservoir up and out of radiator shroud
(6) Remove wiring connector from multi-function (Fig. 24).
switch (Fig. 20).
S I -10 WIPER AND WASHER SYSTEMS —BR
HOSE CLAMP HOSE RADIATOR FAN

TOOL 6094 CLAMP SHROUD
WASHER FLUID UPPER RADIATOR

J9207-36 RESERVOIR
HOSE J948K-11
Fig. 21 Hose Clamp Tool - Typical Fig. 23 Upper Radiator Hose Remove/Install
TYPICAL
CONSTANT
TENSION HOSE
CLAMP
FAN
SHROUD
WASHER LOW WASHER FLUID

RESERVOIR SENSOR
WASHER PUMP J948K-18
Fig. 24 Washer Fluid Reservoir Remove/Install

TYPICAL
HOSE (6) Remove rubber grommet(s) from reservoir and
CLAMP throw away.
NUMBER/LETTER
LOCATION J9407-39 (7) Reverse removal procedures to install. Install
new grommets in reservoir for pump and/or sensor.
Fig. 22 Clamp Number/Letter Location Refer to Group 7 - Cooling System for instructions on
(5) Gently pry pump and/or sensor away from res refilling engine coolant.
ervoir and out of grommet. Care must be taken not
to puncture reservoir.
LAMPS IL - 1
LAMPS
page page
JLB APPLICATION 14 SERfiCE PROCEDURES ... e

IMP DIAGNOSIS . ... 1
L A U P DIAGNOSIS
IENERAL INFORMATION CAUTION: Do not touch the glass of halogen bulbs

BR vehicles use lighting on the interior and exte with fingers or other possibly oily surface. Reduced
rior of the vehicle for illuminating and indicating bulb life will result.
purposes. Lighting circuits are protected by fuses or Do not use bulbs with higher candle power than
circuit breakers. Lighting circuits require an overload indicated in the Bulb Application table at the end of
protected power source, on/off device, lamps and body this group. Damage to lamp can result.
ground to operate properly. Plastic lamps require a . Do not use fuses, circuit breakers or relays hav
wire in the harness to supply body ground to the ing greater amperage value than indicated on the
lamp socket. Lamp sockets that are exposed to mois fuse panel or in the Owners Manual.
ture should be coated with Mopar, Multi-purpose
When it is necessary to remove components to ser
Grease or equivalent to avoid corrosion. If a socket
vice another, it should not be necessary to apply ex
has become corroded, clean socket and bulb base with
cessive force or bend a component to remove it.
abrasive fiber sanding pad or metallic bristle brush.
Before damaging a trim component, verify hidden
Replace sockets and bulbs that are deformed from
fasteners or captured edges are not holding the com
corrosion that could prevent continuous body ground.
ponent in place.
Wire connectors can make intermittent contact or
become corroded. Before coupling wire connectors, in
HEADLAMP DIAiNOSIS
spect the terminals inside the connector. Male termi
nals should not be bent or disengaged from the BR vehicles built for use in Canada are equipped
insulator. Female terminals should not be sprung with a Daytime Running Lamp (DRL) system. The
open or disengaged from the insulator. Bent and DRL system operates the highbeam headlamps at
sprung terminals can be repaired using needle nose 50% illumination with the headlamp switch OFF and
pliers and pick tool. Corroded terminals appear the engine running. The DRL system is controlled by
chalky or green. Corroded terminals should be re the Daytime Running Lamp Module located on radi
placed to avoid recurrence of the problem symptoms. ator closure panel on the right side of the engine
Wire connector terminals should be coated with MO compartment. The DRL module overrides the head
PAR, Multi-purpose Grease or equivalent to avoid lamp switch when the headlamps are turned OFF.
corrosion. The headlamps operate normally when the head
Begin electrical system failure diagnosis by testing lamps are turned ON.
related fuses and circuit breakers in the fuse block . When a vehicle experiences problems with the
and engine compartment. Verify that bulbs are in headlamp system, verify the condition of the battery
good condition and test continuity of the circuit connections, charging system, headlamp bulbs, wire
ground. Refer to Group 8W, Wiring Diagrams for connectors, relay, high beam dimmer switch and
component location and circuit information. headlamp switch. Refer to Group 8W, Wiring Dia
grams for component locations and circuit informa
S1FETY PRECAUTIONS tion.
Always begin any diagnosis by testing all of the
WARNING: E Y E PROTECTION SHOULD BE U S E D fuses and circuit breakers in the system. Refer to
W H E N SERVICING G L A S S COMPONENTS. P E R Group 8W, Wiring Diagrams.
SONAL INJURY CAN RESULT.
8L - 2 LAMPS BR
HEADLAMP DIAGNOSIS
HEADLAMPS ARE DIM 1. Loose or corroded battery 1. Clean and secure battery cable clamps and posts.
WITH ENGINE IDLING cables.
OR IGNITION TURNED 2. Loose or worn generator 2. Adjust or replace generator drive belt.
OFF. drive belt.
3. Charging system output 3. Test and repair charging system, refer to Group 8A.
too low.
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 7. Replace both headlamp bulbs.
defective.
HEADLAMP BULBS 1. Charging system output 1. Test and repair charging system, refer to Group 8A.
BURN OUT too high.
FREQUENTLY. 2. Loose or corroded terminals or 2. Inspect and repair all connectors and splices, refer to
splices in circuit. Group 8W.
HEADLAMPS 1. Charging system output 1. Test and repair charging system, refer to Group 8A.
ARE DIM WITH ENGINE too low.
RUNNING ABOVE IDLE.* 2. Poor headlamp circuit 2. Test voltage drop across Z1-ground, refer to Group 8W.
ground.
3. High resistance in headlamp , 3. Test amperage draw of headlamp circuit.
circuit.
4. Both headlamp bulbs 4. Replace both headlamp bulbs.
defective.
HEADLAMPS 1. Poor headlamp circuit 1 . Repair circuit ground, refer to Group 8W.
FLASH RANDOMLY. ground.
2. High resistance in headlamp 2. Test amperage draw of headlamp circuit. '
circuit.
3. Faulty headlamp switch 3. Replace headlamp switch.
circuit breaker.
4. Loose or corroded terminals 4. Repair connector terminals or splices, refer to Group 8W.
or splices in circuit.
HEADLAMPS 1. No voltage to headlamps. 1. Replace fuse, refer to group 8W.

DO NOT ILLUMINATE. 2. No ground at headlamps. 2. Repair circuit ground, refer to Group 8W.
3. Faulty headlamp switch. 3. Replace headlamp switch.
4. Faulty headlamp dimmer 4. Replace headlamp dimmer switch.
switch.
5. Broken connector terminal or 5. Repair connector terminal or wire splices.
wire splice in headlamp circui.
* Canada vehicles must have lamps ON,
J958L-5
BR — — — • —^ *—— _ _ _ _ _ _ LAMPS 8L - 3
FOG LAMP DIAGNOSIS
FOG LAMPS A R E DIM 1. Loose or corroded battery 1. Clean and secure battery cable clamps and posts.
WITH ENGINE IDLING cables.
OR IGNITION TURNED 2. Loose or worn generator 2. Adjust or replace generator drive belt.
OFF. drive belt.
3. Charging system output 3. Test and repair charging system, refer to Group 8A.
too low.
4. Battery has insufficient charge. 4. Test battery state-of-charge, refer to Group 8A.
5. Battery is sulfated or shorted. 5. Load test battery, refer to Group 8A.
6. Poor lighting circuit Z1-ground. 6. Test for voltage drop across Z1-ground locations,
refer to Group 8W.
7. Both fog lamp bulbs 7. Replace both lamp bulbs.
defective.
FOG LAMP 1. Charging system output 1. Test and repair charging system, refer to Group 8A.
BULBS BURN OUT too high.
FREQUENTLY. 2. Loose or corroded terminals 2. Inspect and repair all connectors and splices, refer to
or splices in circuit. Group 8W.
FOG LAMPS A R E DIM 1. Charging system output 1. Test and repair charging system, refer to Group 8A.
WITH ENGINE too low.
RUNNING ABOVE IDLE. 2. Poor fog lamp circuit 2. Test voltage drop across Z1-ground, refer to Group 8W.
ground.
3. High resistance in fog 3. Test amperage draw of fog lamp circuit.
lamp circuit.
4. Both fog lamp bulbs 4. Replace both fog lamp bulbs.
defective.
FOG LAMPS FLASH 1. Poor fog lamp 1. Repair circuit ground, refer to Group 8W.
RANDOMLY. circuit ground.
2. High resistance in fog 2. Test amperage draw of fog lamp circuit.
lamp circuit.
3. Faulty fog lamp switch 3. Replace fog lamp switch.
circuit breaker.
4. Loose or corroded terminals 4. Repair connector terminals or splices, refer to Group 8W.
or splices in circuit.
FOG LAMPS DO 1. Blown fuse for fog lamps. 1. Replace fuse, refer to group 8W.
NOT ILLUMINATE.
2. No ground at fog lamps. 2. Repair circuit ground, refer to Group 8W.
3. Faulty fog lamp switch.
3. Replace fog lamp switch.
4. Broken connector terminal
or wire splice in fog 4. Repair connector terminal or wire splices.
lamp circuit.
J958L-12
8L - 4 LAMPS mm
MULTI-FUNCTION SWITCH TESTING PROCEDURES UPPER
The multi-function switch contains electrical cir SHROUD
cuitry for:
• Headlamp Dimmer Switch.
• Passing Lights.
• Turn Signals.
• Hazard Warning.
• Windshield Wiper.
• Pulse Wiper.
® Windshield Washer.
This integrated switch is mounted to the left hand
side of the steering column. Should any function of
the switch fail, the entire switch must be replaced.
The multi-function switch also serves as a fog lamp
lock-out circuit. The circuit to the fog lamp switch is
completed only when the dimmer switch is in the low
beam position.
SWITCH TEST
(1) Disconnect battery negative cable. LOWER
(2) Remove screws along bottom edge of steering SHROUD J9419-17
column (Fig. 1).
Fig. 2 Steering Column Shrouds
J918J-1 CONNECTOR
Fig. 1 Knee Blocker Removal
Fig. 3 Multi-function Switch Connector
(3) Pull knee blocker down to disengage and re
move. DAYTIME RUNNING LAMPS—CANADA ONLY
(4) Remove tilt lever. The daytime running lamps are controlled by the
(5) Remove upper and lower column shrouds to Daytime Running Lamp Relay (DRLR). The DRLR is
gain access to the switch connector (Fig. 2). located in the engine compartment on the left fender
(6) Remove lower fixed column shroud. wheelhouse (Fig. 6). The DRLR allows the high beam
(7) Loosen steering column upper bracket nuts. Do headlamps to illuminate at 50% of the switched ON
not remove nuts. brightness when the engine is running with the
(8) Move upper fixed column shroud to gain access headlamp switch OFF. The Daytime running lamps
to rear of multi-function switch. will go out when the headlamp switch is pulled out.
(9) Remove switch connector (Fig. 3 and 4). The passing light feature will flash bright high
(10) Use an ohmmeter to test for continuity be beams while the daytime running lamps are acti
tween the terminals of the switch as shown in the vated.
continuity chart (Fig. 5).
DAYTIME RUNNING LAMP DIAGNOSTICS
(11) Refer to Service Procedures for assembly.
The daytime running lamp system shares fuse 24,
in the fuse panel, with the back-up lamp circuit. The
BR LAMPS 81 - 5
KEY-IN SWITCH & MULTI-FUNCTION Sensor, Headlamp Switch and the Engine Controller
(SBEC). Refer to Group 8W, Wiring Diagrams for
component location and circuit information.
îYvj^/M RUNNING M-^jV [/MiLf^ S ^ M t
(1) Release hood latch an open hood.
(2) Disconnect wire connector from DRLR (Fig. 6).
(8) Remove screw holding DRLR to engine com
partment dash panel.
(4) Separate DRLR from dash panel.
INSTALLATION
Reverse the removal procedure.
Fig. 4 Steering Column Connectors
VIEW FROM TERMINAL SIDE

SWlfCH POSITION €©NIiNtJI¥Y BETWEEN
LOW BEAM 18 A N D 19
HIGH BEAM 19 A N D 20 Fig. 6 Daytime Running Lamp Relay (DRLR)
OPTICAL HORN 20 AND 21
908J-5
Fig. 5 Dimmer Switch Continuity Chart

DRL is controlled by inputs received from the Speed
page page
Cargo Lamp . . . . . . ....................... 10 Overhead Console 13

Cargo Lamp Bulb 10 Overhead Console Reading Lamp Bulb . . . . . . . . . 13
Center High Mounted Stop Lamp (CHMSL) 10 Park and Turn Signal Lamp Bulb 9
Center High Mounted Stop Lamp (CHMSL) Bulb . . 10 Park, Turn Signal and Side Marker Lamp . . . . . . . . . 9
Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Rear Identification (ID) Lamp Bulbs 12
Fog Lamp Bulb 3 Rear Identification (ID) Lamps 12
Fog Lamp Switch . . . . . . . . . . . . . . . . . . . . . . . . . 10 Roof Clearance Lamp Bulb . . . . . . . . . . . . . . . . . . 10
Fog Lamps 8 Roof Clearance Lamps . . . . . . . . . . . . . . . . . . . . . . 9
Front Side Marker Lamp Bulb . . . . . . . . . . . . . . . . . 9 Side Identification (ID) Lamp Bulbs . . . . . . . . . . . . 12
Headlamp Alignment . . . . . . . . . . . . . . . . . . . . . . . . 6 Side Identification (ID) Lamps . . . . . . . . . . . . . . . . 11
Headlamp Alignment Preparation . . . . . . . . . . . . . . . 6 tall, Stop, Turn Signal and Back-Up Lamp
Headlamp Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Bulb—Chassis Cab 11
Headlamp Module 7 Tail, Stop, Turn Signal and Back-Up Lamp
Headlamp Switch 10 Bulb—Pickup 11
Headlamp/Fog Lamp Adjustment Using Alignment Tail, Stop, Turn Signal and Back-Up Lamps—
Screen 6 _ Chassis Cab 11
License Plate Lamp Bulb . . . . . . . . . . . . . . . . . . . . 12 Tail, Stop, Turn Signal and Back-Up Lamps—
License Plate Lamp Panel 12 Pickup .. . . . . . . . . . . 10
HEADLAMP ALIGNMENT (4) Rock vehicle side-to-side three times to allow

Headlamps can be aligned using the screen method suspension to stabilize.
provided in this section. Alignment Tool C4466-A or (5) Jounce front suspension three times by pushing
equivalent can also be used. Refer to instructions downward on front bumper and releasing.
provided with the tool for proper procedures. The (6) Measure the distance from the center of head
preferred headlamp alignment setting is 0 for lamp lens to the floor. Transfer measurement to the
the left/right adjustment and 1" down for the alignment screen (with tape). Use this line for up/
up/down adjustment. down adjustment reference.
(7) Measure distance from the centerline of the ve
HEADLAMP ALIGNMENT PREPARATION hicle to the center of each headlamp being aligned.
(1) Verify headlamp dimmer switch and high beam Transfer measurements to screen (with tape) to each
indicator operation. side of vehicle centerline. Use these lines for left/
(2) Correct defective components that could hinder right adjustment reference.
proper headlamp alignment.
HEADLAMP(3)ADJUSTMENT
Verify proper tire inflation.
(4) Clean headlamp lenses. A properly aimed low beam headlamp will project
(5) Verify that luggage area is not heavily loaded. top edge of high intensity pattern on screen from 50
(6) Fuel tank should be FULL. Add 2.94 kg "(6.5 mm (2 in.) above to 50 mm (2 in.) below headlamp
lbs.) of weight over the fuel tank for each estimated centerline. The side-to-side outboard edge of high in
gallon of missing fuel. tensity pattern should be from 50 mm (2 in.) left to
50 mm (2 in.) right of headlamp centerline (Fig. 1).
HEADLAMP/FOG LAMP ADJUSTMENT USING The preferred headlamp alignment is 0 for the
ALIGNMENT SCREEN up/down adjustment and Y down for the left/
right adjustment. The high beam pattern should be
ALIGNMENT SCREEN PREPARATION (FIG. 1)
correct when the low beams are aligned properly.
(1) Position vehicle on a level surface perpendicu
To adjust headlamp aim, rotate alignment screws
lar to a flat wall 7.62 meters (25 ft) away from front
of headlamp lens. to achieve the specified high intensity pattern (Fig.
(2) If necessary, tape a line on the floor 7.62 2).
meters (25 ft) away from and parallel to the wall.
FOG LAMP ADJUSTMENT (FIG. 3)
(3) Up 1.27 meters (5 feet) from the floor, tape a
line on the wall at the centerline of the vehicle. Sight Prepare an alignment screen. Refer to Alignment
along the centerline of the vehicle (from rear of vehi Screen Preparation paragraph in this section. A prop
cle forward) to verify accuracy of the line placement. erly aligned fog lamp will project a pattern on the
IPS
CENTER OF LOW BEAM HOT FLOOR TO

VEHICLE T O SPOT AREA CENTER OF
CENTER OF , HEADLAMP
HEADLAMP LENS
LENS
VEHICLE
CENTERLINE
F R O N T OF
HEADLAMP
938 L-61
Fig. 1 Headlamp Alignment Screen—Typical
LEFT AND RIGHT

(4) From behind front bumper, remove screws hold
ADJUSTMENT SCREW ing bottom of headlamp module to radiator closure
panel.
(5) Separate headlamp module from radiator clo
sure panel.
(6) Disengage wire connector from headlamp bulb.
(7) Separate headlamp module from vehicle.
INSTALLATION
Eeverse the removal procedure.
HEADLAMP BULB
On driver side and on vehicles with dual batteries,
UP AND DOWN J958L-23 the headlamp assembly must be removed to service
ADJUSTMENT SCREW
the headlamp bulb.
Fig. 2 Aero Headlamp Alignment REMOVAL
alignment screen 100 mm (4 in.) below the fog lamp (1) Release hood latch and open hood.
centerline and straight ahead. (2) To remove headlamp assembly on drivers side
or passenger side when equipped with dual batteries,
HEADLAMP MODULE refer to Headlamp Removal paragraph of Exterior
Lamps section.
REMOVAL (3) Disengage wire connector from headlamp bulb.
(1) Release hood latch and open hood. (4) Remove retaining ring holding bulb to head
(2) Remove park and turn signal lamp. lamp (Fig. 5).
(3) Remove screws holding top of headlamp module (5) Pull bulb from headlamp.
to radiator closure panel (Fig. 4).
CENTER OF r HIGH-INTENSITY FLOOR TO
VEHICLE TO
j AREA
CSH7ER OF
CEHTfiR ' T r--2- LAMP
LENS
VEHICLE
CENTERLINE
938L-26
F & ; 3 Fog L&mp Alignment —Typical
BULB
RETAINING
. RING
HEADLAMP
SOCKET LOCK / / ELECTRICAL
f^^/ CONNECTOR
CONNECT
SCIEW
PLASTIC
LENS/ BASE
REFLECTOR 918L-34
Fig. 5 Headlamp Bulb Removal

(2) Install retaining ring holding bulb to headlamp
CARRIER
BRACKET (Fig. 5).
(3) Connect wire connector to headlamp bulb.
HEAD LAMP SIDE MARKER FOG LAMPS

HOUSING BULB Fog lamps are turned OFF by the circuit relay
TURN AND P A R K
when the high beam driving lamps are turned ON.
LAMP HOUSING J948L-8 Fog lamps may be operated ONLY when low beam
headlamps are ON. If the headlamps are switched to
Fig. 4 Headlamp Removal high beam, the low beam lamps and fog lamps will
turn OFF. The fog lamps will go back on when the
high beams are switched OFF,
CAUTION: Do not touch, the bulb glass with fingers The indicator lamp on the fog lamp switch will go:
or other oily surfaces. Reduced bulb life will result. o O F F when the high beams lamps are switched
(I) Position bulb in headlamp. ON.
IR LAMPS 8L - 9
© ON when the high beam lamps are switched OFF. (5) Remove side marker socket from back of lamp.
(6) Separate park and turn signal lamp from vehi
REMOVAL cle.
The fog lamps are serviced from the rearward side
of the front bumper. INSTALLATION
(1) Disengage fog lamp harness connector. Reverse the removal procedure.
(2) Remove fog lamp to bumper attaching nuts
(Fig. 6). PARK AND TURN SIGNAL LAMP BULB
(3) Separate fog lamp from bumper.
REMOVAL
INSTALLATION (1) Remove park and turn signal lamp.
(1) Position fog lamp in bumper. (2) Remove park and turn signal lamp socket from
(2) Install fog lamp to bumper attaching nuts. back of lamp.
(3) Connect fog lamp harness connector. (3) Pull park and turn signal lamp bulb from
(4) Check for proper operation and beam align socket.
ment.
INSTALLATION
FOG LAMP BULB (1) Install park and turn signal lamp bulb in
socket.
REMOVAL (2) Install park and turn signal lamp socket into
(1) Disengage fog lamp harness connector. back of lamp.
(2) Rotate bulb assembly counterclockwise and pull (3) Install park/turn signal lamp.
from lamp to separate (Fig. 6).
FRONT SIDE MARKER LAMP BULB
INSTALLATION
REMOVAL
CAUTION: Do not touch the bulb glass with fingers (1) Remove park and turn signal lamp.
or other oily surfaces. Reduced bulb life will result. (2) Remove side marker lamp socket from back of
(1) Position bulb assembly in lamp and rotate lamp.
clockwise. (3) Pull side marker lamp bulb from socket.
(2) Connect fog lamp harness connector.
INSTALLATION
FOG LAMP
ASSEMBLY (1) Install side marker lamp bulb in socket.
(2) Install side marker lamp socket into back of
lamp.
(3) Install park/turn signal lamp.
ROOF CLEARANCE LAMPS

(1) Remove screws holding clearance lamp lens to
roof panel (Fig. 7).
ROOF
J958L-21
Fig. 6 Fog Lamp

PARK, TURN SIGNAL AND SIDE MARKER L A i P
REMOVAL
(1) Remove screw holding park lamp to headlamp
module.
(2) Disengage clip holding park lamp to headlamp
module. J958L-18
(3) Separate park lamp headlamp module.
(4) Remove park and turn signal socket from back Fig. 7 Roof Clearance Lamps
of lamp. (2) Rotate socket 1/4 turn counterclockwise and
8L LAMPS
separate socket from lamp. GEKTER mm COUNTED S T O P LA1P (CHMSL) '

INSTALLATION
(1) Install socket in lamp and rotate socket 1/4
mm
turn clockwise. (1) Remove screws holding CHMSL to roof panel.
(2) Position clearance lamp on roof. (2) Separate CHMSL from roof.
(3) Install screws holding clearance lamp lens to (3) Remove socket from lamp (Fig. 9).
roof panel. Tighten to 1 N-m (13 in. lbs.). (4) Pull bulb from socket.
ROOF CLEARANCE LAMP BULB mmwMLLAwmm
For bulb replacement refer roof clearance lamp re (1) Install bulb in socket.
moval/installation procedure. . (2) Install socket in lamp.
(3) Position CHMSL in roof.
CENTER HIGH MOUNTED S T O P L A M P ( C H M S L ) (4) Install screws holding CHMSL to roof panel.
REMOVAL CARGO LAMP B U L B
(1) Remove screws holding CHMSL to roof panel The cargo lamp bulb is incorporated in the CHMSL
(Fig. 8). assembly, refer to the CHMSL bulb removal and in
stallation procedure for bulb replacement.
Fig. 9 Cargo or Center High Mourned Stop Lamp

Bulbs
HEADLAMP SWITCH
SCREW J948L-4X
To remove or replace the headlamp switch. Refer to
Fig. 8 Center High Mounted Stop Lamp Group 8E, Instrument Panel and Gauges.
(2) Separate CHMSL from roof. .oa imp SWITCH
(3) Disengage wire connector from body wire har The fog lamp switch is located to the right of the
ness. overdrive lock-out switch. For installation and re
(4) Separate CHMSL from vehicle. moval procedures, refer to Group 8E, Instrument
INSTALLATION
Panel.
Reverse the removal procedure. TAIL, STOF, TURN SIGNAL AND BACK-UP
CARGO LAMP
The cargo lamp is incorporated into the CHMSL, if
equipped. Refer to Center High Mounted Stop Lamp (1) Release tailgate latch and open tailgate.
paragraph for proper procedures. (2) Remove screws holding tail lamp to cargo box
(Fig. 10).
(3) Disengage clips holding tail lamp to cargo box.
(4) Separate tail lamp from cargo box.
LAMPS 8L -II
(5) Disengage tail lamp wire connector from body

wire harness. Reverse the removal procedure.
(6) Separate tail lamp from vehicle.
INSTALLATION
Reverse the removal procedure. -
TAIL, STOP, TURN SIGNAL AND BACK-UP LAiP

BULB—PICKUP
REMOVAL
(1) Remove screws from tail lamp and separate tail
lamp from cargo box (Fig. 10).
BRACKET J948L-9
Fig. 11 Tail, Stop, Turn Signal and Back-up

Lamps—Chassis Cab
TAIL, STOP, TURN SIGNAL AND BACK-UP LAiP
BULB—CHASSIS CAB
REMOVAL
(1) Remove screws holding tail lamp lens to lamp
body.
RETAINING (2) Separate lens from lamp.
STUDS J948L-6 (3) Remove bulb from socket.
Fig. 10 Tail, Stop, Turn Signai and Back-up Lamp INSTALLATION
Bum Reverse the removal procedure.
(2) Remove socket from tail lamp.
(3) Pull bulb from socket. SIDE IDENTIFICATION (ID) LAMPS
INSTALLATION REMOVAL
(1) Install bulb in socket. (1) Using a flat blade screw driver, disengage clips
(2) Install socket in tail lamp. holding ID lamp to retainer (Fig. 12).
(3) Position tail lamp in cargo box and' install (2) Separate ID lamp from retainer.
screws (Fig. 10). (3) Disengage wire connector from body wire har
ness.
TAIL, STOP, TURN SIGNAL AND BACK-UP (4) Separate lamp from vehicle.
(5) Remove screws holding lamp retainer to rear
LAMPS—CHASSIS CAB
fender.
REMOVAL (6) Separate retainer from rear fender.
(1) Remove nuts holding tail lamp to mounting
bracket (Fig. 11). INSTALLATION
(2) Disengage tail lamp wire connector from body Reverse the removal procedure.
wire harness.
(3) Separate tail lamp[ from vehicle.
8L -12 LAMPS BR
INSTALLATION
REAR IDENTIFICATION (ID) LAMP BULBS
The bulbs in the rear ID lamps can not be re
placed. If a bulb should fail, the entire lamp would
require replacement.
LICENSE PLATE L11P PANEL
REMOVAL
(1) Remove screws holding license plate panel to
cargo box.
(2) Disengage license plate lamp wire connector
from body wire harness (Fig. 14).
Fig. 12 Side Identification Lamps
SIDE IDENTIFICATION (ID) LAMP BULBS
The bulbs in the side ID lamps can not be replaced.
If a bulb should fail, the entire lamp would require
replacement.
REAR IDENTIFICATION (ID) LAMPS

The bulbs in the side ID lamps can not be replaced.
If a bulb should fail, the entire lamp would require
replacement.
REMOVAL
(1) Remove screws holding rear ID lamps to cargo
box (Fig. 13).
LICENSE
PLATE
LAMP J948L-7
Fig. 14 License Plate Lamp Panel

(3) Separate license plate lamp from vehicle.
INSTALLATION
LICENSE PLATE LAMP BULB
REMOVAL
(1) Remove license plate lamp lens.
(2) Pull bulb from license plate lamp.
TAILGATE
INSTALLATION
MARKER LAMPS J948L-10
Fig. 13 Rear Identification Lamps
(2) Separate ID lamps from cargo box. DOME LAMP
(3) Disengage ID lamp wire connector from body REMOVAL
wire harness.
(4) Separate ID lamp from vehicle. (1) Using a suitable flat blade screw driver, pry
dome lamp lens from dome lamp.
LAMPS 8L -13
(2) Remove screws holding dome lamp to roof rein (4) Place dome lamp lens on dome lamp and snap
forcement (Fig. 15). into place.
OVERHEAD CONSOLE
To service overhead console refer to Group 8C,
Overhead Console.
OWERHEAi CONSOLE READING L A i P 1ULB
REMOVAL
(1) Insert a flat blade screwdriver in slot at front
of lens (Fig. 16).
DOME LAMP
LENS J948L-5
Fig. 15 Dome Lamp

(3) Separate dome lamp from roof.
(4) Disengage dome lamp wire connector from body
Fig. 16 Overhead Console Reading Lamp Bulb
wire harness.
Removal
(5) Separate dome lamp from vehicle.
(2) Rotate the screwdriver until lens snaps out of
INSTALLATION the housing.
(1) Position dome lamp at headliner. (3) Remove lens from housing.
(2) Connect dome lamp wire connector to body wire (4) Remove bulb from terminals.
harness. INSTALLATION
(3) Install screws holding dome lamp to roof rein (1) Insert bulb into reading lamp terminals.
forcement (Fig. 15). (2) Replace lens by holding lens level and pushing
rearward into housing.
(3) Push lens up to snap into housing.
1L - 1 4 LI
GENERAL INFORMATION A/C Heater Control......... 158

The following Bulb Applications list the lamp title Ash Receiver.... 161
on the left side of the column and trade number or Cigar Lighter...................... ...............................161
part number on the right. Headlamp Switch................................. .............158
Heater Control 158
CAUTION: Do not use bulbs that have a higher can Instrument Cluster........... PC194
dle power than the bulb listed In the Bulb Applica Radic.....................................................................ASC
tions. Damage to lamp can result.
Do not touch halogen bulbs with fingers or other
possibly oily surfaces. Bulb life will be reduced. Service procedures for most of the lamps in the in
strument panel, instrument cluster and switches are
located in Group 8E, Instrument Panel and Gauges.
iXTERIOR LAMPS
Airbag High Line PC 194
Back-up 3157
Airbag low Line PC74
Cargo 921
Center High Mounted Stop 921 Anti-lock Brake...................................................PC74
Clearance 194 Battery Voltage ..PC194
Headlamp... 9004 Brake Warning ....PC 194
License Plate ........................................................1155 Check Engine.................................... PC74
License Plate—Step Bumper ................................168 Engine Oil Pressure ...........................................PC74
Park/Turn Signal 3157NA Four Wheel Drive PC194
Snow Plow Control 161 High Beam.... .....PC194
Tail/Stop/Turn Signal 3157 Low Fuel .......PC194
Tail/Stop/Cab-Chassis ...................................1157 Low Washer Fluid...............................................PC74
Underhood 105 Maintenance Required. PC74
Message Center PC194
INTERIifit LA1PS Seat Belt................... ...................PC74
Turn Signal......................................... .........PC194
DIMMER G@mm&LLm LASSPS Upshift ..........PC74
Service procedures for most of the lamps in the in
strument panel, Instrument cluster and switches are
located in Group 8E, Instrument Panel and Gauges. Some components have lamps that can only be ser
Some components have lamps that can only be ser viced by a Authorized Service Center (ASC) after the
viced by a Authorized Service Center (ASC) after the component is removed from the vehicle. Contact local
component is removed from the vehicle. Contact local dealer for location of nearest ASC.
dealer for location of nearest ASC. When illumination Dome ..........1004
goes out in the Electronic Instrument Cluster (EIC) Glove Compartment..... 1891
the complete button module must be replaced. The Ignition Lock ...........1445
Mechanical Instrument Cluster (MIC) uses PC194
bulbs for illumination.
RESTRAINT SYSTEMS 8M - 1
jTRABNT SYS'
page page
AIRBAG SYSTEM 1 SEVERAL INFORMATION 1

DIAGNOSIS . . .
2 SERWiCE PROCEDURES 3
A I R B A G SYSTEM
WARMING: THIS S Y S T E M IS A SENSITIVE, COM WARMING: R E P L A C E A I R B A G S Y S T E M COMPO

P L E X ELECTRO-MECHANICAL UMIT. B E F O R E AT NENTS WITH PARTS S P E C I F I E D IN THE C H R Y S L E R
TEMPTING TO DiAGNOSE, REMOVE OR INSTALL MOPAR PARTS CATALOG ONLY. SUBSTITUTE
THE A I R B A G S Y S T E M OR RELATED S T E E R I N G P A R T S MAY A P P E A R I N T E R C H A N G E A B L E , BUT IN
W H E E L AND S T E E R I N G COLUMN C O M P O N E N T S T E R N A L D I F F E R E N C E S MAY R E S U L T IN INFERIOR
YOU MUST FIRST DISCONNECT AND ISOLATE THE OCCUPANT' PROTECTION. THE FASTENERS,
BATTERY NEGATIVE (GROUND) C A B L E . THEN S C R E W S , AND BOLTS ORIGINALLY U S E D FOR THE
WAIT 2 MINUTES F O R S Y S T E M CAPACITOR TO A I R B A G COMPONENTS HAVE S P E C I A L COATINGS
DISCHARGE B E F O R E FURTHER S Y S T E M S E R V I C E . AND A R E SPECIFICALLY DESIGNED FOR THE AIR-
FAILURE TO DO S O COULD RESULT IN ACCIDEN
B A G S Y S T E M . THEY MUST N E V E R B E R E P L A C E D
TAL DEPLOYMENT AND P O S S I B L E P E R S O N A L IN
WITH ANY S U B S T I T U T E S . ANYTIME A N E W FAS
JURY.
T E N E R IS N E E D E D , R E P L A C E WITH THE C O R R E C T
F A S T E N E R S PROVIDED IN THE S E R V I C E P A C K A G E
WARNING: THE A I R B A G MODULE SNFLATOH A S OR S P E C I F I E D IN THE C H R Y S L E R MOPAR PARTS
S E M B L Y CONTAINS SODIUM AZIDE AND POTAS CATALOG.
SIUM NITRATE. THESE MATERIALS ARE
POISONOUS AND E X T R E M E L Y F L A M M A B L E . CON
TACT WITH ACID, WATER OR HEAVY METALS MAY WARNING: W H E N A STEERING COLUMN HAS AN
PRODUCE HARMFUL AND IRRITATING G A S E S (SO A I R B A G MODULE ATTACHED, N E V E R P L A C E THE
DIUM HYDROXIDE IS FORMED IN THE P R E S E N C E COLUMN ON THE FLOOR OR OTHER S U R F A C E
OF MOISTURE) OR C O M B U S T I B L E COMPOUNDS. WITH THE S T E E R I N G W H E E L OR A I R B A G MODULE
DO NOT ATTEMPT TO DISMANTLE THE MODULE FACE DOWN.
OR TAMPER WITH ITS INFLATOR. DO NOT PUNC
TURE, INCINERATE OR BRING INTO CONTACT
WITH ELECTRICITY. DO NOT S T O R E AT TEMPERA
TURES E X C E E D I N G 200°F.
GEm , INFORMATION
The airbag system is a standard equipment safety Following are general descriptions of the major
device on Ram truck models. It is designed to protect components in the airbag system. Refer to Group 8 W
the driver from serious injury, caused by a frontal - Wiring Diagrams for complete circuit descriptions
impact of the vehicle. To inspect this system use Air- and diagrams.
bag System - Body Diagnostic Procedures manual. If
the airbag module assembly is defective and non-de AIRBAG MODULE
ployed, refer to Chrysler Corporation current return The airbag module protective cover is the most vis
list for proper handling procedures. ible part of the system. The module is mounted di
rectly to the steering wheel Under the airbag
8M - 2 RESTRAINT SYSTEMS — gft
module cover, the airbag cushion and its supporting The impact sensors are threshold sensitive
components are contained. The airbag module con switches that complete an electrical circuit when an
tains a housing to which the cushion and inflator are impact provides a sufficient deceleration force to
attached and sealed. The airbag module is non-ser close the switch. The sensors are calibrated for the
viceable, and must be replaced if deployed or dam specific vehicle, and react to the severity and direc
aged in any way tion of the impact.
The inflator assembly is mounted to the back of the
module. The inflator seals the hole in the airbag CLOCKSPRING
cushion so it can discharge the gas it produces di The clockspring is mounted on the steering column
rectly into the cushion when supplied with the
behind the steering wheel. It is used to maintain a
proper electrical signal. The protective cover is fitted
to the front of the airbag module and forms a deco continuous electrical circuit between the wiring har
rative cover in the center of the steering wheel. Upon ness and the driver's side airbag module. This assem
airbag deployment, this cover will split horizontally. bly consists of a flat, ribbon-like electrically
conductive tape which winds and unwinds with the
STORAGE steering wheel rotation.
The airbag module must be stored in its original,
special container until used for service. Also, it must AIRBAG CONTROL MODULE
be stored in a clean, dry environment; away from The airbag control module (ACM) contains the saf
sources of extreme heat, sparks, and high electrical ing sensor, and monitors the system to determine its
energy. Always place or store the module on a surface readiness. The ACM contains on-board diagnostics
with the trim cover facing up to minimize movement (OBD), and will light the airbag warning lamp in the
in case of accidental deployment. instrument cluster when a monitored airbag system
fault occurs.
IMPACT SENSOR The ACM also contains an energy storage capacitor.
The impact sensors provide verification of the di This capacitor stores enough electrical energy to de
rection and severity of the impact. Three impact sen ploy the airbag for up to 2 minutes following a bat
sors are used. One is called a safing sensor. It is tery disconnect or failure. The purpose of this unit is
located inside the airbag control module (ACM), to provide airbag protection in a severe secondary
which is mounted to a bracket under the instrument impact if the initial impact has damaged or discon
panel on the top of the floor pan transmission tunnel. nected the battery, but was not severe enough to de
The other two sensors are mounted on the inner ploy the airbag.
fender extension panels behind the grille opening re
inforcement on the left and right side of the vehicle.
DIAGNOSIS
A DRB scan tool is required for diagnosis of the air- (7) Refer to the Airbag System - Body Diagnostic
bag system. Refer to Airbag System - Body Diagnos Test Procedures manual, if any DTC is found in steps
tic Procedures manual for more information. 5 or 6.
(8) Erase stored DTC, if there are no active fault
AIRBAG SYSTEM CHECK codes. If problems remain, DTC will not erase.
(1) Disconnect battery negative cable and isolate. (9) With the ignition switch in the ON position,
(2) Connect DRB scan tool to ACM diagnostic make sure nobody is in the vehicle.
6-way connector. The connector is clipped under the (10) From right side of vehicle, turn the ignition
lower left corner of the instrument panel. switch to OFF then ON. Observe airbag warning
(3) From right side of vehicle (away from airbag in lamp on the instrument cluster. It should light for 6
case of accidental deployment), turn the ignition to 8 seconds, then go out; indicating system is func
switch to the ON position. Exit vehicle with DRB. tioning normally.
Use the latest version of the proper DRB cartridge. If the airbag warning lamp fails to light, or
(4) After checking that nobody is inside the vehi lights and stays on, there is a system malfunc
cle, reconnect the negative battery terminal. tion. Refer to the Airbag System - Body Diag
(5) Using the DRB, read and record active diagnos
nostic Test Procedures manual to diagnose the
tic trouble code (DTC) data.
(6) Read and record any stored DTC. problem.
•Plfl RESTRAINT SYSTEMS 81 - 3
SERVICE P H @ e E © U R E S
IRBau SYSTEM SERVICE (DEPLOYED) If you e x p e r i e n c e skin i r r i t a t i o n during

Any vehicle which is to be returned to use after an cleanup, ran cool w a t e r over t h e affected area*
airbag deployment, must have the airbag module and Also, i f you e x p e r i e n c e i r r i t a t i o n of t h e m©se or
clockspring replaced. These are one-time components • t h r o a t , e x i t t h e v e h i c l e for fresh a i r until t h e ir
and cannot be reused. Other airbag system compo ritation c e a s e s . If irritation continue^ see a
nents are replaced as required by the extent of dam physician.
age.
In addition, the airbag module should be disarmed CLEANUP PROCEDURE
whenever the steering wheel or steering column re Begin cleanup by putting tape over the airbag ex
quires service or removal Failure to observe this haust vent (Fig. 2) so that no more powder will find
warning could result in accidental airbag deployment its way into the vehicle interior. Then remove the air-
and possible personal injury. Eefer to Group 19 - bag and airbag module from the vehicle.
Steering for additional service procedures on steering
wheel and steering column.
AIRBAG MODULE HANDLING
M no time should any source of electricity be per

mitted near the inflator on the back of the module.
When carrying an undeployed module, the trim cover
should be pointed away from the body to minimize
injury in the event of accidental deployment. If the
module is placed on a bench or other surface, the
plastic trim cover should be face up to minimize
movement in case of accidental deployment.
Following an airbag deployment, the vehicle inte

rior will contain a powdery residue. This residue is
primarily sodium bicarbonate (baking soda), used as
an airbag cushion lubricant. However, there will also Use a vacuum cleaner to remove any residual pow
be traces of sodium hydroxide powder, a chemical der from the vehicle interior. Clean from outside the
byproduct of the generant used for airbag deploy vehicle and work your way inside, so that you avoid
ment. Since this powder can irritate the skin, eyes, kneeling or sitting on an uncleaned area.
nose or throat, be sure to wear safety glasses, rubber Be sure to vacuum the heater and A/O outlets as
gloves and a long-sleeved shirt during cleanup (Fig. well (Fig. 3). Eun the blower on low and vacuum any
1). powder expelled from the plenum. You may need to
vacuum the interior of the car a second time to re
cover all of the powder.
Place the deployed airbag and module in your ve
hicular scrap pile.
AIRBAG MODULE REMOVE/INSTALL
WARNING: THIS S Y S T E M IS A SENSITIVE, COM

PLEX ELECTRO-MECHAMICAL UNIT. BEFORE AT
TEMPTING TO DIAGNOSE, REMOVE OR INSTALL
THE AIRBAG SYSTEM COMPONENTS YOU MUST
FIRST DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) G A B L E . THEN WAIT 2 MIN
UTES FOR SYSTEM CAPACITOR TO DISCHARGE
BEFORE FURTHER S Y S T E M SERVICE. FAILURE TO
DO S O COULD R E S U L T IN ACCIDENTAL DEPLOY
Fig, 1 Wear Safety Glasses And Rubber Gloves MENT AND POSSIBLE P E R S O N A L INJURY.
SI - 4 RESTRAINT SYSTEMS
Fig. 3 Vacuum Heater And A/C Outlets Fig. 5 Speed Control Switch Connector Remove/
Install
When removing a deployed airbag module,
rubber gloves, eye protection and long-sleeved
shirt should be worn. There may be deposits on
the airbag module and other interior surfaces,
which can cause irritation to the skin and eyes
in large doses.
(1) Disconnect battery negative cable and isolate.
If airbag module is undeployed, wait 2 minutes for
system capacitor to discharge before further service.
(2) If equipped, remove speed control switch
mounting screws (Fig. 4) from underside of steering
wheel.
(8) When installing, connect clockspring wiring

connector to the module by pressing straight in on
the connector. The connector should latch securely
beneath the module connector locking clip to assure
Fig. 4 Speed Control Switch Remove/Install positive connection.
(3) Pull switches from wheel and unplug connector (9) Install 4 nuts and tighten to 9 - 11 N-m (80 -
(Fig. 5). 100 in. lbs.).
(4) Using a small screwdriver, remove right rear (10) Do not connect negative battery cable at this
steering wheel cover (Fig. 6). time. See Airbag System Check for proper procedure.
(5) Remove 4 nuts attaching airbag module to
steering wheel (Fig. 7). IMPACT SENSOR REMOVE/INSTALL
(6) Remove airbag module from steering wheel. The impact sensors are located on the inner
(7) Unplug electrical connector from airbag mod fender extensions behind the grille opening re
ule. inforcement.
lit RESTRAINT SYSTEMS 8 1- S
(4) Unplug connector from sensor and remove sen

sor (Fig. 15).
(5) To install, connect sensor wiring lead from har
ness to connector on body of sensor.
(6) Mount sensor (arrow pointed forward) using 3
screws provided with new sensor. Tighten screws to 4
- 5 N-m (35 - 45 in. lbs.).
(7) Install rubber air dam across opening.
(8) Do not connect negative battery cable at this
time. See Airbag System Check for proper procedure.
¥-11 AND DIESEL ENGINE
(2) Remove 2 battery holddown bolts (Fig. 9).
J948G-2
Fig,
l e f t mm
V-6 110 ¥-8 ENGINE
(2) Remove plastic retainers holding rubber air
dam to radiator support on driver's side.
. J M J ^ ;
(3) Working through air dam opening remove 3
screws holding sensor to front wheelhouse extension. FI§ 9 BattQiy
B Holddown
Remove sensor (Fig. 8). (3) If equipped, pull up on battery heat shield to
remove it (Fig. 10).
SPEED CONTROL
SERVO
LEFT IMPACT
SENSOR
/ J J948M-4
BATTERY HEAT SHIELD J948B-3
Fig. 8 Left impact Sensor
Fig. 10 Battery Heat Shield
Bo not remove tape holding harness to connector.
Si -1 RESTRAINT SYSTEMS BR
(4) Remove battery from vehicle.

(5) From under left front wheel opening remove 2
forward battery tray nuts (Fig. 11).
Fig. 13 Speed Control Servo Mounting

(9) Move battery tray enough to access impact sen
sor.
Fig. 11 Forward Battery Tray Nuts (10) Remove 3 screws holding sensor to front
(6) Remove 2 nuts and 2 bolts holding battery tray wheelhouse extension. Remove sensor (Fig. 8).
to vehicle (Fig. 12). Do not remove tape holding harness to con
nector.
(11) Unplug connector from sensor and remove
sensor (Fig. 15).
(12) To install, connect sensor wiring lead from
harness to connector on body of sensor.
- 5 N-m (35 - 45 in. lbs.).
(14) Plug harness connector into speed control
servo.
(15) Install battery tray. Tighten all battery tray
mounting hardware to 16 N-m (140 in. lbs.).
(16) Install battery in vehicle making sure that
battery is properly positioned on battery tray.
(17) If equipped, install battery heat shield.
(18) Install battery holddown clamp, making sure
that it is properly positioned on battery, use holes
across from each other. Tighten holddown bolts to 4
N-m (35 in. lbs.).
Fig. 12 Battery Tray Mounting RIGHT BIDE

(7) Lift battery tray up far enough for access to V-6 AND V-8 ENGINE
speed control servo electrical connector (Fig. 13).
(8) Unplug electrical connector from speed control
servo. system capacitor to discharge before further service.
(2) Remove 3 screws holding sensor to front wheel- (3) Unplug connector from sensor and remove sen
house extension. Remove sensor (Fig. 14). sor (Fig. 15).
(4) To install, connect sensor wiring lead from har
RIGHT IMPACT - 5 N-m (35 - 45 in. lbs.).
SENSOR (6) Do not connect negative battery cable at this
AIRBAG CONTROL MODULE REMOVE/INSTALL
WARNING: THE ACM CONTAINS ONE O F THE IM

PACT S E N S O R S WHICH E N A B L E THE S Y S T E M TO
DEPLOY THE A I R B A G . TO AVOID ACCIDENTAL DE
PLOYMENT, N E V E R CONNECT ACM ELECTRICALLY
J948M-5 TO THE SYSTEM U N L E S S IT SS BOLTED TO VEHI
C L E . BEFORE BEGINNING ANY A I R B A G SYSTEM
Fig. 14 Right impact Sensor REMOVAL OR INSTALLATION P R O C E D U R E S , RE-
Do not remove tape holding harness to con i l Q V E AND ISOLATE THE BATTERY NEGATIVE (-)
nector. C A B L E FROM THE VEHICLE BATTERY. THEN WAIT
(3) Unplug connector from sensor and remove sen 2 MINUTES F O R S Y S T E M CAPACITOR TO DIS
sor (Fig. 15). CHARGE B E F O R E FURTHER SYSTEM S E R V I C E .
THIS IS THE ONLY S U R E W A Y TO DISABLE THE
SENSOR A I R B A G S Y S T E M . FAILURE TO DO THIS COULD
IMPACT CONNECTOR
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT,
SENSOR
AND P O S S I B L E P E R S O N A L I N J U R Y

If airbag is undeployed, wait 2 minutes for system
capacitor to discharge before further service.
(2) Remove 2 screws and cover from bottom of cen
ter console (Fig. 16).
J948M-8
AIRBAG
Fig. 15 Impact Sensor Connector - Typical CONTROL
MODULE
(4) To install, connect sensor wiring lead from har COVER
- 5 N-m (35 - 45 in. lbs.).
(6) Do not connect negative battery cable at this .INSTRUMENT
PANEL TRANSMISSION
time. See Airbag System Check for proper procedure. TUNNEL J948M-1
¥-11 AND DIESEL EN11NE
Fig. 16 Airbag Control Module Cover Screws
If airbag module is undeployed, wait 2 minutes for (3) Remove 4 screws holding ACM to transmission
system capacitor to discharge before further service. tunnel (Fig. 17).
(2) Remove 3 screws holding sensor to front wheel- (4) Disconnect wiring at ACM.
house extension. Remove sensor (Fig. 14). (5) Remove ACM.
Do not remove tape holding harness to con (6) To install, position the ACM with the arrow
nector. pointing forward.
8 1 - 8 RESTRAINT S Y S T E M S — B R
UPPER SHROUD GROUND UPPER

CLIP FIXED SHROUD
SUPPORT BRACKET
WIRE HARNESS
CONNECTOR
AIRBAG
CONTROL
MODULE
J948M-2
Fig. 17 Airbag Control Module

(7) Connect wiring at ACM, making sure both con
nectors are seated and locking tabs engaged. LOWER
(8) Attach ACM to the transmission tunnel with LOWER FIXED
SHROUD SHROUD J9119-22
the 4 screws. Tighten to 9.5 - 14 N-m (85 - 125 in.
lbs.). Fig. 18 Steering Column Shrouds
(9) Install ACM cover.
CLOCKSPRING REMOVE/INSTALL
(1) Place the front wheels in the straight-ahead po
sition before starting the repair.
(3) Remove the airbag module. See Airbag Module
Remove/Install.
(4) If equipped, remove speed control switch and
connector.
(5) Remove the steering wheel with steering wheel
puller (Special Tool C-3428B).
(6) Unplug wiring connectors from horn switches. Fig. If Knee Blocker Remove/Install
(7) Remove lower steering column shroud to gain cator clips are properly seated on the outside of the
access to clockspring wiring (Fig. 18). wiring trough and locking tabs are engaged.
(8) Remove lower fixed shroud. (14) Install knee blocker.
(9) Remove knee blocker (Fig. 19). (15) Install steering column shrouds. Be sure air-
(10) Disconnect the 2-way connector between the bag wire is inside of shrouds.
clockspring and the instrument panel wiring harness (16) Road wheels should still be in the straight-
at lower left corner of instrument panel. ahead position. Install steering wheel making sure to
(11) To remove clockspring, pull assembly from fit the flats on the hub of the steering wheel with the
steering column by lifting locating fingers as neces formations on the inside of clockspring. Pull the horn
sary. The clockspring cannot be repaired, and must lead through the wheel. The airbag and speed control
be replaced if faulty. leads go through the bottom larger hole in the steer
(12) To install, snap clockspring onto the steering ing wheel. Make sure not to pinch them between the
column. If the clockspring is not properly positioned, steering wheel and nut. Tighten steering wheel nut
follow the clockspring centering procedure before in to 61 N-m (45 ft. lbs.).
stalling steering wheel. (17) Connect airbag lead wire to the airbag mod
(13) Connect' the clockspring assembly to the in ule. To ensure complete connection, latching arms
strument panel wiring harness. Make sure wiring lo- must be visibly on top of connector housing.
BR RESTRAINT SYSTEMS 8M - 9
l
(18) Install airbag module and tighten nuts to 9 -
11 N-m (80 - 100 in. lbs.).
CLOCKSPRING CENTERING
If the rotating tape within the clockspring is not
positioned properly in relation to the steering wheel
and the front wheels, the clockspring may fail during
use. The clockspring MUST BE CENTERED, if it is
not known to be properly positioned, or if the front
wheels were moved from the straight-ahead position.
(1) Place front wheels in the straight-ahead posi
tion.
(3) Remove airbag module. Remove steering wheel
with steering wheel puller (Special Tool C-3428B).
(4) Depress the two plastic auto-locking tabs (Fig.
20).
(5) Keeping locking mechanism disengaged, rotate
the clockspring rotor CLOCKWISE to the end of its Fig. 20 Clockspring Auto-Locking Tabs
travel. Do not apply excessive torque.
(6) From the end of travel, rotate the rotor two and (8) Install airbag module. Tighten nuts to 9 - 11
one-half turns COUNTER CLOCKWISE. The horn N-m (80 - 100 in. lbs.).
wire should end up at the top, and the airbag wire at (9) Do not connect battery negative cable at this
the bottom. time. See Airbag System Check for proper procedure.
(7) Reinstall steering wheel.
BR POWER LOCKS 8P - 1
POWER LOCKS
CONTENTS
page ' page
DIAGNOSIS ............................. 1 SERVICE PROCEDURES 2

GENERAL INFORMATION
Power door locks are optional'equipment on Ram switch controls both the battery and ground feeds to
truck models. Both doors can be locked or unlocked the door lock motors. The battery and ground feeds
electrically by operating the switch on either door are reversed between the LOCK and UNLOCK
panel. The power door locks operate with battery switch positions. The door lock switches can not be
power supplied independent of the ignition switch. repaired. If faulty, the entire switch must be re
Following are general descriptions of the major placed.
components in the power door lock system. Refer to
Group 8 W - Wiring Diagrams for complete circuit de POWER LOCK MOTOR
scriptions and diagrams. The door locks are operated by a reversible motor
mounted within each door. The motor direction is
POWER LOOK SWITCH controlled by the battery and ground feeds from the
The power door locks are controlled by a two-way door lock switches. The motor can not be repaired. If
switch mounted on the trim panel of each door. The faulty, the entire motor must be replaced.
DIAGNOSIS
POWER LOCI SWITCH the OFF, LOCK and UNLOCK switch positions. If
(1) Check fuse 19 in fuseblock module. If OK, go to OK, go to Power Lock Motor diagnosis. If not OK, re
next step. If not OK, replace fuse. place the switch.
(2) Check for battery voltage at fuse 19. If OK, go
to next step. If not OK, repair circuit from power dis
tribution center. SWITCH CONTINUITY
(3) Remove switch from trim panel. See Power POSITION BETWEEN
Lock Switch Remove/Install. Carefully separate mul

O
2
® OFF
PINS 1 & 4
tiple terminal block on wiring harness from switch 1 PINS 2 & 3
body. V UNLOCK PINS 1 & 4

(4) Check continuity between switch connector cav (UP) PINS 3 & 5
ity for switch pin 2 and a good ground. Repeat check
between cavity for switch pin 4 and a good ground. 3 LOCK PINS 2 & 3
4
In each case, there should be continuity. If OK, go to (DOWN) PINS 1 & 5
next step. If not OK, repair circuit to ground as re o
quired.
(5) Check for battery voltage at switch connector
D- ®
PIN IDENTIFICATION
J958P-1
PIN SIDE OF SWITCH
cavity for switch pin 5. If OK, go to next step. If not
OK, repair circuit to fuse 19 in the fuseblock module. Fig. 1 Switch Continuity
(6) Test switch continuity. See Switch Continuity
chart (Fig. 1) to determine if continuity is correct in
8P - 2 POWER LOCKS BR
POWER LOCK MOTOR (3) If both motors are inoperative, the problem
Before you proceed with this diagnosis, confirm may be caused by one shorted motor. Disconnecting a
proper switch operation. See Power Lock Switch di shorted motor will allow the good motor to operate.
agnosis. Disconnect each motor connector, one at a time, and
(1) Check each door motor for both lock and unlock re-check both lock and unlock functions while operat
function while operating the switch. If both motors ing the door lock switch. If both motors are still in
are inoperative, go to step 3. If one motor is inoper operative after above test, repair wire harness
ative, go to next step. between motor and switch as required. If disconnect
(2) Once it is determined which lock motor is inop ing one motor causes the other motor to become func
erative, that motor can be tested. Disconnect the wire tional, go back to step 2 to test the disconnected
connector at the motor. Apply 12 volts across the mo motor.
tor terminals to check its operation in one direction.
Reverse the polarity to check the operation in the
other direction. If OK, repair wire harness from the
motor to the switch as required. If not OK, replace
the motor.
SERVICE PROCEDURES
POWER LOCI SWITCH REMOVE/INSTALL

REMOVE 2 SCREWS
J948S-2
Fig. 2 Door Pull Cup TABS FRONT CLIP J948S-8

(2) Remove power window/lock switch by reaching
Fig. 4 Door Switch Connectors
through door pull cup opening and depressing rear
switch retaining tab (Fig. 3). (6) Install a new switch by inserting front of
switch into trim panel then pushing down rear of
switch.
POWER LOCK MOTOR AND LATCH REMOVE/

INSTALL
(1) Remove switch as described in Power Lock
Switch Remove/Install.
(2) If equipped, pull power mirror switch control
knob rearward to remove from switch (Fig. 5).
6).
To aid in removal of the trim panel, start at
the bottom of the panel.
(3) Pull rear of switch up and away from door. (4) Using a wide flat-bladed tool such as a trim
(4) Unplug connectors from switch (Fig. 4). stick, pry trim panel away from door around perime
(5) Plug connector onto new switch. ter and remove trim panel.
BR POWER LOCKS SP - 3
Fig. 5 Power Mirror Knob Remove/install
Fig. 7 Lock Motor and Latch Remove/install

(6) Remove 3 screws holding lock motor and latch
assembly to door.
(7) Disconnect linkage rods.
(8) Pull motor and latch out far enough to unplug
electrical connector and remove motor and latch from
door.
screws to 10.5 N-m (95 in. lbs.).
Fig. 6 Power Mirror Switch Nut

(5) Roll door watershield away from bottom of door
to allow access to lock motor (Fig. 7).
BR — — — — P O W E R SEATS 8R - 1
POWER SEATS
CONTENTS
page page
DIAGNOSIS ....................... 1 8ERWICE P R O C E D U R E S 3

G E N E R A L INFORMATION 1
G E N E R A L INFORMATION
A six-way driver's side power seat is an available dently of each other. When the center seat switch is
option on Ram truck models. The power seat system pushed to the UP or DOWN position, both front and
receives battery feed through fuse 1 in the power dis rear motors operate in unison, moving the entire seat
tribution center and circuit breaker 2 in the fuse- up or down. The forward-rearward motor is operated
block module at all times. by pushing the center seat switch to the FORWARD
Following are general descriptions of the major or REARWARD position.
components in the power seat system. Refer to Group . When a switch is actuated, battery feed and a
8W - Wiring Diagrams for complete circuit descrip ground path are applied through the switch contacts
tions and diagrams. to the motor(s). The motor(s) operate to move the
seat in the selected direction until the switch is re
POWER SEAT SWITCH leased, or until the travel limit of the power seat ad
The power seat can be adjusted in six different juster is reached. When the switch is moved in the
ways using the power seat switch. The switch is lo opposite direction, the battery feed and ground path
cated on the lower outboard side of the seat. Refer to to the motor(s) are reversed through the switch con
the owner's manual for more information on power tacts. This causes the motor to run in the opposite di
seat switch functions and seat adjusting procedures. rection.
The individual switches cannot be repaired. If one
switch fails, the entire switch module must be re Each motor contains a self-resetting circuit breaker
placed. to protect it from overload. Consecutive or frequent
resetting must not be allowed to continue or the mo
POWER SEAT ADJUSTER/MOTORS tors may be damaged. Make the necessary repairs.
There are three reversible motors that operate the The power seat adjuster and motors can not be re
power seat adjuster. The motors are connected to paired, and are serviced only as a complete unit. If
worm-drive gearboxes in the adjuster by drive cables. any component in this unit should fail, the entire as
The front and rear of a seat are operated by differ sembly must be replaced.
ent motors. They can be raised or lowered indepen
DIAGNOSIS
Before any testing is attempted the battery should POWER SEAT ADJUSTER/MOTORS
be fully charged and all connections and pins cleaned Operate the power seat switch to move all three
and tightened to ensure proper continuity and seat motors. The seat should move in all directions.
grounds. If not OK, proceed as follows. If one or more motors
With the dome lamp on, apply switch in direction operate, see diagnosis for Power Seat Switch.
of the failure. If the dome lamp dims, the seat may (1) Check circuit breaker 2 in the fuseblock mod
be jamming. Check for binding or obstructions. If the ule. If OK, go to next step. If not OK, replace circuit
dome lamp does not dim, then proceed with the fol breaker.
lowing electrical tests.
POWER SEAT SWITCH CONTINUITY
SWITCH POSITION CONTINUITY BETWEEN
B-N, B-J, B-M, AFT/FORWARD — •

OFF
B-E, B-L, B-K
VERTICAL UP A-E, A-M, B-N, B-J
VERTICAL D O W N A-J, A - N , B-M, B-E
HORIZONTAL FORWARD A-L, B-K
HORIZONTAL AFT A-K, B-L

DOWN
FRONT TILT UP A-M, B-N
FRONT TILT D O W N A - N , B-M
TERMINALS SHOWN AS VIEWED

REAR TILT UP A-E, B-J FROM REAR OF SWITCH
REAR TILT D O W N A-J, B-E

908R-4
(2) Remove switch mounting screws and check for POWER SEAT SWITCH
battery voltage at red/light blue wire of switch con To check the power seat switch, remove the switch
nector. If OK, go to next step. If not OK, repair wir from its mounting position. Use an ohmmeter and
ing to circuit breaker. see the Power Seat Switch Continuity chart. Deter
(3) Check for continuity between black/orange wire
mine if switch continuity is correct. If OK, see Power
at switch connector and a good ground. There should
be continuity. If OK, replace faulty switch. If not OK, Seat Adjuster/Motors diagnosis. If not OK, replace
repair wiring to ground. faulty switch assembly.
BR POWER SE1TS 8R - 3
POWER SEAT CIRCUIT
CIRCUIT BREAKER #2
(30 A M P )
BATTERY
J948R-1
SERVICE PROCEDURES
POWER SEAT SWITCH REMOVE/INSTALL RELEASE TABS (3)

(2) Remove 2 screws holding switch and bezel to
seat (Fig. 1).
J948R-3
Fig. 2 Seat Switch Remove

(4) Pull switch from seat far enough to access con
nector, and unplug.
POWER SEAT ADJUSTER/MOTORS REiOWE/

J948R-2 INSTALL
Fig. 1 Seat Switch and Bezel Remove (2) Remove 3 bolts attaching seat frame to floor
(3) Remove 2 screws holding switch to bezel (Fig. pan.
2). (3) Remove 1 nut from stud locating seat frame to
floor pan.
li - 4 POWER SEATS BR
(4) Remove 2 bolts holding power seat to center (5) Unplug power seat wire harness connector lo
seat section (Figs. 3 and 4). cated under seat.
(6) Remove driver's seat assembly from vehicle.
(7) Remove 4 screws attaching seat track to seat
(Fig. 5).
Fig. 3 Driver's Power Seat Remove

Fig. 5 Power Seat Track Assembly
seat mounting screws to 20-N-m (15 ft. lbs.).
Fig. 4 Center Seat Section Attachment

BR — POWER _ WINDOWS 8S - 1
POWER WINDOWS
CONTENTS
page page
DIAGNOSIS ...........1 SERWICE PROCEDURES 3

GENERAL INFORMATION
Power door windows are optional 'equipment on positive and negative battery connection to the two
Earn truck models. The power windows operate only motor terminals will cause the motor to rotate in one
with the ignition switch in the ON position. This direction. Reversing current through these same two
group covers diagnosis and service of the electrical connections will cause the motor to rotate in the op
components peculiar to the power window system. posite direction. In addition, each power window mo
For service of mechanical components such as the tor is equipped with an integral automatic re-setting
regulator, lift plate or window tracks refer to Group circuit breaker to protect the motor from overloads.
23 - Body Components. The power window motor and gearbox assembly can
Following are general descriptions of the major not be repaired. If faulty, the entire assembly must
components in the power window system. Eefer to be replaced.
Group 8W - Wiring Diagrams for complete circuit de
scriptions and diagrams. CIRCUIT BREAKER
POWER WINDOW SWITCH An automatic re-setting circuit breaker in the fuse-
block module is used to protect the power window
Both door windows can be raised or lowered elec
trically by operating the dual two-way switches on system circuit. The circuit breaker can protect the
the driver's door panel. A single two-way switch on system from a short circuit, and can also protect the
the passenger's door panel operates only the window system from an overload condition caused by an ob
on the passenger's side. The switches cannot be re structed or stuck window glass or regulator. The cir
paired. If faulty, they must be replaced. cuit breaker can not be repaired. If faulty, it must be
replaced.
POWER WINDOW MOTOR
A permanent magnet motor moves the window reg
ulator through an - integral gearbox mechanism. A
DIAGNOSIS
It is necessary that the window be free to slide up tight in the tracks. If window is free, proceed with di
and down for the power window system to function agnosis that follows. If window is not free, refer to
properly. If the window is not free to move up and Group 23 - Body Components for service procedures.
down, the motor will overload and trip the circuit
breaker. To determine if the glass is free, disconnect CIRCUIT 1REAKER
regulator plate from the glass and slide window up Locate correct circuit breaker in fuseblock module.
and down by hand. Pull out slightly, but be sure that circuit breaker ter
An alternate method is to shake the glass in the minals still contact terminals in fuseblock module.
door, with the glass positioned between the up and Turn ignition switch to ON position. Connect ground
down stop positions. Check that the' glass can be wire of voltmeter to a good ground. With probe of
moved slightly from side to side, front to rear, and up voltmeter positive lead, check both terminals of cir
and down. Then check that window is not bound cuit breaker for battery voltage. If only one terminal
8S - 2 POWER WINDOWS BR
has battery voltage, circuit breaker is faulty and

must be replaced. If neither terminal has battery o ®l
voltage, repair circuit from ignition switch as re 2 I
quired.
5
3
I 4
POWER WINDOW SWITCH
Before you proceed with this diagnosis, confirm
I® o
proper circuit breaker operation. See Circuit Breaker

diagnosis. VIEW S H O W N FROM BACK OF SWITCH
(1) Remove switch from door trim panel. See
Power Window Switch Remove/Install. Carefully sep
arate multiple terminal block on wiring harness from SWITCH CONTINUITY
switch body. POSITION BETWEEN
(2) Check for continuity between connector cavity
for left switch pin 2 (Fig. 1) or connector cavities for PINS l & 4
right switch pins 2 and 4 (Fig. 2) and a good ground. OFF PINS 2 & 3
There should be continuity. If OK, go to next step. If
not OK, repair ground circuit as required. Note that PINS I & 4
right switch gets ground feed through the left switch. UP PINS 3 & 5
(3) Turn ignition switch to ON position. Check for
battery voltage at connector cavity for switch pin 5
PINS 2 & 3
(Fig. 1 or 2). If OK, go to next step. If not OK, repair DOWN PINS I & 5
wiring to circuit breaker as required.
(4) Test switch continuity. See Switch Continuity
charts (Fig. 1 or 2) to determine if continuity is cor
J958S-1
rect in the OFF, UP and DOWN switch positions. If
OK, go to Power Window Motor diagnosis. If not OK, Fig. 2 Right Side Switch Continuity
replace the switch.
(1) Remove door trim panel as described in Power
POWER WINDOW MOTOR Window Motor Remove/Install.
(2) Disconnect motor connector. Apply 12 volts
Before you proceed with this diagnosis, confirm across the motor terminals to check its operation in
proper switch operation. See Power Window Switch one direction. Reverse the polarity to check the oper
diagnosis. ation in the other direction. Remember, if window is
in the full up or down position the motor will not op
erate in that direction by design. If OK, repair wire
harness from the motor to the switch as required. If
not OK, replace the motor.
(3) If motor operates in both directions, check op
eration through its complete up and down travel. If
not OK, refer to Group 23 - Body Components to
VIEW S H O W N FROM BACK OF SWITCH
check window glass, tracks, and regulator for stick
SWITCH
POSITION
CONTINUITY BETWEEN ing, binding or improper adjustment.
OFF PINS 1 & 2, PINS 2 & 3
PINS 3 & A, PINS 4 & 6
PINS 1 & 5, PINS 2 & 3
LEFT PINS 3 & 4, PINS 4 & 6
iUin
r
PINS 1 & 2, PINS 2 & 4
RIGHT PINS 3 & 5, PINS 4 & 6
PINS 1 & 2, PINS 2 & 3
LEFT PINS 3 & 4, PINS 5 & 6
no\A/ivi
U v J V V IN PINS 1 & 2, PINS 2 & 3
RIGHT PINS 3 & 6 , PINS 4 & 5
J958S-2
Fig. 1 Left Side Switch Continuity

BR POWER WINDOWS 8S - 3
SERVICE PROCEDURES
POWER WINDOW SWITCH REMOWE/INSTALL (6) Install a new switch by inserting front of
(1) Remove 2 screws and door pull cup (Fig. 3). switch into trim panel then pushing down rear of
switch.
REMOVE 2 SCREWS
POWER WINDOW MOTOR REMOVE/INSTALL

To repair or inspect the entire electric window reg
ulator, remove from door as follows:
(1) Remove switch as described in Power Window
Switch Remove/Install.
(2) If equipped, pull power mirror switch control
knob rearward to remove from switch (Fig. 6).
J948S-2

switch retaining tab (Fig. 4).
Fig. 6 Power Mirror Knob Remove/lnstali

Fig. 4 Switch Bezei Rear Retaining Tab
7).
SWITCH RETAINING / / \
(3) Pull rear of switch up and away from door.
(4) Unplug connectors from switch (Fig. 5).
TABS FRONT CLIP J948S-8
Fig. 5 Door Switch Connectors
(5) Plug connector onto new switch.
Fig. 7 Power Mirror Switch Nut

8S - 4 POWER WINDOWS - —
To aid in removal of the trim panel, start at

the bottom of the panel.
(4) Using a wide flat-bladed tool such as a trim
stick, pry trim panel away from door around perime
ter and remove trim panel
(5) Roll door watershield away from bottom of door
to allow access to regulator screws (Fig. 8).
Fig. 10 Glass Channel Rear Attaching Nut
Fig. 8 Window Regulator Mounting Screws

(6) Move glass to allow access to glass channel at
taching hardware (Figs. 9 and 10).
J948S-7
Fig. 11 Window Regulator Remove

(14) Install remaining 4 screws.
(15) Tighten 4 regulator screws to 12 N-m (105 in.
lbs.).
(16) Move glass as far rearward into channel as
possible and push down. Tighten 2 window track
screws to 12 N-m (105 in. lbs.).
(17) Attach door glass by sliding 2 nuts into the
slots on the channel (Figs. 9 and 10). Tighten door
glass nuts to 12 N-m (105 in. lbs.).
Fig. 9 Glass Channel Front Attaching Nut (18) Connect wire harness connector to regulator.
(7) Slide the glass rearward to remove nuts from (19) Using 3M 08044 or 3M 08041 adhesive/seal
door panel. ant, install plastic watershield.
(8) Pull glass to full up position and tape to door. (20) If equipped, install power mirror switch into
(9) Unplug wiring connector from motor. trim panel using retaining nut (Fig. 7).
(10) Remove 2 window track and 2 regulator (21) Place trim panel in the installation position
screws (Fig. 8). and press in nylon retainers.
(11) Loosen 2 regulator screws (Fig. 8). (22) Install door pull cup and trim panel attaching
(12) Remove window regulator from door (Fig. 11). screws.
(13) To install, place regulator inside door and (23) Install power window/lock switch panel.
slide 2 loose screws into slots in door.
POWER MIRRORS
CONTENTS
page page

GENERAL INFORMATION . .. 1
This group covers power outside mirrors and the

automatic day/night inside rear view mirror, which
are available options on Ram truck models. Following
are general descriptions of the major components in
the power outside mirror and automatic day/night in
side rear view mirror systems. Refer to Group 8 W -
Wiring Diagrams for complete circuit descriptions
and diagrams.
POWER MIRRORS
The power mirrors are connected to battery feed at
all times. Each mirror head contains two electric mo
tors, two drive mechanisms and the mirror glass.
One motor and drive controls mirror up-and-down
movement, and the other controls right-and-left
movement.
The mirror glass is the only serviced replacement
part for the power mirror assembly. If any other com
ponent of the mirror unit is faulty or damaged, the
entire assembly must be replaced.
POWER MIRROR SWITCH
Both the right and left mirror are controlled by a Fig. 1 Power Mirror Switch
single multi-function switch located in the left door light levels received at the rear window side of the
trim panel (Fig. 1). The switch knob is rotated clock mirror. When the difference between the two levels
wise (right mirror) or counter-clockwise (left mirror) becomes too great (light level received at rear of mir
to select the mirror to be adjusted. The switch knob ror is much higher than front of mirror), the mirror
is then moved in a joystick fashion to control move begins to darken.
ment of the selected mirror up, down, right, or left. The mirror switch controls whether the automatic
dimming feature is on or off. When on is selected, the
AUTOMATIC DAY/NIGHT MIRROR switch is lighted by an integral LED. The mirror will
The automatic day/night mirror automatically only operate when the ignition switch is in the ON
changes its reflectance to reduce glare in all types of position. The mirror also senses the back-up lamp
driving conditions. A thin layer of electrochromic ma circuit and turns off whenever the transmission
terial between two pieces of conductive glass make (manual or automatic) is in reverse.
up the face of the mirror. As light conditions change,
The automatic day/night mirror can not be re
two photocell sensors adjust the reflectance while re
ducing glare from headlamps approaching from the paired. If faulty, the entire assembly must be re
rear. placed.
The mirror incorporates 2 sensors. The ambient
sensor (forward facing) detects normal outside light
levels. The headlamp sensor (rear facing) detects
8T - 2 POWER MIRRORS BR
DIAGNOSIS
POWER MIRRORS M S H i O I I REACTION

(1) Check fuse 17 in fuseblock module. If OK, go to 12 ¥©its Right Loft
next step. If not OK, replace fuse. YL/BK WT UP
(2) Check for battery voltage at fuse 17 in fuse- YL YL/PK UP
block module. If OK, go to next step. If not OK, re WT YL/BK DOWN
pair circuit to fuse 1 in Power Distribution Center YL/PK YL DOWN
(PDC). WT DB RIGHT
(3) Remove power mirror switch from the door YL/PK DB/WT RIGHT
trim panel. See Power Mirror Switch Remove/Install. DB WT LEFT
(4) Disconnect wiring harness connector from DB/WT YL/PK LEFT
switch. Check for battery voltage at pink wire. If OK, J928T-4
go to next step. If not OK, repair circuit to fuse 17 in
fuseblock module. Fig. 3 Mirror Test
(5) Check for continuity between black/orange wire
in switch harness connector and a good ground. AUTOMATIC DAY/NIGHT MIRROR
There should be continuity. If OK, go to next step. If (1) Check fuse 15 in fuseblock module. If OK, go to
not OK, repair circuit to ground. next step. If not OK, replace fuse.
(6) Check switch continuity as shown in the Mirror (2) Turn ignition switch to the ON position. Check
Switch Continuity chart (Fig. 2). If OK, go to next for battery voltage at fuse 15 in fuseblock module. If
step. If not OK, replace switch. OK, go to next step. If not OK, repair circuit from
fuse to ignition switch as required.
M i r r o r Selector K n o b i n "I" Position (3) Unplug harness connector from mirror (Fig. 4).
MOVE LEVER CONTINUITY BETWEEN Check for battery voltage at connector cavity with
YL/BK and PK, YL/PK and BK brown/light green wire. If OK, go to next step. If not
YL and PK OK, repair circuit to fuse 15 as required.
YL/PK and PK, DB and BK
DB/WT and BK
YL/PK and PK, YL and BK
YL/BK and BK
YL/PK and BK, DB and PK
DB/WT and PK
Miirir©/ SoSestor K n o b i n " R " Position
MOVE LEVER CONTINUITY iETWEIN
W T and BK, YL and PK
YL/BK and PK
W T and PK, DB and BK
DB/WT and BK
W T and PK, YL and BK
YL/BK and BK
W T and BK, DB and PK
0 DB/WT and PK 1
FORWARD FACING SENSOR J948T-9
J928T-5
Fig. 4 Automatic Day/Night Mirror
Fig. 2 Mirror Switch Continuity
• (4) Turn ignition switch to OFF position. Check for
(7) Use 2 jumper wires, one connected to a 12-volt continuity between connector cavity with black wire
source, and the other connected to a good body and a good ground, There should be continuity. If
ground. See Mirror. Test chart (Fig. 3) for correct OK, go to next step. If not OK, repair circuit to
jumper wire connections at the power mirror switch ground as required.
connector (harness side, not switch side). If mirror(s) (5) Turn ignition switch to ON position. Set park
don't respond as indicated, remove mirror connector ing brake. Place transmission gear selector in Re
as described in Power Mirror Remove/Install. Check verse position. Check for battery voltage at connector
the wires in that circuit between mirror and switch cavity with violet/black wire. If OK, plug mirror con
for a short or open. If circuits check OK, replace mir nector back in and go to next step. If not OK, repair
ror assembly. circuit to back-up lamps as required.
13 R POWER MIRRORS 8T - 3
(6) Place transmission gear selector in Neutral. (7) Shine a light into the rear facing sensor. The
Place mirror switch in ON (switch lighted) position. mirror should darken. If OK, go to next step. If not
Cover the forward facing sensor to keep out any am OK, replace mirror
bient light. Light sensor must be covered com (8) With the mirror darkened, place the transmis
pletely so that no light reaches the sensor. Use sion gear selector in Reverse. The mirror should re
only one finger pressed tightly against sensor, turn to its normal condition. If not OK, replace
or cover sensor completely with electrical tape. mirror.
SERVICE PROCEDURES
POWER MIRROR SWITCH REMOVE/INSTALL

REMOVE 2 SCREWS
J948S-2

switch retaining tab (Fig. 6).

(3) Pull rear of switch up and away from door.
(4) Unplug connectors from switch (Fig. 7). Fig. 8 Power Mirror Knob Remove/Install
(5) Pull power mirror switch control knob rearward
(9) To install switch, mount into trim panel using
to remove from switch (Fig. 8).
retaining nut (Fig. 9).
9).
(10) Plug switch connector together (Fig. 10).
To aid in removal of the trim panel, start at (11) Place trim panel in position and press in nylon
the bottom of the panel. retainers.
(7) Using a wide flat-bladed tool such as a trim (12) Install power mirror switch control knob by
stick, pry trim panel away from door around perime pushing onto control stem.
ter and remove trim panel. (13) Place front of door switch panel into opening.
(8) Unplug power mirror switch connector (Fig. Press rear of switch panel into place.
10). (14) Install door pull cup.
8T - 4 POWER MIRRORS BR
Fig. 11 Power Mirror Remove/Install

AUTOMATIC DAY/NIGHT MIRROR REMOVE/
INSTALL
(1) If so equipped, remove wire cover by grasping
lower portion of wire cover and sliding into upper
portion and off of mirror base (Fig. 12).
ON/OFF ELECTRICAL
Fig. 10 Power Mirror Switch Connector SWITCH CONNECTOR
(15) Install door panel attaching screws.
Fig. 12 Automatic Day/Night Mirror Remove/Install
POWER MIRROR REMOVE/INSTALL (2) Unplug connector behind mirror.
(1) Remove door trim panel as described in Power (3) Remove screw holding mirror to windshield.
Mirror Switch Remove/Install. (4) Push mirror up far enough to clear the support
(2) Unplug mirror motor connector (fig. 11). and remove mirror.
(3) Remove 3 nuts holding mirror to door. (5) Reverse removal procedures to install.
BR — — — ——— CHIME/BUZZER WARNING SYSTEMS 8U - 1
CHIME/BUZZER WARNING SYSTEMS
CONTENTS
page page
ilAGNOSIS . 2 SERVICE PROCEDURES .................... 4

GENERAL INFORMATION .. 1
This group covers the buzzer warning system,

which is standard equipment on Ram truck models.
The system provides an audible warning to the
driver when it monitors the following conditions:
• key is in ignition switch with the driver's door
open BUZZER
• head or park lamps are on with driver's door open MODULE
• driver's seat belt is not buckled with ignition
switch in ON position.
Following are general descriptions of the major
components in the buzzer warning system. Refer to
Group 8 W - Wiring Diagrams for complete circuit de
scriptions and diagrams.
BUZZER MODULE
The buzzer module is located on the fuseblock mod
ule (Fig. 1). It receives battery voltage at all times Fig. 1 Buzzer Module
from fuse 17 in the fuseblock module. It also receives
column. It closes a path to ground for the buzzer
a second battery feed through fuse 11 when the igni
tion switch is in the ON or START position. module when the ignition key is inserted in the igni
Other inputs to the module include the driver's tion lock cylinder and the driver's door jamb switch
door jamb switch, the driver's seat belt switch, the ig is closed (door open). The switch opens when the key
nition key-in switch, and the headlamp switch. The is removed from the ignition lock cylinder. This
only output of the module is a timed 4 to 8 second switch can not be repaired. If faulty, the entire igni
feed to the seat belt reminder lamp in the instru tion switch must be replaced. Refer to Group 8D - Ig
ment cluster. The timer function begins after the ig nition Systems for service procedures.
nition switch is turned to the ON position.
The buzzer module can not be repaired. If faulty, it HEADLAMP SWITCH
must be replaced. The headlamp switch is located in the instrument
panel. It closes a path to ground for the buzzer mod
DRIVER'S DOOR JAMB SWITCH ule when the park or headlamps are on and the driv
The driver's door jamb switch is mounted to the er's door jamb switch is closed (door open). The
driver's door hinge pillar. The switch closes a path to switch opens the ground path when the park and
ground for the buzzer module through the key-in headlamps are turned off. The headlamp switch can
switch or headlamp switch when the driver's door is not be repaired. If faulty, it must be replaced. Refer
opened, and opens when the driver's door is closed. to Group 8E - Instrument Panel and Gauges for ser
This switch can not be repaired. If faulty, it must be vice procedures.
replaced.
DRIVER'S SEAT BELT SWITCH
IGNITION KEY-IN SWITCH The driver's seat belt switch is integral to the driv
The key-in switch is integral to the ignition switch, er's seat belt buckle-half assembly. The switch is nor
which is mounted on the right side of the steering mally closed, providing a ground path to the buzzer
§U - 2 CHIME/BUZZER WARNING SYSTEMS B R
module. When the tip-half of the seat belt is inserted paired. If faulty, the entire driver's seat belt buckle-
into the seat belt buckle, the switch opens the buzzer half' must be replaced. Eefer to Group 23 - Body
ground path. The seat belt switch can not be re- Components for service procedures.
DIAGNOSIS
BUZZER MODULE
(1) Check fuse 17 and fuse 11 in the fuseblock
module. If fuses are OK, go to next step. If not OK, S E A T BELT
replace fuses as required. SWITCH
(2) Check for battery voltage at fuse 17 in fuse-

block module, if OK, go to next step. If not OK, re
pair feed circuit from power distribution center as
required.
battery voltage at fuse 11 in the fuseblock module, if
OK, go to next step, if not OK, repair feed from ig
nition switch as required. GROUND
(4) Turn ignition switch to OFF position. Replace SEAT B E L T ! r f L

buzzer module with a known good unit and test op
eration. If not OK, remove buzzer module and go to LIGHT
next step. IGNITION

(5) Check for battery voltage at cavity for buzzer
terminal 7 (Fig.2) in fuseblock module (Fig. 3). If OK,
go to next step. If not OK, repair circuit to fuse 17. TO D O O R SWITCH
- KEY I N SWITCH A N D
UGHTS-ON / KEY-1N - IGNITION HEAD LAMP O N SWITCH J948U-3
WARNING
/ TOP. Fig. 3 Buzzer Module Connector
BATTERY ( + )
DRIVER'S DOOR JAMB SWITCH
(1) Open driver's door and note whether interior
lamps light. They should light. If OK, see diagnosis
for Ignition Key-In Switch or Headlamp Switch. If
not OK, go to next step.
(2) Check for continuity between door jamb switch
body and a good ground. There should be continuity.
If OK, go to next step. If not OK, tighten or clean
switch attachment to hinge pillar as required to re
SEAT BELT
SWITCH store ground path.
IGNITION SEAT BELT GROUND
\RHMG LIGHT J928U-9 (3) Remove switch from hinge pillar and check
wire connections for clean and tight engagement. If
Fig. 2 Buzzer Module Terminals OK, replace faulty switch. If not OK, clean and
tighten connections as required.
battery voltage at cavity for buzzer terminal 1 in
IGNITION KEY-IN SWITCH
fuseblock module. If OK, go to next step. If not OK,
repair circuit to fuse 11 in fuseblock module. (1) Remove steering column shrouds (refer to
(7) Turn ignition switch to OFF position. Check for Group 8D - Ignition Systems for procedure). Unplug
continuity between cavity for buzzer terminal 3 and ignition key-in switch connector from ignition switch
a good ground. There should be continuity if OK, go (Fig. 4). Open driver's door. Check for continuity be
to diagnosis for switch that is related to buzzer mal tween key-in connector (Fig. 5) cavity 4 (black/light
function. If not OK, repair circuit to ground" as re blue wire) and a good ground. There should be conti
quired. nuity. If OK, go to next step. If not OK, repair circuit
to driver's door jamb switch as required.
BR CHIME/BUZZER WARNING SYSTEMS 8U - 3
KEY-IN SWITCH & MULTI-FUNCTION (3) Check continuity between headlamp switch ter
HALO LIGHT SWITCH m i n a l for connector cavity w i t h black/light blue wire
and t e r m i n a l for cavity w i t h light blue wire. There
should be no continuity w i t h switch i n off position,
and there should be continuity w i t h switch i n p a r k
lamps or headlamps on position. I f not OK, replace
headlamp switch.
DRIVER'S SEAT BELT SWITCH

TURN SIGNAL (1) U n p l u g seat belt switch connector near seat
SWITCH & LEVER
belt anchor on floor. Check for continuity between
t w o cavities of seat' belt h a l f of connector. There
should be continuity w i t h seat belt unbuckled, and
IGNITION SPEED no continuity w i t h seat belt buckled. I f OK, go to
CONTROL J918J-2 next step. I f not OK, replace seat belt buckle-half as
SWITCH
sembly.
Fig. 4 Key-In Switch Connector (2) Check for continuity between cavity w i t h black/
orange wire i n harness h a l f of seat belt switch con
O O O O nector and a good ground. There should be
continuity. I f O K , go to next step. I f not OK, repair
4 3 2 1
CONTINUITY circuit to ground as required.
WIRE
APPLICATION BETWEEN (3) Check for continuity between cavity w i t h l i g h t
CAVITY
1 Hab lamp 1 & 2 Almost zero ohms green/red wire i n harness h a l f of seat belt switch con
2 Hab lamp (bulb filament) nector and cavity for t e r m i n a l 4 of buzzer module i n
3 Key-in warning switch 3 & 4 with key in ignition fuseblock module. There should be continuity. I f not
4 Key-in warning switch
O K , repair circuit f r o m seat belt switch connector to
J918M-3 fuseblock module as required.
Fig. 5 Key-In Switch Continuity BUZZER MODULE SCHEMATIC
(2) Insert ignition key i n ignition lock cylinder.
Check for continuity between key-in switch cavities 3
r—i DOOR s w
and 4. There should be continuity u n t i l key is re
moved. I f OK, go to next step. I f not OK, replace ig J (SHOWN DOOR CLOSED)
n i t i o n switch. KEY SW* il LIGHTS S W
(3) Check for continuity between key-in switch har (SHOWN KEY OUT) / / (SHOWN LIGHTS OFF)
!
—H 1—h/H-°B+
ness connector cavity 3 (light blue wire) and cavity
5 6 7 8
for t e r m i n a l 6 of buzzer module i n fuseblock module. • • • •
There should be continuity. I f not OK, repair circuit • • • •
from switch to fuseblock module as required. 1 2 3 4
HEADLAMP SWITCH , ,^,l#nfej^ m

1 SEAT BELT S W
(1) Remove headlamp switch from i n s t r u m e n t (SHOWN IGN OFF) BULKLtu)
panel (refer to Group 8E - I n s t r u m e n t Panel and PIN VIEW (SAME AS REAR SIDE [WIRE SIDE)
Gauges for procedure). U n p l u g headlamp switch con CONNECTOR VIEW)
nector. Open driver's door. Check for continuity be X = Do Not Care
SEAT DRIVER'S
tween headlamp switch connector cavity w i t h black/ FUNCTION DESCRIPTION IGN. KEY HEAD
BELT DOOR LAMPS
l i g h t blue wire and a good ground. There should be
4 to 8 Second ^ O n Not
continuity u n t i l driver's door is closed. I f OK, go to Tone and X X X
Seat Lamp Output O P Bckld
next step. I f not OK, repair circuit f r o m headlamp Belt
switch to driver's door j a m b switch as required. Reminder 4 to 8 Second ^ O n
(2) Check for continuity between headlamp switch LamoÔutput Bckld X X X
OP
connector cavity w i t h light blue wire and cavity for
t e r m i n a l 6 of buzzer module i n fuseblock module. Key and Continuous, In X
There should be continuity. I f OK, go to next step. I f Head Lamp Steady X X Open
Reminder* Tone X On
not OK, repair circuit from headlamp switch to fuse-
block module as required. J948U-9
3U - 4 CHIME/BUZZER WARNING SYSTEMS BR
BUZZER MODULE REMOVE/INSTALL

(2) Remove 5 screws and knee blocker from lower
instrument panel (Fig. 6).
Fig. 6 Knee Blocker

(3) Remove 2 screws holding fuseblock module to Fig. 7 Fuseblock Module Remove/Install
instrument panel (Fig. 7).
(4) Pull fuseblock module back far enough to gain
access to buzzer module.
(5) Pull buzzer module out of fuseblock module.
SWITCHES REMOVE/INSTALL
Service procedures for switches used in the buzzer
system can be found in the appropriate groups as fol
lows:
• driver's door jamb switch - refer to Group 8L -
Lamps
• ignition key-in switch - refer to Group 8D - Igni
tion Systems
• headlamp switch - refer to Group 8E - Instrument
Panel and Gauges
• driver's seat belt switch - refer to Group 23 - Body
Components.
BR WIRING DIAGRAMS 8W - 1
WIRING Dl AGF
CONTENTS
page page
8W-01 GENERAL INFORMATION - \WRING 8W-44 INTERIOR LIGHTING 8W-44-1

DIAGRAMS 8W-01-1 8W-45 MESSAGE CENTER 8W-46-1
8W-10 FUSE/FUSE BLOCK 8W-10-1 8W-47 AUDIO SYSTEMS 8W-47-1
8W-11 POWER DISTRIBUTION . . . 8W-11-1 8W-49 OVERHEAD CONSOL 8W-49-1
8W-12 JUNCTION BLOCK 8W-12-1 8W-50 FRONT LIGHTING 8W-50-1
8W-15 GROUND DISTRIBUTION .. 8W-15-1 8W-51 REAR LIGHTING . 8W-51-1
8W-20 CHARGING SYSTEM . . . . . . 8W-20-1 8W-52 TURN SIGNALS .. 8W-52-1
8W-21 STARTING SYSTEM 8W-21-1 8W-53 WIPERS 8W-53-1
8W-30 FUEL/IGNITION . . . . . . . . . . 8W-30-1 8W-54 TRAILER TOW . . . 8W-54-1
8W-31 TRANSMISSION CONTROL . . . . 8W-31-1 8W-60 POWER WINDOWS 8W-60-1
8W-32 ANTI-LOCK BRAKES 8W-32-1 8W-61 POWER DOOR LOCK 8W-61-1
8W-33 VEHICLE SPEED CONTROL 8W-33-1 8W-62 POWER MIRRORS 8W-62 1
8W-39 VEHICLE THEFT ALARM . . . 8W-39-1 8W-63 POWER SEAT . . . 8W-63-1
8W-40 INSTRUMENT CLUSTER . . . . . . . . 8W-40-1 8W-70 SPLICE INFORMATION . 8W-70-1
8W-41 HORNS/CIGAR LIGHTER . . . . . . . . 8W-41-1 8W-80 CONNECTOR PIN OUTS 8W-80-1
8W-42 AIR CONDITIONING-HEMS? . . . . 8W-42-1 8W-90 CONNECTOR LOCATIONS 8W-90-1
8W-43 AIRBAG SYSTEM . . . . . . . . 8W-43-1 8W-95 SPLICE LOCATIONS . . . 8W-95-1
HOW TO USE THIS GROUP tems or components between the models, an identi
The purpose of this group is to show the electrical fier is placed next to the component.
circuits in a clear, simple fashion and to make trou
bleshooting easier. Components that work together SECTION IDENTIFICATION
are shown together. All electrical components used in Sections in Group 8W are organized by sub-sys
a specific system are shown on one diagram. The feed tems. The sections contain circuit operation descrip
for a system is shown at the top of the page. All tions, helpful information, and system diagrams. The
wires, connectors, splices, and components are shown intention is to organize information by system, con
in the flow of current to the bottom of the page. Wir sistently from year to year.
ing which is not part of the circuit represented is ref
erenced to another page/section, where the complete CONNECTOR LOCATIONS
circuit is shown. In addition, all switches, compo Section 8W-90 contains Connector Location illus
nents, and modules are shown in the at rest posi trations. The illustrations contain the connector
tion with the doors closed and the key removed number and component identification. Connector Lo
from the ignition. cation charts in Section 8W-90 reference the illustra
If a component is part of several different circuits, tion number for components and connectors.
it is shown in the diagram for each. For example, the Section 8W-80 shows each connector and the cir
headlamp switch is the main part of the exterior cuits involved with that connector. The connectors
lighting, but it also affects the interior lighting and are identified using the number on the Diagram
the chime warning system. pages.
It is important to realize that no attempt is
made on the diagrams to represent components SPLICE LOCATIONS
and wiring as they appear on the vehicle. For Splice Location charts in Section 8W-70 show the
example, a short piece of wire is treated the entire splice, and provide references to other sections
same as a long one. In addition, switches and the splice serves.
other components are shown as simply as pos Section 8W-95 contains illustrations that show the
sible, with regard to function only. general location of the splices in each harness. The
Both the standard cab and club cab models are illustrations show the splice by number, and provide
shown in this section. If there is a difference in sys a written location.
BR 8W-01 GENERAL INFORMATION—WIRING D1AGRA1S 8W - 01 - 1
GENERAL INFORMATION—WIRING DIAGRAMS
INDEX
page page
Circuit Identification . . *. . . . . . . . . . . 1 Take Outs 2

Connector and Terminal Replacement 7 Terminal Replacement 8
Connector Replacement 6 Terminal/Connector Repair—Molex Connectors .... 6
Connectors 2 Troubleshooting Tests 4
Diode Replacement 8 Troubleshooting Tools 4
Electrostatic Discharge (ESD) Sensitive Devices ... 2 Troubleshooting Wiring Problems 5
Intermittent and Poor Connections 4 Wire Code Identification 1
Notes, Cautions, and Warnings 1 Wiring Repair 6
Symbols 2
NOTES, CAUTIONS, and WARNINGS TO P R E V E N T S E R I O U S B U R N S , AVOID CONTACT

WITH HOT PARTS S U C H A S THE RADIATOR, E X
Throughout this group additional important infor
HAUST MANIFOLD(S), TAIL P I P E , CATALYTIC CON
mation is presented in three ways; Notes, Cautions,
V E R T E R , AND M U F F L E R .
and Warnings.
NOTES are used to help describe how switches or
components operate to complete a particular circuit. DO NOT A L L O W FLAME OR S P A R K S NEAR THE
They are also used to indicate different conditions BATTERY. G A S E S A R E ALWAYS P R E S E N T IN AND
that may appear on the vehicle. For example, an AROUND THE BATTERY.
up-to and after condition.
CAUTIONS are used to indicate information that
could prevent making an error that may damage the ALWAYS REMOVE RINGS, WATCHES, L O O S E
vehicle. HANGING J E W E L R Y , AND LOOSE CLOTHING.
WARNINGS provide information to prevent per
sonal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a WIRE CODE IDENTIFICATION
vehicle is being serviced. Each wire shown in the diagrams contains a code
ALWAYS WEAR S A F E T Y G L A S S E S FOR E Y E PRO (Fig. 1) which identifies the main circuit, part of the
TECTION. main circuit, gauge of wire, and color. The color is
shown as a two letter code which can be identified by
referring to the Wire Color Code Chart (Fig. 2).
USE SAFETY STANDS ANYTIME A P R O C E D U R E
A 2 18 LB/YL
R E Q U I R E S B E I N G UNDER A VEHICLE.
B E S U R E THAT THE IGNITION SWITCH ALWAYS IS

IN THE O F F POSITION, U N L E S S THE P R O C E D U R E I COLOR OF WIRE
R E Q U I R E S IT TO B E ON. (Light Blue with Yellow Tracer)
GAUGE OF WIRE
S E T THE PARKING B R A K E W H E N WORKING ON
(1 8 Gauge)
ANY VEHICLE. AN AUTOMATIC TRANSMISSION
SHOULD B E IN PARK. A MANUAL TRANSMISSION I PART OF MAIN CIRCUIT
SHOULD B E IN NEUTRAL. (Varies Depending on Equipment)
— MAIN CIRCUIT IDENTIFICATION
O P E R A T E THE ENGINE ONLY IN A WELL-VENTI J958W-37
LATED A R E A .
Fig. 1 Wire Color Code Identification
K E E P AWAY FROM MOVING PARTS W H E N THE E N CIRCUIT IDENTIFICATION

GINE IS RUNNING, E S P E C I A L L Y THE FAN AND All circuits in the diagrams use an alpha/numeric
BELTS. code to identify the wire and its function (Fig. 3). To
8W - 01 - 2 8W-01 GENERAL INFORMATION—WIRING DIAGRAMS BR
STANDAiD STANDARD CONNECTORS

C O L O i COLOi COLOI
TRACE! COLOi TRACER
CODE CODE
CODE
Connectors shown in the diagrams are identified
COLOR
using the international standard arrows for male and
BL BLUE WT OR ORANGE BK female terminals (Fig. 4). A connector identifier is
placed next to the arrows to indicate the connector
BK BLACK WT PK PINK BK OR WT number (Fig. 4).
BR BROWN WT RD RED WT (MALE TERMINAL) (CONNECTOR
IDENTIFICATION
DB DARK WT TN TAN WT NUMBER)
BLUE
DG DARK WT VT VIOLET WT
GREEN
(FEMALE
GY GRAY BK WT WHITE BK TERMINAL)
LB LIGHT BK YL YELLOW BK
BLUE 948W-191
* WITH TRACER
LG LIGHT BK
Fig. 4 Connector Identification
GREEN
For viewing connector pin outs, with two terminals
918W-136 or greater, refer to section 8W-80. This section iden
tifies the connector by number and provides terminal
Fig. 2 Wire Color Code Chart
numbering, circuit identification, wire colors, and
identify which circuit code applies to a system, refer functions.
to the Circuit Identification Code Chart. This chart All connectors are viewed from the terminal end
shows the main circuits only and does not show the unless otherwise specified. To find the connector loca
secondary codes that may apply to some models. tion in the vehicle refer to section 8W-90. This sec
tion uses the connector identification number from
the wiring diagrams to provide a figure number ref
CIRCUIT FUNCTION erence.
A Battery Feed
B Brake Controls FAKE OUTS
C Climate Controls The abbreviation T/O is used in the component lo
D Diagnostic Circuits
cation section to indicate a point in which the wiring
E Dimming Illumination Circuits
F Fused Circuits (Secondary Feed) harness branches out to a component.
G Monitoring Circuits (Gauges)
H Open SYMBOLS
I Not Used Various symbols are used throughout the Wiring
J Open Diagrams. These symbols can be identified by refer
K Powertrain Control Module ring to the symbol identification chart (Fig. 5).
L Exterior Lighting
M Interior Lighting ELECTROSTATIC DISCHARGE (ESD) SENSITIVE
N ESA Module
O Not Used DEVICES
P Power Option (Battery Feed) All ESD sensitive components are solid state and a
Q. Power Options (Battery Feed) symbol (Fig. 6) is used to indicate this. When han
R Passive Restraint dling any component with this symbol, comply with
S Suspension/Steering the following procedures to reduce the possibility of
T Transmission/Transaxle/Transfer Case
U Open
electrostatic charge build up on the body and inad
V Speed Control, Washer/Wiper
vertent discharge into the component. If it is not
Open known whether the part is ESD sensitive, assume
w that it is.
X Audio Systems
Y Open (1) Always touch a known good ground before han
z Grounds dling the part. This should be repeated while han
948W-190 dling the part and more frequently after sliding
across a seat, sitting down from a standing position,
Fig. 3 Circuit Identification or walking a distance.
BR — — — 8W-01 GENERAL INFORMATION—WIRING DIAGRAMS 8W - 01 - 3
LIGEND OF SYMBOLS USED O N W I R I N G DIAGRAMS
+ POSITIVE BY-DIRECTIONAL Z E N E R DIODE
_ NEGATIVE
o MOTOR
GROUND
0 ARMATURE A N D B R U S H E S
FUSE CONNECTOR IDENTIFICATION
G A N G F U S E S W I T H B U S S BAR
-» MALE CONNECTOR
CIRCUIT BREAKER >— FEMALE CONNECTOR
DENOTES W I R E C O N T I N U E S ;
CAPACITOR —S ELSEWHERE |
DENOTES W I R E G O E S TO O N E O F T W O
n OHMS
CIRCUITS
RESISTOR SPLICE
VARIABLE RESISTOR S100 SPLICE IDENTIFICATION
SERIES RESISTOR —rftp— THERMAL ELEMENT
COIL | TIMER ™|
TIMER
—vfl{Lr—11 MULTIPLE CONNECTOR 1

STEP UP COIL
' y y y '
OPTIONAL W I R I N G WITH |
O P E N CONTACT
W I R I N G WITHOUT
CLOSED CONTACT y " Y " WINDINGS
CLOSED SWITCH BBBB DIGITAL READOUT
O P E N SWITCH SINGLE FILAMENT LAMP
CLOSED G A N G E D SWITCH DUAL FILAMENT LAMP
O P E N G A N G E D SWITCH L.E.D. - LIGHT EMITTING DIODE
T W O POLE S I N G L E THROW SWITCH THERMISTOR
PRESSURE SWITCH GAUGE
n S O L E N O I D SWITCH
MERCURY SWITCH
SENSOR
FUEL INJECTOR
DIODE OR RECTIFIER
948W-192
Fig. 5 Symbol Identification

8W - 01 - 4 8W-01 GE1ERAL INFORMATION—WIRING DIAGRAMS BR
(2) Avoid touching electrical terminals of the part, • Probing Tools - These tools are used for probing
unless instructed to do so by a written diagnostic terminals in connectors (Fig. 7). Select the proper
procedure. size tool from Special Tool Package 6807, and insert
(3) When using a voltmeter, be sure to connect the it into the terminal being tested. Use the other end
ground lead first. of the tool to insert the meter probe.
(4) Do not remove the part from its protective
packing until it is time to install the part. SPECIAL TOOL
(5) Before removing the part from its package, 6801
ground the package to a known good ground on the
vehicle.
PROBING
END 948W-233
Fig. 7 Probing Tool

INTERMITTENT AND POOR CONNECTIONS
Most intermittent electrical problems are caused by
948W-193
faulty electrical connections or wiring. It is also pos
Fig. 6 Electrostatic Discharge Symbol
sible for a sticking component or relay to cause a
problem. Before condemning a component or wiring
TROUBLESHOOTING TOOLS assembly check the following items.
When diagnosing a problem in an electrical circuit • Connectors are fully seated
there are several common tools necessary. These tools • Spread terminals, or terminal push out
are listed and explained below, ® Terminals in the wiring assembly are fully seated
• Jumper Wire - This is a test wire used to connect into the connector/component and locked in position
two points of a circuit. It can be used to bypass an © Dirt or corrosion on the terminals. Any amount of
open in a circuit. corrosion or dirt could cause an intermittent problem
• Damaged connector/component casing exposing the J
WARNING: NEVER USE A JUMPER WIRE ACROSS item to dirt and moisture
A LOAD, S U C H A S A MOTOR, CONNECTED B E © Wire insulation that has rubbed through causing a
TWEEN A BATTERY F E E D AND GROUND. short to ground
• Wiring broke inside of the insulation
© Voltmeter - Used to check for voltage on a circuit.
Always connect the black lead to a known good TROUBLESHOOTING TESTS
ground and the red lead to the positive side of the
circuit. Before beginning any tests on a vehicle's electrical
system, use the Wiring Diagrams and study the cir
CAUTION: Most of the electrical components used cuit. Also refer to the Troubleshooting Wiring Prob
in today's vehicle are solid state. When checking lems section in this section.
voltages in these circuits use a meter with a 10-me-
TESTING FOR VOLTAGE
gohm or greater impedance.
(1) Connect the ground lead of a voltmeter to a
• Ohmmeter - Used to check the resistance between known good ground (Fig. 8).
two points of a circuit. Low or no resistance in a cir (2) Connect the other lead of the voltmeter to the
cuit means good continuity. selected test point. The vehicle ignition may need to
be turned ON to check voltage. Refer to the appropri
CAUTION: Most of the electrical components used ate test procedure.
in today's vehicle are Solid State. When checking
resistance in these circuits use a meter with a 10- TESTING FOR CONTINUITY
megohm or greater impedance. In addition, make (1) Remove the fuse for the circuit being checked
sure the power is disconnected from the circuit. or, disconnect the battery.
Circuits that are powered up by the vehicle electri (2) Connect one lead of the ohmmeter to one side
cal system can cause damage to the equipment and of the circuit being tested (Fig. 9).
provide false readings.
BR — 8W-01 GENERAL INFORMATION—WIRING DIAGRAMS — — — 8W - 01 - 5
(3) Starting at the fuse block, wiggle the wiring

harness about six to eight inches apart and watch
- n r + the voltmeter/test lamp.
(4) If the voltmeter registers voltage or the test
lamp glows, there is a short to ground in that gen
eral area of the wiring harness.
4 ///
TESTING FOR A SHORT TO GROUND ON
FUSES POWERING SEVERAL LOADS
(1) Refer to the wiring diagrams and disconnect or
isolate all items on the fused circuit.
(2) Replace the blown fuse.
(3) Supply power to the fuse by turning ON the ig
+ - nition switch or re-connecting the battery.
6 o
(4) Start connecting the items in the fuse circuit
one at a time. When the fuse blows the circuit with
the short to ground has been isolated.
TESTING FOR A VOLTAGE DROP
(1) Connect the positive lead of the voltmeter to
948W-194 the side of the circuit closest to the battery (Fig. 10).
(2) Connect the other lead of the voltmeter to the
Fig. 8 Testing for Voltage other side of the switch or component.
(3) Connect the other lead to the other end of the (3) Operate the item.
(4) The voltmeter will show the difference in volt
circuit being tested. Low or no resistance means good
age between the two points.
continuity.
r JDL
+
FUSE R E M O V E D
F R O M CIRCUIT
+ -
C ( M ) ]
948W-196
948W-195
Fig. 10 Testing for Voltage Drop
Fig. 9 Testing for Continuity
TESTING FOR A SHORT TO GROUND
TROUBLESHOOTING WIRING PROBLEMS
(1) Remove the fuse and disconnect all items in When troubleshooting wiring problems there are
volved with the fuse. six steps which can aid in the procedure. The steps
(2) Connect a test light or a voltmeter across the are listed and explained below. Always check for non-
factory items added to the vehicle before doing any
terminals of the fuse.
diagnosis. If the vehicle is equipped with these items,
disconnect them to verify these add-on items are not
the cause of the problem.
8W - 01 - 6 — — 8W-01 GENERAL INFORMATION—WIRING DIAGRAMS
(1) Verify the problem.

(2) Verify any related symptoms. Do this by per
forming operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
(3) Analyze the symptoms. Use the wiring dia
grams to determine what the circuit is doing, where
the problem most likely is occurring and where the
diagnosis will continue.
(4) Isolate the problem area.
(5) Repair the problem.
(6) Verify proper operation. For this step, check for
proper operation of all items on the repaired circuit.
Refer to the wiring diagrams.
WIRING REPAIR
When replacing or repairing a wire, it is important
that the correct gauge be used as shown in the wir
ing diagrams. The wires must also be held securely
in place to prevent damage to the insulation.
(2) Remove 1 inch of insulation from each end of 918W-20
the wire.
(3) Place a piece of heat shrink tubing over one Fig. 11 Wire Repair
side of the wire. Make sure the tubing will be long
enough to cover and seal the entire repair area.
(4) Spread the strands of the wire apart on each
part of the exposed wires (Fig. 11 example 1).
(5) Push the two ends of wire together until the
strands of wire are close to the insulation (Fig. 11 ex
ample 2).
(6) Twist the wires together (Fig. 11 example 3).
(7) Solder the connection together using rosin core
type solder only. Do not use acid core solder.
(8) Center the heat shrink tubing over the joint,
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing. SPECIAL TOOL
(9) Secure the wire to the existing ones to prevent 6742 948W-234
chafing or damage to the insulation.
(10) Connect battery and test all affected systems. Fig. 12 Molex Connector Repair
(2) Disconnect the connector that is to be repaired
TERMINAL/CONNECTOR REPAIR—MOLEX from its mating half/component.
CONNECTORS (3) Remove connector locking wedge, if required
(1) Disconnect battery. (Fig. 14).
(2) Disconnect the connector from its mating half/ (4) Position the connector locking finger away from
component. the terminal using the proper pick from special tool
(3) Insert the terminal releasing special tool 6742 kit 6680. Pull on the wire to remove the terminal
into the terminal end of the connector (Fig. 12). from the connector (Fig. 15, and Fig. 16).
(4) Using special tool 6742, release the locking fin (5) Reset the terminal locking tang, if it has one.
gers on the terminal (Fig. 13). (6) Insert the removed wire in the same cavity on
(5) Pull on the wire to remove it from the connec the repair connector.
tor. (7) Repeat steps four through six for each wire in
(6) Repair or replace the connector or terminal as the connector, being sure that all wires are inserted
necessary. into the proper cavities. For additional connector pin-
out identification, refer to the wiring diagrams.
CONNECTOR REPLACEMENT (8) Insert the connector locking wedge into the re
(1) Disconnect battery. paired connector, if required.
BR 8W-01 GENERAL INFORMATION—WIRING DIAGRAMS 8W - 01 - 7
CONNECTOR
SPECIAL TOOL
948W-235 CONNECTOR 948W-237
6742
Fig. 13 Using Special Tool 6742 Fig. 16 Terminal Removal Using Special Tool
CONNECTOR (2) Disconnect the connector (that is to be re
paired) from its mating half/component.
(3) Cut off the existing wire connector directly be
hind the insulator. Remove six inches of tape from
the harness.
(4) Stagger cut all wires on the harness side at 1/2
inch intervals (Fig. 17).
(5) Remove 1 inch of insulation from each wire on
the harness side.
(6) Stagger cut the matching wires on the repair
connector assembly in the opposite order as was done
on the harness side of the repair. Allow extra length
for soldered connections. Check that the overall
length is the same as the original (Fig. 17).
CONNECTOR LOCKING
WEDGE TAI 928W-143
REPAIR SIDE STAGER CUTS
WIRES
Fig. 14 Connector Locking Wedge Tab (Typical)
(9) Connect connector to its mating half/compo
nent.
(10) Connect battery and test all affected systems.
HARNESS WIRES 928W-145
Fig. 17 Stagger Cutting Wires (Typical)

(7) Remove 1 inch of insulation from each wire.
(8) Place a piece of heat shrink tubing over one
FROM side of the wire. Be sure the tubing will be long
SPECIAL TOOL
KIT 6680 948W-236 enough to cover and seal the entire repair area.
(9) Spread the strands of the wire apart on each
Fig. 15 Terminal Removal part of the exposed wires (Fig. 11 example 1).
CONNECTOR AND TERMINAL REPLACEMENT strands of wire are close to the insulation (Fig. 11 ex
(1) Disconnect battery. ample 2).
SW - 11 - 8 8W-I1 GENERAL INFORMATION—WIRING DIAGRAMS BR
(11) Twist the wires together (Fig, 11 example 3). (15) Insert the repaired wire into, the connector.
(12) Solder the connection together using rosin (16) Install the connector locking wedge, if re
core type solder only. Do nut use acid core solder. quired, and reconnect the connector to its mating
(13) Center the heat shrink tubing over the joint half/component.
and heat using a heat gun. Heat the joint until the (17) Re-tape the wire harness starting 1-1/2 inches
tubing is tightly sealed and sealant comes out of both behind the connector and 2 inches past the repair.
ends of the tubing. (18) Connect the battery, and test all affected sys
• (14) Eepeat steps 8 through 13 for each wire. tems.
(15) Ee-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. DIODE REPLACEMENT
(16) Re-connect the repaired connector.
(1) Disconnect the battery.
(17) Connect the battery, and test all affected sys
tems. (2) Locate the diode in the harness, and remove
the protective covering.
TERMINAL REPLACEMENT (3) Remove the diode from the harness, pay atten
(1) Disconnect battery. tion to the current flow direction (Fig. 18).
(2) Disconnect the connector being repaired from
its mating half. CURRENT FLOW
(3) Remove connector - locking wedge, if required
(Fig., 14). . BAND AROUND DIODE
INDICATES CURRENT FLOW
(4) Position the connector locking finger away from
the terminal using the proper pick from special tool
kit 6680. Pull on the wire to remove the terminal
from the connector (Figs. 15 and 16).
(5) Cut the wire 6 inches from the back of the con
nector.
(6) Remove 1 inch of insulation from the wire on M
the harness side. DIODE AS SHOWN IN
THE DIAGRAMS
(7) Select a wire from the terminal repair assembly
that best matches the color wire being repaired.
(8) Cut the repair wire to the proper length and re 948W-197
move 1 inch of insulation.
(9) Place a piece of heat shrink tubing over one Fig. 18 Diode Identification
side of the wire. Make sure the tubing will be long (4) Remove the insulation from the wires in the
enough to cover and seal the entire repair area. harness. Only remove enough insulation to solder in
(10) Spread the strands of the wire apart on each the new diode.
part of the exposed wires (Fig. 11 example 1). (5) Install the new diode in the harness, making
sure current flow is correct. If necessary, refer to the
strands of wire are close to the insulation (Fig. 11 ex
ample 2). appropriate wiring diagram for current flow.
(12) Twist the wires together (Fig. 11 example 3). (6) Solder the connection together using rosin core
(13) Solder the connection together using rosin type solder only. Do not use acid core solder.
core type solder only. Do not use acid core solder. (7) Tape the diode to the harness using electrical
(14) Center the heat shrink tubing over the joint tape. Make sure the diode is completely sealed from
and heat using a heat gun. Heat the joint until the the elements.
tubing is tightly sealed and sealant comes out of both (8) Re-connect the battery, and test affected sys
ends of the tubing. tems.
8W-10 FUSE/FUSE BLOCK 8W - 10 - 1
FUSE BLOCK
GENERAL INFORMATION DIAGRAM INDEX
T h i s section covers the Fuse Block and all circuits
involved w i t h i t . For additional information on sys Component P§fli
t e m operation, refer to the appropriate section of the ABS Control Module 8W-10-6
w i r i n g diagrams. Airbag Control Module 8W-10-5, 6
Buzzer Module • • 8W-10-7
Circuit Breaker (Cavity 1, ruse Biock) 8W-10-6
Circuit Breaker (Cavity 2, Fuse Block) 8W-10-4
Fuse 1 (PDC) 8W-10-4, 7, 8
Fuse 2 (Fuse Block) 8W-10-6
Fuse 2 (PDC) 8W-10-6
Fuse 3 (PDC) 8W-10-3, 5
Fuse 17 (Fuse Block) . . 8W-10-7
Fuse Block 8W-10-2, 3
Headlamp Switch 8W-10-8
Ignition Switch 8W-10-4, 5
Ignition Switch 8W-10-6
Instrument Cluster 8W-10-5
Message Center 8W-10-5
RWAL Module 8W-10-6
8W -10 - 2 8W-10 FUSE/FUSE BLOCK BR
C241
J958W-9
BR 8W-10 FUSE/FUSE BLOCK 8W -10 - 3
FUSE AMPS COLOR SECTION/PAGE

I
2
3
4
5 20 YELLOW 811-10-4
6 15 LIGHT BLUE 8W-10-4
7 10 RED 8W-10-4
8 20 YELLOW 81M0-4
9 10 RED 8U-10-5
10 2 GRAY 8W-10-5
11 10 RED 8W-10-5
12 15 LIGHT BLUE 81M0-5
13 5 TAN 81M0-8
14 20 YELLOW 81M0-6
15 10 RED 8W-10-6
16 15 LIGHT BLUE sy-io-s
17 15 LIGHT BLUE 81M0-7
18 15 LIGHT BLUE 8W-10-8
19 20 YELLOW 8W-10-7
20 15 LIGHT BLUE 8H-10-8
Fi
F2 30 GREEN 8W-10-6
CB1 30 CIRCUIT BREAKER 8W-10-6
CB2 30 CIRCUIT BREAKER 8W-10-4
TURN CAY CIRCUIT FUNCTION SECTION/PAGE

SIGNAL 1 L6 20RD/GY TURN SIGNAL FLASHER OUTPUT 8W-52-3
FLASHER 2 L5 20BK FUSED IGNITION SWITCH OUTPUT (RUN) 8W-52-3
HAZARD CAV CIRCUIT FUNCTION SECTION/PAGE

WARNING 3 L19 18PK/WT HAZARD FLASHER OUTPUT 8W-52-3
FLASHER 4 L9 18BK/VT FUSED B I 811-52-3
CAV . CIRCUIT FUNCTION SECTION/PAGE

TIME 53 12 22YL COURTESY LAMP DRIVER 8W-44-3
DELAY
RELAY 54 M50 22YL/RD KEY-IN LAMP DRIVER 8W-44-3
55 Ml 20PK FUSED B + 8W-44-3
J958W-9
8W -10 - 4 8W-10 FUSE/FUSE BUCK BR
POWER
DISTRIBUTION r~' ' '1
CENTER FUSE 1 BATTERY
-AO 6RD- POSITIVE
50A I TERMINAL
A7 FUSE 3 I
iORD I8NITI0N
BK SWITCH
C180 40A
S14?
C133
I Isw-70-21 Ai 12RD- -Al 12RD
A7
12RD
BK
^ CI33
A41 18DB/YL »-—A41 18DB/YL
A7
12RD
BK . CLUTCH
A7
I
A1S|8W-70-24|
204
POSITION
SWITCH
A31 12BK/WT
12RD PliAL
BK OR JUMPER
(8W-21-2)
C241
FUSE^BLOCK
DS
CB2
8 • HOT I N ACC AND RUN 4
30A iS ioaS 15AS 20AS
20A
L, J
:C241
_ POWER OUTLET
F37 F30 18RD/0R- (8W-41-2)
14RD
LB
C2Q2 TURN SIGNAL

L5 20BK- . FLASHER
(8W-52-3)
F37 V6
14RD 16DB
LB BK
RADIO
X12 18RD/WT- • (8W-47-2.
C303 8W-47-4)
F37
14RD INTERMITTENT
LB V6 16DB/BK- • WIPER SWITCH
(8W-53-2)
POWER S202
SEAT „ , . INTERMITENT
SWITCH 8W-70-22 ^f f I SWITCH I WIPER
(8W-63-2) V6 18DB/BK - ( f - 3 OUTPUT CONTROL
I ! (MASH) j MODULE
V6 i ; : j (TOP REAR CENTER
18DB OF I . P . )
BK
C133
INTERMITTENT
V6 I8DB/BK WIPER MOTOR
(8W-53-3)
J958W-9
BR 8W-10 FUSE/FUSE BLOCK 8W -10 - 5
BATTERY
POSITIVE
TERMINAL IGNITION
POWER SWITCH
DISTRIBUTION
AO CENTER
6RD
FUSE 3 |
I 40A
<(^Xr^>U)
C18Q C133
Al I 2 R D — » — A l 12RD
A21 12DB
C241
FUSE BLOCK
I
12 11 10 9
ISA «?
IOA 2A
1 0 A C | HOT ZN RUN OR START -4
t I
. J
C241
F12
22DB
WT V34 F18
22WT 22LG
RD BK
r _ —I— - n
F14
18LG i 2 2
.1 C133
YL ,
1
FUSED »
1
IGNITION
| SWITCH |
, OUTPUT , F18
* (START/RUN) J 20LG
BK
JOINT
CONNECTOR C
(BEHIND KNEE
VEHICLE
BOLSTER) SPEED
CONTROL S114
S209 SWITCH
8W-70-27 (8W-33-2) 8W-70-6 CI2S
— F18 18LG/BK » —
F14 F14 FI4

20LG 18LG 20LG
YL YL YL F18 F18 F18 F18
^C224 4^€2IS 20LG 20LG 20LG 18LG
r n BK BK BK BK
~ 3 r 1
I FUSED | 7 '
. IGN SW . I FUSED I | FUSED 1
I IGN SW , , IGN SW ,
1 OUTPUT I I OUTPUT I I OUTPUT I f
I (START/1 I(START/1 I(START/1
1
RUN) 1 1
RUN) 1 FUEL PUMP A/C AUTOMATIC SPLICE
I L J
N
L £f l J L _ _ J RELAY COMPRESSOR SHUT DOWN S132
MESSAGE AIRBAG INSTRUMENT (8W-11-8) CLUTCH RELAY RELAY (8W-70-13)
CONTROL CLUSTER (8W-11-5) (8W-11-4)
CENTER
(CENTER MODULE
OF I . P . ) (CENTER OF I . P . ) J958W-9
SW -11 - i 8W-10 FUSE/FUSE BLOCK BR
BATTERY
POSITIVE
TERMINAL POWER
DISTRIBUTION LEFT DOOR
POWER
CENTER WINDOW
AO SWITCH
6RD IGNITION (8W-60-2)
FUSE SWITCH
40A €180
• ACC
C212 F21
OFF
1C212 14TN
RUN
A2 A2 ( 4 ) -H)—I RIGHT DOOR
12PK 12PK | # START 1(3) I POWER
BK BK I A22 WINDOW
12BK C207 SWITCH
S146 C133
OR (8W-60-3)
8W-70-20l#—A2 12PK/BK-))
REAR WHEEL
ANTI-LOCK
CONTROL
FUSED NODULE
B+
BLOWER MOTOR
(8W-42-3.
j 8W-42-4)
FJJESJ) « A I R B A G
F23 18DB/YL—<fJ5 IGN SW I q ql C N T R
A20 A20 L10 C L
18RD 18RD 22BR L

OUTPUT I °y,7°
DB DB LG JOINT - (RUN) MODULE
C209 , BACK-UP ,
Lo LAMP I CONNECTOR C 1 (CENTER
2 8
| SWITCH I (BEHIND KNEE OF I . P . )
1
OUTPUT J BOLSTER)
—A20 18RD/DB ABS PUMP RELAY
S110 (8W-32-9)
C121TZ ANTI-LOCK
8W-70-5
BRAKE
•A20 18RD/DB—<f| 12 SYSTEM
\ I | FUSED CONTROL
MODULE
A20 18RD/DB—<fl 17
L IZ _
(LEFT FENDER
SIDE SHIELD)
-A20 18RD/DB- VACUUM

SENSOR
(8W-32-5.
A20 18RD/DB - 8W-32-12)
J958W-9
B R 8W-10 FUSE/FUSE BLOCK SW - 1 1 - 7
POWER
D I S T R I B U T I O N
CENTER
Off n B A T T E R Y
-AO 6RD- POSITIVE
RIGHT DOOR
TERM I N AL
1 FUSE 1 • LOCK S W I T C H
SOA (8W-61-3)
LEFT DOOR
LOCK S W I T C H
(8W-61-2)
A7
10RD
F35
16RD
BK
F35
16RD
S 1 4 7 C239
8W-70-21
•C2flZ
A7
F35
12RD F35 IBRD
BK 16RD
C133 FUSE BLOCK
• HOT AT ALL T I N E S 4 S 2 1 6
A7 1 1
" C241 8W-70-30
12RD 19
BK F35 16RD
20A
C241 I
A7 12RD/BK
POWER OVERHEAD
S204 MIRROR S P L I C E
17 MAP
8W-70-24 S W I T C H S 3 2 0 LAMP
^ J_5A
-»- ( 8 W - 6 2 - 2 ) ( 8 W - 7 0 - 3 7 ) (8W-49-4)
JOINT
CONNECTOR B
(NEAR REAR
Ml Ml Ml Ml
OF FUSE BLOCK)
18PK 20PK 20PK 20PK
I 1
FUSED
B+
1 -C801 C2©1
8
I IL l
^ C231
Ml Ml
Ml 20PK 20PK
18PK
C133
Ml 20PK Ml 18PK-
y S 2 0 5 C202
I8W-70-25
Ml Ml Ml Ml
20PK 20PK 20PK 18PK
C218
Fu
f
S P L I C E
S 1 4 9
( 8 W - 7 0 - 2 1 )
BUZZER
! i? !
i
I
6
"
MODULE
i
I
T I M E
RELAY
DELAY
( 8 W - 4 4 - 3 )
S P L I C E
S 3 0 3
(8W-70-31)
(IN FUSE BLOCK) J958W-9

8W - 1 0 - 8 8W-10 FUSE/FUSE BLOCK BR
BATTERY
r 6 R D ^ POSITIVE JOINT
M
TERMINAL COWMECTPR A
POWER (NEAR REAR- OF
fuse block)
DISTRIBUTION 1
CENTER [park, lamp,
i switch i
FUSE if
§OA | OUTPUT j
^pC2l7
C180
A7
10RD
A3 BK
12RD 1 S147
L6 8W-70-21
A7
12RD
BK
C133
A3 A7 F33
12RD 12RD 20PK
L6 BK RD (NEAR REAR OF
FUSE BLOCK)
1
T
I I
S203 S204
8W-70-23 8W-70-24 | FUSED |
A3
12RD
A7
12RD FUSE BLOCK
! °:
Z.
I
LG BK i i
r: 1
€241 18 C241 C231
15A
•HOT AT ALL TIMES41
20
F32 18PK/DB
ISA
JOINT
COMlECTPR^ C
| FUSED | C209 M
HEADLAMP -^ ~ 13
I SWITCH 511> • E2 200R • -»- El 20TN/0R
| OUTPUT | 5A
u . , I
(BEHIND KNEE
BOLSTER)
TRANSMISSION
OVERDRIVE • E2 200R
SWITCH
(8W-31-2)
J958W-9
BR 8W-11 POWER DISTRIBUTION 8W - 11 - 1
POWER DISTRIBUTION
This section covers the power distribution center
and all circuits involved with it. For additional infor Component P A
9 E
mation on system operation, refer to the appropriate A/C Compressor Clutch Relay 8W-11-5
section of the wiring diagrams. ABS Control Module 8W-11-6
ABS Pump Relay 8W-11-6
ABS Warning Lamp Relay 8W-11-6
ASD Relay 8W-11-4
Engine Starter Motor Relay 8W-11-7
Fuel Pump Relay 8W-11-8
Fuse A (PDC) 8W-11-5
Fuse B (PDC) • 8W-11-5
Fuse C (PDC) 8W-11-9
Horn Relay 8W-11-5
Power Distribution Center 8W-11-2, 3
Powertrain Control Module 8W-11-5, 8
Trailer Tow Relay 8W-11-4
8W - 11 - 2 8W-11 POWER DISTRIBUTION BR
POWER DISTRIBUTION CENTER
C180
CM CM
ea
CI
«< OO
0 ©
HO/LP
F 6
oo °°tZt •
y_
, EEi §EE1 , fZL fZL,

rgzz
^£ y_ »—».«< UuUuJ
TZT
CAV CIRCUIT AMPS FUNCTION SECTION/PAGE

1 A7 10RD/BK 50 FUSED B + 8W-11-5
2 A2 12PK/BK 40 FUSED B + 8W-11-7
3 Al 12RD 40 FUSED B + 8W-11-9
4 A16 14GY/WT 30 FUSED B + 8W-11-4
FUSE 5 A10 12RD/DG 40 FUSED B + 8W-U-6
6 A3 12R0/LG 40 FUSED B 4- 8W-11-7
6 A3 3 2RD/LG 40 FUSED B + 8W-11-7
7 A6 14RD/TN 30 FUSED B + 8W-I1-4
8 A H 16RD/WT 20 FUSED B + 81M1-8
8 am tsm/m 20 FUSED B + 8W-11-8

FUSE A Al A7 12RD/BK FUSED B + 8W-11-5
15
A2 L38 20LB/BK FUSED B + 8W-11-5
CAV CIRCUIT AMPS FUNCTION 5ECTI0N/PAGE

FUSE 6 Bl A7 12RD/BK FUSED B + 8W-11-5
20
B2 F31 18VT FUSED B + 8W-11-5

FUSE C CI A15 16PK FUSED B + 8W-U-9
15
C2 L9 18BK/VT FUSED B + 8W-11-9

FUSE ' A l l 6BK/GY 120 FUSED B + 8H-I1-8
J958W-9
BR 8W-11 POWER DISTRIBUTION 8W -11 - 3
CAV CIRCUIT FUNCTION SECTION/PAGE

ENGINE 30 A2 FUSED B +
12PK/BK 8W-11-7
STARTER 85 T41 22BK/WT ENGINE STARTER MOTOR RELAY CONTROL 8W-11-7
MOTOR 86
RELAY
A41 14YL IGNITION SWITCH OUTPUT (START) sw-n-7
87 T40 12BR ENGINE STARTER MOTOR RLY OUT (START/RUN) 8W-1I-7
87 T40 12BR ENGINE STARTER MOTOR RLY OUT (START/RUN) 8W-]!~7
30 A10 12RD/DG FUSED B + 8H-J1-S
ANTI-LOCK
BRAKE SYSTEM 85 Bl16 20GY ABS PUMP RELAY CONTROL 8W-J1-6
PUMP RELAY 86 A20 18RD/DB FUSED IGNITION SWITCH OUTPUT 8W-11-6
86 A20 18RD/DB FUSED IGNITION SWITCH OUTPUT BM-ll-B
87 B120 12BR/WT ABS PUMP RELAY OUTPUT 8W-II-S

ANTI-LOCK 30 619 20LG/RD ABS WARNING LAMP RELAY OUTPUT 8M-11-6
BRAKE SYSTEM 30 G19 20LG/RD ABS WARNING LAMP RELAY OUTPUT 8W-11-6
WARNING LAMP 85 B47 20RD/LB ABS WARNING LAMP RELAY CONTROL 8W-11-6
RELAY
86 A20 18RD/DB FUSED IGNITION SWITCH OUT (START/RUN) 8W-11-6
87A Zl 20BK GROUND 8W-11-6
FUEL 30 A14 16RD/WT FUSED B + 8W-11-8
85 K51 22DB/YL ASD/FUEL PUMP RELAY CONTROL 8W-11-8
PUMP
RELAY 85 K51 22DB/YL ASD/FUEL PUMP RELAY CONTROL 8W-11-8
86 F18 20LG/BK FUSED IGNITION SWITCH OUTPUT (START/RUN) 8W-11-8
87 A61 16D6/BK FUEL PUMP RELAY OUTPUT 8U-11-8

AUTOMATIC 30 A16 14GY/WT FUSED B + 8M-11-4
SHUT DOWN 85 K51 22DB/YL ASD/FUEL PUMP RELAY CONTROL 8M-11-4
RELAY 86 F18 20LG/BK FUSED IGNITION SWITCH OUTPUT (START/RUN) 8W-11-4
87 A142 14DG/0R ASD RELAY OUTPUT BW-li-4
A/C CAV CIRCUIT FUNCTION SECTION/PAGE

COMPRESSOR 30 F31 20VT FUSED B + 8W-1.1-5
CLUTCH 85 C13 22DB/0R A/C CLUTCH RELAY CONTROL 8W-1.1-5
RELAY 86 F18 20LG/BK FUSED IGNITION SWITCH OUTPUT (START/RUN) 8W-1.1-5
87 C3 18DB/BK A/C CLUTCH RELAY OUTPUT 8W-L1-5
' 30 F31 20VT FUSED B + 8W-U-5
30 F31 18VT FUSED B + 8W-U-5
85 X3 22BK/RD HORN RELAY CONTROL 8W-U-5
86 F31 20VT FUSED B + 8W-U-5
86 F31 20VT FUSED B+- 8W-11-5
87 X2 18DG/RD HORN RELAY OUTPUT 8W-L1-5
87 12 18DG/RD HORN RELAY OUTPUT 8W-11-5
TRAILER 30 A6 14RD/TN FUSED 8 + 8W-11-4
TOW 85 Zl 20BK GROUND 8W-U-4
RELAY 86 L7 20BK/YL PARK LAMP SWITCH OUTPUT 8W-U-4
87 L76 14BK/0R TRAILER TOW RELAY OUTPUT 8W-11-4
J958W-9
SW - 11 - 4 SW-11 POWER DISTRIBUTION BR
BATTERY POWER
POSITIVE
CENTER
SPLICE
S106
(8W-70-3)
SPLICE
S143
TRAILER (8W-70-20)
TOW SPLICE
CONNECTOR SI38 SPLICE
(8W-54-2) (8W-70-17) S133
8.0L ENGINE- (8W-70-14)
ONLY J958W-9
mm 8W-11 POWEi DISTRIBUTION 8W -11 - 5
BATTERY
n
A° ft
POSITIVE
TERMINAL POWER
PISTRIBUTION
CENTER
S147
—1 8W-70-21
[C180
Â7 10RD/BK- A7 12RD/BK-
• FUSE 1 I
50A
i F31
I 20VT
A/C
COMPRESSOR
CLUTCH
RELAY
:86
85
1^1
30
ft.
87
F18 CI3 C3 F31

20L6 22DB 18DB 20VT
BK OR BK ,
CI2S C127
C13 C3
20DB 18DB
OR BK
WITH
C135 POWER
GROUP
34
I A/C COMP I
.CLUTCH RELAYs
^ CONTROL J
POWERTRAIN
SPLICE A/C . HORN HORN . HORN FOG LAMP
S1&4 CONTROL COMPRESSOR SWITCHES ( H I G H NOTE) (LOW NOTE) RELAY 1
(8V-7 0-6) MODULE CLUTCH (8W-41-3) (8W-41-3) (8W-41-3) (8W-50-6)
(8W-42-6)
(RIGHT SIDE
OF DASH
PANEL)
J958W-9
8W -11 - 8 8W-11 POWER DISTRIBUTION mm
BATTERY —I
POSITIVE
AO 6RD • TERMINAL AM POWER
IBRD
WT eisfmiTiiM
Jk—A C180 CENTER
mm*
^ 5 FUSE 8
(? FUSE C 20A FUEL
120A PUBP
/ \
30<f
-II- -»87
86<f ,85
-#nrp#-
K5l
220B
YL
AUTOMATIC
SHUT DOWN
, RELAY '
(8V-11-4)
C180
AM F18 - K51 A61

IBRD 20LG 22DB 1606
WT BK YL BK
C126 C125 €128
GENERATOR AM K5i
(8W-80-S. SPLICE A61
8W-20-4)
16RD S114 20DB 1BDG
WT (8W-70-6) YL BK
C135
' 1
3 51 FUEL TANK
FUSED ASD/FUEL ! LEVEL GAUGE
B + PUMP RELAY! SENDING U N I T
CONTROL I (8W-30-48)
POWERTRAIN CONTROL MODULE

(RIGHT SIDE OF DASH PANEL)
J958W-9
BR 8W-11 POWER DISTRIBUTION aw -11 - 9
S148
~~ ~ ~ ~ ~> JOINT
C 0 N W K T 5 R C
IGNITI ON I
SWITCH | {BEHIND
, OUTPUT ,% KNEE
C119 (START/RUN) I BOLSTER)
C133
HAZARD
WARNING
FLASHER
(8W-52-3)
CLUTCH PEDAL
POSITIONSWITCH
OR JUMPER
(8W-21-2)
RADIO
| (8W-47-2.
POWER TURN 8W-47-4)
OUTLET SIGNAL SPLICE
(8W-41-2) FLASHER S202
(8W-52-3) (8W-70-22)
J958W-9
8W-12 JOINT CONNECTORS 8W - 12 - 1
JOINT CONNECTORS
This section identifies the i n t e r n a l circuity of the
j o i n t connectors. For additional i n f o r m a t i o n on sys Component i Page
t e m operation, refer to the appropriate group of the ABS Control Module . .8W-12-7
w i r i n g diagrams. Daytime Running Lamps (DRL) Module . . . . . . . .8W-12-6, 8
Fuse 1 (PDC) .8W-12-2, 4
Fuse 2 (PDC) .8W-12-8
Fuse 3 (PDC) . .8W-12-6
Fuse 6 (PDC) . .8W-12-4
Fuse 11 (Fuse Block) . .8W-12-6
Fuse 13 (Fuse Block) .8W-12-2, 5
Fuse 18 (Fuse Block) .8W-12-2, 5
Headlamp Switch 8W-12-2, 3, 5, 7
Ignition Switch 8W-12-6, 8
Instrument Cluster .8W-12-5, 6, 8
Joint Connector A (C217) .8W-12-2. 3
Joint Connector B (C231) 8W-12-4
Joint Connector C (C209) .8W-12-5, 6, 7, 8
Overhead Console .8W-12-2
Park Brake Switch 8W-12-6
RWAL Control Module . . . ..... 8W-12-4, 6, 7, 8
SW -12 - 2 8W-12 JOINT CONNECTOiS B R
BATTERY
POSITIVE
TERMINAL
POWER
DISTRIBUTION
CENTER SI4I S204
AO 1
6RD 8W-70-21 C133 8W-70-24
< f - J o ^ ^ > ^ ) — A7 10RD/BK A7 12RD/BK »—A7 12RD/BK ®
FUSE I !
S©A
A7
12RD
BK
E2 200R-
TRANSMISSION
OVERDRIVE
SWITCH
C>
5A
13
7 1 8
ISA )
FUSE BLOCK
(8W-31-2) I
:C24l
SPLICE RADIO Ei F33

S106 (8W-47-2. 20TN 20PK
(8W-70-3) 8W-47-4) OR RD
f
(4): C208
L7
I8BK
YL
HEAD HEADLAMP
L7 SWITCH
E2 C133 20BK OFF
YL PARK
200R
L7 (i): "(3) C206

18BK
YL
:C209 ^C217
i
I ;
7 C217
I FUSED I L7 20BK/YL
I HEADLAMP I I
SWITCH J O I N T CONNECTOR A
I OUTPUT I (NEAR REAR
I I
OF FUSE BLOCK)
JOINT C217
CONNECTOR C C 3 3 8 i, PARK LAMP OVERHEAD
(BEHIND KNEE L7 20BK/YL 12 SWITCH CONSOLE
BOLSTER) H/0-
I OUTPUT
CLEARANCE
C208 LAMPS
SPLICE S317
-L7 20BK/YL- - L7 18BK/YL ^ (8W-49-4)
J958W-9
BR 8W-12 JOINT CONNECTORS 8W -12 - 3
OVERHEAD
CONSOLE OVERHEAD LEFT DOOR RIGHT DOOR
i ' ~ l MAP LAMP J A M B SWITCH J A M B SWITCH DOME LAMP
(8W»49»4) (8W-49-3) (8W-49-3) (BW-44-3)
I . I
' courtesy' -W/0 OVERHEAD
I LAMPS I CONSOLE M2
| DRIVER | 20YL
I | i
:C338 M2 M2 M2 C202
22YL
18YL
I8YL T
H2
20YL
«—M2 22YL-
C208 C20I C240 S218
8W-70-30
M2 M2 M2
22YL 22YL 22YL N2
20YL
^C817
10 JOINT
C1MWCCT0R A
1 <> 1 (NEAR REAR
| OF FUSE BLOCK)
! I
C217
T I M E DELAY
- RELAY
M2 22YL- (8W-44-3)
HEADLAMP
SWITCH
l 1
£204
DOME
W 'J8~ M2 20YL
(1)
C204
£206 C202 C308
CARGO LAMP 1
CARGO H3 22PK/08 » M3 20PK/0B >V- M3 18PK/DB • * (8W-44-3)
13 f (3)
3)
20BK
OR
L .CARGO LAMP 2
M3 18PK/DB (8W-44-3)
S206
8W-70-26
23
12BK
OR
G201
8W-15-6]
J958W-9
8W - 12 - 4 8W-12 JOINT CONNECTORS B R
BATTERY
POSITIVE
TERMINAL
SPLICE S 2 0 5
II 18PK
(8W-70-25)
AIRBAG/ABS
DATA L I N K
Ml 20PK- ' CONNECTOR
(8W-32-H)
RADIO CHOKE
Ml 18PK- ' (8W-47-5)
GLOVE BOX
LAMP AND
Ml 20PK- SWITCH
(8W-44-6)
RADIO
Ml 20PK- (8W-47-2,
8W-47-4)
STOP LAMP
F32 18PK/DB • SWITCH
(8W-33-3)
REAR WHEEL
ANT1-LOCK
CONTROL MODULE
(CENTER OF I.P.)
I '— — 1
C228
F32 20PK/DB //J n FUSED
J958W-9
BR 8W-12 JOINT CONNECTOiS 8W -12 - 5
BATTERY
POSITIVE
TERMINAL
POWER
DISTRIBUTION
CENTER S147 S204
AO
6RD 8W-70-21 8W-70-24
C180 C133
<f4p\y#^>7-^>— A7 10RD/BK # A7 12RD/BK- —»—A7 12RD/BK
FUSE 1
SOA
I
I i
A7
-E2 200R
12RD
BK
JOINT
E2
CONNECTOR C 200R FUSE BLOCK
(BEHIND KNEE C241
BOLSTER)
I
~ C209 TRANSMISSION
OVERDRIVE 18
5|
1> SWITCH
(8W-31-2) ISA
:C241
RADIO
E2 220R- *m (8W-47-2.
8W-47-4)
INSTRUMENT F33
20PK
RD
C215! FUSED !
4 E2 220R- JZJZJ
v n H
iA HEADLAMP
SWITCH
I
I
HEADLAMP
SWITCH (4) C206
OUTPUT
HEATER
SWITCH OR
E2 220R- HVAC SWITCH
(8W-42-3 t
8W-42-4)
OVERHEAD CONSOLE
1
C208 C338 FUSED I (9);
E2 2 2 0 R ^ > - E 2 2 2 0 R ~ < f - ' i 3
H
|jJftJ|J P
! Uh C206
l' _ AIITmiT
M T P U T _ _*J
JOINT 1
C217 n
CONNECTOR A I PARK LAMP | "T- 4 1
SWITCH 6 -4) L7 2 0 B K / Y L -
(NEAR REAR OF
FUSE BLOCK) I OUTPUT I
17 STOP LAMP
V32 20YL/RD- m
SWITCH
(8W-33-3)
VEHICLE POWERTRAIN
15 SPEED CONTROL MODULE
4 V32 2 2 Y L / R D - — « • CONTROL
SWITCH
(RIGHT S I D E
OF DASH PANEL)
(8W-33-2)
VEHICLE
C133 C126 COS SPEED
16 CONTROL
V32 2 2 Y L / R D - — ( ( V32 2 0 Y L / R D — ) ) — V32 20YL/RD
SWITCH
i i OUTPUT
(ON)
J958W-9
8W -12 - 6 8W-12 JOINT CONNECTORS BR
BATTERY
POSITIVE
TERMINAL
T
AO
6R0
±_-
P FUSE 3
power
distribution
IGNITION
1 4©A CENTER SWITCH
FUSE BLOCK
ACC I 1
OFF
IC212 £241 I A 1 OA 1
C241
cteo C133 C212
RUN
-A21 12DB-
1
—Al 12RD—»—Al 12RD-
$ | JJJ •'START , (6)
I I
F12
OVERHEAD 220B
WT
CONSOLE
f ~~" fusTd"" 1
C338I
TRANSMISSION IGNITION 1
OVERDRIVE BUZZER F12 22DB/WT — ( F H 7 SWITCH |
SWITCH MODULE OUTPUT ,
(8W-31-2) (8W-44-5) [(START/RUN) 1
C208
F12 F12 F12

22DB 20DB 22DB
WT WT WT
C209
20 21 19 22
II 10
C209 JOINT
CONNECTOR C
Gil (BEHIND KNEE
22WT BOLSTER)
BK
Gil Gil
22WT 22WT
Gil BK BK
20WT
BK
C2IS C228
3 1 10 5
PARK 1 1 PARK. I I ~ PARK I
BRAKE | | BRAKE | I BRAKE |
SWITCH i i SWITCH j I SWITCH 1 PARK
SENSE J N
L H î J L J BRAKE
DAYTIME RUNNING INSTRUMENT REAR WHEEL SWITCH
LAMPS MODULE CLUSTER ANTI-LOCK
(LEFT FENDER CONTROL MODULE
SIDE SHIELD) (CENTER OF I.P.) J958W-9
BR 8W-12 JOINT CONNECTORS 8W - 12 - 7
A N T I - L O C K BRAKE REAR WHEEL
POWERTRAIN SYSTEM ANTI-LOCK
CONTROL CONTROL MODULE STOP LAMP CONTROL MODULE
MODULE SWITCH
I 1 (8W-33-3) (CENTER
(LEFT OF I . P . )
| STOP LAMP j § ! § j ! ( T | STOP LAMP |
SWITCH FENDER I ' 1
OUTPUT SIDE
SHIELD) | STOP LAMP I
i 8 S 8 « S
> " 9 1
SWITCH 5
L
I
i £i. i I OUTPUT I
7
V40 I I 1
20WT
C228
PK
Bin
V40 22WT/PK-
[8W-70-5
V40 ¥40
W/0 20WT 22WT
ANTI-LOCK PK PK
BRAKE
SYSTEM
V40 20WT/PK-
€133
Y40
22WT
PK
C209
31 32 33
JOINT
CONNECTOR C
(BEHIND
KNEE BOLSTER)
13 14 12
C209
K E Y - I N SWITCH
616 616 •616 22BK/LB- 1
(8W-44-5)
22BK 22BK
LB LB
CAOI
LEFT DOOR
-G16 18BK/LB JAMB SWITCH
(8W-49-3)
I OFF C208
C206 BUZZER
MODULE
— PARK
(6) Ox
I HEAD (5)
-626 18LB
(8W-44-5)
J958W-9
8W - 1 2 - 8 8W-12 JOINT CONNECTORS BR
BATTERY
positive IGNITION
terminal- - - - S W I T C H ••
1
aI power
6rd distribution ACC
rj^ n CENTER C212 C212
— A2 12PK/BK (f
(4) I .RUN (3)
r> FUSE 2 C133
^ 40A I START
A2
I
12PK | • ACC
C18Q BK
fRUN
A2 12PK/BK (5)
START # -
BRAKE S146
SPLICE WARNING 8W-70-20 l
S109 SWITCH
(8W-70-4)(8W-32-5)
f GAS EN6INES
W/REAR WHEEL REAR WHEEL
ANTI-LOCK ANTI-LOCK
BRAKES ONLY
CONTROL MODULE
69 69 INSTRUMENT 69
206Y 186Y (CENTER
CLUSTER 226Y
BK BK BK
T BRAKE ~! f BRAKE ~]
I WARNING I I WARNING I I J_ 1
I LAMP DRIVER I I LAMP DRIVER I C241- FUSE BLOCK
133
L .
IL
I
t
L ^C216 J^C228
69 69 69 L10
226Y 226Y 226Y 22BR
BK BK BK L6
C209
26 23 24 25 28 I JOINT
[CONNECTOR C
1 (BEHIND
KNEE
30 I BOLSTER)
29
C209
C208 DAY/NIGHT
L10 LIO 22BR/LG LIO 22BR/L6 > MIRROR
22BR (8W--44-7)
LG W/0 DRL BACK-UP LAMP
C133 SWITCH OR
LIO 18BR/L6 LIO 18BR/LG- i PARK/NEUTRAL
POSITION SWITCH
(8W-31-5)
DAYTIME RUNNING
LAMPS MODULE
C1311 FUSED | (LEFT

IGNITION FENDER
•LIO 20BR/LG LIO 18BR/LG- SWITCH I SIDE
OUTPUT |SHIELD)
S120 I (RUN)
8W-70-9
J958W-9
11-2 8W-15 GROUND DISTRIBUTION BR
TRAILER ABS WARNING

TOW RELAY LAMP RELAY
(8W-11-4) (8W-U-6)
Zl
20BK
Zl
20BK
LOW
- Z l 18BK- WASHER FLUID
LEVEL SWITCH
(8W-53-3)
• Z l 20BK
S108
~1
VEHICLE SPEED
CONTROL SERVO
8W-70-4 (8W-33-2)
I
Zl Zl Zl
18BK
18BK 12BK
C131
Zl
8 I2BK
9
GND GND I
I
DAYTIME RUNNING
LAMPS MODULE Zl VACUUM
12BK SENSOR ^
(LEFT FENDER (8W-32-5. -Zl 18BK
SIDE SHIELD) 8W-32-I1) GROUND J O I N T
(NEXT TO PDC) CI23
WITHOUT
HIGH LINE
CLUSTER
Zl
12BK HORN
LOW NOTE LEFT PARK
DIESEL
(8W-41-3) AND TURN
ENGINE
SPLICE ONLY SIGNAL LAMP
S115 (8W-50-5)
(8W-70-7)
<*G101 HORN SPLICE

HIGH NOTE S103
(8W-41-3) (8W-70-2)
J958W-9
BR 8W-15 GROUND DISTRIBUTION SW -15 -
PTO OR 4X4
SWITCH
(8W-31-3)
GROUND J O I N T
(NEXT TO PDC)
( 1
' GROUND J
L _ 3 _ _ J
C123
Z l 18BK- J
SPLICE RIGHT PARK AND
S409 Zl 20BK Zl 18BK TURN SIGNAL LAMP
(8W-70-39) (8W-50-5)
WINDSHIELD
WASHER
PUMP MOTOR Zl 20BK
(8W-53-3)
RIGHT HEADLAMP
-Zl 20BK 1
(8W-50-3)
G102
C133
_ SPLICE S 2 1 2
Z2 18DK/LG »—Z2 188K/L6- (8W-70-28)
Z2 18BK/LG- -WITH HIGH LINE

CLUSTER
Z2 ABS 2-WAY
18BK . POWER Z2
LG FEED 18BK
(8W-32-10) LG
f G107
Z2 18BK/LG • S:>>—Z2 18BK/DG-
C133
|8W-15-4| G1Q3 # G202
|8W-15-7|
J958W-9
8W -15 - 4 • 8W-15 GROUND DISTRIBUTION BR
GROUND
JOINT
(NEXT TO
i •—i PDC)
INSTRUMENT
WIPER
UNDERHOOD LAMP NO CONNECTION MOTOR
| GROUND I (8W-44-6) (FOR FUTURE USE) (8W-53-3)
C183
C123
-DIESEL
ENGINE
ONLY
Zl Zl Zl Zl Zl
14BK 12BK 20BK
18BK 18BK
WITH
TRAILER
TOW
Z13 12BK
Z13 16BK
LEFT SIIS
HEADLAMP 8W-70-7
(8W-50-3)
GAS
Zi Zl ENGINE Zl Zl Zl Z13 Z13
20BK ONLY 14BK 12BK 16BK 12BK
18BK 16BK
G104 6105 * G106

SPLICE
S311
(8W-70-33)
C133
SPLICE
—» Z2 18BK/LG S212
(8W-70-28)
Z2
18BK !
LG
S122
8W-70-10 G202
12 18BK/LG- Z2 18BK/LG• Z2 18BK/LG 8W-15-7
Z2 - ABS
8W-15-3
18BK CONTROL MODULE
LG C121 < —
"1
REAR
ANTI-LOCK Z8 16BK/PK- Z7 18BK/RD ( f - | 20 GROUND |
VALVE
(8W-32-8) G1Q7 L I
(LEFT FENDER SIDE SHIELD)
J958W-9
BR 8W-15 GROUND DISTRIBUTION 8W -15 - 5
AIRBAG
CONTROL MODULE
CI33 €232 r — ——1
Z6 18BK/0R »— •Z6 18BK/0R — - < ( - | 11 GROUND |
I . J
(CENTER OF L P . )
•zo loetc-
-ZO 6BK- BATTERY
NEGATIVE
sies 6110
(8.0L ENGINE ONLY) S.OL ENGINE ONLY)
POWERTRAIN
CONTROL
MODULE
(RIGHT SIDE OF ENGINE
DASH PANEL) DATA L I N K
CONNECTOR EMSINI
(8W-30-15. COOLANT
SPLICE GROUND 8W-30-24, TEMPERATURE
S141 12 8W-30-33. SENSOR
(8W-70-19) LlL 8W-3G-42) (8W-40-5)
LEFT
C135 HEATED
OXYGEN
SPLICE SENSOR
S11S (8W-30-29.
T4! Z12 Z12 Z12 Z12
(8W-70-7) 8W-30-3S)
20BK 16BK 16BK 20BK 20BK f
WT TN TN TN TN
Zll Zll
16BK 18BK
WT WT
•Z12 20BK/TN-
8.0L 5.2L.5.9
C12S sua ENGINE
ONLY C125 18.OL
8W-70-I8 ENGINES
Z12 18BK/TN-
IGNITION ONLY
8
MODULE Zll
Z12 (8W-30-33) 16BK
14BK WT
TN
T41 GAS
22BK Zll 16BK/WT- ENGINES
WT Gill S140 ONLY
Zll 18BK/WT
Z12 8W-70-19 Zll
14BK 18BK
TN WT RIGHT
DIESEL
ENGINE ENGINE
HEATED
STARTER OXYGEN
ONLY SENSOR
MOTOR A/C
RELAY SPLICE (8W-30-20,
S142 COMPRESSOR
(8W-11-7. 8W-30-29,
( 8 W - 7 0 - 1 8) CLUTCH
8W-21-2) 8W-30-39J
(8W-42-6)
J958W-9
SW -11 - S — _ _ _ _ 8 W - 1 5 GROUND DISTRIBUTION — — — — — BR
FUEL SHUT §iW!

- Z 1 2 10BK/TN m SOLENOID
(8W-30-45)
f SII2
(DIESEL ENGINE ONLY)
GENERATOR
• Zl 6BK- (8W-20-2.
8W-20-4)
t 0113
LEFT BATTERY
NEGATIVE
-ZO 6BK
— TERMINAL
(8W-20-4)
DIESEL ZO 10BK
ONLY
= §114 = 6115
RIGHT BATTERY
NEGATIVE
TERMINAL
(8W-20-4)
INTERMITTENT
WIPER CONTROL INSTRUMENT
FOG LAMP MODULE CLUSTER
SWITCH i " n
(8W-50-7) (TOP REAR
CENTER I GROUND I
OF I . P . )
1
5 I
C218
Z3 20BK/0R Z3 20BK/0R
IGNITION
Z3 20BK/0R SWITCH LAMP
(8W-44-3)
Z3 20BK/0R Z3 20BK/0R
:C218
BUZZER 5
MODULE I GROUND
( I N FUSE I
HEADLAMP BLOCK) L
. _ J
SWITCH
(8W-44-3)
REAR WHEEL
SPLICE
ANTI-LOCK
SI 15
(8W-70-29) CONTROL MODULE
I 1
C228»
(CENTER
Z3 16BK/0R- « — 1 2 GROUND
OF LP.)
G201
J958W-9
BR 8W-15 GROUND DISTRIBUTION 8W - 15 - 7
LEFT DOOR
SPEAKER RI6HT DOOR
(PREMIUM) •Z2 1BBK/LG •Z2 18BK/LG- SPEAKER
(8W-47-6) (PREMIUM)
(8W-47-6) SPLICE
S122
C201 C240 (8W-70-10)
Z2
18BK Z2
LG 18BK
LG C133
-Z2 18BK/LG —({—22 18BK/LG

RADIO
CHOKE 1
Z2 18BK/LG- •Z2 18BK/LG
(8W-47-5)
S212
Z2 18BK/LG 12 18BK/LG •
8W-70-28
WITH HIGH
C202: LINE CLUSTER
Z2
18BK Z2
LG 18BK
LG
-Z2 18BK/LG
G103
SPLICE
S301
6202 W/0 8W-15-3
(8U-70-30) PREMIUM
RADIO
OVERHEAD
POWER CIGAR LIGHTER CONSOLE
OUTLET (8W-41-2)
(8W-41-2)
GLOVE BOX LAMP . GROUND
-Z3 18BK/0R Z3 16BK/0R- • AND SWITCH I
2
(8W-44-6) L.
C338
FOG LAMP RELAY 2
SPLICE .
' S206 1 Z3 I8BK/0R- • (8W-50-6)
(8W-70-26) Zll
FOG LAMP SWITCH 20BK
Z3 20BK/0R — (8W-50-7) WT
~ ~[1NSTRUMENT
8W-70-29 I
GROUND CLUSTER
• C808
Z3
12BIC -Zll 20BK/WT-
OR C2I5 J j C816
AIRBAG/ABS
Zll Zll l DATA LINK
20BK 20BK -Zll 20BK/WT• CONNECTOR
HEATER SWITCH Z3 WT WT
OR HVAC SWITCH 20BK (8W-32-11)
(8W-42-3. OR
8W-42-4) -Zll 18BK/WT - -<f
S208 C133
STOP 8W-70-27 Zll

TRANSMISSION LAMP -Zll 20BK/WT- Zll 18BK
OVERDRIVE SWITCH SWITCH 18BK WT
(8W-31-2) (8W-33-3) WT
Zll 18BK/WT SPLICE

S116
(8W-70-7)
6203
J958W-9
-11-8 8W-15 GROUND DISTRIBUTION B R
CENTER HIGH MOUNTED

Z3 18BK/0R -—^ «m STOP LAMP 1
(8W-5W)
r-Z3 18BK/0R
CENTER HIM MOUNTED
Z3 18BK/0R ^ STOP LAMP 2
(8W-51-7)
SEAT BELT POWER SEAT

SWITCH -Z3 18BK/0R Z3 14BK/0R -» Z3 14BK/0R • SWITCH
(8W-44-5) (8W-63-2)
C303
S3Q1
LEFT DOOR POWER

•Z3 14BK/0R i WINDOW SWITCH
(8W-80-2)
-Z3 14BK/0R
LEFT DOOR
LOCK SWITCH
(8W-61-2) - ZZ3
3 18BK/0R
S306
8W-70- 32
-Z3 14BK/0R
W/0 POWER-
Z3 WINDOWS
14BK AND LOCKS
LEFT DOOR OR
POWER MIRROR
JAMB SWITCH Z3 18BK/0R -Z3 18BK/0R 1
SWITCH
(8W-49-3) (8W-B2-2)
G3Q2
RIGHT DOOR
Z3 18BK/0R- JAMB SWITCH
(8W-49-3)
• G3Q3 OVERHEAD
CONSOLE
i 1
' GROUND !
CENTER L_
IDENTIFICATION C328
LEFT OUTBOARD LAMP RIGHT OUTBOARD
IDENTIFICATION (8W-50-10) DAT/NIGHT
IDENTIFICATION
LAMP MIRROR
LAMP
(8W-50-10) (8W-44-7)
(8W-5O-10)
Z4
18BK Z4
Z4 18BK- -Z4 18BK- 22BK
LEFT OUTBOARD
' CLEARANCE RIGHT OUTBOARD
LAMP i -Z4 18BK- -24 18BK <** CLEARANCE LAMP
(8W-50-10) S318 (8W-50-10)
Z4
8W-70-38
Z4 18BK
18BK
OVERHEAD
MAP LAMP -Z4 18BK- -Z4 18BK-
(8W-49-4) v .
G304 S319
8W-70-36
J958W-9
BR 8W-20 CHARGING SYSTEM 8W - 20 - 1
CHARGING SYSTEM
CHARGING SYSTEM • From the ASD relay, circuit A142 splices to supply
The charging system is an integral part of the bat voltage to the fuel injectors, ignition coil, fuel pump
tery and starting systems. Because all these systems module, and the heated oxygen sensor on gasoline
work in conjunction, diagnose and test them together. engines.
Circuit AO from the battery connects to a bus bar
in the Power Distribution Center (PDC). Circuit A l l DIAGRAM INDEX—GASOLINE ENGINES
connects to the PDC bus bar and the output terminal
of the generator. A fuse in the PDC between AO and Component Page
All circuits protects the charging system. Circuit Zl ASD Relay 8W-20-3
provides ground for the generator. Clutch Pedal Position Switch 8W-20-3
On the diesel engine applications an additional bat Engine Starter Motor .8W-20-3
tery is used. Circuit AO connects between the battery Engine Starter Motor Relay 8W-20-3
positive terminals of the batteries. Fuse 2 (PDC) .8W-20-2
When the ignition switch is in either the START or Fuse 3 (PDC) 8W-20-2
RUN positions, it connects battery voltage from cir Fuse 4 (PDC) 8W-20-2
cuit Al to the A21 circuit. Circuit A21 powers circuit Generator 8W-20-2
F18 through Fuse 9 in the fuse block. Circuit F18 Ignition Switch 8W-20-3
connects to the coil side of the Automatic Shut Down Powertrain Control Module 8W-20-2
(ASD) relay. Circuit Al originates in the PDC and is
connected to battery voltage. A 40 amp fuse in cavity DIAGRAM INDEX—DIESEL ENGINES
3 of the PDC protects the Al circuit.
When the ASD relay energizes, it contacts connect Component Page
circuit A14 from the PDC to circuit A142. Circuit
ASD Relay 8W-20-5
A142 splices to connect to the generator connector
Clutch Pedal Position Switch .8W-20-5
supplying battery voltage to the generator field. Engine Starter Motor Relay 8W-20-5
The Powertrain Control Module (PCM) has an in Engine Starter Motor . 8W-20-5
ternal voltage regulator that controls generator out Fuse 2 (PDC) 8W-20-4
put. Circuit K20 connects to generator and PCM Fuse 3 (PDC) . . . . . . . .8W-20-4
cavity 20. The PCM controls the generator field on Fuse 4 (PDC) 8W-20-4
the K20 circuit. Generator 8W-20-4
When the engine operates and there is current in Ignition Switch 8W-20-5
the generator field, the generator produces a B+ volt Powertrain Control Module 8W-20-4
age. The generator supplies B+ voltage to the battery
through the A l l and AO circuits.
HELPFUL I N F Q i i A T I O N
• Check the 120 amp fuse located in the PDC
8W - 20 - 2 • 8W-20 CHARGING SYSTEM BR
GASOLINE ENGINES
AO 6RD AO 6RD
AO 6RD
AO 20PK-
SPLZCE
S148
(8W-70-21)
BATTERY AO A16
POWER 6RD 14GY
DISTRIBUTION WT
CENTER
\ FUSE k FUSE 3 k FUSE 2 K FUSE 4

C 120A C 40A r *OA C 30A
C180
A16 14GY/WT
A2 12PK/BK
C133
-Al 12RD- Al 12RD-
| GENERATOR I POWERTRAIN
t i t L U
CONTROL
I CONTROL I
2 0
MODULE
S134 L
"I (RIGHT SIDE
8W-70-14 J/C135 OJ DASH
PANEL
)>— K20 18DG •K20 18DG
S133
» — A142 14DB # — A 1 4 2 14DG/0R-—#[8W-70-14
2) S135
A142
8W-70-15 3.9L.- 1406
5.2L. OR
I
5.9L C125
8.0L ENGINE- ENGINES
ONLY —7<f-A142 14DG/0R-
ONLY
A142
14DG
OR
S138
8W-70-17 -A142 14DG/0R-
J958W-9
BR 8W-28 CHARGING SYSTEM 8W - 20 - 3
GASOLINE ENGINES
AO 6 R D
E N G I N E STARTER MOTOR
A16 14GY/WT
HOLD- PULL- 4 f
FUEL ON ON 2 J
PUMP
RELAY
(8W-11-8)
m 5 J
AO
SRD
SPLICE
S114
(2) C181
(8W-70-6) Y
T40
12BR
K51 F 1 8 A16 ^CllS
22DB 20L6 14GY POWER
YL BK WT DISTRIBUTION T40 €125
CENTER 12BR
T 4 1 22BK/WT » —
R
, C180
C180
Z12
20BK
30
TN
S139
AUTOMATIC
8 W - 7 0 - 1 8
SHUT DOWN
RELAY
Z12
14BK
TN
A2
it2PK
BK
8W-15-5
CLUTCH PEDAL
POSITION SWITCH
MANUAL TRANSMISSION)
BYPASS JUMPER
(AUTOMATIC
TRANSMISSION
ONLY}
•A142 14DG/0R
SPLICE
S201
(8W-70-22)
-A22 1 2 B K / 0 R — < (
S T A R T * ^
J958W-9
8W - 20 - 4 8W-20 CHARGING SYSTEM BR
DIESEL ENGINES
AO 6 R D AO 6 R D
AO 6 R D
SPLICE
S148
(8W-70-21)
AO
6RD
A16
14GY
WT
POWER
DISTRIBUTION
CENTER
A16 14GY/WT
A2 12PK/BK-
Al 1 2 R D -
POWERTRAIN
CONTROL
MODULE
G H
[ G E N E R A T O R A S D ~! J ^ l J -
I FIELD RELAY ISIDE >OF
CONTROL OUTPUT I Jt^s
1 1
20 57 PANEL)
l _ ; i
C135
K20 1 8 D G T
A142 16DG/0R-
A142 14DG/0R-
J958W-9
BR 8W-20 CHARGING SYSTE1 8W - 20 - 5
DIESEL ENGINES
AO 6RD
FUEL SHUT
DOWN RELAY
(8W-30-45)
A16 14GY/WT
FUEL
PUHP
RELAY
(8W-11-8)
T40
SPLICE 12BR
S114 2 :
(8W-70-6) C I 19 ( )
-T40 12BR
K51 F18 A16

22DB 20L6 14GY POWER
YL BK WT DISTRIBUTION C125
CENTER j-T41 22BK/WT-
C180
•** C180
Z12
87 85 20BK
86 30 TN
ENGINE S139 |
AUTOMATIC
STARTER 8W-70-18
SHUT ''PQWN
MOTOR
RELAY
RELAY
Z12
30 86 14BK
85 87 TN
I
: C180 C180
A2
Y- Gill
12PK S146 A2
BK 12PK A41 8W-15-5
8W-70-20 14YL
BK
A2 12PK/BK-
(2) C132
-Al 12RD
CLUTCH PEDAL
IGNITION
A142 P O S I T I O N SWITCH
SWITCH Al
1406 [MANUAL TRANSMISSION)
OR <~ n 12RD A2
12PK A41
C212
ACC fi BK 20YL
i • I Hi
BYPASS JUMPER
(1) 132 (AUTOMATIC
RUN \ TRANSMISSION
A41 ONLY)
CI25 START*"
(7) 18DB
-A142 14DG/0R — ( ( — YL
A2 A41
SPLICE
12PK 18DB C133
S201
BK YL
(8W-7Q-22)
C212 ACC
L A22 12BK/0R—<f
m
4)
(3)
J958W-9
START • vM
BR 8W-21 STARTING SYSTEM 8W - 21 - 1
STARTING SYSTEM
AUTOMATIC TRANSMISSION Circuit AO from the battery is double crimped at
The Power Distribution Center (PDC) supplies bat the positive battery post. One branch of circuit AO
tery voltage to the engine starter motor solenoid on (battery positive cable) connects to the battery
circuit T40 when the coil side of the engine starter starter motor. The other AO branch supplies voltage
motor relay energizes. to a bus bar in the PDC. Fuse 2 (40 amp) connects to
Circuit AO from the battery is double crimped at the bus bar and protects circuit A2. Circuit A2 con
the positive battery post. One branch of circuit AO nects to the contact side of the engine starter motor
(battery positive cable) connects to the starter motor. relay.
The other AO branch supplies voltage to a bus bar in The ignition switch supplies battery voltage to the
the PDC. Fuse 2 (40 amp) connects to the bus bar coil side of the engine starter motor relay on circuit
and protects circuit A2. Circuit A2 connects to the A41 when the key is moved to the START position
contact side of the engine starter motor relay. and the operator depresses the clutch pedal. When
The ignition switch supplies battery voltage to the the operator depresses the clutch pedal, the clutch
coil side of the engine starter motor relay on circuit pedal position switch CLOSES. Ground for the coil
A41 when the key is moved to the START position. side of the engine starter motor relay is supplied on
Ground for the coil side of the starter motor relay is circuit T41. This circuit is spliced with circuit Z12.
supplied by the case grounded PARK/NEUTRAL Circuit Z12 connects to ground.
switch. Circuit T41 connects the coil side of the relay
to the PARK/NEUTRAL switch. When the starter motor relay energizes and the
When the starter motor relay energizes and the contacts CLOSE, circuit T40 supplies battery voltage
contacts close, circuit T40 supplies battery voltage to to the starter motor solenoid. Circuit AO from the
the starter motor solenoid. Circuit AO from the bat battery supplies voltage to the starter motor when
tery supplies voltage to the starter motor when the the solenoid energizes.
solenoid energizes.
HELPFUL INFORMATION
HELPFUL INFORMATION ^ . . • Check the 40 amp fuse located in cavity 2 of the
• Check the 40 amp fuse located in cavity 2 of the PDC
PDC • Circuit Zl also provides ground for the vehicle
• The PARK/NEUTRAL switch CLOSES when the speed sensor, A/C compressor clutch, 4x4 switch, ve
transmission is in either the PARK or NEUTRAL po hicle speed control, heated oxygen sensor, and PCM.
sitions The engine will not start if the vehicle loses
• Circuit T41 splices to cavity 30 of the Powertrain this ground. The grounding point for the Zl ground
Control Module (PCM) This input tells the PCM the is the left side shield.
operator is starting the vehicle • On diesel engines the T40 circuit is spliced and
• Circuit T41 is spliced to circuit Zl. Circuit Zl pro supplies power for the fuel shut down solenoid
vides ground for the vehicle speed sensor, A/C com
pressor clutch, 4x4 switch, vehicle speed control, DIAGRAM INDEX
heated oxygen sensor, and PCM. The engine will
not start if the vehicle loses this ground.
Component Page
• On diesel engines the T40 circuit is spliced and
Clutch Pedal Position Switch 8W-21-2
supplies power for the fuel shut down solenoid
Engine Starter Motor 8W-21-2
Engine Starter Motor Relay 8W-21-2
MANUAL TRANSMISSION
The Power Distribution Center (PDC) supplies bat Fuse 3 (PDC) . .......... .8W-21-2
tery voltage to the engine starter motor solenoid on Ignition Switch .8W-21-2
circuit T40 when the coil side of the engine starter Park/Neutral Position Switch 8W-21-2
motor relay energizes.
aw - 21 - 2 8W-21 STARTING SYSTEM BR
BATTER?
POSITIVE AO 6RD
TERMINAL
SPLICE
S201 BYPASS JUMPER
(8W-70-22)
AUTOMATIC TRANSMISSION)
C212
A22 12BK/0R—«•
START
J958W-9
BR 8W-30 FUEL/IGNITION 8W - 30 - 1
FUEL/IGNITION
CONTENTS
page page
FUEL/IGNITION—GASOLINE ENGINES ,.. 1 FUEL/IGNITION—DIESEL ENGINES ..7
GENERAL INFORMATION scriptions are divided into two sub-sections; Gasoline

This section contains separate wiring diagrams for Engine, and Diesel Engine. When referring to the cir
the 3.9L V-6 engine, 5.2L and 5.9L V-8 engines, 8.0L cuit descriptions or wiring diagrams, use the correct
V-10 engine and for the diesel engine. The circuit de- sub-section.
FUEL/IGNITION—GASOLINE ENGINES
INDEX
page page
Automatic Shut Down (ASD) Relay 1 Idle Air Control (IAC) Motor 3
Battery Feed 2 Ignition Coil—V-10 Engines 2
Camshaft Position Sensor . 4 Ignition Coil—V-6 and V-8 Engines . . . . . . . . . . . . . 2
Crankshaft Position Sensor . . . . . . . . . . . . . . . . . . . 4 Ignition Control Module—V-10 Engines . . . . . . . . . . 6
Data Link Connector . 6 Ignition Switch 1
Diagram Index . 6 Intake Air Temperature Sensor 5
EGR Solenoid 5 Malfunction Indicator Lamp (MIL) 6
Engine Coolant Temperature Sensor 4 Manifold Absolute Pressure Sensor 5
EVAP/Purge Solenoid 5 Overdrive Solenoid 5
Fuel Injectors—V-10 Engines 2 Park/Neutral Position Switch 5
Fuel Injectors—V-6 and V-8 Engines . . . . . . . . . . . . 2 Power (Device) Ground 6
Fuel Pump Module 3 Service Reminder Indicator Lamp . 6
Fuel Pump Relay ..... 2 Tachometer 6
Heated Oxygen Sensor—V-6 and Light Duty V-8 TCC Solenoid 5
Engines 3 Throttle Position Sensor 4
Heated Oxygen Sensors—Heavy Duty V-8 Engines Upshift Lamp 5
and V-10 Engines . 3 Vehicle Speed Sensor 3
IGNITION SWITCH r
also connects to the fuse block and feeds circuits F30,
When the ignition switch is in the RUN position, it L5, X12, and V6. Separate fuses protect each circuit.
connects circuit A2 from fuse 2 in the Power Distri
AUTOMATIC SHUT DOWN (ASD) RELAY
bution Center (PDC) to circuit A22. Circuit A22 con
nects to the fuse block. Through the fuse block, Circuit A16 from fuse 4 in the Power Distribution
circuit A22 feeds circuits A20, LIO, F23, CI and F21. Center (PDC) supplies battery voltage to the contact
Circuits A20, LIO, F23, and CI are protected by sep side of the Automatic Shut Down (ASD) relay. Circuit
arate fuses. A circuit breaker protects circuit F21. A16 is HOT at all times.
When the ignition switch is in the START or RUN When the ignition switch is in the START or RUN
position, it connects circuit Al from fuse 3 in the position, it connects circuit Al from fuse 3 in the
PDC to circuit A21. Circuit A21 powers circuits F18, PDC to circuit A21. Circuit A21 powers circuit F18
V34, F12, and F14 through the fuse block. Separate through fuse 9 in the fuse block. Circuit F18 supplies
fuses protect each circuit. In the START position, the battery voltage to the coil side of the ASD relay. The
ignition switch connects circuit G9 to ground. Powertrain Control Module (PCM) provides the
- In the ACCESSORY or RUN position, the ignition ground path for the coil side of the relay on circuit
switch connects circuit Al to circuit A31. Circuit A31 K51. Circuit K51 connects to cavity 51 of the PCM
connector.
8W - 30 - 2 8W-30 FUEL/IGNITION—GASOLINE ENGINES
When the PCM provides grounds the ASD relay, cuit A142 supplies voltage to the fuel injectors. The
the relay contacts close and connect circuit A16 to Powertrain Control Module (PCM) provides the
circuit A142. Circuit A142 splices to supply voltage to ground for the injectors. The PCM grounds two injec
the fuel injectors, ignition coil, and heated oxygen tors at the same time. Injectors are paired as follows:
sensor. Circuit A142 also connects to cavity 57 of the 1 and 10, 2 and 7, 3 and 6, 4 and 9, 5 and 8.
PCM. Circuit K116 provides ground for injectors 1 and
10. The K116 circuit connects to cavity 16 of the
BATTERY FEED PCM.
Circuit A14 from the Power Distribution Center Circuit K158 provides ground for injectors 2 and 7.
(PDC) supplies battery voltage to cavity 3 of the Pow The K158 circuit connects to cavity 58 of the PCM.
ertrain Control Module (PCM). A 30 amp fuse in cav Circuit K114 provides ground for injectors 3 and 6.
ity D of the PDC protects circuit A14. The K114 circuit connects to cavity 14 of the PCM.
Circuit K115 provides ground for injectors 4 and 9.
HELPFUL INFORMATION
The K115 circuit connects to cavity 15 of the PCM.
Circuit A14 supplies power to the contact sides of
the Automatic Shut Down (ASD) relay and fuel pump Circuit K113 provides ground for injectors 5 and 8.
relay. The K113 circuit connects to cavity 13 of the PCM.
FUEL INJECTORS—V-6 AND V-8 ENGINES IGNITION COIL—V-6 AND V-8 ENGINES
When the Automatic Shut Down (ASD) relay con When the Powertrain Control Module (PCM)
tacts close, they connect circuits A14 and A142. Cir grounds the Automatic Shut Down (ASD) relay, the
cuit A142 supplies voltage to the fuel injectors. Each contacts close and connect circuits A14 and A142.
injector has a separate ground circuit controlled by Circuit A142 supplies battery voltage to the ignition
the Powertrain Control Module (PCM). coil. The PCM controls the ground path for the igni
Circuit K l l provides ground for injector number tion coil on circuit K19. Circuit K19 connects to cav
one. The Kll circuit - connects to cavity 16 of the ity 19 of the PCM.
PCM.
Circuit K12 provides ground for injector number IGNITION COIL—V-10 ENGINES
two. The K12 circuit connects to cavity 15 of the V-10 engines use two ignition coil packs. One coil
PCM. pack supplies spark to cylinders 5, 8, 9, and 10. The
Circuit K13 provides ground for injector number other coil pack connects to cylinders 1, 2, 3, 4, 6, and
three. The K13 circuit connects to cavity 14 of the 7.
PCM. When the Powertrain Control Module (PCM)
Circuit K14 provides ground for injector number grounds the Automatic Shut Down (ASD) relay, the
four. The K14 circuit connects to cavity 13 of the contacts close and connect circuits A14 and A142.
PCM. Circuit A142 supplies battery voltage to the ignition
Circuit K38 provides ground for injector number coil. Either the PCM or the Ignition Control Module
five. The K38 circuit connects to cavity 38 of the (ICM) provide ground for each individual coil.
PCM. The PCM controls the ground path for the coil that
Circuit K58 provides ground for injector number supplies spark to cylinders 1 and 6 on circuit K19.
six. The K58 circuit connects to cavity 58 of the Circuit K19 connects to cavity 19 of the PCM.
PCM. The PCM controls the ground path for the coil that
On the 5.2L and 5.9L engines, circuit K17 provides supplies spark to cylinders 2 and 3 on circuit K43.
ground for injector number seven. The K17 circuit Circuit K43 connects to cavity 18 of the PCM.
connects to cavity 17 of the PCM. The PCM controls the ground path for the coil that
Also on the 5.2L and 5.9L engines, circuit K18 pro supplies spark to cylinders 8 and 9 on circuit K18.
vides ground for injector number eight. The K18 cir Circuit K18 connects to cavity 17 of the PCM.
cuit connects to cavity 18 of the PCM. The ICM controls the ground path for the coil that
supplies spark to cylinders 4 and 7 on circuit K32.
HELPFUL INFORMATION Circuit K32 connects to cavity 1 of the ICM.
• Circuit A142 splices to supply voltage to the fuel The ICM controls the ground path for the coil that
injectors, ignition coil, and heated oxygen sensor. supplies spark to cylinders 5 and 10 on circuit K17.
• For information about fuel injector operation, refer Circuit K17 connects to cavity 5 of the ICM.
to Group 14.
FUEL PUMP RELAY
FUEL INJECTORS—V-10 ENGINES Circuit A14 from fuse 8 in the Power Distribution
When the Automatic Shut Down (ASD) relay con Center (PDC) supplies battery voltage to the contact
tacts close, they connect circuits A14 and A142. Cir side of the fuel pump relay. Circuit F18 from fuse 9
BR 8W-30 FUEL/IGNITION—GASOLINE ENGINES 8W - 30 - 3
in the fuse block supplies battery voltage to the coil VEHICLE SPEED SENSOR
side of the fuel pump relay. The Powertrain Control Circuit K7 supplies 8 volts from the Powertrain
Module (PCM) provides the ground path for the coil Control Module (PCM) to the vehicle speed sensor.
side of the relay on circuit K51. Circuit K51 connects The K7 circuit connects to cavity 7 of the PCM con
to cavity 51 of the PCM connector. nector.
When the PCM grounds the fuel pump relay and Circuit G7 from the vehicle speed sensor provides
the contacts close, they connect circuits A14 and A61. an input signal to the PCM. The G7 circuit connects
Circuit A61 supplies power to the fuel pump motor. to cavity 47 of the PCM connector.
The PCM provides a ground for the vehicle speed
HELPFUL INFORMATION
sensor signal (circuit G7) through circuit K4. Circuit
Along with supplying voltage to the fuel pump re
K4 connects to cavity 4 of the PCM connector.
lay contacts, circuit A14 splices to supply voltage to
the contact side of the ASD relay. HELPFUL INFORMATION :
Circuit F18 splices to supply battery voltage to the • Circuit G7 splices to the speedometer.
coil sides of the ASD relay and fuel pump relay. • Circuit K7 splices to supply 8 volts to the camshaft
position sensor, crankshaft position sensor, and Igni
FUEL PUMP MODULE tion Control Module (ICM).
Circuit K4 splices to supply ground for the signals
FUEL PUMP MOTOR from the following:
When the fuel pump relay contacts close, circuit ® Heated oxygen sensor(s)
A14 connects to circuit A61. Circuit A61 supplies • Camshaft position sensor
voltage to the fuel pump motor. Circuit Z13 provides • Crankshaft position sensor
ground for the fuel' pump motor. • Throttle position sensor
• Manifold absolute pressure sensor
"UEL LEWEL SENSOR • Engine coolant temperature sensor
The fuel level sensor is a variable resistor. Circuit • Intake air temperature sensor
G4 connects the fuel level sensor to the fuel gauge in
the instrument cluster. Circuit F14 from fuse 12 in HEATED OXYGEN SENSOR—V-6 AND LIGHT DUTY
the fuse block supplies voltage to the fuel gauge. The
V-8 ENGINES
fuel level sensor draws voltage from circuit F14
through the fuel gauge on circuit G4. Circuit Zll pro When the Powertrain Control Module (PCM)
vides the ground path for the fuel level sensor. grounds the Automatic Shut Down (ASD) relay, the
contacts close and connect circuits A14 and A142.
As current flows through the coils in the fuel Circuit A142 supplies battery voltage to the heated
gauge, it creates a magnetic field. One of the coils in oxygen sensor.
the gauge receives fixed current. The other coil is Circuit K41 delivers the signal from the heated ox
connected to the level sensor. The magnetic field con ygen sensor to the PCM. Circuit K41 connects to cav
trols the position of the fuel gauge pointer. ity 41 of the PCM.
The fuel level sensor contains a variable resistor. The PCM provides a ground for the heated oxygen
As the position of the float arm on the fuel level sen sensor signal (circuit K41) through circuit K4. Circuit
sor changes, the resistor changes the current flow K4 connects to cavity 4 of the PCM connector. Circuit
through second coil" in the fuel gauge. A change in Zll provides a ground for the heater circuit in the
current flow alters the magnetic field in the fuel sensor.
gauge, which changes the pointer position. •
HEATED OXYGEN SENSORS—HEAVY DUTY V-8
IDLE AIR CONTROL (IAC) MOTOR ENGINES AND V-10 ENGINES
The Powertrain Control Module (PCM) operates The 8.0L V-10 engine uses two oxygen sensors, one
the Idle Air Control (IAC) motor through 4 circuits - in each exhaust down pipe. When the Powertrain
K39, K40, K59, and K60. Each circuit connects to Control Module (PCM) grounds the Automatic Shut
separate cavities in the PCM connector. Down (ASD) relay, the contacts close and connect cir
• Circuit K39 connects to cavity 39 of the PCM con cuits A14 and A142. Circuit A142 supplies battery
nector. voltage to the heated oxygen sensors.
• Circuit K40 connects to cavity 40 of the PCM con Circuit K41 delivers the signal from the right
nector. heated oxygen sensor to the PCM. Circuit K41 con
• Circuit K59 connects to cavity 59 of the PCM con nects to cavity 41 of the PCM.
nector. Circuit K141 delivers the signal from the left
• Circuit K60 connects to cavity 60 of the PCM con heated oxygen sensor to the PCM. Circuit K141 con
nector. nects to cavity 23 of the PCM.
8W - 30 - 4 8W-30 FUEL/IGNITION—GASOLINE ENGINES
The PCM provides a ground for the heated oxygen Circuit K4 splices to supply ground for the signals
sensor signals (circuit K141 and K41) through circuit from the following:
K4. Circuit K4 connects to cavity 4 of the PCM con • Heated oxygen sensor
nector. Circuit Z l l provides a ground for the heater ® Camshaft position sensor
circuit in each sensor. • Intake air temperature sensor
• Throttle position sensor
HELPFUL INFORMATION • Manifold absolute pressure sensor
Circuit A142 splices to supply voltage to the fuel • Engine coolant temperature sensor
injectors, ignition coil, and heated oxygen sensor. • Vehicle speed sensor
Circuit K4 splices to supply ground for the signals
from the following: ENGINE COOLANT TEMPERATURE SENSOR
• Camshaft position sensor The engine coolant temperature (ECT) sensor pro
• Crankshaft position sensor vides an input to the powertrain control module
® Intake air temperature sensor (PCM) on circuit K2. From circuit K2, the engine
• Throttle position sensor coolant temperature sensor draws up to 5 volts from
• Manifold absolute pressure sensor the PCM. The sensor is a variable resistor. As coolant
• Engine coolant temperature sensor temperature changes, the resistance in the sensor
© Vehicle speed sensor changes, causing a change in current draw. The K2
circuit connects to cavity 2 of the PCM.
CAMSHAFT POSITION SENSOR The PCM provides a ground for the engine coolant
The Powertrain Control Module (PCM) supplies 8 temperature sensor signal (circuit K2) through circuit
volts to the camshaft position sensor (in distributor) K4. Circuit K4 connects to cavity 4 of the PCM con
on circuit K7. Circuit K7 connects to cavity 7 of the nector.
PCM.
The PCM receives the camshaft position sensor sig HELPFUL INFORMATION
nal on circuit K44. Circuit K44 connects to cavity 44 Circuit K4 splices to supply ground for the signals
of the PCM. from the following:
The PCM provides a ground for the camshaft posi • Heated oxygen sensor(s)
tion sensor signal (circuit K44) through circuit K4. • Camshaft position sensor
Circuit K4 connects to cavity 4 of the PCM connector. • Crankshaft position sensor
• Intake air temperature sensor
HELPFUL INFORMATION • Throttle position sensor
• Circuit K7 splices to supply 8 volts to the crank • Manifold absolute pressure sensor
shaft position sensor and the vehicle speed sensor. • Vehicle speed sensor
• Circuit K4 splices to supply ground for the signals
from the following: THROTTLE POSITION SENSOR
• Heated oxygen sensor(s) From the Powertrain Control Module (PCM), cir
• Crankshaft position sensor cuit K6 supplies 5 volts to the Throttle Position Sen
® Intake air temperature sensor sor (TPS). Circuit K6 connects to cavity 6 of the
• Throttle position sensor PCM.
o Manifold absolute pressure sensor Circuit K22 delivers the TPS signal to the PCM.
• Engine coolant temperature sensor Circuit K22 connects to cavity 22 of the PCM.
• Vehicle speed sensor The PCM provides a ground for the throttle posi
tion sensor signal (circuit K22) through circuit K4.
CRANKSHAFT POSITION SENSOR Circuit K4 connects to cavity 4 of the PCM.
The Powertrain Control Module (PCM) supplies 8
volts to the crankshaft position sensor on circuit K7. HELPFUL INFORMATION
Circuit K7 connects to cavity 7 of the PCM. Refer to Group 14 for throttle position sensor oper
The PCM receives the crankshaft position sensor ation.
signal on circuit K24. Circuit K24 connects to cavity Circuit K6 splices to supply 5 volts to the manifold
24 of the PCM. absolute pressure sensor.
The PCM provides a ground for the crankshaft po Circuit K4 splices to supply ground for the signals
sition sensor (circuit K24) through circuit K4. Circuit from the following:
K4 connects to cavity 4 of the PCM connector. • Heated oxygen sensor(s)
• Camshaft position sensor
HELPFUL INFORMATION • Crankshaft position sensor
Circuit K7 splices to supply 8 volts to the camshaft ® Intake air temperature sensor
position sensor and the vehicle speed sensor. & Manifold absolute pressure sensor
8W-30 FUEL/IGNITION—GASOLINE ENGINES 8W - 30 - 5
© Engine coolant temperature sensor Module (PCM). The PARK/NEUTRAL position switch
© Vehicle speed sensor provides an input to the PCM.
MANIFOLD ABSOLUTE PRESSURE SENSOR TCC SOLENOID

From the Powertrain Control Module (PCM), cir The TCC solenoid and overdrive solenoid are
cuit KB supplies 5 volts to the manifold absolute molded together. They are only used on automatic
pressure (MAP) sensor. Circuit K6 connects to cavity transmissions. The Powertrain Control Module
6 of the PCM. (PCM) operates the TCC solenoid by providing a
Circuit Kl delivers the MAP signal to the PCM. ground path on circuit K54. Circuit K54 connects to
Circuit Kl connects to cavity 1 of the PCM. PCM cavity 54.
The PCM provides a ground for the MAP sensor When the ignition switch is in the START or RUN
signal (circuit Kl) through circuit K4. Circuit K4 con position, it connects circuit Al from, fuse 3 in the
nects to cavity 4 of the PCM. PDC to circuit A21. Circuit A21 powers circuit F18
through fuse 9 in the fuse block. Circuit F18 supplies
HELPFUL INFORMATION
Refer to Group 14 for MAP sensor operation. battery voltage to the TCC solenoid.
Circuit K6 splices to supply 5 volts to the throttle UPSHIFT LAMP
position sensor.
Circuit K4 splices to supply ground for the signals On vehicles equipped with a manual transmission,
from the following: the Powertrain Control Module (PCM) provides a
• Heated oxygen sensor(s) ground path for the instrument cluster upshift lamp
• Camshaft position sensor on circuit K54. Circuit F14 provides battery voltage
© Crankshaft position sensor to the lamp.
• Intake air temperature sensor
• Throttle position sensor OVERDRIVE SOLENOID
© Engine coolant temperature sensor The overdrive solenoid and TCC solenoid are
o Vehicle speed sensor molded together. They are only used on automatic
transmissions. The Powertrain Control Module
INTAKE AIR TEMPERATURE SENSOR (PCM) operates the overdrive solenoid by providing a
The intake air temperature sensor provides an in ground path on circuit T60. Circuit T60 connects to
put to the Powertrain Control Module (PCM) on cir PCM cavity 55.
cuit K21. Circuit K21 connects to cavity 21 of the When the ignition switch is in the START or RUN
PCM. position, it connects circuit Al from fuse 3 in the
From circuit K21, the intake air temperature sen PDC to circuit A21. Circuit A21 powers circuit F18
sor draws voltage from the PCM. The sensor is a through fuse 9 in the fuse block. Circuit F18 supplies
variable resistor. As intake air temperature changes, battery voltage to the overdrive solenoid.
the resistance in the sensor changes, causing a
change in current draw. EGR SOLENOID
The PCM provides a ground for the intake air tem The Powertrain Control Module (PCM), operates
perature sensor signal (circuit K21) through circuit the Exhaust Gas Recirculation (EGR) solenoid by
K4. Circuit K4 connects to cavity 4 of the PCM. providing a ground path on circuit K35. Circuit K35
HELPFUL INFORMATION connects to PCM cavity 35.
Circuit K4 splices to supply ground for the signals When the ignition switch is in the START or RUN
from the following: position, it connects circuit Al from fuse 3 in the
• Heated oxygen sensor(s) PDC to circuit A21. Circuit A21 powers circuit F18
© Camshaft position sensor through fuse 9 in the fuse block. Circuit F18 supplies
• Crankshaft position sensor battery voltage to the EGR solenoid.
• Throttle position sensor
® Manifold absolute pressure sensor EVAP/PURGE SOLENOID
• Engine coolant temperature sensor The powertrain control module (PCM) operates the
© Vehicle speed sensor EVAP/purge solenoid by providing a ground path on
circuit K52. Circuit K52 connects to PCM cavity 52.
PARK/NEUTRAL POSITION SWITCH :
When the ignition switch is in the START or RUN
When closed, the case-grounded PARK/NEUTRAL position, it connects circuit Al from fuse 3 in the
position switch provides a ground path on circuit T41 PDC to circuit A21. Circuit A21 powers circuit F18
for the coil -side of the starter motor relay. Circuit through fuse 9 in the fuse block. Circuit F18 supplies
T41 splices to cavity 30 of the Powertrain Control battery voltage to the EVAP/Purge solenoid.
8W - 30 - 6 8W-30 FUEL/IGNITION—GASOLINE ENGINES BR
IGNITION CONTROL MODULE—V-10 ENGINES provides ground for PCM internal drivers that oper
The Ignition Control Module (ICM) and Powertrain ate high current devices like the injectors and igni
Control Module (PCM) communicate on circuits K137 tion coil.
and K138. Circuit K137 connects to cavity 7 of the Internal to the PCM, the power (device) ground cir
ICM and Cavity 37 of the PCM. Circuit K138 con cuit connects to the PCM sensor return circuit (from
nects to cavity 8 of the ICM and Cavity 38 of the circuit K4).
PCM.
HELPFUL INFORMATION
MALFUNCTION INDICATOR LAMP (MIL) If the system loses ground for the Z12 circuits, the
The PCM provides ground for the instrument clus vehicle will not operate.
ter malfunction indicator lamp on circuit G3. Circuit
G3 connects to cavity 32 of the PCM. Circuit F14 DIAGRAM INDEX—GASOLINE ENGINE
provides voltage for the lamp. The MIL displays the
message CHECK ENGINE when illuminated. Component ; Page
For information regarding diagnostic trouble code ABS Control Module . . .8W-30-15, 24, 34
access using the MIL lamp, refer to Group 14, Fuel Airbag Control Module . . . . . . . . . . . . . . . . . . . . .8W-30-12
Systems. ASD Relay . . . . . . . . . . . . . . . . . . . . . . .8W-30-20, 27, 39
Camshaft Position Sensor 8W-30-16, 25, 35
TACHOMETER Circuit Breaker (Cavity 1, Fuse Block) 8W-30-12
The tachometer module in the instrument cluster Crankshaft Position Sensor. 8W-30-18, 27, 37
operates the tachometer. The Powertrain Control Data Link C o n n e c t o r . . . . . . . . . . . . . . . . .8W-30-15, 24, 33
Module (PCM) supplies the signal for the tachometer EGR Solenoid . 8W-30-17, 26, 36
on circuit G21. Circuit G21 connects to cavity 43 of Engine Coolant Temperature Sensor 8W-30-16, 25, 35
the PCM. EVAP/Purge Solenoid 8W-30-17, 26, 36
Fuel Pump Relay. . . . . . . . . . . . . . . . . . . . . . . . .8W-30-48
SERVICE REMINDER INDICATOR LAMP Fuel Tank Gauge Level Sending U n i t . . . . . . . . . . . .8W-30-48
The Powertrain Control Module (PCM) provides Fuse 2 (Fuse Block) . . .8W-30-12
ground for the Service Reminder Indicator (SRI) Fuse 2 (PDC) 8W-30-10
lamp on circuit G24. Circuit G24 connects to cavity Fuse 3 (PDC) 8W-30-10, 21, 30, 40
56 of the PCM. Circuit F14 provides voltage for the Fuse 5 (Fuse Block) . . . . . . . . . . . . . . . . . . . . . .8W-30-10
lamp. The SRI lamp displays the message MAINT Fuse 6 (Fuse Block) . .8W-30-10
REQ'D. Fuse 7 (Fuse Block) . .8W-30-10
DATA LINK CONNECTOR Fuse 9 (Fuse Block). . 8W-30-11, 21, 30, 40
Fuse 10 (Fuse Block). . . .8W-30-11
Circuit F18 supplies battery voltage to the data
Fuse 11 (Fuse Block). 8W-30-11
link connector. When the ignition switch is in the
Fuse 12 (Fuse Block) . .8W-30-11
START or RUN positions, it connects circuit Al from
the Power Distribution Center (PDC) with circuit
Fuse 15 (Fuse Block) .8W-30-12
A21. Circuit A21 feeds circuit F18 through fuse 9 in Fuse 16 (Fuse Block). . . . . . . . . . . . . . . . . . . . . .8W-30-12
the fuse block. Heated Oxygen Sensor(s) 8W-30-20, 27, 39
Circuit D20 connects to cavity 45 of the PCM. Cir Idle Air Control Motor 8W-30-13, 22, 36
cuit D20 is the SCI receive circuit for the PCM. Ignition Coil(s). 8W-30-14, 23, 34
Circuit D21 connects to cavity 25 of the PCM. Cir Ignition Switch . . . . . . . . . . . 8W-30-11, 12, 21, 30, 40
cuit D21 is the SCI transmit circuit for the PCM. Injectors (3.9L) .8W-30-13, 14
Circuit Z12 provides ground for the data link con Injectors (5.2L/5.9L) . . .8W-30-22, 23
nector. Injectors (8.0L) 8W-30-31, 32
Intake Air Temperature Sensor 8W-30-16, 25, 35
HELPFUL INFORMATION
Manifold Absolute Pressure (MAP) Sensor. . .8W-30-18, 27, 37
If the system loses ground for the Z12 circuits, the
Powertrain Control Module. . . . . . . . . . . . .8W-30-13 thru 39
vehicle will not operate.
RWAL Control Module 8W-30-12
Throttle Position Sensor 8W-30-18, 27, 37
POWER (DEVICE) GROUND
Vehicle Speed Sensor . 8W-30-19, 27, 38
Circuit Z12 connects to cavities 11 and 12 of the
Powertrain Control Module (PCM). The Z12 circuit
BR 8W-30 FUEL/iGNITiOi—DIESEL ENGINES 8W - 30 - 7
FUEL/IGNITION—DIESEL ENGINES
INDEX
page page
Automatic Shut Down (ASD) Relay . 7 Ignition Switch 7

Battery Feed 7 Intake Air Temperature Sensor 9
Diagram Index 9 Intake Manifold Air Heater Relays . . . . . . . . . . . . . . 8
Engine Speed Sensor 9 Malfunction Indicator Lamp (MIL) . . . . . . . . . . . . . . . 8
Fuel Heater Relay 8 Tachometer 8
Fuel Pump Module 7 Throttle Position Sensor 8
Fuel Pump Relay . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Vehicle Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . 9
Fuel Shut Down Relay 8 Water-ln-Fuel Sensor 9
IGNITION SWITCH ertrain Control Module (PCM). A 30 amp fuse in cav

When the ignition switch is in the RUN position, it ity D of the PDC protects circuit A14.
connects circuit A2 from fuse 2 in the Power Distri
FUEL PUMP RELAY
bution Center (PDC) to circuit A22. Circuit A22 con
nects to the fuse block. Through the fuse block, Circuit A14 from fuse 8 in the Power Distribution
circuit A22 feeds circuits A20, LIO, F23, CI and F21. Center (PDC) supplies battery voltage to the contact
Circuits A20, LIO, F23, and CI are protected by sep side of the fuel pump relay. Circuit F18 from fuse 9
arate fuses. A circuit breaker protects circuit F21. in the fuse block supplies battery voltage to the coil
When the ignition switch is in the START or RUN side of the fuel pump relay. The Powertrain Control
Module (PCM) provides the ground path for the coil
position, it connects circuit Al from fuse 3 in the
side of the relay on circuit K51. Circuit K51 connects
PDC to circuit A21. Circuit A21 powers circuits F18,
to cavity 51 of the PCM connector.
V34, F12, and F14 through the fuse block. Separate When the PCM grounds the fuel pump relay and
fuses protect each circuit. In the START position, the the contacts close, they connect circuits A14 and A61.
ignition switch connects circuit G9 to ground. Circuit A61 supplies power to the fuel pump motor.
In the ACCESSORY or RUN position, the ignition
switch connects circuit Al to circuit A31. Circuit A31 HELPFUL INFORMATION
also connects to the fuse block and feeds circuits F30, Circuit F18 splices to supply battery voltage to the
L5, X12, and V6. Separate fuses protect each circuit. coil sides of the ASD relay and fuel pump relay.
AUTOMATIC SHUT DOWN (ASD) RELAY FUEL PUMP MODULE .
Circuit A16 from fuse 4 in the Power Distribution
Center (PDC) supplies battery voltage to the contact FUEL PUMP MOTOR
side of the Automatic Shut Down (ASD) relay. Circuit When the fuel pump relay contacts close, circuit
A16 is HOT at all times. A14 connects to circuit A61. Circuit A61 supplies
When the ignition switch is in the START or RUN voltage to the fuel pump motor. Circuit Z13 provides
position, it connects circuit Al from fuse 3 in the ground for the fuel pump motor.
PDC to circuit A21. Circuit A21 powers circuit F18
through fuse 9 in the fuse block. Circuit F18 supplies FUEL LEWEL SENSOR
battery voltage to the coil side of the ASD relay. The The fuel level sensor is a variable resistor. Circuit
Powertrain Control Module (PCM) provides the G4 connects the fuel level sensor to the fuel gauge in
ground path for the coil side of the relay on circuit the instrument cluster. Circuit F14 from fuse 12 in
K51. Circuit K51 connects to cavity 51 of the PCM the fuse block supplies voltage to the fuel gauge. The
connector. fuel level sensor draws voltage from circuit F14
When the PCM provides grounds the ASD relay, through the fuel gauge on circuit G4. Circuit Zll pro
the relay contacts close and connect circuit A16 to vides the ground path for the fuel level sensor.
circuit A142. Circuit A142 splices to supply voltage to As current flows through the coils in the fuel
the generator field. Circuit A142 also connects to cav gauge, it creates a magnetic field. One of the coils in
ity 57 of the PCM. the gauge receives fixed current. The other coil is
connected to the level sensor. The magnetic field con
BATTERY FEED trols the position of the fuel gauge pointer.
Circuit A14 from the Power Distribution Center The fuel level sensor contains a variable resistor.
(PDC) supplies battery voltage to cavity 3 of the Pow- As the position of the float arm on the fuel level sen-
SW -30-8 8W-30 FUEL/IGNITION—DIESEL ENGINES BR
sor changes, the resistor changes the current flow through fuse 9 in the fuse block. Circuit F18 supplies
through second coil in the fuel gauge. A change in battery voltage to the coil side of each intake mani
current flow alters the magnetic field in the fuel fold air heater relay.
gauge, which changes the pointer position. The Powertrain Control Module (PCM) provides
ground for the coil in each relay on separate circuits.
FUEL HEATER RELAY The PCM grounds first relay on circuit S21; it
When the ignition switch is in the START or RUN grounds the second relay on circuit S22.
position, it connects circuit Al from fuse 3 in the When the first intake manifold air heater relay en
PDC to circuit A21. Circuit A21 powers circuit F18 ergizes, its contacts close and connect circuit A19
through fuse 9 in the fuse block. Circuit F18 supplies from the left battery positive terminal to circuit A58.
battery voltage to the coil side of the fuel heater re Circuit A58 connects to the intake air heater.
lay. , Circuit Z12 provides ground for the coil side of When the second intake manifold air heater relay
the relay. energizes, its contacts close and connect circuit A8
Circuit A12 from the Power Distribution Center from the left battery positive terminal to circuit
(PDC) supplies battery voltage to the contact side of A122. Circuit A122 connects to the intake air heater.
the fuel heater relay. When voltage is present on cir The intake manifold air heaters are case grounded.
cuit F18, the relay energizes and its contacts close to Refer to Group 14, Fuel Systems, for intake manifold
connect circuits A12 and A93. heater Pre-Heat and Post-Heat Cycles.
Circuit A93 supplies power to the fuel heater. Cir
cuit Z12 provides ground for the fuel heater. MALFUNCTION INDICATOR LAMP (MIL)
The PCM provides ground for the instrument clus
FUEL'SHUT DOWN RELAY ter malfunction indicator lamp on circuit G3. Circuit
When the engine starter motor relay energizes, its G3 connects to cavity 32 of the PCM. Circuit F14
contacts close and connect circuit A2 from fuse 2 in provides voltage for the lamp. The MIL displays the
the Power Distribution Center (PDC) to circuit T40. message CHECK ENGINE when illuminated.
Circuit T40 supplies battery voltage to the engine For information regarding diagnostic trouble code
starter motor solenoid and to the coil side of the fuel access using the MIL lamp, refer to Group 14, Fuel
shut down relay. Systems.
Circuit Z12 provides ground for the coil side of the
relay. TACHOMETER
Circuit A18 from the Power Distribution Center The tachometer module in the instrument cluster
(PDC) supplies battery voltage to the contact side of operates the tachometer. The Powertrain Control
the fuel heater relay. When voltage is present on cir Module (PCM) supplies the signal for the tachometer
cuit T40, the relay energizes and its contacts close to on circuit G21. Circuit G21 connects to cavity 43 of
connect circuits A18 and A123. Circuit A123 supplies the PCM.
power to one of the two coils in the fuel shut down
solenoid. THROTTLE POSITION SENSOR
When circuit A123 energizes, the fuel shut down From the Powertrain Control Module (PCM), cir
solenoid raises the injection pump shut down lever to cuit K6 supplies 5 volts to the Throttle Position Sen
the RUN position. sor (TPS). Circuit K6 connects to cavity 6 of the
When the ignition switch is released to the RUN PCM.
position, it connects circuit Al from fuse 3 in the Circuit K22 delivers the TPS signal to the PCM.
PDC to circuit A21. Circuit A21 powers circuit F18 Circuit K22 connects to cavity 22 of the PCM.
through fuse 9 in the fuse block. Circuit F18 supplies The PCM provides a ground for the throttle posi
battery voltage to the second coil in the fuel shut tion sensor signal (circuit K22) through circuit K4.
down lever. When Circuit F18 energizes, the fuel Circuit K4 connects to cavity 4 of the PCM.
shut down solenoid holds the injection pump shut Refer to Group 14 for throttle position sensor oper
down lever in the RUN position. ation.
Circuit Z12 provides ground for the fuel shut down
solenoid. Refer to Group 14, Fuel Systems, for fuel HELPFUL INFORMATION
shut down solenoid operation. Circuit K4 splices to supply ground for signals from
the following:
INTAKE MANIFOLD AIR HEATER RELAYS • intake air temperature sensor
When the ignition switch is in the START or RUN @ vehicle speed sensor
position, it connects circuit Al from fuse 3 in the • engine speed sensor
PDC to circuit A21. Circuit A21 powers circuit F18 © water-in-fuel sensor
BR 8W-30 FUEL/IGNITION—DIESEL ENGINES 8W - 30 - 9
INTAKE AIR TEMPERATURE SENSOR • throttle position sensor

The intake air temperature sensor provides an input • water-in-fuel sensor
to the Powertrain Control Module (PCM) on circuit K21. • engine speed sensor
• intake air temperature sensor
Circuit K21 connects to cavity 21 of the PCM.
From circuit K21, the intake air temperature sen ENGINE SPEED SENSOR
sor draws voltage from the PCM. The sensor is a
' Circuit K7 supplies 8 volts from the Powertrain Con
variable resistor. As intake air temperature changes,
trol Module (PCM) to the engine speed sensor. The K7
the resistance in the sensor changes, causing a circuit connects to cavity 7 of the PCM connector.
change in current draw. Circuit K24 from the engine speed sensor provides
The PCM provides a ground for the intake air tem an input signal to the PCM. The K24 circuit connects
perature sensor signal (circuit K21) through circuit to cavity 24 of the PCM connector.
K4. Circuit K4 connects to cavity 4 of the PCM. The PCM provides a ground for the engine speed
HELPFUL INFORMATION sensor signal (circuit G7) through circuit K4. Circuit
Circuit K4 splices to supply ground for the signals K4 connects to cavity 4 of the PCM connector.
from the following:
HELPFUL INFORMATION
• throttle position sensor
• vehicle speed sensor Circuit K4 splices to supply ground for the signals
• engine speed sensor from the following:
• water-in-fuel sensor • throttle position sensor
• water-in-fuel sensor
WATER-IN-FUEL SENSOR • engine speed sensor
The water-in-fuel sensor provides an input to the • intake air temperature sensor
Powertrain Control Module (PCM) on circuit Kl. Cir
cuit Kl connects to cavity 1 of the PCM. DIAGRAM INDEX—DIESEL ENGINE
• From circuit Kl,' the water-in-fuel sensor draws
voltage from the PCM. The sensor is a variable resis Component Page
tor. As the amount of water in the fuel separator ABS Control Module . .8W-30-42
changes, the resistance in the sensor changes, caus Airbag Control Module .8W-30-12
ing a change in current draw. ASD Relay 8W-30-43
The PCM provides a ground for the water-in-fuel Circuit Breaker (Cavity 1, Fuse Block) 8W-30-12
sensor signal (circuit Kl) through circuit K4. Circuit Data Link Connector .8W-30-42
K4 connects to cavity 4 of the PCM. Fuel Heater 8W-30-45
Fuel Heater Relay . . . . 8W-30-45
HELPFUL INFORMATION Fuel Pump Relay .8W-30-48
Circuit K4 splices to supply ground for signals from Fuel Shut Down Relay .8W-30-45
the following: Fuel Shut Down Solenoid .8W-30-45
• intake air temperature sensor Fuel Tank Gauge Level Sending Unit 8W-30-48
• vehicle speed sensor Fuse 2 (Fuse Block) 8W-30-12
® engine speed sensor Fuse 2 (PDC) .8W-30-10
• throttle position sensor Fuse 3 (PDC) . . . . . . . . . . . . . . . . . . .8W-30-10, 44
Fuse 7 (Fuse Block) . 8W-30-10
Circuit K7 supplies 8 volts from the Powertrain Con
trol Module (PCM) to the vehicle speed sensor. The K7
Fuse 9 (Fuse Block) 8W-30-11, 44
circuit connects to cavity 7 of the PCM connector. Fuse 10 (Fuse Block) .8W-30-11
Circuit G7 from the vehicle speed sensor provides Fuse 11 (Fuse Block) 8W-30-11
an input signal to the PCM. The G7 circuit connects Fuse 12 (Fuse Block) 8W-30-11
to cavity 47 of the PCM connector. Fuse 14 (Fuse Block) 8W-30-12
The PCM provides a ground for the vehicle speed Fuse 15 (Fuse Block) .8W-30-12
sensor signal (circuit G7) through circuit K4. Circuit Fuse 16 (Fuse Block) 8W-30-12
K4 connects to cavity 4 of the PCM connector. Ignition Switch 8W-30-11, 12, 44
Intake Air Heater Relays . .8W-30-41
HELPFUL INFORMATION
Intake Air Temperature Sensor .8W-30-46
Circuit G7 splices to connect to the speedometer in Powertrain Control Module 8W-30-41 thru 47
the instrument cluster. RWAL Control Module . 8W-30-12
Circuit K4 splices to supply ground for the signals Throttle Position Sensor .8W-30-46
from the following: Water-ln-Fuel Sensor .8W-30-46
8W - 30 -10 8W-30 FUEL/IGNITION BR
BATTERY
POSITIVE
TERMINAL
POWER
AO DISTRIBUTION
6RD
CENTER
FUSE 2 FUSE 3 Al 12RO

40A f 40A
. I
C1SO
A2
12PK
BK
Al 12RD
C133
ISNITION
A2 12PK/BK- A2 12PK/BK • SWITCH
S146 (8W-30-12)
8W-70-20
A3i 12BK/WT
»> HOT I N ACC OR RUN «S C241

J '
6 5
l . 8 FUSE BLOCK
15A 20A
1
20A'
I
C241
V6 X12 F30
1SDB IBRD L5 IBRD
BK WT 20BK OR
F30 18RD/OR POWER OUTLET

(8W-41-2)
TURN S I G N A L
L5 20BK ' FLASHER
(8W-52-3)
RADIO
•X12 18RD/WT • (8W-47-2,
8W-47-4)
. SPLICE S 2 0 2
•V6 16DB/BK (8W-70-22)
J958W-9
BR 8W-30 FUEL/IGNITION 8W - 30 -11
VEHICLE
SPEED-
SPLICE * CONTROL
IGNITION BUS SWITCH
SWITCH (8W-70-6) (8W-33-2)
C 1 3 3 C2I2
- kl 12RD ))—Al 12RD <f
I I
I (7)1
r A4i 180B/YL—)>~A4l 18DB/YL—<f
FIB V34
CLUTCH PEDAL 12BK 12DB 20LG 22WT
POSITION BK RD
SWITCH WT
OR JUMPER
(8W-21-2)
A3! 12BK/WT
• HOT I N RUN OR START < C133

:CMJ
1 0
9 I F18 V34
F u s g b l o c k
i IL< IL< <?
2A <• 22LG 22WT
10A
BK RD
J
-
C241
SPLICE S 2 0 9
(8W-70-27) F14 1BLG/YL
F12
22DB
WT
C209
22
FUSED ICONNECTOR
1
JOINT
C
IGNITION
SWITCH I (BEHIND
OUTPUT KNEE
[(SJARJVRUN)] BOLSTER) J958W-9
30-12 8W-30 FUEL/IGNITION BR
S P L I C E S148
(8W-30-10)
IGNITION
SWITCH
ACC
^ m
C133 C212 OFF
1
C212
A2 12PK/BK ) > - A2 12PK/BK (f-
(4) RUN
(3)
,ACC
BLOWER
SPLICE MOTOR
S214 (8W-42-3.
f RUN (8W-70-29) 8W-42-4)
START # A22
12BK
OR
(5) :
C212
G9 22GY/BK
REAR WHEEL
ANTI-LOCK
CONTROL S201
MODULE y 8W-70-22
(CENTER
OF L P . ) A22 A22 A22
F21 CI
I 1 12BK 12BK 12BK
14TN
OR OR OR 1206
I FUSED I
| B( + ) i HOT I N « C241
i * RUN ONLY
~1
14 S 16 S F2 CB1 ( . FUSE
10A ISA 1
C 30A 3QAI BLOCK
j
;C241
„ i FUSED AIRBAG
C 2
hMMl IGNITION CONTROL

WITH MODULE
ABS F23 18DB/YL (f-|5 SWITCH
, OUTPUT (CENTER
(RUN) OF I . P . )
r
C209 BACK-UP |
LIO 22BR/LG ^H 2 8
SWITCH I
| |OUTPUT | JOINT
VACUUM SPLICE
SENSOR | CONNECTOR C
S110
(1W-32-S) (8W-70-5) | (BEHIND
I I
KNEE
I | BRAKE I BOLSTER)
« J WARNING
G9 22GY/BK- - \ H 25 LAMP
I DRIVER
I J
J958W-9
8W-30 FUEL/IGNITION 8W - 30 -13
3 J L ENGINE
SPLICE
S135
(8W-30-15)
INJECTOR #1 INJECTOR #3 INJECTOR #5
A142
14DB
OR
Kll A142 K13 A142 A142

18WT 16D6 18YL 16DG
K38
16DG
OB OR WT OR 18GY OR
S133
8 W - 7 0 - 1 4
4 -A142 160G/0R-
~) A142 16DG/0R
I P L E AIR
CONTROL MOTOR
(ON THROTTLE
BODY)
C150
(4) (3) (2) :d
Kll K13 K59 K 4 0 K 6 0 K 3 9

K38
18WT 18YL 18VT 18BR 18YL 18GY
WT 18GY BK WT BK RD
DB
£135
16 14 38 59 40 60 39 POWERTRAIN
I N J * 1 1NJ# 3 I N J # 5 I I
CONTROL
DRIVER DRIVER DRIVER IAC
MOTOR I MODULE
(RIGHT SIDE
OF DASH PANEL)
J958W-9
30 -14 8W-30 FUEL/IGNITION
3.9L ENGINE
SPLICE
S133
(8W-30-I3)
INJECTOR #8 INJECTOR # 4 INJECTOR #8
GENERATOR
{8W-10-2)
A142
14DB
OR
C145
(2) (1)
A142
14DI
K12 A142 K14 A142 K58 A142

18TN 16D6 18LB 1606 18BR 16DG S13S
OR BR OR DB OR
8W-70-15
^ A142 16DG/0R
A142
14DG
^ A142 16DG/0R OR
IGNITION
COIL
(RIGHT FRONT
OF ENGINE)
KM K58 A142
K12 18BR 16DG
18LB
18TN BR DB OR
C13S
15 13 SB 19 57 .
INJ*2 INJ# 4 INJ#6 COIL ASD I POWERTRAIN
DRIVER DRIVER DRIVER DRIVER RELAY I CONTROL
OUTPUT MODULE
I (RIGHT SIDE
j OF DASH PANEL)
J958W-9
BR 8W-30 FUEL/IGNITION 8W-30 15
3 J L ENGINE JOINT
ENGINE CONNECTOR
STARTER PARK/NEUTRAL
SPLICE MOTOR POSITION
S140 RELAY SWITCH
(8W-70-19) (8W-21-2) (8W-31-5)
!output! bolster)
C2Q9
111 T41 T41 V4Q

16BK 22BK 18BI 22WT
WT WT WT PK
S141
C12S C133
8W-70-19
K T41 2#fiK/MT-
V40
20WT
ENGINE PK
DATA L I N K
112 CONNECTOR
20BK (RIGHT SIDE OF
TN DASH PANEL)
C136
r V40
22WT
Sill
8W-70-5
PK
V40 V40
CJL36 22WT 20WT
PK PK
Z12
20BK
TN F18
20LG
BK
125
SPLICE REAR WHEEL C121

S132 ANTI-LOCK
SOI ONLY
(8W-30-13) I I (left
l8W-70-18| ff FENDER
V40 'cDVVru' SIDE
1
Z12 Z12 Z12 T4i 20MT iluTPyT SHIELD)

zit 14BK D21 D20
I6BK 16BK 16BK 20PK 20BK ANTI-LOCK
TN TN TN 20LG WT
WT BRAKE SYSTEM
CONTROL MODULE
C135
11 12, 25 45 30 29
SCI SCI PARK/ STOP I
Gill GROUND TRANSMIT RECEIVE NEUTRAL LAMP ( (RIGHT SIDE
POSITION SWITCH OF DASH PANEL)
1
|8W-15-5| | SWITCH OUTPUT |

OUTPUT
J958W-9
8W - 30 -16 8W-30 FUEL/IGNITION BR
3 J L ENGINE CAMSHAFT
POSITION
SPLICE SENSOR
S136
( I N DISTRIBUTOR)
(8W-30-19)
C171
(2) (3)
K4 K4
18BK 208K
LB LB
S12S
CRANKSHAFT
8W-70-12 POSITION
SENSOR
(8W-30-18)
K7 K7
200R
200R
K4
20BK
LB
r S13Q
K7
K4 180R 8W-70-12
I8BK
LB
VEHICLE
SPEED
SENSOR
(8W-30-19)
(2) C152
ENGINE
COOLANT
TEMPERATURE
SENSOR
(FRONT OF
ENGINE) INTAKE A I R C1S7
TEMPERATURE (I)
C152 SENSOR
(RIGHT FRONT
OF INTAKE
MANIFOLD)
K4 K21 K44
K7
20BK 18BK 20TN
200R
LB RD YL
C135
2 4 , 21 7 44
ECT 8V I (RIGHT
SENSOR INTAKE CAM
SUPPLY SIDE
GROUND AIR TENP POSITION
SENSOR 1 OF DASH
SENSOR
| PANEL)
SIGNAL

J958W-9
BR 8W-30 FUEL/IGNITION SW - 31 -17
3 J L ENGINE TRANSMISSION
SPLICE OVERDRIVE
ENGINE S114 SOLENOID
DATA L I N K (8W-70-6) (8W-31-2)
CONNECTOR
(8W-3Q-1S)
F I B
18LG
BK
F18 F 1 8
2 0 1 6 CI2B 20LG
BK BK
INSTRUMENT
CLUSTER
FIB
18L6
BK
ITACH MIL
12 9
•FIB 20LG/BK- 5Q2
621 63
22m 22BK
LB PK
EXHAUST GAS
RECIRCULATION
SOLENOID
C148
C133
621 63
22GY 22BK
LB PK
(RIGHT REAR (LEFT REAR
OF ENGINE) OF ENGINE)
CI27 CI28
621 63 F 1 8 K35 K52

20GY 20BK 20L6 20GY 20PK
LB PK BK YL BK
COS
32 9 35 52
POWERTRAIN
1 TACH MIL FUSED EGR EVAP/
IGNITION PURGE
CONTROL
SWITCH OUTPUT MODULE
(START/RUN) (RIGHT SIDE
OF DASH PANEL)
J958W-9
8W - 30 -18 8W-30 FUEL/iGNITiOi BR
MAP SENSOR
(ON THROTTLE BODY 3 J L EIGINE CRANKSHAFT POSITION SENSOR
COO (RIGHT
REAR OF
ENGINE)
I MAP
I SENSOR

J958W-9
BR 8W-30 FUEL/IGNITION SW - 30 • 11
3 J L ENGINE
SPLICE
SI2S
(8V-30-16)
THROTTLE
POSITION
HEATED | / —j(4 18BK/LB- < SENSOR
OXYGEN K4 18BK/LB (8W-30-18)
. .SftfSfft K4
(8W-30-20) 18BK
MAP SENSOR
LB / , — K4 18BK/LB • (8W-30-18)
TRANSMISSION
TEMPERATURE CRANKSHAFT
SENSOR K4 18BK/LB K4 20BK/LB-
POSITION
(8W-31-3) SENSOR
(8W-30-I8)
CAMSHAFT
POSITION ^
SENSOR K4 20BK/LB
(8W-30-16)
VEHICLE
SPEED
SENSOR
€t§3
K4 18BK/LB—((f
SPLICE
S130 »- K7 mm
(8W-30-I6) - K7 180R
67 18WT/0R
(REAR OF
TRANSMISSION)
C127
S131
67 22WT/OR ))— •67 20WT/0R
8W-70-I3
£133
67 67
20WT 20WT
OR OR
| S210
8W-70-28
t
67
20WT
OR
C135
' 47~~1 (RIGHT SIDE

I VSS I I VSS I OF DASH
J I L » PANEL)
INSTRUMENT POWERTRAIN
CLUSTER CONTROL
MODULE
J958W-9
8W - 30 - 20 8W-30 FUEL/iGNiTiON
3 J L ENGINE
BATTERY
AO 6RD- POSITIVE -A16 14GY/WT
TERMINAL
C18Q
POWER
DISTRIBUTION
CENTER
FUSE 4
3DA
86 : 30
AUTOMATIC
SHUT DOWN
RELAY
:
85 87
_ _J
CI8Q CI8i
A142 - F18 20LG/BK-

14D6
OR
:CI25
FUEL PUMP
RELAY K51 22DB/YL- A142
(8W-30-48) 1406
OR
A i 4 2 16D6/0R •
HEATED INJECTORS
A142 16D6/0R 1,3.AMI 5
OXYGEN C160 (8W-30-13)
SENSOR
A142 14DG/0R- A142 16DG/0R
S133
K4 18BK/LB —
8W-70-14
( I N RIGHT K41 1 8 B K / D 6 -
EXHAUST
DOWN P I P E ]
111 SPLICE
S136
A142
18BK 14D6
WT (8W-30-19) OR
SPLICE I
S139
(8W-30-15)
S14©
[8W-7Q-19
SPLICE
112 Zl K41 S135
146K 16BK 18BK (8W-30-19)
TN WT D6
A
41
C13S
I ( R I 6 H T SIDE
, l , OF DASH
Gill « I PANEL)
i . I
8W-15-5 POWERTRAIN
CONTROL MODULE J958W-9
BR> 8W-30 FUEL/IGNITION 8W - 30 - 21
BATTER? 3 J L ENGINE
POSITIVE
TERMINAL
POWER
AO OISTR1BUTIOM IGNSTION
6RD CENTER SWITCH
I • ACC
FUSE 3
40A I OFF
fS j C180 C133 cai2 C2I2
KHpV^>p> Al 12RD —»—Al 12RD- -<f RUN
(i) (6)
START
A21
1208
FI8
20L6
BK
S114
18W-70-61
F18
20LG
BK
C133
C24lT l l C241
A 2 ! i 2 0 B
F I B 22LG/8I •- <fr^+"^"TT^)
1
10A
I • I
FUSE BLOCK
J958W-9
SW - 31 - 22 8W-30 FUEL/IGNITION BR
5.2L AND 5.9L ENGINE
INJECTOR #1 INJECTOR #3 INJECTOR #S SPLICE

S13S
(8W-30-23)
C1S9
(1)| |(2)
Kll AH2 K13 A142 K38 A H 2
18WT 160G 18YL 16DG 18GY I606
DB OR WT OR OR
A142 16DG/0R
A H 2 16D6/0R
IDLE A I R
CONTROL MOTOR
(ON THROTTLE
BODY)
Kll K5S K40 K60 K39

18MT 18VT 18BR 18YL 186Y
DB BK WT BK RD
16 17 14 38 59 40 60 39 POWERTRAIN
INJ* 1 1NJ*7 jjy#3 INJ*5 J | CONTROL
DRIVER DRIVER DRIVER DRIVER IAC
MOTOR MODULE
(RI8HT SIDEt
OF DASH PANEL)
J958W-9
mm 8W-30 FUEL/IGNITION 8W - 30 - 23
SPLICE
S03
(8W-30-22)
INJECTOR #2 INJECTOR #4 INJECTOR #8 GENERATOR
(8W-20-2)
A142
14DB
OR
C147 CI45
S< - - - - >^> A142
(D| ](2) (l)j |(2) 1406
K12 A142 K14 A142 K58 A142
18TN 16DG 18LB 160G 18BR 16DG SOS
OR BR OR DB OR
8W-70-15
•A142 16DG/0R
A142
A142 16DG/0R 1606
m
- A142 16DG/0R
INJECTOR #8
K18 A142 IGNITION

18RD 16DG
YL OR COIL
(RIGHT
FRONT SIDE
OF ENGINE)
K12 K18 K14 K58 A142

18TN 18RD 18LB 18BR 1606
YL BR DB OR
• COS
15 18 13 58 19 57
INJ#2 I N J # 8 INJ/M INJ#6 COIL ASD POWERTRAIN
DRIVER DRIVER DRIVER DRIVER DRIVER RELAY CONTROL
OUTPUT MODULE
I (RI6HT SIDE
OF DASH PANEL)
J958W-9
SW - 31 - 24 8W-3G FUEL/IGNITION BR
5.2L AND 5.91 ENGINE JOINT
ENGINE CONNECTOR C
STARTER PARK/NEUTRAL I— 1
SPLICE MOTOR POSITION CTflP

S140 RELAY SWITCH
(8W-70-I9) (8W-S1-8) (8W-31-5)
ISStpSt! m l s t e
^
C209
zii T41 T41 V40

168K 22m 188ft 22WT
WT WT WT PK
S141
C125 C133
8W-70-19
•T41 20BK/WT-
V40
20WT
ENGINE PK
DATA LINK
Z12 CONNECTOR
20BK (RIGHT SIDE OF
TN DASH PANEL) Sill
V40 8W-70-5
C136 22WT
PK
•<f
V40 V40
C136 22WT 20WT
PK PK
ZI2
20BK F18
TN 20LG
BK
C125 :C181
-REAR WHEEL
SPLICE
ANT I-LOCK , o r i (LEFT
S139
S132
ONLY I STOP I FENDER
(8W-30-13) 1 LAMP | SIDE
8W-70-18 I SWITCH j
V40 [OUTPUTJ SHIELD)
T41 20WT
Zll Z12 Z12 Z12 D21 D20 PK ANTI-LOCK
1SBK 14BK 16BK 16BK 20PK 20LG 20BK BRAKE SYSTEM
WT TN TN TN WT CONTROL MODULE
C13S
11 12, 25 45 30 29 POWERTRAIN
SCI SCI ' PARK/ STOP CONTROL
Gill GROUND TRANSMIT RECEIVE NEUTRAL LAMP MODULE
POSITION SWITCH
8W-15-5I | SWITCH OUTPUT (RIGHT SIDE
OUTPUT OF DASH PANEL)
J958W-9
BR 8W-3Q FUEL/IGNITION 8W-30 - 2 1
CAMSHAFT
P O S I T I O N SENSOR
(IH DISTRIBUTOR)
SPLICE
S13S
(8W-30-28)
ciii
K4
18BK
LB
S129
CRANKSHAFT
8W -70-121 POSITION
SENSOR
(8W-30-27)
m K7 K7
I8BK
200R 200R
LB
ENGINE
COOLANT ( 1 ) S130
TEMPERATURE % C152 8W-70-12
SENSOR
(FRONT
OF
ENGINE)
K7
180R
INTAKE A I R €157
TEMPERATURE
C1S2 SENSOR (1)
(RIGHT
FRONT OF VEHICLE
INTAKE SPEED
K4 MANIFOLD) K21 SENSOR K44
(8W-30-28) K7 20TN
20BK 1BBK 200R
LB RD YL
C13S
4 21 7 - 44
SENSOR INTAKE 8V ••• CAM (RIGHT
GROUND AIR TEMP SUPPLY POSITION SIDE OF
SENSOR SENSOR DASH
SIGNAL PANEL)

J958W-9
8W - 30 - 28 8W-30 FUEL/iGNIHON BR
ENGINE TRANSMISSION
INSTRUMENT DATA L I N E SPLICE OYERORIVE
CLUSTER CONNECTOR SU4 SOLENOID
(8W-30-24) (8W-70-6) (8W-31-2)
JTACH SRI MIL

IJ2 10 9
J
C215
621 624 63
22GY 226Y 22BK
LB PK PK
•FIB 2 0 L 6 / B K
C133
EXHAUST GAS
RECIRCULATION
SOLENOID
621 624 63 C146
226Y 226Y 20BK
LB PK PK
(RI6HT REAR (LEFT REAR

O F ENGINE) O F ENGINE)
C127 'CMS
621 624 63 F I B K35 152

206Y 206Y 20BK 20L6 20GY 20PK
LB PK PK BK YL BK
>k C13S
43 56 32 9 35 52 POWERTRAIN
TACH SRI MIL FUSED EGR EVAP/ CONTROL
IGNITION PURGE
MODULE
SWITCH OUTPUT
(START/RUN) (RIGHT SIDE OF
DASH PANEL)
J958W-9
BR 8W-30 FUEL/IGNITION — 8W - 30 - 27
5.2L AND 5 J L ENGINE
MAP SENSOR CRANKSHAFT POSITION SENSOR

{ON THROTTLE BODY) (RIGHT REAR OF ENGINE)
CI38
C13S
I 24
MAP CRANK
SENSOR POSITION
SENSOR
SIGNAL
P O W E R T R A I N CONTROL MODULE
(RIGHT SIDE OF DASH PANEL) J958W-9
-31-28 8W-30 FUEL/IGNITION BR
SPLICE
S129
(8W-30-25)
THROTTLE
LEFT POSITION
HEATED OXYGEN (SENSOR)
SENSOR (8W-30-27)
(8W-36-M)
MAP SENSOR
(8W-30-27)
TRANSMXSSZON
TEMPERATURE CRANKSHAFT
SENSOR POSITION
(8W-31-3) SENSOR
(8W-30-27)
RIGHT
HEATED OXYGEN
SINSOi
(8W-30-29)
VEHICLE
SPEED
SENSOR
SPLICE
S130
(8W-30-25)
(REAR OF
TRANSMISSION)
C133
G7 22WT/0R
G7
20WT
OR
POWERTRAIN
C2 IS CONTROL
G7 20WT/0R (fi 4 VSS MODULE
S210 (RIGHT SIDE OF
8 W - 7 0 - 2 8 DASH PANEL)
I J
INSTRUMENT
CLUSTER
J958W-9
BR 8W-3Q FUEL/IGNITION 8W - 3D - 29
BATTERY
POSITIVE 5.2L AND § J L ENGINE
TERMINAL
-A16 14GY/WT-
( I N LEFT
EXHAUST
mm pipe)
CONTROL
MODULE
(RIGHT SIDE OF
DASH PANEL) J958W-9
8W - 30 - 30 8W-30 FUEL/IGNITION BR
BATTERY
POSITIVE
TERMINAL
POWER
A 0 DISTRIBUTION IGNITION
6RD CENTER SWITCH
• ACC
FUSE 3
40A OFF C212
C180 C133 C212
Al 1 2 R D - ) ) — Al 12RD-
(1)
AUTOMATIC
SHUT DOWN ' A21
RELAY 12DB
(8W-10-29)
F!8
20LG
BK
SIM
•8W-7Q-&1
FIB
20LG
BK
NIL
€ 2 4 1 j~ | " | C241
F I B 22LG/BK : (( | • ^ I | )) A21 120B
I IDA * I
I I
PUSS BLOCK
J958W-9
BR 8W-30 FUEL/IGNITION SW - 38 - 31
8 J L ENGINE
L I F T HEATED
O l f G E N SENSOR
INJECTOR #1 (8W-30-39) -A142 1406/(W A142 1WG/0R-
RIGHT HEATED INJECTORS

OXYGEN SENSOR 3,7.AND 9
(8W-30-39) < -A142 14D6/0R -A142 16D6/0R- (8W-30-3S)
A142 16DG/0R •A142 16D6/0R

S133
8W-70-14
INJECTOR #10
(1)
© C 1 4 0 r—A142 I6DG/0R
(2)
A142
1406
OR
A142 14D6/0R
C12S
« —
1 S138 A142
I — K t 18 18WT/DB— V A142 16D6/0R 1406
S128 8W-70-17 OR
8W-70-11
INJECTOR #5 INJECTOR #8 AUTOMATIC
Kl 16 A142
20HJ SHUT DOWN
i#DG RELAY
DB OR A142 (8W-30-39)
16DG
OR INJECTORS
cise C142
2 , 4,AND 6
(0 (2) (1) (2) wmmmm (8W-30-32)
(8W-20-2)
1113
18LB
KH3
18LB A142
A142
HD6
A142
1606
f t I A142
1606
A142
1606
BR BR 14DB OR W m or
S12S
8W-70-10
~Kah2 mmjm—-
S135
3W-7Q-15J
A142 A142
1406 1406
OR OR
1 IGNITION
Kl 16 Kl 13 A142
20LB COIL S-PACK
20WT 1£DG {8W-30-34)
DB BR OR
IGNITION
^ C O I L 4-PACK
C13S (8W-30-34)
, 16 13 57 ] POWERTRAIN
1NJ#5.#8 ASD 1
CONTROL
! # 1 ,#10 DRIVER RELAY I MODULE
DRIVER OUTPUT
I (RIGHT SIDE OF
. J DASH PANEL)
J958W-9
SW -.30-32 8W-3S FUEL/IGNITION BR
8 J L ENSUE
IMJECTOR #3 INJECTOR #B
SI33 C154
:
(2)
A142 16DG/0R-
1115
18TN
Kl15 18TN-
58 POWERTRAIN
I INJ I N J #2,#7 CONTROL
I #3.#S DRIVER MODULE
DRIVER (RIGHT SIDE OF
DASH PANEL)
J958W-9
B R aw-30 FUEL/IGNITION 8W--30-33
• 8 J L ENGINE
ENGINE
PARK/NEUTRAL STARTER
POSITION . MOTOR
SWITCH RELAY
(8W-31-5) (8W-21-2)
f f I G N I T I O N MODULE
(BEHIND COOLANT RESERVOIR)
FUSED
T41 IGNITION
T41 SWITCH DWELL
18 BK 22BK
WT OUTPUT SIGNAL
WT (START/RUN)
GND 1 !
9
6
C137
C12S F18
20LG
— T41 20BK/FT BK
S141
8W-70-I9
SI32
8W-70-13
ENGINE
DATA L I N K F18
Z12 ZI2 CONNECTOR 20LG
20BK 18BK BK
TN (RIGHT SIDE OF
TN
DASH PANEL)
SPLICE
S I AO
(8W-70-19)
Zll
16BK
WT
T41 Z12
20BK 14BK
WT TN Z12 Z12 020 K138 K137
D21 20BR 20WT
16BK 16BK 20LG
20PK OR BK
TN TN
8W-15-5
C135
POWERTRAIN
30 11 25 45 38 j. CONTROL
PARK/ 12j SCI SCI
37
1
MODULE
NEUTRAL GROUND TRANSMIT RECEIVE DWELL
POSITION I (RIGHT SIDE OF
SWITCH SIGNAL j DASH PANEL)
J J958W-9
8W - 30 - 34 8W-30 FUEL/SGN1TION — BR
3 J L ENGINE
mmum can
B-PACK
(RIGHT SIDE OF ENGINE) JOINT
CONNECTOR C
i ' 1
STOP
LAMP ! (BEHIND
SWITCH I KNEE
OUTPUT ( BOLSTER)

BR 8W-30 FUEL/IGNITION 8W-3I-3I
8 J L ENGINE
INSTRUMENT
CLUSTER LEFT HEATED
OXYGEN SPLICE
SENSOR SUB
(8W-30-38) (8W-30-38)
63
22BK MANUAL—^
PK TRANSMISSION K4 14 CRANKSHAFT
ONLY 18BK 18BK POSITION
LB LB SENSOR
I SI2S
l8y-70-I2
-K4 20BK/LB
€133
(RI6HT SIDE
62t 624 63 K4 K4 OF EN6INE
226Y 226Y 22BK 18BK 16BK BLOCK)
LB
:
PK " PK LB LB
I
ENGINE SPLICE
COOLANT SI30
TEMPERATURE (8W-30-37)
SENSOR
v
( 2 )
C152
(FRONT '
OF
EN6INE)
(1) CIS7
INTAKE A I R
C127 'C11G TEMPERATURE
mmsm
(ON INTAKE
621 624 G3 K4 MANlfQL©) K21 124
206Y 206Y 20BK 20BK 16BK 206Y
LB PK PK LB m BK
A- 1.
43
56 12 2 4 21 24
.CJ3S
,
SRI MIL SENSOR INTAKE CAM I
TACH ECT AIR TEMP
6R0UND POSITION 1
SENSOR SENSOR I
SI6NAL

J958W-9
(RIGHT 'SIDE OF DASH PANEL)
8W - 30 - 36 8W-30 FUEL/IGNITION BR
8 J L ENGINE
ENGINE TRANSMISSION
IGNITION DATA L I N K SPLICE OVERDRIVE
MODULE CONNECTOR S114 SOLENOID
(8W-30-33) (8W-30-33) (8W-70-6) (8W-31-2)
9
FUSED (RIGHT SIDE OF
. IGNITION
DASH PANEL)
SWITCH OUTPUT
(START/RUN)

J958W-9
BR > 8W-30 FUEL/IGNITION 8W - 30 - 37
MAP SENSOR
8 J L ENGINE
(ON THROTTLE BODY) CAMSHAFT (FRONT OF ENGINE)
POSITION
S E N S O R C166
•<f
THROTTLE (2)
P O S I T I O N SENSOR
(ON THROTTLE BODY)
C148 C166
(3) (i)
CRANKSHAFT
POSITION
SENSOR
(8W-30-35)
C149
K6 K4 K4 K4 K 2 2 K6
K7 K7
18VT 1BBK 1BBK 18BK I80R 18VT
200R 180R
WT LB LB LB DB WT
S136
8 W - 3 0 - 3 8
-K6 18VT/WT•
S137 y S130
8 W - 7 0 - 1 7 8 W - 7 0 - 1 2
K7 K7
180R I80R
IGNITION VEHICLE
MODULE SPEED
(8W-30-34) SENSOR
(8W-30-38)
Kl K6 K22 K44
K7
18DG 20VT 180R 18TN
200R
RD WT DB YL
.COS
1 6 22 7 4 4
MAP 5V TPS 8V CAM
SENSOR OUTPUT SUPPLY POSITION
SENSOR

8W - 30 - 38 • • 8W-30 FUEL/IGNITION BR
f J L ENGINE
SPLICE
# "Slt8-
(8W-30-35)
I
LEFT THROTTLE
HEATED OXYGCN- K4 I 8 8 K / L B
_ POSITION
K4 18BK/LB
SENSOR SENSOR
(8W-30-39) (8W-30-37)
MAP SENSOR
(8W-30-37)
TRANSMISSION CAMSHAFT
TEMPERATURE^ K4 18BK/LB POSITION
SENSOR SENSOR
(8W-31-3) (8W-30-37)
RI8NT
MEATED OXYOEN K4 18BK/LB
SENSOR
(8W-30-38)
VEHICLE
SPEED
SENSOR
8130
|8W-30-37|
O I80R
K7 (REAR Of
200R TRANSMISSION)
C127 [
67 22HT/0R-^>—67 20MT/0R
C133
T
67
20WT
OR S210
8 W - 7 0 - 2 8
67
20MT
OR
G7
^ C H i 20WT
OR
VSS 1
€135
J
INSTRUMENT 47
CLUSTER C13S VSS I POWERTRAIN
• K 7 mm — « — h |X
SUPPLY
1 CONTROL
I MODULE
(RI6HT SIDE OF DASH PANEL) J958W-9

BR 8W-30 FUEL/IGNITION 8W--30-3S
BATTERY
POSITIVE S.OL ENGINE
TERMINAL
AO A16 14GY/WT-
6RD
4 m e
n
POWER
FUSE 4 DISTRIBUTION
CENTER
W O A
30A
86: 30;
AUTOMATIC
SHUT DOWN
RELAY
;
85 87'
C180
A142
SPLICE S 1 1 4 , 14DG
(8W-30-40) 1 F18 20LG/BK-
OR
^ C125
FUEL PUMP SPLICE
RELAY - K51 22DB/YL- •A142 14DG/0R- « SX38
(8W-30-48) (8W-3Q-31)
S P L I C E S138
(8W-30-31) " A142 14D6/0R- A142 16D6/0R •
RIGHT A142 16D6/0R •

HEATED INJECTORS
OXYGEN S133 A142 1SD6/0R
1,3.5.7,AND 9
CI6Q 8W-70-14 (8W-30-31.
SENSOR 8W-30-32)
»—AM2 14D6/0R- A142 16D6/0R
K4 18BK/LB —
SPLICE
V - AI42 16D6/0R •
( I N RI6HT S129
EXHAUST (8W-30-35)
DOWN P I P E ) K4
Zll K41 C162
18BK 18BK 18BK LEFT
WT 06 LB •A142 14D6/0R ((
SPLICE I
S139 S136
(8W-30-33) 8W-30-38
Zll s t 4 Q
Zll K4 18BK/LB
16BK I8W-70-19 18BK K4 18BK/LB
WT — WT
MANUAL TRANSMISSION ONLY
Z12
14BK Z l l 18BK/WT ( I N LEFT
TN EXHAUST
K41 DOWN P I P E )
18BK -K141 18TN/WT
DG
\ i: C135
j POWERTRAIN
23 J j CONTROL
Gill , 41
MODULE
8W-15-5 1
(RIGHT SIDE OF
1 DASH PANEL) J958W-9
31 - 41 8W-30 FUEL/IGNITION B R
8.0L ENGINE
BATTERY
POSITIVE
TERMINAL
POWER
DISTRIBUTION ION I T ION
AO
6R0 CENTER SWITCi
f »
FUSE 3
I j • ACC
m O FF F
R ^ | cm CI33 £2 18] r r ^ 0
€212
12RD-)) Al 12RD-
RUN
(6)
i , START
AUTOMATIC
S i U T DOWN ' A21
RELAY 12DB
(8W-30-39)
FIB
20LG
BK
S114
F18
20LG
BK
€133
l
C241I 1 1C241
F I B 22LG/BK — ( f ^ ^ ^ v ^ ^ ) A 2 'i 120B
• 9
1
10A
FUSE BLOCK
J958W-9
BR 8W-30 FUEL/IGNITION - 8W-40-41
DIESEL ENGINE SPLICE
S114
(8W-70-6)
FUEL
SHUT DOWN
BATTERY SOLENOID"* - F 1 8 20LG/BK
POSITIVE (8W-30-45)
TERMINAL TRANSMISSION
OVERDRIVE
SOLENOID
(8W-31-2)
ENGINE
DATA L I N K
CONNECTOR* F18 20LG/BK
(8W-30-42)
A19 A8
12BK 12BK
FUEL
HEATER
- F 1 8 20L6/BK
RELAY
S404 (8W-30-45)
- F 1 8 20LG/BK
8 W - 7 0 - 3 7
S403
FIB A8
20LG
6BK
BK
F18 20L6/BK
INSTRUMENT
CLUSTER
HEATED HEATED
INTAKE INTAKE
AIR MIL TACH j
AIR
9 12
SYSTEM SYSTEM
RELAY 1 RELAY 2
C2I5
G3 621
22BK 226Y
PK BK
C133
AI22
T
63 621
HEATED 6BK 226Y
22BK
Mi® INTAKE
AIR
(on- PK BK
SYSTEM C127
CI28
S21 S22 FIB 6 3 621
20YL 200R 18L6 20BK 206Y
BK BK BK PK LB
—sir- — X* C135
r
N
15 9 3 2 43 .
i6 HEATED FUSED M I L
1 HEATED TACH 1
| # 1 # 2 IGNITION
SWITCH OUTPUT
I
, RELAY RELAY 1
I (START/RUN) 1
i . 1
( R I 6 H T SIDE OF DASH PANEL) J958W-9
8W - 30 - 42 - 8W-30 FUEL/IGNITION BR
DIESEL ENGINE
ENGINE
PARK/NEUTRAL STARTER
POSITION MOTOR
SWITCH RELAY
(8W-31-5) (8W-21-2)

BR 8W-30 FUEL/IGNITION - 8W - 30 - 43
BATTERY DIESEL ENGINE
POSITIVE
TERMINAL
A16 MGY/WT
AO
SRD C18Q
POWER
DISTRIBUTION
FUSE 4 CENTER
BOA
8 6 : 30
AUTOMATIC
SHUT DOWN
RELAY
8 5 : 87
T
I . . .
C180
SPLICE S U 4
F 1 8 20L6/BK-
(8W-30-44)
A142
HOG
OR
C12S
FUEL PUMP
RELAY • K51 22DB/YL
(8W-30-48)
A142
1406
OR
GENERATOR
A142 14DB S143
(8W-20-4)
8 W - 7 0 - 2 0
A142
1606
OR
C13S
"l POWERTRAIN
57
| CONTROL
ASD
i MOOUU
RELAY
OUTPUT , (RIGHT SIDE
I OF DASH
, J PANEL)
J958W-9
8W - 30 - 44 - SW-30 FUEL/IGNITION BR
DIESEL ENGINE
BATTERY
POSXTXVE
TERMINAL
AO
6RD
POWER
DISTRIBUTION ISMITION
CENTER SWITCH
FUSE 3
40A
1 CX8Q C133
-)>f» Al ' l 2 R D - > ; Al 12RD
AUTOMATIC
SHUT DOWN
RELAY
(8W-30-43)
F18
20L6
BK
S114
( J [8W-70-6
A21 12DB
F18
20LG C241
BK
FUSE BLOCK
1
S 10A
C241
C133
F18 22LG/BK
J958W-9
DIESEL ENGINE
SI38
8W-30-42
FUEL FUEL
HEATER SI44 SHUT DOWN
FEED 8W-70-20 FEED
A12 200R- AI8
(LEFT BATTERY % (LEFT BATTERY
Z12 POSITIVE TERMINAL) A12 POSITIVE TERMINAL)
14BK 14RD
TN TN
FUEL FUEL
HEATER SHUT DOWN
RELAY RELAY
(NEAR BRAKE (NEAR BRAKE
MASTER CYLINDER) MASTER CYLINDER)
^_^C173
(4) (2)
A93
14RD
BK
C177 C12S
F18
FUEL 20LG
HEATER BK
(LEFT SIDE
OF ENGINE)
SPLICE
S113
C177 (8W-70-6)
FUEL
SHUT DOWN
Z12 Z12 SOLENOID
14BK 16BK
TN TN
S142 S132
8W-70-I9 8W-30-41
F18 20LG/BK
Z12
14BK (NEAR INJECTION
TN PUMP)
Z12
10BK
TN
SPLICE
Zll 16BK/TN S140
Gill (8W-70-19) G112
8W-15-5I |8W-15-61
J958W-9
SW - 31 - 46 - 8W-30 FUEL/IGNITION BR
DIESEL ENGINE THROTTLE
POSITION
SENSOl
TRANSMISSION ENGINE VEHICLE
TEMPERATURE SPEED SPEED (ON INJECTION
SENSOR. SENSOR SENSOR PUMP)
(8W-31-3) (8W-30-47) (8W-30-47)
C178
K4 K4 K4 K4 K 2 2 K6
16BK 20BK I8BK 2GBK 200R 20VT
LB LB LB LB DB WT
S136
8 W - 7 0 - I 6
INTAKE A I R
TEMPERATURE WATER-IN-FUEL
SENSOR SENSOR
(REAR OF (LEFT SIDE
INTAKE OF ENGINE)
MANIFOLD)
K22 K6
200R 20VT
DB WT
C13S
21 4 22 6
INTAKE SENSOR WATER- TPS 5V
AIR GROUND IN- OUTPUT
TEMP FUEL
SENSOR
SIGNAL

DIESEL ENGINE
VEHICLE
SPEED
S136 SENSOR
8W-30-46
K4 18BK/LB
-K7 180R
G7 18WT/0R
(REAR OF
TRANSMISSION)
- 6G7
7 20WT/0R
K7 S O I C127
180R
8W-70- 13
67
G7 22WT
20WT OR
OR
C133
S130
K7 200R 8W-70-12 67
20WT
OR
S210
8W-70-28
(FRONT OF
67
ENGINE) 20WT
OR
K24 67 I VEHICLE I
K7 20WT
206Y I SPEED j
200R OR
BK 1
SENSOR 1
I i
I 1
C135 INSTRUMENT
CLUSTER
- 1
24 7 47
EN6INE 8V VEHICLE POWERTRAIN
SPEED SUPPLY SPEED
CONTROL
SENSOR SENSOR
l_ .
MODULE

8W - 30 - 48 8W-30" FUEL/iGNiTION BR
BATTERY POWER
r A0 6RD—« P O S I T I V E
CENTER
FUSE 3 FUSE 8
40A 20A
-A14 16RD/WT-
FUEL PUMP RELAY
30
87
86 I
85
:C18Q
A14 16RD/WT-
K51 A61 K5i AM
Al 220B 16DG 22DB 16R0
-F18 20LG/BK• YL BK YL WT
12RD S114
AUTOMATIC C125 i C126
F18
20LG
8W-70-6 SHUT DOWN
RELAY T T
(8W-11-4) A14
BK K51 16RD
20DB WT
C133 C133 YL
C 128
• '
-A61 16D6/BK—— ASO/FUEL 3
F18 PUMP RELAY FUSED

Al 22LG CONTROL B+
12RD BK
l
POWERTRAIN
C241 CONTROL MODULE
~i (RI6HT SIDE
C 128 OF DASH PANEL)
FUSE BLOCK |
mm
OA I
C328 J L
64 20DB-
-<f- — 64 22DB-
L -— | I C133
Al C241 64
IGNITION
12RD SWITCH 22DB
A21 )>—Zll 20BK/WT—I

• ACC 12DB
OFF C128; I FUEL I
(6) I LEVEL 1
RUN
(1)1 Zll I SENSOR
SI6NAL I
€212 20BK l . _ J
, . . START WT
C2121 FUEL TANK INSTRUMENT
C328 (4) CLUSTER
LEVEL GAUGE
SENDING U N I T
SPLICE SPLICE
S311 -Z13 16BK- S I 16
(8W-70-33) (8W-70-7)
J958W-9
BR 8W-31 TRANSMISSION CONTROLS 8W - 31 - 1
TRANSMISSION CONTROLS
OVERDRIVE SWITCH Module (PCM). Ground for the sensor is supplied on
Automatic transmission equipped vehicles may circuit K4. This circuits is spliced and provides a
have an overdrive switch. The operator disables or common sensor ground for various sensors used in
enables overdrive when the switch is depressed. the engine control system.
The overdrive switch consists of a switch connected Circuit T54 connects to cavity 42 of the PCM con
to the Powertrain Control Module (PCM), an illumi nector, and circuit K4 connects to cavity 4 of the con
nation lamp, and an overdrive ON/OFF indicator nector.
lamp. The sensor is a variable resistor. When the PCM
If overdrive is currently enabled, it is disabled determines that the transmission oil temperature is
when the operator presses the overdrive switch. Con above a predetermined level it supplies a ground
versely, if the operator already disabled overdrive, it path for circuit G14. This circuit connects from the
is enabled when the switch is pressed. PCM to the message center warning lamp.
Circuit T6 from the overdrive switch connects to Power for the lamp is supplied on circuit F14. The
cavity 10 of the PCM and provides the overdrive sig F14 circuit is protected by a 15 amp fuse located in
nal. Circuit Z3 provides ground for the switch. cavity 12 of the fuse block and HOT in the START/
The PCM turns the overdrive ON/OFF indicator RUN position only.
lamp ON or OFF by providing a ground for the lamp
Circuit G14 connects to cavity 31 of the PCM con
on circuit T18. Power for the lamp is supplied by cir
cuit F12 from the fuse block. nector on all engine applications, except for the 8.0L.
When the headlamps or parking lamps are ON, cir On the 8.0L the G14 circuit connects to cavity 36 of
cuit E2 from fuse 13, a 5 amp, in the fuse block pow the PCM connector.
ers the illumination lamp in the overdrive switch.
Circuit E l from the headlamp switch feeds fuse 13. HELPFUL INFORMATION
Circuit Z3 provides ground for the illumination • Refer to the appropriate section of the service
lamp in the overdrive switch. manual or the diagnostic test procedures manual
FOUR-WHEEL DRIVE INDICATOR DIAGRAM INDEi

Power for the four-wheel drive indicator lamp is
supplied on circuit F14. Ground for the lamp is sup Component Page
plied on circuit G107 to the switch. The ground is ABS Control Module 8W-31-3
passed through the CLOSED contacts in the switch Back-Up Lamp Switch 8W-31-5
to circuit Zl. Fuse 1 (PDC) 8W-31-2
Fuse 2 (PDC) .8W-31-4
PTO LAMP Fuse 13 . . . .8W-31-2
Power for the Power Take-Off (PTO) indicator lamp Fuse 15 .8W-31-4
is supplied on circuit F14. Ground for the lamp is Fuse 18 8W-31-2
supplied on circuit G107 to the switch. The ground is 4X4 Switch . 8W-31-3
passed through the CLOSED contacts in the switch Headlamp Switch 8W-31-2
to circuit Zl. Ignition Switch 8W-31-4
Instrument Cluster 8W-31-2, 3
OVERDRIVE. SOLENOID Park/Neutral Position Switch 8W-31-5
Power Distribution Center 8W-31-2
The Powertrain Control Module (PCM) operates
the overdrive solenoid by providing a ground path on PTO Switch , . . 8W-31-3
circuit T60. Circuit T60 connects to PCM cavity 55. RWAL Control Module ....... .8W-31-3
Circuit F18 supplies battery voltage to the overdrive Transmission Overdrive Solenoid .8W-31-2
solenoid. Transmission Overdrive Switch 8W-31-2
Transmission Temperature Sensor 8W-31-3
TRANSMISSION OIL TEMPERATURE LAMP
Power for the transmission temperature sensor is
supplied on circuit T54 from the Powertrain Control
8W - 31 - 2 - 8W-31 TRANSMISSION CONTROLS BR
BATTERY
POSITIVE JOINT
TERMINAL
CONNECTOR
f POWER
AO DISTRIBUTION
6RD
CENTER
FOG LAMP
SWITCH
(8W-50-7)
SPLICE SPLICE
S215 S132 POWERTRAIN CONTROL MODULE
(8W-70-29)(8W-70-13) (RIGHT SIDE OF DASH PANEL) J958W-9
BR 8W-31 TRANSMISSION CONTROLS 8W-31
t 1
4WD
RE^R WHigL • 4 WD ,
SW INSTRUMENT 1 1
ANTI-LOCK SW
OUT
CLUSTER CONTROL I OUT |
MODULE
- i _ J (CENTER OF I . P . )
C215 €228
6107 20BK/GY•
— G 1 0 7 22BK/GY- 6107 20BK/GY
-WITH A B S ONLY €133

— G 1 0 7 20BK/GY•
G107
20BK
GY
SIPS S 1 3 S S128
8 W - 7 0 - 3 [8W-70-16[ [8W-70-12I
G107 20BK/GY• K4 18BK/LB•
€106
K4 K4
18BK 16BK
Li LB
DIESEL
: C407 ONLY
PTO OR
4X4 TRANSMISSION
SWITCH TEMPERATURE
(ON TRANSFER SENSOR
CASE OR (ON TRANSMISSION)
TRANSMISSION)
C407
€108
G107 K4
20BK
T54
20BK
18VT
GY LB
S103
(8W-70-2
Zl
18BK C135
C121
— "1
— ANTI-LOCK
n
0102 42 4
B
4MD ! BRAKE
8W-15-3
TRANS SENSOR
I sw ! SYSTEM TEMP GND
I OUT , CONTROL -
l l MODULE
(LEFT FENDER (RIGHT SIDE OF DASH PANEL)
SIDE SHIELD) J958W-9
8W - 31 - 4 8W-31 TRANSMISSION CONTROLS BR
BATTERY
POSITIVE
TERMINAL
f
AO POWER
6RD DISTRIBUTION
J-
r —CENTER
FUSE 2
40A
L4- J IGNITION
C180 SW I T C H
A2 I " 1
12PK
BK S201
C133 €2121 k OFF
C212 8 W - 7 0 - 2 2
A2 1 2 P K / B K — ) ) — A 2 1 2 P K / B K — ( (
S146 - » - A 2 2 1 2 B K / 0 R - #
(4) RUN
8 W - 7 0 - 2 0
START
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A22
12BK
OR
J^C24t
• Si OA I FUSE BLOCI
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€241
LIO
22BR
L6
:£2§S
28
I JOINT
I CONNECTOR C
1
29 (BEHIND
J
- KNEE BOLSTER)
€209
L I O
22BR
S12Q LG
8 W - 7 0 - 9
: t A i 3
L10 20BR/LG-^
W/0 DAYTIME
RUNNING
L I O 18BR/LG LAMP
L I O 18BR/LG
L I O 18BR/LG
J958W-9
8W-31 TRANSMISSION CONTROLS 8W - 31 - 5
PARK/NEUTRAL
P O S I T I O N SWITCH
(AUTOMATIC
TRANSMISSION)
LI LtO
18VT 18BR
BK L6
BACK-UP
LAMP S W I T C H LtO
(MANUAL 18BR
TRANSMISSION) L6
:CMi
- o - § U 2L I 18VT/BK-
8W-70-8
(TRAILER
Ll TOM ONLY)
18VT
LI 18VT/BK
€133 £118
T
Li LIO
22VT 18BR
BK LG
Ll LIO T41
C2Q8 18VT 18BR 18BK
BK LG WT
Li
22VT
BK
DAY/NIGHT SPL2CI
MIRROR SJI3 SPLICE
(8W-44-7) (8W-70-34) 5141
(8W-70-19)
J958W-9
8W-32 ANTI-LOCK BRAKES 8W - 32 - 1
ANTI-LOCK BRAKES
CONTENTS
page page
ALL WHEEL ANTI-LOCK BRAKE SYSTEM (ABS) .. 3 REAR WHEEL ANTI-LOCI (RWAL) 1RAIES ... 1
GENERAL INFORMATION Brake System (ABS). When referring to the circuit

This section of the wiring diagrams is divided into descriptions or wiring diagrams, ensure that you use
two sub-sections; one for the Rear Wheel Anti-Lock the ones for the appropriate system.
(RWAL) system and one for the all wheel Anti-Lock
REAR WHEEL ANTI-LOCK (RWAL) B R A K E S
INDEX
page page
Brake Warning Lamp Switch Input 2 Rear Anti-Lock Valve 2

Data Link Connector . 2 Rear Wheel Speed Sensor 1
Diagram Index —Rear Wheel Anti-Lock Brakes . . . . . 2 Stop Lamp Switch Input 2
Four-Wheel Drive Switch Sense . . . . . . . . . . . . . . . 2 Vacuum Switch . 2
General Information . . . . . . . . . . . . . . . . . . . . . . . . 1 Warning Lamp 2
Park Brake Switch Input 2
GENERAL INFORMATION On diesel engines circuit A20 is double crimped at

Power for the Rear Wheel Anti-Lock (RWAL) con cavity 3 of the RWAL control module and provides
trol module is supplied on circuit A20. This circuit is battery voltage to the vacuum switch.
connected to the fuse Mock and protected by a 20 Circuit F32 provides battery voltage to the RWAL
amp fuse located in cavity 14. Power for the fuse is module. Circuit F32 is HOT at all times. Fuse 20 in
supplied on circuit A22 from the ignition switch. This the fuse block protects circuit F32. Circuit A3 from
circuit is HOT in the START/RUN position only. the PDC feeds the fuse block bus bar that powers
Power for the A22 circuit is supplied by circuit A2. fuse 20 and circuit F32. Fuse 6 in the PDC protects
This circuit originates at the Power Distribution Cen circuit A3. Circuit Z3 provides ground for the RWAL
ter (PDC) and is protected by a 40 amp fuse located control module.
in cavity 2.
Four fuses supply power for the Rear Wheel Anti- REAR WHEEL SPEED SENSOR
Lock (RWAL) Brake System. They are fuses 2, and 6 The rear wheel speed sensor is mounted on the top
in the Power Distribution Center (PDC), and fuses 14 of the rear axle differential. The sensor converts
and 20 in the fuse block. Fuses 2 and 6 in the PDC, wheel speed into an electrical signal that it transmits
and fuse 20 in the fuse block are connected directly to the Rear Wheel Anti-Lock (RWAL) control module.
to battery voltage and are HOT all times. Fuse 14 in Circuits B113 and B114, a pair of twisted wires
the fuse block is HOT when the ignition switch is the connect to the sensor to provide signals to the ABS
RUN Position. control module. These circuits also connect to the
In the RUN position, the ignition switch connects rolls test connector used during manufacture of the
circuit A2 from a 40 amp fuse in cavity 2 of the PDC vehicle.
with circuit A22. Circuit A22 connects to a bus bar in Circuit B113 connects to cavity 18 of the RWAL
the fuse block. The bus bar feeds circuit A20 through module. Circuit B114 connects to cavity 9 of the
fuse 14. Fuse 14 is a 20 amp fuse. RWAL module.
8W - 32 - 2 8W-32 REAR WHEEL ANTI-LOCK BRAKES BR
REAR ANTI-LOCK VALVE in the START position, or the park brake warning
The rear anti-lock valve contains an isolation sole lamp switch in the hydraulic combination valve
noid, a dump solenoid and a reset switch. Each is closes.
powered by the Rear Wheel Anti-Lock (RWAL) mod
ule on separate circuits. STOP LAMP SWITCH INPUT
Circuit B108 from cavity 14 of the RWAL module Circuit V40 provides an input to the Rear Wheel
feeds the dump solenoid. The isolation solenoid is Anti-Lock (RWAL) control module as to when the op
powered on circuit B101 from cavity 1 of the RWAL erator is applying the brakes. The V40 circuit con
module. Circuit Z8 provides ground for both sole nects to cavity 7 of the RWAL control module.
noids.
Circuit B i l l from cavity 11 of the RWAL module VACUUM SWITCH
connects to the reset switch. The case grounded rear The vacuum switch is' used on the diesel engine
anti-lock valve provides ground for the reset switch, only. Power for the switch is supplied on circuit A20.
This circuit is HOT in the RUN position only and
FOUR-WHEEL DRIVE SWITCH SENSE protected by a 20 amp fuse located in cavity 14 of the
From circuit G107, the Rear Wheel Anti-Lock fuse block. Ground for the switch is supplied on cir
(RWAL) module senses when the four-wheel drive/ cuit Zl.
PTO indicator lamp switch CLOSES. Circuit G107 Circuit G9 connects to the vacuum switch and sup
connects to cavity 4 of the RWAL module. plies a ground path for circuit G9. If there is a prob
lem in the system, the switch grounds circuit G9 and
WARNING LAMP
the red brake warning lamp in the instrument clus
The Rear Wheel Anti-Lock (RWAL) module pro
ter is illuminated.
vides ground for the instrument cluster Check Anti-
Lock warning lamp on circuit G19. Circuit F14 DIAGRAM INDEX—REAR WHEEL ANTI-LOCI
provides voltage to the instrument cluster to feed the
warning lamp. 1RAIES
DATA LINK CONNECTOR Component ^ ^ Page

Circuit B112 from cavity 10 of the Rear Wheel An 4WD Switch" .~~ . T ~ . 8W-32-7
ti-Lock (RWAL) module connects to the RWAL data Brake Warning Switch .8W-32-5
link connector. System fault codes can be read by mo Data Link Connector . . . . . . . . . . . . . . . . . . . . . .8W-32-8
mentarily grounding the RWAL diagnostic connector. Daytime Running Lamp (DRL) Module . . . . . . . . . . .8W-32-7
Fuse 2 (PDC) . . .8W-32-5
Refer to Group 5, Brakes, for more information.
PARI BRAIE SWITCH INPUT Fuse 14 (Fuse Block) .8W-32-5
Fuse 20 (Fuse Block) . 8W-32-6
On circuit G i l , the Rear Wheel Anti-Lock (RWAL) Ignition Switch .8W-32-5
module senses when the park brake switch CLOSES. Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . .8W-32-7
Circuit G i l from the park brake switch connects to Powertrain Control Module . .8W-32-6
cavity 5 of the RWAL module. PTO Switch .8W-32-7
Rear Anti-Lock Valve .8W-32-8
BRAKE WARNING LAMP SWITCH INPUT
Rear Wheel Anti-Lock Brake Sensor .8W-32-8
Circuit G9 from provides an input to the Rear RWAL Control Module 8W-32-5, 6, 7, 8
Wheel Anti-Lock (RWAL) control module. The module Vacuum Sensor .8W-32-5
receives the input when either the ignition switch is
BR SW-32 REAR WHEEL ANTI-LOCI BRAKES 8W - 32 - 3
ALL WHEEL ANTI-LOCK BRAKE SYSTEM (ABS
iiiEX
page page
A B S Data Link Connector 4 Front Anti-Lock Valve . 3

A B S Pump Relay . . . . . . . . . . . . . . . . . . . . . 3 General Information 3
A B S Warning Lamp 4 Rear Anti-Lock Valve 4
Brake Warning Lamp Switch input . . . . . . . . . . . . . . 4 Stop Lamp Switch Sense 4
Diagram Index 4 Vacuum Switch 4
Four-Wheel Drive/PTO Switch Sense . . . . . . . . . . . 4 Wheel Speed Sensors 3
GENERAL INFORMATION ' . Circuit B114 connects to cavity 14 of the ABS con
Three fuses supply power for the Anti-Lock Brake trol module and to the rear wheel speed sensor. Cir
System (ABS); fuses 2 and 5 in the Power Distribu cuit B113 connects to cavity 1 of the ABS control
tion Center (PDC) and fuse 14 in the fuse block. module and to the rear wheel speed sensor. Circuit
Fuses 2 and 5 in the PDC are connected directly to B114 provides the rear wheel speed sensor HIGH in
battery voltage and are HOT all times. Fuse 14 is put while circuit B113 provides the LOW input.
HOT when the ignition switch is the RUN position.
In the RUN position, the ignition switch connects 'ABS PUMP RELAY
circuit A2 from a 40 amp fuse in cavity 2 of the PDC When the ABS control module grounds the ABS
with circuit A22. Circuit A22 connects to a bus bar in pump relay on circuit B116, the relay contacts close
the fuse block. The bus bar feeds circuit A20 through connecting circuit A10 from the Power Distribution
fuse 14. Fuse 14 is a 20 amp fuse. Center (PDC) and circuit B120. Circuit A10 connects
Circuit' A20 is spliced and provides an ignition in to fuse 5 in the PDC. Circuit A20 from the fuse 14 in
put to the control module (cavities 12, and 17), feed the fuse block splices to feed the coil side of the ABS
for the coil side of the ABS pump relay, feed for the warning low lamp relay.
coil side of the ABS warning lamp relay, and on die From the ABS pump relay, circuit B120 splices to
sel engines, feed for the vacuum sensor. supply voltage to the ABS pump motor and all sole
Circuit Z7 provides ground for the ABS control noids in the front brake anti-lock valve. Circuit B120
module. Circuit Z7 connects to cavity 20 of the ABS also supplies power to the solenoids in the rear anti-
control module connector. Circuit Z8 connects to cav lock valve. Additionally, circuit B120 provides an in
ity 1 of the two-way connector. put to cavity 34 of the ABS module. The input tells
the module that voltage has been supplied to the
WHEEL SPEED SENSORS pump motor.
The all wheel Anti-Lock Brake. System (ABS) uses
three wheel speed sensors; a single sensor for both FRONT ANTI-LOCI WALfE
rear wheels and individual sensors for the front Circuit B120 from the- ABS pump relay supplies
wheels. The single sensor used for the rear wheels voltage for the ABS pump motor plus the isolation
mounts on the top of the rear axle differential hous and dump solenoids in the front anti-lock valve. The
ing. Each sensor converts wheel speed into an elec ABS control module activates the pump motor and
trical signal that it transmits to the ABS control the solenoids by providing separate ground paths for
module. A pair of twisted wires connect to each sen each.
sor and provide signals to the ABS control module. The ABS module provides a ground path for the
Circuits B6 and B7 provide signals to ABS control motor on circuit B60. Circuit B60 connects to cavity 2
module from right front wheel speed sensor. Circuit of the ABS control module two-way connector.
B6 which provides the LOW signal, connects to cav The ABS control module cycles the isolation and
ity 15 of the ABS control module. Circuit B7 connects dump solenoids in the front anti-lock valve by provid
to cavity 2 of the module and provides the HIGH sig ing a ground path for each on separate circuits:
nal. • Circuit B248 connects to cavity 30 of the ABS con
Circuits B8 and B9 provide signals to ABS control trol module and provides ground for the right front
module from left front wheel speed sensor. Circuit B8 dump solenoid.
which provides the LOW signal, connects to cavity 16 • Circuit B249 connects to cavity 33 of the ABS con
of the ABS control module. Circuit B9 connects to trol module and provides ground for the right front
cavity 3 of the module and provides the HIGH signal. isolation solenoid.
8W - 32 - 4 8W-32 REAR WHEEL ANTI-LOCK BRAKES BR
• Circuit B243 connects to cavity 35 of the ABS con switch CLOSES or the brake warning lamp switch in
trol module and provides ground for the left front the hydraulic combination valve CLOSES.
dump solenoid.
• Circuit B245 connects to cavity 37 of the ABS con STOP LAMP SWITCH SENSE
trol module and provides ground for the left front iso On circuit V40, the ABS control module senses
lation solenoid. when the brake pedal has been depressed. Circuit
There are two reset switches in the front anti-lock V40 connects to cavity 9 of the ABS control module
valve; a left switch and a right switch, both provide and splices to the stop lamp switch and the Power-
train Control Module (PCM).
inputs to the ABS control module. Circuit B5 from
the left reset switch connects to ABS module cavity 5 FOUR-WHEEL DRIWE/PTO SWITCH SENSE
while circuit B18 from the right reset switch connects From circuit G107, the ABS control module senses
to cavity 18. when the four-wheel drive/PTO indicator lamp switch
closes. Circuit G107 connects to cavity 8 of the ABS
HELPFUL INFORMATION control module and splices to the four-wheel drive/
The front anti-lock valve is case grounded. PTO indicator lamp switch and instrument panel
four-wheel drive/PTO indicator lamp indicator lamp.
REAR ANTI-LOCK VALVE
Circuit B120 from the ABS pump relay supplies ABS DATA LINK CONNECTOR
voltage for the isolation and dump solenoids in the The DRB scan tool connects to the ABS data link
rear anti-lock valve. The ABS control module acti connector. Circuits Dll and D12 from the ABS con
vates the solenoids by providing separate ground trol module connect to the data link connector. Cir
paths for each. cuit D12 connects to cavity 10 of the ABS control
• Circuit B254 connects to cavity 26 of the ABS con module. The ABS control module transmits data to
trol module and provides ground for the right rear the DRB scan tool on circuit D12.
The DRB scan tool receives data from the ABS con
dump solenoid.
trol module on circuit Dll. Circuit Dll connects to
• Circuit B252 connects to cavity 28 of the ABS con cavity 11 of the ABS control module.
trol module and provides ground for the right rear
isolation solenoid. WACUUM SWITCH
The rear anti-lock valve has one reset switch that The vacuum switch is used on the diesel engine
provides an input to the ABS control module. Circuit only. Power for the switch is supplied on circuit A20.
B19 from the reset switch connects to ABS control This circuit is HOT in the RUN position only and
module cavity 19. protected by a 20 amp fuse located in cavity 14 of the
fuse block.
ABS WARNING LAMP Ground for the switch is supplied on circuit Zl.
The ABS control module operates the ABS yellow Circuit G9 connects to the vacuum switch and sup
warning lamp through the ABS warning lamp relay. plies a ground path for circuit G9. If there is a prob
When the ABS module grounds the warning lamp re lem in the system, the switch grounds circuit G9 and
lay on circuit B47, the relay contacts close and com the red brake warning lamp in the instrument clus
plete the ground path for the ABS warning lamp. ter is illuminated.
Circuit B47 connects to pin 13 of the ABS module
and the coil side of the relay. Circuit A20 from fuse DIAGRAM INDEX—ANTI-LOCK BRAKES
14 in the fuse block supplies power to the coil side of
the relay. Component Page
Circuit G19 from the ABS warning lamp in the in ABS Control Module 8W-32-9 thru 13
strument cluster is double crimped at the contact ABS Pump Relay 8W-32-9
side of the ABS warning lamp relay. Power for the ABS Warning Lamp Relay 8W-32-9
bulb is supplied by the printed circuit board in the Data Link Connector 8W-32-11
instrument cluster. The G19 branch leaving the relay Front Anti-Lock Valve . . 8W-32-10
provides an input to the ABS control module at cav Front Wheel Speed Sensor . 8W-32-11
ity 24 of the module. Circuit Zl provides a ground Fuse 2 (PDC) . . . . . .8W-32-12
path for the contact side of the relay. Fuse 14 (Fuse Block) . .8W-32-9, 12
Ignition Switch 8W-32-9, 12, 13
BRAKE WARNING LAMP SWITCH INPUT Instrument Cluster 8W-32-9
Circuit G9 provides an input to the ABS control mod Rear Anti-Lock Valve 8W-32-9
ule. The module receives the input when either the ig Rear Wheel Anti-Lock Brake Sensor 8W-32-11
nition switch is in the START position, the park brake Vacuum Sensor 8W-32-12
BR 8W-32 ANTI-LOCK BRAKES — 8W - 32 - 5
BATTERY
POSITIVE REAR WHEEL ANTI-LOCK BRAKES
TERMINAL
T POWER
DISTRIBUTION
(DIESEL
ENGINE 18BK-
ONLY)
6RD CENTER ^
_ C123
I I GROUND
J FUSE 2 JOINT
404
i
I . I(NEXT TO
L _ ] _ J PDC)
C123
WITHOUT- X
»
Y C18Q HIGH L I N E
A2 CLUSTER Zl
12PK 12BK
BK
8W-70-4
1 S146 Zl S108
— G 9 20GY/BK- HBK
YI8W-70-20 8W-70-4
GAS-
A2 ENGINES' Zl
12PK ONLY 12BK
6K IGNITION IGNITION
^C133
A2
I2PK
BK
~~
SWITCH
r
ACC
C133 G9
16GY
BK BK
G9
18GY
C133
1G1Q1
SWITCH
^-p ACC
#
I ^ O F F G9
| C212 8W-15-2
22GY
• r ^ IRUN 3 h BK
GRAY ^ RUN
(4)
START START*
l v C209
!3) C212 ' 1 (5): C212
26 '
A22 A20 25 I C209
12BK 18RD «f-+-)>-G9 22GY/BK-
OR DB
JOINT
S201 CONNECTOR C
24 23
8W-70-22 BRAKE 'ca'M (BEHIND
A22 WARNING
* ^209 KNEE
12BK SWITCH BOLSTER)
OR
INSTRUMENT FUSE I
CLUSTER JL
BLOCK ^ C 2 4 1
R
, WARNING"!
I LAMP I
| DRIVER | I 9flA
C 20A |I
I ' I
C21S C241
Y
G19 A20 DIESEL G9 G9
22LG 18RD ENGINE 22GY 22GY
RD DB ONLY BK BK
C228 C216
2 3 6 1 1
WARNING FUSED BRAKE

I BRAKE I
LAMP B + WARNING
I WARNING I
DRIVER LAMP
, LAMP ,
DRIVER 1 1
DRIVER
I J
REAR WHEEL A N T I - L O C K CONTROL MODULE INSTRUMENT
CLUSTER
(CENTER OF I . P . )
J958W-9
8W - 32 - — 8W-32 ANTI-LOCK BRAKES B R
POSITIVE REAR WHEEL ANTI-LOCK BRAKES

TERMINAL
POWERTRAIN
CONTROL
MODULE
PiWEI f 1
STOBUTION I STOP j ,
1
I LAMP (RIGHT SIDE
CENTER | SWITCH I OF
OUTPUT DASH PANEL)
! 29 ; .
COS
V40
20WT
PK
ens
V40
22WT
PK
Sill
8W-70-5
STOP LAMP
SWITCH V40
(8W-33-3) 22WT
PK
:C133
F32 V40 V40 V40
18PK 20WT 22WT 20WT
DB PK PK PK
:C1®9
JOINT
31
mm i132 CONNECTOR
(BEHIND
KNEE
_ _ J 33 J BOLSTER
(NEAR REAR OF mm
FUSE BLOCK)
F32 V40
20PK 22WT C121: ANTI-LOCK
DB PK BRAKE
I
9 ,
1
C228 I SYSTEM
I 1 STOP I CONTROL
I LAMP |] MODULE
7 SWITCH
FUSED 6+ STOP I OUTPUT i
LAMP i (LEFT
_ J FENDER
SWITCH SIDE
OUTPUT SHIELD)
REAR WHEEL A N T I - L O C K CONTROL MODULE

J958W-9
(CENTER OF I.P.)
m m — — 8W-32 ANTI-LOCK BRAKES — 8W ~ 32 ~ 7
PATTIHE REAR WHEEL ANTI-LOCK BRAKES
RUNNING
LAMP
MODULE
{LEFT FENDER INSTRUMENT
SIDE SHIELD) CLUSTER
f PARK 1 PARK
1 1
BRAKE BRAKE 4WD
| SWITCH | SWITCH SWITCH I
| SENSE | SENSE OUTPUT I
10 2
C131 C2tS C215
Gil
20WT
BK
Gil G107
:C133 22WT 20BK
BK GY
Gil
22WT
BK
PTO
OR
4K4
: C209 SWITCH
11 "1 JOINT (ON TRANSFER CASE)
| CONNECTOR C zaq7 r——\C407
0- | (BEHIND ^y
KNEE (2)
(i)
| BOLSTER) G107
18BK Zl
J
^ C209 GY 18BK
f
G107
20BK
Zl
20BK
GY
S103
C133
8W-70-2
Gil G107
22WT PARK 20BK Zl
BK BRAKE GY 18BK
SWITCH
C228
5 4
PARK 4WD
BRAKE SWITCH S102
SWITCH OUTPUT
SENSE 8W-15-3
REAR WHEEL A N T I - L O C K CONTROL MODULE

(CENTER OF L P . )
J958W-9
8W - 32 - 8 — 8W-32 ANTI-LOCK BRAKES BR
REAR WHEEL ANTI-LOCK BRAKES
REAR WHEEL
ANTI-LOCK
BRAKE
SENSOR
C409
• DASHED
LINES
INDICATE
TWISTED
B l 13 i PAIR
B U 3 + B114
20RD
VT |1
i
— ^ £330
B l 13 B l 14
20R0 20WT
VT VT REAR A N T I - L O C K VALVE
i (LEFT FENDER SIDE SHIELD)

*~ —
5^
i
C12i
B l 13 Bl H
20RD 20WT
VT VT
i ^ C133
Y
B l 13 BI'H
22RD 22WT
VT VT SPLICE
S122
(8W-70-10)
REAR WHEEL
ANTI-LOCK
CONTROL
-J MODULE
(CENTER OF I . P .
J958W-9
BR — SW-32 ANTI-LOCK BRAKES 8W - 32 - 9
BATTERY
POSITIVE
TERMINAL
POWER
DISTRIBUTION
CENTER
5201 ANTI-LOCK BRAKE SYSTEM CONTROL MODULE

8W-70-22 (LEFT FENDER SIDE SHIELD) J958W-9
-32-10 8W-32 ANTI-LOCK BRAKES BR
FRONT A N T I - L O C K V A L V E
B249 B248 B I 8
18WT 1GDG 20VT REAR
TN WT LG ANTI-LOCK
VALVE
( 8 W - 3 2 - 9 )
B I 2 0
I2BR
WT
C 1 2 0
POWER
FEED
(ON ABS
CONTROL
MODULE) ABS
P U M P
.. RELAY
(8W-32-9)
C 1 3 3
w/o
PREMIUM
RADIO
B249 B248 B18 B245 B243 B5

18WT 1GDG 20VT 18WT 16DG 20VT
TN WT LG LG BK RD B120
14BR
WT
C 1 2 1
JL C 1 2 I
33 30 18 37 35 34 ]
PUMP/ I
PUMP/VALVE MOTOR |
RELAY ,
OUTPUT
ANTI-LOCK BRAKE SYSTEM CONTROL MODULE J958W-9

BR 8W-32-ANTI-LOCK BRAKES 8W 32 -11
ENGINE
DATA
LINK — D21 20PK - — — *)) •—
REAR WHEEL
CONNECTOR
ANTI-LOCK
(8W-30-15,
BRAKE SENSOR
81-30-14,
82-30-33.
82-30-42)
(LEFT FENDER SIDE SHIELD) J958W-

8W - 32 -12 8W-32 ANTI-LOCK BRAKES BR
BATTERY VACUUM
j — AO GRD—• i POSZTYE
SENSOR
JL , TERMINAL
r
(LEFT FENDER
SIDE SHIELD)
> J FUSE 1
!
l
POWER
DISTRIBUTION
CENTER
C134
21 18BK
40A
* -GRAY
C180
A2
12PK BRAKE
BK WARNING
S146 SWITCH
8W-70-20
A2 A20 G9
12PK 18RD 20GY 69
BK DB BK 16GY
BK
IGNITION
C133 SWITCH
A2 ^ m ACC
12PK
BK 1 OFF
Ml? C212
(4) RUN
13) A22 C133
'START 12BK I—G9 20GY/BK-)>-G9 22GY/BK-
OR
5109
A22 8W-70-4
j hll 12BK/0R S201
^C24J
SW-70-22
SPLICE
S122
FUSE BLOCK (8W-70-10)
20A|
I
C241 12
18BK
A20 LG
18RD
DB £133 G1Q7
-<f-A20 18RD/DB 8W-15-4
ABS PUMP
SPLICE A20 18RD/DB - RELAY
sin (8W-32-9)
(8W-70-5)
V40 A20 A20 A20 A20 A20 G9 11

20WT 18RD 18RD 18RD 18RD 18RD 20GY I8BK
PK DB DB DB DB DB BK RD
C121
— —
r' ~i ANTI-LOCK
12 17 21, 25 20
I STOP BRAKE GND | BRAKE
| LAMP FUSED IGNITION SWITCH OUTPUT WARNING SYSTEM
I
SW (RUN) LAMP CONTROL
» OUT DRIVER MODULE

J958W-9
BR 8W-32 ANTI-LOCK BRAKES 8W - 32 -
Zl 18BK I 1
C123
I *T ACC
#
I I GROUND
, . JOINT j f RUN IGNITION
(NEXT TO SWITCH
] PDC) I START*
I
47 , I
T
C123 C212
WITHOUT- X
HIGH LINE
CLUSTER Zl
12BK
Zl 5108
14BK 8W-70-4
- 69
Zl
22GY
12BK BK
G1Q1
8W-15-2
PTO
Of
G9 22GY/BK• 414
SWITCH
C209
(ON TRANSFER
26 CASE)
C209 C407/ "\C407
25
24 23
JOINT
CONNECTOR C 6107
(1) <f (2)
I8BK Zl
(BEHIND
C209 KNEE GY 18BK
BOLSTER)
1 C106
T"
6107 Zl
20BK 20BK
G9 GY
22GY
BK BIOS S103
G107 20BK/GY•
8W-70-3 I8W-70-2I
C133
C228
REAR G9 6107 6107
22GY 22BK 20BK Zl
1 BRAKE WHEEL
I WARNING BK 6Y GY 18BK
ANTI-LOCK
LAMP
I DRIVER CONTROL
MODULE C216 C215 C121
(CENTER j ANTI-LOCK
11 2 BRAKE
OF L P . ) : BRAKE 4WD I 1 1
4WD SYSTEM
WARNING SWITCH I I SWITCH I
LAMP OUTPUT j OUTPUT j CONTROL
DRIVER MODULE G102
1 1
INSTRUMENT (LEFT FENDER |8W-15-3
SIDE SHIELD)
CLUSTER
J958W
BR 8W-33 WEHiGLE SPEED CONTROL 8W - 33 - 1
VEHICLE SPS ED CONTROL

VEHICLE SPEED CONTROL Circuit V31 provides the SET/COAST signal to cav
The vehicle speed control system is operated by the ity 48 of the PCM. Circuit V33 sends the RESUME/
Powertrain Control Module (PCM). The vehicle speed ACCEL signal to cavity 50 of the PCM.
control switches are located in the steering wheel, be Circuit V40 connects to cavity 29 of the PCM and
low the airbag. to ground through the stop lamp switch. The stop
Circuit V34 from fuse 10 in the fuse block supplies lamp switch OPENS when the operator presses the
battery voltage to the vehicle speed control ON/OFF brake pedal. The PCM disables speed control when
switch. Circuit A21 supplies voltage to fuse 10 when the stop lamp switch opens. From the stop lamp
the ignition switch is in the START or RUN position. switch, circuit Z l l provides ground for circuit V40.
In the START or RUN position the ignition switch
connects circuit A21 with circuit Al. Fuse 3, a 40 HELPFUL INFORMATION
amp, in the Power Distribution Center (PDC) pro • Circuit V40 also connects to the ABS control mod
tects circuit Al. ule on vehicles with all wheel anti-lock brakes
The vehicle speed control ON/OFF switch supplies o Circuit V40 also connects to the RWAL control
voltage to the SET/COAST and RESUME/ACCEL module on vehicles with rear wheel anti-lock brakes
switches. Both switches send signals to the PCM ® Check the 40 amp fuse located in cavity 3 of the
(which supplies the ground path for the switches). PDC
The PCM controls the vent and vacuum functions © Check the 2 amp fuse located in cavity 10 of the
of the vehicle speed control servo on circuits V35 and fuse block
V36. Depending on the signal it receives from the ve
hicle speed control switches, the PCM either applies DIAGRAM INDEI
vacuum to, or vents vacuum from, the servo. Circuit
V36 from cavity 33 of the PCM sends the vacuum
signal to the servo. Circuit V35 from cavity 53 sends Component Page
the vent signal. Fuse 3 (PDCn~~~•"" • 777777 . ."".78W-33-2
Circuit V32 signals to the PCM that the speed con Fuse 10 8W-33-2
trol switch is in the ON position. The V32 circuit con Ignition Switch . . 8W-33-2
nects to cavity 49 of the PCM. Circuit V32 also Powertrain Control Module .8W-33-2
connects to the stop lamp switch. Stop Lamp Switch .8W-33-3
In the CLOSED position, the stop lamp switch con Vehicle Speed Control Servo 8W-33-2
nects circuit V32 with circuit V30 to power the speed Vehicle Speed Control Switch .8W-33-2
control servo. Circuit Zl provides ground for the
speed control servo.
8W - 33 - 2 — ^ 8W-33 VEHICLE SPEED CONTROL — BR
BATTERY :C241
POSITIVE IGNITION
TERMINAL
SWITCH A21
12DB 10 FUSE BLOCK
POWER • ACC
AO n j _
6 R D DISTRIBUTION . J
^ > 0 FOFF
F
CENTER C212
RUN ^C241
- i r C212 1
I | W
(6)
V34
H f f — I I START 22WT
RD
FUSE 3 (i) a . ,
40A
V32 20YL/RD
Al V40 20WT/PK
C180 12RD
V30 20DB/RD
Al
12RD C133
VEHICLE SPEED
C211 : (3) CONTROL SWITCH
j . 1
V32 V40
20YL 20WT
RD PK
- » — V30 20DB/RD -
C209 OFF # f f-
JOINT ON
CONNECTOR C - n SET
V30 17 32 RESUME/
Mt/#
(BEHIND ACCEL. COAST
20DB KNEE BOLSTER)
RD
VEHICLE SPEED
16 15 31 OFF ON OFF ON J
CONTROL SERVO _ J
(2)
C1Q9 (BELOW BATTERY) ' C2Q9 (5) C211
C109 (2) (4)
V32 V32 V40 ¥32
22YL 22YL 22WT 22YL V33 V31
(4) RD RD PK RD 22WT 22BR
L6 RD
(3)
C133
3 V
V40 22WT/PK
V35 V36 »32 H/o' V40
1 V33 V31
20L6 20TN SPLICE S i l l 20WT 20BR
Zl 20YL ANTI- 22WT (8W-70-5)
RD RD PK L6 RD
20BK LOCK
S108 BRAKE
V40 20WT/PK
SYSTEM
8W-70-4 C126 C126
C125
Zl V35 V36 V32 V40 V33 V31
G101 12BK 20L6 20TN 20YL 20WT 20WT 20BR
8W-15-2 RD RD RD PK L6 RD
C135
53 33 49 29 50 48
POWERTRAIM I VENT VACUUM I G N I T I O N STOP RESUME SET
CONTROL LAMP SWITCH
I OUTPUT
MODULE
I
I „ , I
J958W-9
BR 8W-33 VEHICLE SPEED CONTROL 8W - 33 - 3
TURN SIGNAL
AND HAZARD L50 18WT/TN
FLASHER
SWITCH S2Q7
(8W-52-3) 8W-70-26
V32 20YL/RD
V40 20WT/PK
Z l l 18BK/WT
V30 S2©8
20DB G203 8W-70-27
RD ~ 8W-15-7
V30 20DB/RD
JOINT
CONNECTOR B
C23X V30 Zll V40 V32 L50

I FUSED 20DB 20BK 20WT 20YL 18WT
-F32 18PK/DB
RD WT PK RD TN
I . I
(NEAR REAR C214
OF FUSE BLOCK)
C214 C214
F32 V30 Zll V40 V32 L50 F32 V30 V32 L50
18PK 20DB 20BK 20WT 20YL 18WT 18PK 20DB 20YL 18WT
DB RD WT PK RD TN DB RD RD TN
STOP LAMP AND VEHICLE SPEED STOP LAMP SWITCH

CONTROL SWITCH W I T H WITHOUT V E H I C L E
VEHICLE SPEED CONTROL SPEED CONTROL
J958W-9
BR 8W-40 INSTRUMENT CLUSTER 8W - 4 0 - 1
INSTRUMENT CLUSTER
, . . INDEX
page page
ABS Warning Lamp 2 Manual Transmission Up-Shift Lamp . 2

Airbag Warning Lamp . . . . . . . . . . . . . . . . . . . . . . . 2 Oil Pressure Gauge 1
Diagram Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Oil Pressure Warning Lamp 1
Engine Coolant Temperature Gauge . . . . . . . . . . . . 1 Parking Brake Lamp 2
Four-Wheel Drive Indicator . . 3 PTO Lamp .. 3
Fuel Gauge 1 Seat Belt Indicator Warning Lamp . 2
High-Beam Indicator Lamp 2 Service Reminder Indicator (SRI) Lamp . . 3
Instrument Cluster 1 Speedometer 2
Low Fuel Warning Lamp 1 Tachometer . . 2
Low Washer Fluid 2 Turn Signal Indicator Lamps 2
Malfunction Indicator Lamp (MIL) . 2 Voltmeter . 2
INSTRUMENT CLUSTER gauge. The fuel level sensor draws voltage from cir
cuit F14 through the fuel gauge on circuit G4.
The instrument cluster contains the gauges and
warning lamps. All gauges have magnetic move As current flows through the coils in the fuel
ments. gauge, it creates a magnetic field. The magnetic field
When the ignition switch is in the START or RUN controls the position of the fuel gauge pointer.
position, circuit A21 feeds circuit F14 through a bus The fuel level sensor contains a variable resistor.
bar in the fuse block and fuse 12. Circuit Al from As the position of the float arm on the fuel level sen
fuse 3 in the Power Distribution Center (PDC) sup sor changes, the resistor changes the current flow
plies voltage to circuit A21. through the fuel gauge circuit. A change in current
Circuit F14 provides battery voltage for the warn flow alters the magnetic field in the fuel gauge,
ing lamps (except seat belt indicator lamp), transmis which changes the pointer position.
sion up shift lamp, and all gauges. Circuit Zll provides the ground path for the fuel
Circuit E2 from fuse 13 in the fuse block feeds the level sensor.
illumination lamps. Circuit El from the headlamp
switch powers fuse 13 when the parking lamps or LOW FUEL WARNING LAMP
headlamp are ON. Circuit G4 connects the fuel level sensor to the low
Circuit Z3 provides ground for the indicator lamps fuel relay in the instrument cluster. When the fuel
and illumination lamps. Circuit Zll provides the level in the fuel tank reaches a calibrated level, the
ground path for the gauges. low fuel warning lamp relay illuminates the lamp.
ENGINE COOLANT TEMPERATURE GAUGE OIL PRESSURE GAUGE
Circuit G20 connects the engine coolant tempera The case grounded oil pressure sensor is a variable
ture gauge to the engine coolant temperature sensor. resistor that connects to circuits G60 and G6. Circuit
The sensor is a variable resistor and case grounded G60 connects to the oil pressure gauge. Circuit G6
to the engine on all engines except the V-10. The connects to the oil pressure warning lamp.
V-10 engine coolant temperature sensor has an exter Circuit F14 connects to the instrument cluster and
nal ground. Circuit F14 connects to the instrument supplies battery voltage to oil pressure gauge. The
cluster and supplies voltage for the gauge. gauge uses two coils. Current passing through the
The gauge uses two coils. Current passing through coils creates a magnetic field. Position of the gauge
the coils creates a magnetic field. Position of the needle is controlled by the amount of current passing
gauge needle is controlled by the amount of current through the coils to ground at the sensor.
passing through the coils to ground at the sensor.
OIL PRESSURE WARNING LAMP
FUEL GAUGE The case grounded oil pressure sensor is a variable
Circuit G4 connects the fuel level sensor to the fuel resistor that connects to circuits G60 and G6. Circuit
gauge in the instrument cluster. Circuit F14 from G60 connects to the oil pressure gauge. Circuit G6
fuse 12 in the fuse block supplies voltage to the fuel connects to the oil pressure warning lamp.
8W - 40 - 2 8W-40 INSTRUMENT CLUSTER BR
Circuit F14 connects to the instrument cluster and MIL displays the message CHECK ENGINE. For in
supplies battery voltage to oil pressure lamp. formation regarding diagnostic trouble code access
When the oil pressure is below a predetermined using the MIL, refer to Group 14, Fuel Systems.
level the engine oil pressure switch CLOSES com
pleting a path to ground causing the lamp to illumi LOW WASHER FLUID
nate. Circuit G29 connects the low washer fluid switch to
the warning lamp in the instrument cluster. Circuit
TACHOMETER F14 supplies battery voltage to the lamp.
The Powertrain Control Module (PCM) signals the When the low washer fluid switch CLOSES, it con
tachometer on circuit G21. The PCM provides engine nects circuits G29 and Zl. Circuit Zl provides a
speed information to the tachometer. Circuit F14 ground path, illuminating the warning lamp. Circuit
from the fuse block provides voltage for the tachom Zl also provides ground for the windshield washer
eter. Circuit Zll provides ground for the tachometer. pump motor.
SPEEDOMETER SEAT BELT INDICATOR WARNING LAMP
The speedometer and odometer receive a signal The seat belt indicator warning lamp is activated
from the Vehicle Speed Sensor (VSS) on circuit G7. by the buzzer module on circuit G13. Circuit G13
Circuit G7 is spliced and also connects to the Power- supplies power to instrument cluster for the lamp.
train Control Module (PCM). Circuit Z3 provides ground for the lamp.
Circuit F14 from the fuse block provides voltage for
the tachometer. Circuit Zll provides ground for the HIGH-BEAM INDICATOR LAMP
tachometer.
Circuit G34 supplies power for the high-beam indi
VOLTMETER cator lamp. The ground path for the lamp is through
Power for the voltmeter is supplied on circuit F14. circuit Z3. If the vehicle has Daytime Running
This circuit is spliced and supplies power to all the Lamps (DRL), the DRL module powers circuit G34.
gauges. Ground for the voltmeter is supplied on cir On vehicles not equipped with DRL, circuit G34
cuit Zll. splices to circuit L3. Circuit L3 feeds the high beam
The F14 circuit is also used to measure the voltage circuit of the headlamps.
level. The gauge reading changes based on the sys
tem voltage in the F14 circuit. TURN SIGNAL INDICATOR LAMPS
Circuits L61 and L60 power for the turn signal in
ABS WARNING LAMP dicator lamps. Circuit L61 powers the left indicator
lamp. Circuit L60 powers the right indicator lamp.
ALL-WHEEL ANTI-LOCK BRAKES Circuit Z3 provides ground for the lamps.
The ABS module controls the ABS warning lamp
through the ABS warning lamp relay. When the ABS PARKING BRAKE LAMP
module grounds the warning lamp relay on circuit Circuit F14 supplies power to the park brake lamp.
B47, the relay contacts close and complete the Ground for the park brake lamp through the case
ground path for the ABS warning lamp. Circuit B47
grounded park brake switch on circuit Gil.
connects to pin 13 of the ABS module and the coil
side of the relay. Circuit A20 from fuse 14 in the fuse If the vehicle is equipped with Rear Wheel Anti-
block supplies power to the coil side of the relay. Lock (RWAL) brakes, circuit Gil provides an input to
Circuit G19 from the ABS warning lamp in the in the RWAL module.
strument cluster is double crimped at the contact MANUAL TRANSMISSION UP-SHIFT LAMP
side of the ABS warning lamp relay. Power for the
bulb is supplied by circuit F14. Circuit F14 supplies power for the manual trans
mission up-shift lamp. The lamp illuminates when
REAR WHEEL ANTI-LOCK (RWAL) BRAKES the Powertrain Control Module (PCM) provides
The RWAL module provides ground for the instru ground for the lamp on circuit K54. Circuit K54 con
ment cluster Check Anti-Lock warning lamp on cir nects to cavity 54 of the PCM.
cuit G19. Circuit F14 provides voltage to the
instrument cluster to feed the warning lamp. AIRBAG WARNING LAMP
Circuit F14 supplies power for the airbag warning
MALFUNCTION INDICATOR LAMP (MIL) lamp. The lamp illuminates when the Airbag Control
The Powertrain Control Module (PCM) provides Module (ACM) provides ground for the lamp on cir
ground for the MIL on circuit G3. Circuit G3 con cuit R41.
nects to cavity 32 of the PCM. When illuminated the
8W-40 INSTRUMENT CLUSTER SW - 40 - 3
FOUR-WHEEL DRIVE INDICATOR Component P a

P e
Power for the four-wheel drive indicator lamp is Engine Coolant Temperature Sensor .8W-40-5
supplied on circuit F14. Ground for the lamp is sup Engine Oil Pressure Gauge .8W-40-5
plied on circuit G107 to the switch. The ground is Engine Oil Pressure Sensor .8W-40-5
passed through the CLOSED contacts in the switch Fog Lamp Relays • .8W-40-11
to circuit Zl. Fuel Gauge 8W-40-5
Fuel Tank Gauge Level Sending Unit -8W-40-5
PTO LAMP Fuse A .8W-40-11
Power for the Power Take-Off (PTO) indicator lamp Fuse 1 (PDC) 8W-40-10, 11
is supplied on circuit F14. Ground for the lamp is Fuse 2 (PDC) 8W-40-8
supplied on circuit G107 to the switch. The ground is Fuse 3 (PDC) 8W-40-4, 6, 8, 12
passed through the CLOSED contacts in the switch Fuse 12 8W-40-4, 6, 8, 12
to circuit Zl. Fuse 13 .- 8W-40-10
Fuse 14 . . . . . . . . . . . . . . . . . • 8W-40-8
SERVICE REMINDER INDICATOR (SRI) LAMP Fuse 18 8W-40-10
Power for the SRI lamp is supplied on circuit F14. 4WD Lamp 8W-40-9
4X4 Switch 8W-40-9
Ground for the lamp is controlled by the Powertrain
Headlamp Switch .8W-40-10
Control Module (PCM) on circuit G24. This circuit
High Beam Indicator 8W-40-11
connects to cavity 32 of the PCM connector. Ignition Switch 8W-40-4, 6, 8, 12
HELPFUL INFORMATION Illumination Lamps 8W-40-10
Low Washer Fluid Lamp . . . . . . . . . . . . . . .8W-40-12
If the warning lamps don't operate, check fuse 12
Low Washer Fluid Sensor 8W-40-12
in the fuse block. Maintenance Required Lamp (SRI) .8W-40-12
DIAGRAM INDEX Message Center 8W-4Q-4
Oil Pressure Gauge 8W-40-5
Overhead Console . .8W-40-10
Component PaQe Parking Brake Switch 8W-40-7
ABS Control Module . .8W-40-6, 8 Powertrain Control Module 8W-40-4, 6, 12
ABS Warning Lamp Relay 8W-40-8 PTO Switch . . . 8W-40-9
Airbag Control Module 8W-40-4, 12 RWAL Control Module 8W-40-7, 9
Airbag Lamp 8W-40-12 Seat Belt Lamp 8W-40-10
Brake Warning Lamp .8W-40-67 Speedometer .8W-40-4
Brake Warning Switch .8W-40-7 Tachometer 8W-40-4
Buzzer Module .. JW-4Q-10 Turn Signal Indicator Lamps 8W-40-11
Check Anti-Lock Lamp 8W-40-9 Upshift Lamp 8W-40-12
Check Engine Lamp JW-40-6 Voltmeter 8W-40-4
Daytime Running Lamps Module 8W-40-7, 11
Engine Coolant Temperature Gauge . . . . . . . . . . . . .8W-40-5
8W - 40 - 4 — _ SW-40 INSTRUMENT CLUSTER — — mm
FUSE 3
40A C180 CI33
BATTERY
POSITIVE -AO 6RD At 12RD Al 12RD
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B R 8W-40 INSTRUMENT CLUSTER 8W 4 0 - 5
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C139 (2) C O S 8W-7Q-7
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Zll
ENGINE O I L 20BK Zll
PRESSURE WT 16BK
SENSOR WT
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C128
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14BR LEVEL GAUGE
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SENDING U N I T 20BK
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18GY (DIESEL
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18GY ENGINE) 8W-15-5
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J958W-9
SW - 41 - i 8W-40 INSTRUMENT CLUSTER BR
FUSE 3
BATTERY
40A €180 CI33
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S209 POWERTRAIN
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8W-70-27 (CENTER
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F14 63 69
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J958W-9
BR 8W-40 INSTRUMENT CLUSTER 8W - 40 - 7
DAYTIME
RUNNING WHEEL
REAR
LAMPS MODULE ANT I-LOCK
(LEFT FENDER
CONTROL MODULE
SIDE SHIELD) (CENTER OF I P . )
T PARK BRAKE ~! T PARK BRAKE "I

SWITCH SENSE 1
SWITCH SENSE
1
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BRAKE
WARNING
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INSTRUMENT PARK
CLUSTER -C216 BRAKE
SWITCH
10
J958W-9
SW - 41 - 8 8W-40 INSTRUMENT CLUSTER BR
BATTERY
POSITIVE
TERMINAL 619 20L6/RD
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IGNITION
J958W-9
BR 8W-40 INSTRUMENT CLUSTER 8W - 40 - 9
619 20L6/RD
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J958W-9
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J958W-9
BR 8W-40 INSTRUMENT CLUSTER 8W-40-11
fog lamp FOG L A M P
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B A T T E R Y ( 8 W - 5 0 - 7 )
C 1 3 3 C 2 2 1
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TRANSMISSION
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OVERDRIVE AIRBAG
SWITCH AIRBAG j
CONTROL
(8W-31-2) 624 629 WARNING
22GY 18BK LAMP I MODULE
PK TN DRIVER I (CENTER
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UPSHIFT MA I NT LOW AIRBAG SPARE INSTRUMENT
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J958W-9
BR 8W-41 HORN/CIGAR LIGHTER 8W - 41 - 1
HORN Check for a good ground

The horn system is powered by a 20 amp fuse lo • Check the cigar lighter element J
cated in the Power Distribution Center (PDC), cavity
B, which is HOT at all times on circuit P31. This cir POWER OUTLET
cuit supplies voltage to the coil and contact side of The power outlet is powered by a 40 amp fuse lo
the horn relay. cated in the Power Distribution Center (PDC), cavity
When the operator presses the horn switch, a 3. There is also a 20 amp fuse located in cavity 5 of
ground path is completed on the coil side of the horn the fuse block dedicated for the power outlet.
relay through the switch. The horn relay, located in Ground for the power outlet is supplied on circuit
the power distribution center (PDC), then closes the Z3.
relay contacts. Voltage is passed through the closed
relay contacts on circuit X2 to the horns. Grounding HELPFUL INFORMATION
for the horns is on the Zl circuit. • Check the 40 amp fuse located in cavity 3 of the
PDC
HELPFUL INFORMATION • Check the 20 amp fuse located in cavity 5 of the
• Check the 20 amp fuse located in cavity B of the fuse block
PDC.
• Press the horn switch and listen for the horn relay DIAGRAM INDEX
to click. A clicking relay indicates voltage is present
up to the switch.
Comp©ifE©qj _____ ,,._...___„tlll
CIGAR LIGHTER Cigar Lighter 777777 777.'.. .7 777 .777777 77.8W-41-2
Fuse B (PDC) . 8W-41-3
The cigar lighter is powered by a 40 amp fuse lo
Fuse 1 (PDC) . .8W-41-2
cated in the Power Distribution Center (PDC), cavity
Fuse 3 (PDC) . 8W-41-2
3. There is also a 20 amp fuse located in cavity 5 of Fuse 5 .8W-41-2
the fuse block dedicated for the cigar lighter. Horn Relay 8W-41-3
When the operator depresses the lighter, contacts Horn Switches 8W-41-3
inside of the lighter element close and voltage flows Horns . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-3
through the heating element to ground. Ignition Switch . .8W-41-2
Power Distribution Center . .8W-41-2
HELPFUL INFORMATION
Power Outlet 8W-41-2
• Check the 40 amp fuse located in cavity 3 of the
PDC
• Check the 20 amp fuse located in cavity 5 of the
fuse block
SW - 41 - 2 8W-41 HORN/CIGAR LIGHTER BR
S147
BATTERY
POSITIVE 8W-76-2!
TERMINAL , — A7 10RD/BK- A7 12RD/BK
AO
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J958W-9
BR 8W-41 HORN/CIGAR LIGHTER 8W 41-3
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A7 12RD/BK-
CENTER
CI8Q
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GROUND J O I N T
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C123
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HORN
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C123 Zl
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SWITCHES
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S108 (LOW NOTE)
14BK ^ 8W-70-4
WITHOUT-
HIGH LINE
CLUSTER Zl
12BK
G101
|8W-15-21
J958W-9
BR 8W-42 AIR CONDITIONING/HEATER 8W - 42 - 1
AIR CONDITIONING/HEATER
GENERAL INFORMATION age passes through one or more resistors to ground.
This section of the wiring diagrams covers the op Blower motor fan speed is controlled by the number
eration of the Heater only and the Heater-A/C sys of resistors voltage passes through to ground.
tems. When the fan switch is in the LOW position, circuit
Several fuses supply power for the A/C-Heater sys C4 provides the ground path. In the Ml position, cir
tem. Fuse B, a 20 amp, from the Power Distribution cuit C5 provides ground. In the M2 position, the
Center (PDC) supplies battery voltage on circuit F31 ground path is through circuit C6. Circuit C7 pro
to the contact side of the A/C compressor clutch relay. vides path for ground when the switch is in the
Circuit'F31 is HOT at all times. HIGH position.
In the START or RUN position, the ignition switch
connects circuit Al from fuse 3 in the PDC to circuit AIR CONDITIONING OPERATION
A21. Circuit A21 feeds fuse 9, a 10 amp, in the fuse When the A/C-Heater control switch is moved to an
block. Circuit F18 connects from fuse 9 to the coil A/C position or the defrost position, and the A/C low
side of the A/C compressor clutch relay
pressure and high pressure switches are CLOSED,
In the RUN position only, the ignition switch con
the Powertrain Control Module (PCM) receives an
nects circuit A2 from fuse 2, a 40 amp, in the PDC to
circuit A22. Circuit A22 supplies voltage to a bus bar A/C request signal on circuit C20. Circuit C20 con
in the fuse block. Fuse 2, a 30 amp, connects to bus nects to cavity 27 of the PCM.
bar and protects circuit CI which feeds the blower After receiving the A/C request signal, the PCM
motor. supplies ground for the coil side of the A/C clutch re
Circuit E2 from fuse 13 in the fuse block powers lay on circuit C13. Circuit C13 connects to cavity 34
the illumination lamps in the A/C heater control of the PCM. Circuit F18 supplies battery voltage to
switch. the coil side of the relay. Circuit F31 from fuse B in
the Power Distribution Center (PDC) supplies volt
BLOWER MOTOR age to the contact side of the relay.
When the ignition switch is in the RUN position, When the PCM grounds the A/C compressor clutch
circuit A2 from fuse 2, a 40 amp, in the Power Dis relay, the contacts close and connect circuits F31 and
tribution Center (PDC) connects with circuit A22. C3. Circuit C3 supplies voltage to the A/C compressor
Circuit A22 supplies voltage to a bus bar in the fuse clutch. Ground for the compressor clutch is provided
block that powers fuse 2. Fuse 2 protects circuit CI on circuit Zll.
which supplies battery voltage to the blower motor. The A/C compressor clutch connector has a built-in
From the blower motor, circuit C7 splices to the diode. The diode controls the induced voltage that re
blower motor resistor and the A/C-Heater control sults from the magnetic field collapsing when the
switch. clutch disengages. The diode provides a current path
The ground path for the blower motor is through to protect other components and systems.
the circuits that connect from the blower motor resis
tor block and then through the fan switch in the A/C HELPFUL INFORMATION
heater controls to circuit Z3. The blower motor resis • Check the 40 amp fuses located in cavity 2, and 3
tor block consists of three resistors connected in se of the PDC
ries (only two on the heater only vehicles). • Check the 30 amp fuse located in cavity 2 of the
Each resistor in blower motor resistor block is fuse block
spliced to the fan switch on separate circuits; C4, C5, • Check the 10 amp fuse located in cavity 9 of the
C6, and C7. Depending on fan switch position, volt fuse block
8W - 42 - 2 8W-42 AIR CONDITIONING/HEATER BR
DIAGRAM INDEX
Component Page Component Page

A/C Compressor 8W-42-6 Fuse 2 (PDC) 8W-42-3, 4
A/C Compressor Clutch Relay 8W-42-6 Fuse 3 (PDC) 8W-42-6
A/C Low Pressure Switch 8W-42-4 Fuse 9 (Fuse Block) 8W-42-6
A/C-High Pressure Switch 8W-42-4 Fuse 13 (Fuse Block) 8W-42-5
Blower Motor (A/C-Heater) 8W-42-4 Fuse 18 (Fuse Block) 8W-42-5
Blower Motor (Heater Only) 8W-42-3 Headlamp Switch 8W-42-5
Blower Motor Resistor (Heater Only) 8W-42-3 Heater Switch 8W-42-3
Blower Motor Resistor (A/C-Heater) 8W-42-4 Ignition Switch 8W-42-3, 4, 6
Fuse 1 (PDC) 8W-42-5 Powertrain Control Module 8W-42-4, 6
Fuse 2 (Fuse Block) 8W-42-3, 4
BR 8W-42 AIR CONDITIONING/HEATER 8W - 42 - 3
HEATER ONLY
v-p m ACC | S201

8W-70-22
€212 i , OFF I C212
A2 12PK/BK ((— A22 12BK/0R- A22 12BK/0R-
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S146 F2 I
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FUSE 2 DISTRIBUTION C238 C238
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C7
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BATTERY TN
>—AO 6RD- POSITIVE
TERMINAL S217
C7 12BK/TN
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C5 16LG/YL -
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OR (RIGHT S I D E
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° G203
8 H - 1 5 - 7
J958W-9
8W - 42 - 4 8W-42 A i l CONDITIONINGS EATER BR
BATTERY
POSITIVE
I "~_ 1
TERMINAL
E2 220R
HVAC SWITCH
E2 220R
C90
18L6
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C90 18L6/WT —<f ) > ~ C 2 0 18BR-
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PRESSURE SWITCH PRESSURE SWITCH I 27 POWERTRAIN
(NEAR A / C REQUEST CONTROL
COMPRESSOR) I SIGNAL 1 MODULE
J958W-9
I J
8W-42 AIR COiilTIOilii/HEATER 8W - 42 - 5
BATTERY
POSITIVE
TERMINAL
POWER S204
AO
6RD DISTRIBUTION 8W-70-24
CENTER
A7 12RD/BK
E2 200R
A7
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C209 f 1
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RADIO
(8W-47-2 *m E2 220R JOINT
8W-47-4) CONNECTOR C
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OVERHEAD I HEADLAMP ^ 1 \ \ 1
CONSOLE I SWITCH | " J J E2 220R •<f

OUTPUT
J958W-9
8W - 42 - 6 IW-42 AIR CONDmONINtyHEATER BR
BATTERY
POSITIVE
TERMINAL
POWER
C127
J958W-9
IR 8W-43 AIRBAG SYSTEM 8W - 43 - 1
AIRBAG SYSTEM
AIRBAG CONTROL MODULE (ACM) AIRBAG SQUIB (AIRBAG IGNITER)
Two circuits provide battery voltage to the Airbag Two circuits, R43 and R45, connect the ACM to the
Control Module (ACM); F14 and F23. Circuits F14 driver's side airbag squib (igniter) after passing
and F23 are connected to separate bus bars in the through the clock spring connector. Circuit R43 con
fuse block. Different circuits from the Power Distri nects to cavity 2 of the ACM 4 way connector; circuit
bution Center (PDC) and the ignition switch supply- R45 connects to cavity 3 of the ACM 4 way connector.
battery voltage to the fuse block bus bars.
R43 and R45 are a twisted pair of wires.
Circuit F23 supplies battery voltage to the ACM
only when the ignition switch is in the RUN position. AIRBAG WARNING LAMP
Circuit F14 powers the ACM when the ignition
Circuit R41 connects the airbag warning lamp to
switch is in either the START or RUN position.
cavity 7 of the ACM 13 way connector. The airbag
In either the START or RUN position, the ignition
switch connects circuit A21 circuit with circuit Al warning lamp is part of the instrument cluster. Refer
from fuse 3, a 40 amp, in the PDC. Circuit A21 cir to section 8W-40, Instrument Cluster.
cuit supplies battery voltage to the fuse block bus bar
AIRBAG DIAGNOSTIC CONNECTOR
that feeds circuit F14. Fuse 12, a 15 amp, in the fuse
block protects circuit F14. Circuit F14 connects to The DRB scan tool connects to the airbag/ABS data
cavity 6 of the ACM. link connector. A twisted pair of wires, circuits Dl
When the ignition switch is in the RUN position, it and D2, send and transmit data between the ACM
connects circuit A2 from fuse 2, a 40 amp, in the and the DRB scan tool. Circuit Dl connects to cavity
PDC to circuit A22. Circuit A22 supplies battery volt 4 of the ACM 13 way connector. Circuit D2 connects
age to the fuse block bus bar that feeds circuit F23. to cavity 3 of the ACM 13 way connector.
Fuse 16, a 15 amp, in the fuse block protects circuit
F23. Circuit F23 connects to cavity 5 of the ACM. DIAGRAM 1NDEI
The ACM is case grounded and has an external
dedicated ground, circuit Z6. Component ^ Page
Airbag .". . . . . .......8W-43-3
AIRBAG IMPACT SENSORS Airbag Control Module 8W-43-3
Two airbag impact sensors provide input to the Air- Airbag Impact Sensors 8W-43-3
bag Control Module (ACM). Each sensor has two cir Data Link Connector .8W-43-3
cuits that connect to the ACM. Fuse 2 (PDC) . .8W-43-2
From the left impact sensor, Circuit R47 connects Fuse 3 (PDC) .8W-43-2
to the ACM at cavity 1 of the 13 way connector. Cir Fuse 12 .8W-43-2
cuit R49 connects to cavity 2 of the 13 way connector. Fuse 16 . .8W-43-2
From the right impact sensor, Circuit R46 connects Ignition Switch .8W-43-2
to the ACM at cavity 13 of the 13 way connector. Cir Instrument Cluster 8W-43-3
cuit R48 connects to cavity 12 of the 13 way connec
tor.
SW - 43 - 2 8W-43'liRBAI SYSTEM BR
BATTERY
POSITIVE
TERMINAL
f
AO _. 1
6RD
1
I POWER
FUSE 2 SFUSE 3 I DISTRIBUTION
40A m 40A 1 CENTER
C180
A2
12PK Al
FUSE BLOCK
IK 12RD
C24I C241
F14 18LG/YL -
12 i
S146 C133 15A
- F23 18DB/YL-
8W-70-20 A21 I
12DB
16
I |
A2 15A I 1
12PK Al
BK 12RD • ACC
OFF I I
C212
CI33
RUN
C212 (6) S201
I #$TART
8W-70-22
(D| A22 12BK/0R
A2
12PK
BK ACC
OFF
A22 12BK/0R
RUN
(4)
(3)
START
IGNITION
SWITCH
J958W-9
BR • 8W-43 AIRBAG SYSTEM • — 8W - 43 - 3
-PART OF
STEERING
COLLUMN
- ) > - R43 20BK~<f- -))- — -R43 1 Bfil/LB - — — — n

AIRBAG CLOCK I |
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DRIVER S l O E AIRBAG ^ C205
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F14 18L6/YL• R45
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F23 18D8/YL I I
F23 FI4 AIRBAG
180B 18LG
YL YL CONTROL
MODULE
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INDICATE TWISTED PAIRS (CENTER
D1 + D2. R43 + R45 5-C232 A- OF I . P . )
JL
AIRBAG
CCD CCD
BUS BUS WARNING
R LAMP GROUND
DRIVER
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3 13 12 11 ,
7
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C216 CI33
6
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| WARNING I 18DB R49 R48
18BR 18BK
, LAMP » 18LB
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INSTRUMENT 6108
C110 ^ C103
CLUSTER 8W-15-5
I I
Kf|6 If^-i LEFT RIGHT
C223 1 C223
AIRBAG AIRBAG
i
SENSOR SENSOR
AIRBAG/ABS
DATA L I N K
CONNECTOR
(CENTER BOTTOM
OF L P . ) J958W-9
BR 8W-44 INTERIOR LIGHTING 8W - 44 - 1
INTERIOR LIGHTING
INDEl
page page
Buzzer Module 2 Helpful Information . . . . . . . . . . . . . . . . . . . . . . . . . 2

Cargo Lamps 1 Ignition Switch Lamp 1
Day/Night Mirror 1 Key-In Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Diagram Index 2 Seat Belt Switch 2
Dome Lamp 1 Time Delay Relay 1
General Information 1 Underhood Lamp 1
Glove Box Lamp 1
GENERAL INFORMATION p a t h to ground on circuit Z3.

Circuit M l supplies power to the underhood lamp,
glove box lamp, dome lamp, buzzer module, cargo UNDERHOOD LAMP
lamps, and the t i m e delay relay. Circuit M50 from Circuit M l from the I O D fuse (fuse 17) i n the fuse
the time delay relay powers the ignition switch lamp. block supplies battery voltage for the underhood
Circuit M l is protected by the Ignition Off Draw lamp. A mercury switch, i n series after the lamp, con
(IOD) fuse i n the fuse block, cavity 17. This fuse is a nects the lamp to ground on circuit Z l . W h e n the
15 amp. hood is raised, mercury inside the switch moves to a
Power for the M l fuse is supplied on circuit A7. position where i t connects circuit M l to ground cir
This circuit originates i n the Power Distribution Cen cuit Z l , i l l u m i n a t i n g the lamp.
ter (PDC) and is protected by a 50 amp fuse located
i n cavity 1. DOME LAMP
Circuit M l from the I O D fuse (fuse 17) i n the fuse
IGNITION SWITCH LAMP block supplies power to the dome lamp. This circuit
Circuit M50 f r o m the time delay relay supplies is H O T at all times. The ground path for the lamp is
voltage to the ignition switch lamp. Circuit Z3 pro provided i n two different ways.
vides ground for the lamp. One way is through the door j a m b switches. Circuit
Circuit M l supplies voltage to the time delay relay.
M 2 connects to the door j a m b switches f r o m the
Circuit M 2 provides ground for the relay through the
dome lamp. The switches are connected to ground
dome/cargo lamp switch or the door jamb switch.
circuit Z3. When a door is O P E N E D , the switch
TIME DELAY RELAY CLOSES, completing a path to ground on circuit Z3.
- The time delay relay is used to allow a time-ON The second ground path is through the headlamp
function for the ignition switch lamp. Power for the switch. Circuit M 2 is spliced i n w i t h the headlamp
relay is provided on the M l circuit from the I O D fuse switch. When the operator turns the headlamp
(fuse 17) i n the fuse block. switch to the dome lamp O N position, a ground path
Circuit M 2 provides ground for the time delay relay is provided through the switch on circuit Z3.
through the r i g h t and left door j a m b switches and
the headlamp switch. When a door is OPENED, or DAY/NIGHT MIRROR
the headlamp switch is moved to the dome/cargo The day/night m i r r o r receives power f r o m circuit
lamp O N position, a ground path is provided for the L I O when the ignition switch is i n the R U N position.
relay on circuit M 2 . This energizes the relay, causing This circuit is protected by a 10 amp fuse located i n
the contacts to close. cavity 15 of the fuse block.
When the relay contacts close, power is provided Circuit Z4 provides ground for the day/night mir
through the relay to circuit M50. The M50 circuit ror.
supplies current to the ignition switch lamp. Circuit W h e n the back-up lamps switch CLOSES, circuit
Z3 provides ground for the lamp. L I provides a signal to the day/night mirror. The day
n i g h t m i r r o r turns OFF when the vehicle is i n re
GLOfE 101 LAMP verse.
Circuit M l f r o m the I O D fuse (fuse 17) i n the fuse
block powers the glove box lamp. A case grounded CARGO LAMPS
switch, i n series after the lamp, CLOSES when the Circuit M l from the I O D fuse (fuse 17) i n the fuse
glove box door is OPENED. The switch completes a block supplies power to the cargo lamps. This circuit
8W - 44 - 2 8W-44 INTERIOR LIGHTING BR
is HOT at all times. The ground path for the lamp is Circuit G10 from the buzzer module connects to the
provided on circuits M3 and Z3. seat belt switch. When the seat belt switch closes a
When the operator turns the cargo lamps ON, cir path to ground is completed on circuit Z3. Circuit Z3
cuit M3 connects from the lamps to the headlamp also grounds the buzzer module.
switch. The ground path passes through the switch
to circuit Z3. HELPFUL INFORMATION
© Check the 15 amp fuse in cavity 17 of the fuse
KEY-IN SWITCH block
For operation of the key-in switch refer to the cir • Check the 50 amp fuse located in cavity 1 of the
cuit descriptions for the buzzer module in this sec PDC
tion. ® Check the door jamb switches for a good ground
SEAT BELT SWITCH • Check the lamp filaments
• For the day/night mirror, check the back-up lamp
For operation of the seat belt switch refer to the switch, the 10 amp fuse in cavity 15 of the fuse
circuit descriptions for the buzzer module in this sec block, and the 40 amp fuse in cavity 2 of the PDC
tion.
BUZZER MODULE DIAGRAM INDEI
The buzzer module sounds an audible warning
tone. The tone sounds for seat belt warning, when Component ; Page
the ignition key is in the ignition switch while the Buzzer Module 8W-44-5
drivers door is OPEN, or the headlamps are left ON Cargo Lamps .8W-44-3
with the drivers door open. The tone also sounds Day/Night Mirror .8W-44-7
when the ignition key is in the ON position while the Dome Lamp .8W-44-3
drivers side seat belt is not buckled. Refer to Group Fuse 1 (PDC) 8W-44-3, 5, 6
8U for buzzer module operation. Fuse 2 (PDC) 8W-44-7
Fuse 3 (PDC) .8W-44-4
Power for the buzzer module is supplied on circuit
Ml from fuse 17, a 15 amp, in the fuse block. This
fuse is the Ignition-Off Draw fuse (IOD) and is HOT
Fuse 17 (Fuse Block) 8W-44-3, 5, 6
at all times. Power for the fuse is supplied on circuit
Glove Box Lamp 8W-44-6
A7. This circuit is protected by a 50 amp fuse located Headlamp Switch .8W-44-3, 5
in cavity 1 of the Power Distribution Center (PDC). Ignition Switch 8W-44-4, 7
When the parking lamps or headlamps are ON, the Ignition Switch Lamp .8W-44-3
headlamp switch connects circuit G16 from the driv Key-In Switch .8W-44-5
ers side door jamb switch to circuit G26. Circuit G26 Overhead Console 8W-44-4
connects to the buzzer module and the key-in switch. Seat Belt Switch 8W-44-5
Circuit G16 from the drivers side door jamb switch Time Delay Relay .8W-44-3
also connects to the key-in switch. Underhood Lamp .8W-44-6
Circuit G13 from the buzzer module powers the
seat belt warning lamp in the instrument cluster.
Circuit Z3 at the instrument cluster provides ground
for the lamp.
BR 8W-44 INTERIOR LIGHTING 8W 44 3
BATTERY
POSITIVE
TERMINAL l 1
| FOSE 1 | SI47
50A | C180 8W-70-21 C133 S204
AO -I-)) A7 10RD/BK # A7 12RD/BK • — » A7 12RD/BK
6RD 8W-70-24
l l
POWER
DISTRIBUTION A7
CENTER 12RD
BK
M2 22YL-
C241
C213 C241 53 TIME

M50 22YL/RD (f-j DELAY
—<(
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!
IGNITION 55 I
SWITCH
LAMP C241
Z3
20BK Ml Mi
OR 20PK 18PK
C410/^\C410
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Mi 18PK-
1 8W-70-25
(i) v y (2)
Mi
CARGO
20PK
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M3 C202
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8W-70-26 C4tt X ^ X C4I1 C3Q8
S3Q3
Ml 18PK- \{—Ml 18PK
M3
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20PK CARGO
DB LAMP 2
Z3 Z3
M2 12BK 20BK HEADLAMP
22YL OR OR SWITCH
M3
C204 20PK
CARGO DB
C204
M2
20YL
*-
M3
22PK
—<f C206
DB
(2) DOME f
S218
|(3)
8W-70-30
G201
JOINT C217
8W-15-6 M2
CONNECTOR A r
20YL
(NEAR REAR OF I C217
FUSE BLOCK) ^ j 3 10,
C217 I
J958W-9
SI 44-4 8W-44 INTERIOR LIGHTING BR
BATTERY
POSITIVE
TERMINAL
f
AO POWER
6RD DISTRIBUTION
JL- , CENTER
I
FUSE 3 I
0 40A |
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F12 20DB/WT"
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C133
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Ai 12RD (f-i—
UK
(i) L C241
G16 22BK/LB
TRANSMISSION
FUSE BLOCK
OVERDRIVE
SWITCH
(8W-31-2)
I
s I I
F12 616
20DB 22BK
:£24l WT LB
F12 616
22DB r— F12 22DB/WT 22BK
WT LB
C209
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20 22 21 12 13
19 14
C2Q8 J O I N T CONNECTOR C C209

F12 616
22DB 22IK
WT LB
C208 C201
F12 616
22DB 18BK
WT LB
C338
FUSED I6N . OVERHEAD LEFT DOOR

SW OUTPUT I CONSOLE JAMB SWITCH
(START/RUN) (8W-49-3)
J958W-9
BR SW-44 INTERIOR LIGHTING 8W - 4 4 - 5
BATTERY
POSITIVE
TERMINAL
i
i 1 S147
| FUSE 1 I
I 50A j C180 8W-70-21 C133
AO S204
A7 10RD/BK I—A7 12RD/BK » A7 12RD/BK •
6RD 8W-70-24
I 1 I
I J
POWER A7
12RD
DISTRIBUTION BK
CENTER
F12 20DB/WT
C241
KEY-IN
C213 SWITCH
G16 22BK/LB (IGNITION 1 7
SWITCH) I FUSE BLOCK
(1) ISA
(2) C213 l
HEADLAMP
C241
SWITCH
Ml
18PK
C206
S20S
•016 22BK/LB"<f-| IT J
F12 8W-70-25
(6) f fHEAD (5)
626 G26 20DB Ml
18LB 18LB WT 20PK
.1 €218
7 1
KEY - IN FUSED IGN SW FUSED B +
SEAT BUZZER OUTPUT
BELT SW (START/RUN) BUZZER
WARNING MODULE
SW SELT BELT LP
DRIVER GND ( I N FUSE
2 3 BLOCK)
C218
Z3
20BK
OR
613
20DB
RD
S206
Z3 1 8 B K / O R - , 8W-70-26
C308
C216
Z3
12BK
14 OR
Z3 Z3
18BK 18BK SEAT BELT
OR OR LAMP
DRIVER k G201
8W-15-6
CENTER HIGH INSTRUMENT

MOUNTED CLUSTER
STOP LAMPS
(8W-51-7) J958W-9
SW -44 - i - 8W-44 INTERIOR LIGHTING BR
BATTERY
POSITIVE
TERMINAL
r 1
f SI47
| FUSE i | 8W-70-21 C133
» 50A s €18® S204
f-yV* I ))—- A7 10RD/BK A7 12RD/BK — ) ) A7 12RD/BK
8M-70-24
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POWER 12RD
AIRBAG/ABS
DISTRIBUTION BK
DATA LINK
CENTER CONNECTOR
(8W-32-11)
C241
Ml
| 17 1FUSE BLOCK
20PK
, ISA
C231 I
RADIO C231 r " 1 C241

(8W-47-2, 1
8W-47-4) Ml 20PK f(f
Ml
C231 18PK
S20S
Ml 20PK Ml 18PK
8W-70-25
RADIO 1
10 Ml
CHOKE Ml 18PK <f
(8W-47-5) 20PK
L I
JOINT C133
CONNECTOR B
(NEAR REAR OF
FUSE BLOCK) Ml
20PK
BLACK
St 49
GLOVE BOX
LAMP AND
SWITCH
J958W-9
BR 8W-44 INTERIOR LIGHTING 8W - 44 - 7
BATTERY
POSITIVE
TERMINAL
T
AO
6RD
POWER
FUSE 2 DISTRIBUTION
40A CENTER
IGNITION
SWITCH
C180 SI4S ACC

8W-70-20 ^ m
C133 C212 OFF
C212
A2 12PK/BK • A2 12PK/BK -A2 12PK/BK-
(4) RUN
(3)
'START
5201
8W-70-22
A22 12BK/0R -A22 12BK/0R
15 FUSE BLOCK
10A|
SPLICE
S117
(8W-70-8)
LI
18VT
BK
LIO 22BR/L6
I C133
T
LtO LI S319
JOINT 22BR 22VT
LG BK 8W-70-36
CONNECTOR C
(BEHIND KNEE C208
BOLSTER)
t-
LI
LIO
22VT
24 Z4
22BR 22BK
LG BK 18BK
(1)
X- (3)^
•I- (2)^C334 O
FUSED BACK-UP GND

IGN SW LAMP
OUT G304
SW OUT
(RUN) 8W-15-8
DAY/NIGHT
MIRROR
J958W-9
BR 8W-46 MESSAGE CENTER 8W - 46 - 1
MESSAGE CENTER
MESSAGE CENTER lamp. The W A T E R - I N - F U E L lamp is only used on ve
hicles equipped w i t h the diesel engine. C i r c u i t G86
Power for the message center is supplied on circuit
F14. This circuit is H O T i n the START and R U N po connects to cavity 35 of the P C M .
sition and protected by a 15 amp fuse located i n cav
i t y 12 of the fuse block. HELPFUL INFORMATION
Power for the fuse is supplied on circuit A 2 1 from • Check the 40 amp fuse located i n cavity 3 of the
the ignition switch. Power for the A 2 1 circuit is sup PDC
plied on circuit A l . This circuit originates i n the • Check the 15 amp fuse located i n cavity 12 of the
Power D i s t r i b u t i o n Center (PDC) and is protected by fuse block
a 40 amp fuse located i n cavity 3. • Refer to the appropriate section of the service
The Powertrain Control Module (PCM) controls the m a n u a l or the diagnostic test procedures m a n u a l
ground p a t h for the lamps i n the message center.
Circuit G14 is connected f r o m the message center DIAGRAM INDEX
to the P C M and is used for the transmission w a r n i n g
lamp. This circuit connects to cavity 31 of the P C M Component Page
on a l l engine packages except for the 8.0L. O n the
Airbag Control Module 8W-46-2
8.0L the G14 circuit connects to cavity 36 of the
PCM.
Fuse 12 (PDC) 8W-46-2
Circuit G85 is connected from the message center Ignition Switch 8W-46-2
to the P C M and is used for the WAIT-TO-START Message Center .8W-46-2
lamp. The WAIT-TO-START lamp is only used on ve Powertrain Control Module . . . . . . . . . . . . . . . . . .8W-46-2
hicles w i t h the diesel engines. Circuit G85 connects
to cavity 36 of the P C M .
Circuit G86 is connected f r o m the message center
to the P C M and is used for the W A T E R - I N - F U E L
8W - 4S - 2 8W-46 MESSAGE CENTER B R
BATTERY
POSITIVE
TERMINAL
A
I POWER
c D ° n DISTRIBUTION
(-» A21 12DB-
:C241
12
FUSE BLOCK I {. ISA 1
C241
r n
AIRBAG
I OUTPUT I
MODULE
(CENTER
OF I . P . ) I (START/RUN) i
I
' l
POWERTRAIN WATER- TRANS TRANS £ C232
CONTROL IN- WAIT-TO- OD OD I
MODULE FUEL START LAMP LAMP | F14 F14
(RIGHT 35 36 31 18LG 18LG
SIDE OF 36 I
YL YL
DASH • ^ C135
PANEL) -DIESEL-
ONLY
8.0L ONLY
G86 G85 G14
18TN 180R 18PK S209
OR BK BK 8W-70-27
C127 C127
686 G85 GH F14 F14

18TN 180R 18PK 20LG 20LG
OR BK BK YL YL
CX33 r _ TX C_—
215
n
INSTRUMENT • FUSED I
G86 G85 G14
20TN 20OR 20PK CLUSTER I IGN SW |
OR BK BK 1
1
OUTPUT
(START/RUN)J
i
C224
4
r 2
WATER- WAIT-TO-
5
TRANS 3 ^
FUSED
MESSAGE IN- START WARNING IGNITION
CENTER FUEL LAMP
DRIVER
J958W-9
BR 8W-47 AUDIO SYSTEM 8W - 47 - 1
AUDIO SYSTEM
GENERAL INFORMATION Circuit X54 feeds the right front door speaker. Cir
Two radio systems are available in this vehicle; one cuit X56 is the return from the speaker to the radio.
with a standard speaker system and a radio with Circuit X51 feeds the speaker in the left rear of the
premium speaker system. The premium speaker sys vehicle. Circuit X57 is the return from the speaker to
tem uses a power amplifier and radio choke relay not the radio.
used on the standard system. When referencing the Circuit X52 feeds the right rear speaker. Circuit
circuit descriptions or the diagrams, ensure that you X58 is the return from the speaker to the radio.
use the correct ones.
SPEAKERS—PREMIUM RADIO
RADIO OPERATION When the radio choke energizes, circuit X13 sup
In the ACCESSORY or RUN position, the ignition plies voltage to the amplifier circuits in each speaker.
switch connects circuit Al from fuse 3, a 40 amp, in Circuit Z2 provides the ground path for the speaker
the Power Distribution Center (PDC) with circuit amplifiers.
A31. Circuit A31 powers a bus bar in the fuse block Circuit X53 feeds the speakers in the left front
that feeds circuit X12 through fuse 7, a 10 amp. Cir door. Circuit X55 is the return from the speakers to
cuit X12 supplies battery voltage to the radio. Circuit the radio.
Z2 provides ground for the radio. Circuit X54 feeds the right front door speakers.
RADIO iEHORY Circuit X56 is the return from the speakers to the ra
dio.
Circuit Ml from the Ignition Off Draw (IOD) fuse
Circuit X51 feeds the speaker in the left rear of the
(Fuse 17) in the fuse block supplies power for the ra
dio memory. The IOD fuse is removed during vehicle vehicle. Circuit X57 is the return from the speaker to
shipping to prevent excessive battery draw. the radio.
Circuit A7 from fuse 1, a 50 amp, in the Power Dis Circuit X52 feeds the right rear speaker. Circuit
tribution Center (PDC) supplies voltage to the IOD X58 is the return from the speaker to the radio.
fuse. Circuit A7 is HOT at all times.
HELPFUL INFORMATION
RADIO ILLUMINATION • Check the 40 amp fuse located in cavity 3 of the
When the parking lamps or headlamps are ON, cir PDC
cuits E2 and L7 from the headlamp switch power the • Check the 10 amp fuse located in cavity 7 of the
radio illumination lamps. Fuse 13, a 5 amp, in the fuse block
fuse block powers circuit E2 which feeds the radio il • Check the ground at the rear of the radio
lumination lamp. Circuit El from the headlamp • Check the IOD fuse in the fuse block
switch supplies power to fuse 13. Circuit L7 supplies
voltage for the radio lamps. Circuit Z2 supplies the DIAGRAM INDEX
ground path for the illumination and park lamp cir
cuits. Component ^ Page
Fuse 1 (PDC) 8W-47-2, 4
RADIO CHOKE—PREMIUM RADIO ONLY Fuse 3 (PDC) .8W-47-2, 4
The radio choke relay supplies voltage to the am Fuse 7 (Fuse Block) 8W-47-2, 4
plifier circuits in the speakers. The radio supplies Fuse 13 (Fuse Block) . . .8W-47-2, 4
power to the radio choke on circuit X60. Power for Fuse 18 (Fuse Block) 8W-47-2, 4
the choke is also supplied on circuit Ml. This is the Fuse 17 (Fuse Block) 8W-47-2, 4
Ignition-Off Draw (IOD) circuit and is protected by a Headlamp Switch .8W-47-2, 4
15 amp fuse located in cavity 17 of the fuse block. Ignition Switch .8W-47-2, 4
Circuit Z2 provides ground for the radio choke. Radio .8W-47-2 thru 7
When the radio supplies power for the choke, cir Radio Choke 8W-47-5
cuit X13 supplies voltage to the amplifier circuits in Speakers—Premium Radio 8W-47-6, 7
the speakers. Speakers—Standard Radio 8W-47-3
SPEAKERS—STANDARD RADIO
Circuit X53 feeds the speaker in the left front door.
Circuit X55 is the return from the speaker to the ra
dio.
-47-2 - 8W-47 AUDIO SYSTEM BR
STANDARD RADIO
BATTERY
POSITIVE
TERMINAL
f
AO
6RD
5 . 4 6
FUSED PARK FUSED
1 HEADLAMP LP SW ION SW
iSW OUTPUT OUTPUT OUTPUT ,
START/RUN)I
J958W-9
8W-47 AUDIO SYSTEM - 8W - 47 - 3
STANDARD RADIO
LEFT POOR RIGHT POOR LEFT REAR RIGHT REAR

SPEAKER SPEAKER SPEAKER SPEAKER
E 2 Z 2 I gax4
C312 C320 C306 C302
(2) (1) (2) (i) (1) (2) CD (2)
X55 X56 X57 X51 X58 X52

X53 X54 20DB
20BR 18BR 18BR 18DB 18DB
2006 20VT
RD RD LB YL OR WT
C201 C240 C202 C202
X55 X56 X57 X51 X58 X52

X53 X54
20BR 20VT 20DB 20BR 20BR 20DB 20DB
20DG
RD RD LB YL OR WT
C230 C229 C230 C229 C230

r-
4 5 6 2
I + iSTANDARD
+ RADIO
717
G202
8W-15-7
Z2
18BK
LG
C133
Z2
18BK
LG
WITH HIGH—-
LINE CLUSTER 12
S122 18BK
LG
8W-70-10
22
18BK
LG
G103
8W-I5-3
J958W-9
-47-4 8W-47 AUDIO SYSTEM BR
PREMIUM STEREO RADIO
BATTERY
POSITIVE
TERMINAL
f
AO
POWER
DISTRIBUTION
6RD CENTER
5 4 6
FUSED PARK FUSED B + FUSED
HEADLAMP LP SW IGN SW
SW OUTPUT OUTPUT OUTPUT
(START/RUN)
J958W-9
LEFT REAR RIGHT REAR

SPLICE SPLICE SPLICE SPLICE SPEAKER SPEAKER
S304 S305 S307 S308 (8W-47-6) (8W-47-6)
(8W-47-7)(8W-47-7)(8W-47-7)(8W-47-7)
X55 X56 X57 X51 X58 X52

X53 X54
18BR 18DB 18BR 18BR 18DB 18DB
18VT
1806 RD RD LB YL OR WT
C201 C240 C202
X55 X56 X57 X51 X58 X52

X53 X54
20BR 20VT 20DB 20BR 20BR 20DB 20DB
20D6
RD RD LB YL OR WT
C330
C230 C229 C230 C229
• n
4 5 2 7 3 PREMIUM
12V
+ OUT
+ - + STEREO
RADIO
1
C230
"17
m O
G202
X60
2206 8W-15-7
RD
S212
Z2 18BK/L6
8W-70-28
SPLICE Z2
S213 18BK
(8W-47-6) L6
C133
Z2
18BK
L6
C234 WITH HIGH—

LINE CLUSTER S122 Z2
18BK
RADIO 8W-70-10 LG
CHOKE
(LP. Z2
CENTER 18BK
SUPPORT) LG
G103
Z2 18BK/L6 8W-15-3
J958W-9
-47-6 8W-47 AUDIO SYSTEM BR
RADIO PREMIUM STEREO RADIO
CHOICE
(8W-47-5)
X13
isetc
RD
S2I3
8W-70-29 C240
X13 18BK/RD X13 18BK/RD
X I 3 18BK/RD X54 18VT
€201 X5S 180&/RD-

C323 (3) (2)
X13 :
:
C3£3
18BK (4)
§-» • 22 18BK/LG
RD
(1)
RIGHT DOOR
SPEAKER
• X53 18DG -
X55 18BR/RD-
C313
- 22 18BK/LG •
C202
DOOR
L E F T
SPEAKER
RADIO
(8W-47-5)
X51 X57 X52 X58

X13 20BR 20BR 20DB 20DB
18BK YL LB WT OR
RD
T — j C202
T Y C202
X51 X57 X52 X58
18BR 18BR 18DB 18DB
YL LB WT OR
C30S C301
C30S C301
(1) (1)
Xi3 18BK/RD < f f e f e >
8302
8W-70-30
C3Q5
12 X I 3 ^ g ^ * * U
18BK 18BK 188K
LEFT REAR LG RD RIGHT REAR LG
SPEAKER , SPEAKER
X13 18BK/RD
S301 I— Z2 18BK/LG
8W-70-30 J958W-9
RADIO
(8W-47-5)
X56
X53 X54
20DB
20DG
m 20VT
•T
X53
C201 Y ~
X56
18DB
I
X54
£240
1,801 RO 18VT
I S307
- X54 18VT —
8W-70-32
S308
XS6 18DB/RD
8W-70-32
• 22 18BK/LG -
X5S
X53 X54
18DB
180G 18VT
RD
5304
-X53 18D6 -
8W-70-31
S305
X55 18BR/RD
8W-70-31
12 188K/LG —i
X55 X56
X53 X54
18BR 18DB
18VT
C240 RD 1806 RD
C201
£314 | jC3g4
(2)
22 22
18BK
LG
18BK
L6
f Zor\ >
LEFT DOOR RIGHT DOOR

TWEETER TWEETER
•22 18BK/L6-
S2I2
8W-70-28
22 G202
18BK
L6 8W-15-7
22 18BK/L6
C202
J958W-9
EH 8W-49 OVERHEAD CONSOLE — | ! f - 49 - 1
OVERHEAD CONSOLE
OVERHEAD CONSOLE The second ground path is through the headlamp
When the ignition switch is in the RUN or STAET switch. When the operator turns the headlamp
position, circuit F12 from fuse 11, a 10 amp, in the switch to the dome lamp ON position, a ground path
fuse block supplies power to the overhead console. provided on circuit M2 through the switch to ground
When the headlamps or parking lamps are ON, cir on circuit Z3.
cuits L7 and E2 provide voltage to the overhead con
sole for illumination. Voltage on circuit L7 informs HELPFUL INFORMATION
the overhead console that the headlamps or parking • Check the 15 amp fuse located in cavity 17 of the
lamps are ON. Circuit E2 from fuse 13, a 5 amp, in fuse block
the fuse block powers the illumination lamps in the © Circuit Ml splices to supply voltage for the radio
overhead console. Circuit El from the headlamp memory, time delay relay, underhood lamp, and glove
switch feeds fuse 13 and circuit E2. box lamp.
Circuit Zll provides ground for the compass. • Circuit E2 splices to provide voltage to the instru
ment cluster illumination lamps, and radio lamp.
AMBIENT TEMPERATURE SENSOR
© Check the 10 amp fuse in cavity 11 of the fuse
The ambient temperature sensor is a variable re block
sistor. Circuit G31 supplies voltage from the over © Check the grounding point for the overhead con
head console to the sensor. Circuit G32 is the signal sole
return from the sensor to the overhead console.
DIAiRAl 1NDE1
LAMPS
Circuit Ml supplies voltage for the reading lamps,
map lamp and dome lamp in the overhead console. Component ________ ^ _ _ _ _ _
The Ignition Off Draw (IOD) fuse (fuse 17) in the Ambient Air Temperature Sensor 3W-49-4
fuse block supplies voltage to circuit Ml. Circuit A7 Buzzer Module .8W-49-3
from fuse 1 in Power Distribution Center (PDC) feeds Door Jamb Switches .8W-49-3
the IOD fuse. Fuse 1 (PDC) .8W-49-2
Circuit Z4 grounds the reading lamps. Circuit M2 Fuse 3 (PDC) . . . . . . . . . . . . .8W-49-2
also provides ground for the reading lamps and dome Fuse 11 (Fuse Block) . . . . . . . . . . . . . . . . . . . . . .8W-49-2
lamp. Fuse 13 (Fuse Block) . . . .8W-49-2
The M2 circuit supplies ground for the overhead Fuse 17 (Fuse Block) .8W-49-2
console lamp in two ways. One way is through the
Headiamp Switch .8W-49-2, 3
door jamb switches. Circuit M2 connects to the door
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . .8W-49-2
jamb switches. The door jamb switches connect to
Overhead Console . . . . . . . . . . . . . . . . . . . .8W-49-2, 3, 4
ground on circuit Z3. When a door is OPENED, the
Overhead Map Lamp .8W-49-4
plunger in the switch CLOSES, completing a path to
Time Delay Relay . . . . . . . . . . . . . . . . . . . . . . . .8W-49-3
ground.
8 W - 49 - 2 8W-49 Of EFtHEAi CONSOLE BR
BATTERY
POSITIVE
TERMINAL IGNITION
f SWITCH
AO POWER
6RD DISTRIBUTION
_ CENTER
Al 12RD
FUSE 3
40A
C180
C133
A7
10RD S147 — Al 12RD—»-
BK
8W-70-21
-A7 12RD/BK
E2
200R
JOINT
CONNECTOR A
{NEAR REAR OF
FUSE BLOCK)
1
t T a r k " " " . ^
I LAMP 6 Lv\ L7 20BK/YL
2 B
f 20PK
[OUTPUT J C209
C209 J O I N T CONNECTOR C C209

E2 220R -F12 22DB/WT-
:C208 C208:
E2 220R- -F12 22DB/WT-
C338 C338
13 / 1
FUSED FUSED IGN 1
HEADLAMP SW OUTPUT |
SW OUTPUT (START/RUN) i
OVERHEAD CONSOLE J958W-9

BR 8W-49 OWEiiEAi COiSOLE 8W - 49 - 3
C208
Ml 2 0 P K - » - M l 18PK—j S32Q
I 18W-70-37 JOINT CONNECTOR A
(mm REAR OF
FUSE BLOCK)
Ml Ml
1-8PK 18PK C217 1
OVERHEAD
CONSOLE C338
12
I READING
LAMPS r C217
I DOME 22YL 1
LAMP
M2
J
W2
£338 22YL 20YL
M2 22YL
C204
s j > CJ38
Z4
18BK
C204
I S319
r Z4 1 8 B K - C
8W-70-36 I (2)
I
t
21 CARGO •
Z4
20BK
22BK
OR
HEADLAMP
• I 5206
SWITCH
G304 DAY/NIGHT Ol8W-70-26
MIRROR
8W-15-8 (8W-44-7) Z3
12BK OFF |C206
(5) PARK
OR
C206 1(6)
HEAD
KNITI0N caoi G26 l
SWITCH 8W-15-61 18LB
LAMP
(8W-44-3) 4^ £218
BUZZER
G16
22BK
r - - j r - n MOBULE LB
•
M50 I KEY-IN [ ( I N FUSE
M2 . BUZZER 1
22YL BLOCK)
RD 22YL
? C209
C241 C209 13
12
54 €241
53
616
22BK I . . J
LB JOINT 22BK M2 M2
22YL 22YL
CONNECTOR C LB
TIME
KEY-IN (BEHIND KNEE
DELAY C201 C240
SWITCH BOLSTER)
RELAY
55j
(W-44-5) +-
LEFT DOOR
FUSE BLOCK ^C241
JAMB SWITCH
Ml 20PK ^
Z3 18BR/0R
G302
°lBW-15-8l f~ -Z3 18BK/0R
G303
RIGHT DOOR
8W-15-8 J958W-9
JAMB SWITCH
8W - 49 - 4 8W-49 OVERHEAD CONSOLE BR
JOINT
CONNECTOR A SPLICE SPLICE RADIO HEADLAMP
(NEAR REAR S205 SliS (8W-47-2. SWITCH
OF FUSE (8W-70-25) (8W-70-3) 1W-47-4) (8W-49-2)
BLOCK)_
1 COURTESY
I LAMP AMBIENT
I DRIVER AIR
9 TEMPERATURE
SENSOR
C114
(2)
G31 G32
18VT 18BK
LG LB
JOINT
CONNECTOR A
NEAR REAR
OF FUSE
BLOCK)
€217 > C133
631 G32
(WITHOUT 22VT 22BK
OVERHEAD LG LB
CONSOLE)
C208
C208
Zll it— W / 0 L7
18BK
20BK
WT CLEARANCE YL
LAMPS I
Zll L7 631 G32
,1208 20BK 20BK S317 22VT 22BK
8W-70-27I WT YL 8W-70-36 LG LB
L7
18BK
YL
24 Zll
18BK C338
18BK WT C338
12 10
COMPASS HEAD
GROUND LAMPS OVERHEAD
ON
CONSOLE
G304 G203
8W-15-8 8W-15-7 l , . I J958W-9
JR 8W-50 FRONT LIGHTING 8W - 50 - 1
FRONT LIGHTING
HEADLAMPS When the fog lamp switch CLOSES, the fog lamp
The headlamp switch has three positions: OFF, PARK relay #1 contacts CLOSE connecting circuits L38 and
(parking lamps) and ON. The headlamp switch powers L139. Circuit L139 powers the contact side of the fog
the headlamps through the multi-function switch. lamp #2 relay. When the headlamp high beams are
OFF, the fog lamp #2 relay is not energized and volt
FLASH-TO-PASS (OPTICAL HORN) age flows through the normally CLOSED contacts to
Circuit A3 from fuse 6, a 40 amp, in the Power Dis circuit L39.
tribution Center (PDC) supplies battery voltage to Circuit L39 supplies voltage to the fog lamps and
the headlamp switch. The headlamp switch has an the illumination lamp in the fog lamp switch. Circuit
internal circuit breaker that connects circuit A3 to Zl provides ground for the fog lamps.
circuit L20. If the high beam lamps are on, circuit G34 ener
In the OFF or PARK position, the headlamp switch gizes the fog lamp #2 relay. When the relay ener
feeds circuit L20 which connects to the multi-function
gizes, the contacts OPEN and power is not supplied
switch. Circuit L20 powers the high-beam on -circuit L3
when the operator flashes the headlamps with the turn to the fog lamps. Circuit Z3 provides ground for the
signal stalk of the multi-function switch. coil side of the fog lamp #2 relay.
HEADLAMP SWITCH IN ON POSITION DAYTIME RUNNING LAMP (DRL) MODULE

When the headlamp switch is in the ON position, On vehicles built for sale in Canada, the low-beam
circuit A3 connects to circuit L2. Circuit L2 connects headlamps operate when the ignition switch is in the
to the multi-function switch and feeds the low beams RUN position and the park brake switch is OPEN.
on circuit L4. Circuit LIO from fuse 15 in the fuse block supplies
When the operator selects high beam operation, cir voltage to the DRL module. Circuit A3 from the PDC
cuit L2 connects to circuit L3. connects to DRL module.
The DRL module receives information on park
HEADLAMP GROUND brake switch position on circuit Gil.
Although circuit Zl provides ground for both the Circuit L4 powers the low beams of the headlamps.
right and left headlamps, it has different termination When the headlamp switch is OFF, the DRL module
points for each. powers the low beams on circuit L4. When the head
lamps are ON, the multi-function switch powers the
PARKING LAMPS low beams on circuit L4.
The headlamp switch has three positions: OFF, PARK Circuit L3 feeds the high beams of the headlamps.
(parking lamps) and ON, plus a dimmer switch. When When the operator flashes the headlamps with the
the headlamp switch is in the PARK or ON position, the stalk of the multi-function switch, the DRL senses
switch connects circuit F33 to circuit L7. From the voltage on circuit L3 and stops supplying power to
headlamp switch, circuit L7 branches to power the front
the low beams on circuit L4. Circuit Zl provides
parking lamps and rear tail lamps, roof clearance and
ground for the DRL module.
identification lamps, fender lamps and rear license plate
lamps. Circuit Zl provides a ground for the parking DIAGRAM INDEX
lamps. Ground for the roof clearance and identification
lamps is supplied on circuit Z4.
Component __ jpgp
FOG LAMPS Daytime Running Lamps 8W-50-9
The fog lamps are controlled by the fog lamp Fog Lamp Relays . 8W-50-3
switch and fog lamp relays. The fog lamps operate Fog Lamp Switch . .8W-50-7
only when the headlamp switch is in the PARK or Fog Lamps 8W-50-7
ON position, and the operator has selected low-beam Fuse Block Fuses .8W-50-4, 8
Headlamp Switch . . . 8W-50-4
operation. When the headlamps are in high-beam op
Headlamps .8W-50-3, 6
eration, the fog lamps will not operate.
Circuit L38 supplies power to the contact side of
Park/Turn Signal Lamps . 8W-50-5
fog lamp #1 relay. Circuit L7 supplies power to the
PDC Fuses 8W-50-3, 4, 6, 8
coil side of fog lamp #1 relay. Circuit L72 connects to
Roof Clearance Lamps .8W-50-10
the coil side of the relay and to ground on circuit Z3 Roof Identification Lamps .8W-50-10
through the fog lamp switch.
8W - 50 - 2 8W-50 FRONT LIGHTING B R
BATTERY DAYTIME RUNNING

POSITIVE LAMPS MODULE
TERMINAL (LEFT FENDER
SIDE SHIELD)
T
AO
I ' 1
FUSED
6RD B(+)
6
C131
POWER
(f FUSE S DISTRIBUTION
CENTER A3
40A 12RD
LS
J
4 S118
*h C 180
8W-70-8 HEADLAMP
A3 12RD/L6
hi DIMMER SWITCH
A3 (DAYTIME
RUNNING (PART OF
12RD MULTI-FUNCTION
LG LAMPS
ONLY) SWITCH)
-A3 12RD/L6-
^ PASS
133
C2I0
-L20 16LG/WT
(21)
'A3
I2RD C210
LG
S203 (19) HI (20)
L20
8W-70-23 16LG LO (18)
WT L4 L3
HEADLAMP
L2 16VT 16RD
C206 ^ > SWITCH
(7) 16LG WT OR
A3
12RD
LG OFF C133
PARK C206
HEAD -»- L4
16VT
L3
16RD
C206 WT OR
(2)
A3 12RD/LG-
(8)L-
L4 16VT/WT -
J958W-9
BR 8W-50 FRONT LIGHTING 8W - 50 - 3
res lamp
RELAY 1
FOG LAMP
(TOP OF BRAKE SWITCH
BATTERY PEDAL ARM) (8W-50-7)
POSITIVE CI33
TERMINAL L38 20LB/BK- L38 20LB/BK
CQ3
sac C18Q -L7 20BK/YL
L7
20BK
YL
JlFUSE 1 3 FUSE A
^ 50A ^ ISA SPLICE r~634 18RD/GY
S106
(8W-70-3) Z3
18BK
OR
POWER
CI80
DISTRIBUTION
A7 A7 CENTER SPLICE
10RD 12RD S215
BK BK (8W-70-29)
634 SPLICE RELAY 2
18RD (TOP OF
GY (8W-70-2) BRAKE
S147 PEDAL ARM)
S 2 i l
8W-70-21J
8W-70-28
G34 G34
18RD
GY
18RD
GY
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(HIGH) (LOW) LAMPS MODULE
INSTRUMENT a • (LEFT FENDER
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13 16RD/OR HEADLAMP
L3 16RD/OR
G102 Zl 20BK
8W-15-3
-L4 16VT/WT
S107
8W-70-3
L4 J6VT/WT
J958W-9
8W - 51 - 8 - — — 8W-50 FRONT LIGHTING - BR
BATTERY WITH DAYTIME RUNNING LAMPS
POSITIVE
TERMINAL
IGNITIONj
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4
POWER
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1 CENTER
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C18Q S2Q1
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^kc241 8W-70-22
A2 12PK/BK- S148
8W-70-20
FUSE BLOCK
:C241
-LIO 22BR/LG
r — i
REAR WHEEL
ANTI-LOCK
CONTROL MODULE
(CENTER OF l . P . )
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JOINT 22WT ^C216
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CONNECTOR C 22WT 20WT
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C209 BOLSTER) C209
28 10 C209
- » - G l l 22WT/BK•
11
29 30 1
C209
C208 DAY/NIGHT
LIO 22BR/LG » LIO 22BR/LG MIRROR
LIO (8W-44-7)
22BR
LG
W/0 DRL
C133
LIO 18BR/LG 2^ C128
)) -LIO 18BR/LG-
BACK-UP LAMP
SWITCH OR
PARK/NEUTRAL
P O S I T I O N SWITCH
(8W-31-50
LIO
22BR LIO
LG 18BR
LG
-LIO 20BR/LG• LIO 18BR/LG-

S120
8W-70-9
J958W-9
BR - 8W-50 FRONT LIGHTING 8W - 50 - 9
WITH DAYTIME RUNNING LAMPS
BATTERY
P§SITYE
TERMINAL
AO FOG LAMP
6RD RELAY 2 •
(8W-50-6)
POWER 634
DISTRIBUTION 18RD
CENTER GY
FiSl §
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INSTRUMENT S2I1
CLUSTER •634 18RD/GY-
8W-70-28
:C180 l 1
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C113
C131
FUSED B + FUSED DAYTIME

PARK HIGH BEAM
HEADLAMP IGN SW IND LAMP RUNNING LAMPS
HEADLAMP SW BRAKE SW OUT OUTPUT
SW SENSE MODULE
OUT (LOW) (HIGH) (RUN) GND GND
5 3 1 (LEFT FENDER
9 8
SIDE SHIELD)
Gil
22WT
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T L4
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T Zl
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C131
16VT 20WT 18BR

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C133
SX08
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SPLICE 8W-70-4
S107
(8W-50-3) Git
22WT Zl
BK 12BK
G101
8W-15-2
LIO 18BR/LG-
J958W-9
8W - 50 -10 8W-50 FRONT LIGHTING BR
JOINT
CONNECTOR A
f 1 (NEAR REAR LEFT OUTBOARD

| PARK OF CLEARANCE LAMP
LAMP FUSE BLOCK)
I SWITCH (ROOF)
I OUTPUT
C335 C33S
C217 L7 18BK/YL // Z4 18BK
\\
(2) (1)
L7 LEFT OUTBOARD
20BK
IDENTIFICATION
YL
LAMP
(ROOF)
C208
Z4 18BK
L7
18BK
YL
S318
8W-70-36
Z4 18BK
RIGHT OUTBOARD
IDENTIFICATION
L7 LAMP Z4
18BK 18BK
YL
L7 18BK/YL Z4 18BK
C338
12
RIGHT OUTBOARD
CLEARANCE LAMP
G304
(ROOF)
l , J
8W-15-8I
C341 C341
OVERHEAD /
/\ \
L7 18BK/YL- Z4 18BK
CONSOLE
(2) (1)
J958W-9
BR 8W-51 REAR LIGHTING 8W - 51 - 1
REAR LIGHTING
TAIL LAMPS AND REAR LICENSE PLATE LAMPS lamp, back-up lamps, and turn signals. Circuit Z3
Circuit A7 in the Power Distribution Center (PDC) provides ground for the CHMSL lamps.
connects to a bus bar in the fuse block. One of the HELPFUL INFORMATION
four circuits powered by the bus bar is circuit F33.
• Check for blown fuse in circuit F32.
Circuit F33 connects to the headlamp switch. Fuse 1
in the PDC protects the A7 circuit. Fuse 18, a 15 • Check for continuity across the stop lamp switch
amp, in the fuse block protects circuit F33. when it is CLOSED.
The headlamp switch has three positions: OFF, • If the vehicle is equipped with Rear Wheel Anti-
PARK (parking lamps) and ON, plus a dimmer Lock (RWAL) brakes, circuit F32 connects to the
switch. When the headlamp switch is in the PARK or RWAL module.
ON position, the switch connects circuit F33 to cir
cuit L7. From the headlamp switch, circuit L7 BACK-UP LAMPS
branches to power the front parking lamps and rear In the RUN position, the ignition switch connects
tail lamps, roof clearance and identification lamps, circuit A2 from fuse 2 in the Power Distribution Cen
fender lamps and rear license plate lamps. ter (PDC) to circuit A22. Circuit A22 feeds a bus bar
in the fuse block that powers circuit LIO through
GROUND CIRCUIT fuse 15.
Circuit Z13 provides ground for the lamps. Circuit LIO supplies power to the back-up lamp
HELPFUL INFORMATION
switch. On automatic transmission equipped vehicles,
• If the vehicle is equipped with factory installed fog the back-up lamp switch is part of an assembly that
lamps, circuit L7 splices to feed the fog lamp #1 relay includes the PARK/NEUTRAL position switch.
• If the vehicle is equipped with factory installed When the operator puts the transmission in RE
trailer tow, circuit L7 splices to the trailer tow har VERSE, the back-up lamp switch connects circuit
ness LIO to circuit LI. Circuit LI feeds the back-up lamps.
• Check fuse 1, a 40 amp, in the PDC
• Check fuse 18, a 15 amp, in the fuse block GROUND-CIRCUIT
• Circuit L7 also feeds the radio, if equipped Circuit Z13 provides ground for the back-up lamps.
• When the headlamp switch is in the PARK or ON Circuit Z13 also supplies a ground path for the tail
position, the dimmer circuit, F33, also connects to lamps, parking lamps, rear license plate lamp, stop
circuit El. Circuit E l feeds circuit E2, which powers lamps, and turn signals.
the ash receiver lamp, instrument cluster illumina
HELPFUL INFORMATION
tion lamps, under hood lamp, glove box lamp and ra
dio lamp. Fuse 13 in the fuse block protects circuits • Check for blown fuses in circuits A2 and LIO
El and E2 • Check for continuity across the back-up lamp
switch when it is CLOSED
STOP LAMPS AND CHMSL LAMPS • Circuit LI also connects to the day/night mirror
Circuit A3 from fuse 6, a 40 amp, in the Power Dis DIAGRAM INDEX
tribution Center (PDC) supplies voltage to circuit
F32 through fuse 20, a 15 amp, in the fuse block.
Component _ __Pag[e
Circuit F32 connects to the stop lamp switch.
Back-Up Lamp Switch 8W-51-4
When the operator presses the brake pedal, the
Back-Up Lamps 8W-51-5
stop lamp switch CLOSES and connects circuit F32
CHMSL 8W-51-7
to circuit L50. Circuit L50 connects to the Center
Fender Lamps .8W-51-8
High Mounted Stop Lamps (CHMSL) and multi-func Fuse Block 8W-51-2, 4, 6, 8
tion switch. The multi-function switch supplies power Headlamp Switch .8W-51-2, 8
to the L62 and L63 circuits. Circuit L62 powers the Ignition Switch .8W-51-4
right stop lamp. Circuit L63 powers the left stop License Lamps . .8W-51-2, 8
lamp. Park/Neutral Position Switch 8W-51-4
PDC Fuses 8W-51-2, 4, 6, 8
GROUND CIRCUIT
RWAL Control Module .8W-51-6
Circuit Z13 provides a ground for the stop lamps
Stop Lamp Switch . .8W-51-6
and back-up lamps. The Z13 circuit has more than
Tail/Stop/Turn Signal Lamps 8W-51-3
one branch. Circuit Z13 also supplies ground path for
Tailgate Lamps . .8W-51-8
the tail lamps, parking lamps, rear license plate
8W ~ 51 - 2 — • 8W-51 REAR LIGHTIIIG BR
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S I Q S
L - I
sy-70-3
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L7 18BK/YL-
L7 J 8 B K / Y L
L7 18BK/YL L7 f 8BK/YL•
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LEFT RIGHT
LICENSE LICENSE
LAMP LAMP
€417
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Z13 18BK Z13 18BK
C343
J958W-9
B R 8W-51 REAR LIGHTING 8W - 51 - 3
17 18BK/YL •
L7
18BK
TURN S I G N A L YL
AND HAZARD
FLASHER SWITCH TRAILER
[8W-52-3) TOW CONNECTOR C329
(8W-54-2)
L63 L62
1806 18BR
RD PK
C331 C133 C331
L63 L62 L7
18DG 18BR 18BK
RD PK YL
S318 S315
8W-70-35 8W-70-35
L63 18DG/RD L62 18BR/PK •
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LEFT T A I L . RIGHT T A I L ,
STOP, AND TURN STOP, AND TURN
S I G N A L LAMP S I G N A L LAMP
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0-Z13 18BK-»- ZI3 18BK- S312

Z13 188K- 8W-70-34 C329
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8W-70-37 Z13 18BK- Z13 18BK (( Z13 18BK
S402
Z13 Z13 8W-70-37
12BK 16BK
TRAILER | S311
TOW FUEL TANK
ONLY 8W-70-33 LEVEL GAUGE
Z13 16BK SENDING U N I T
Z13 Z13 (8W-30-48)
12BK 16BK
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8W-15-4I J958W-9
8W - 51 - 4 8W-51 REAR LIGHTING B R
BATTCRY
POSITIVE
TUM2MAL
f POWER AGC
I
AO DISTRIBUTION S201
C212 OFF
SRD - - . CENTER C212 8W-70-22
A22 12BK/0R-
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Ok (3)
I *START
J FUS
FUSE 2 A22
\ 4 0t A
A IGNITION 12BK
SWITCH OR
A2
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I — I
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SPLICE
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PARK/NEUTRAL (8W-70-19)
POSITION SWITCH
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CIS!
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|(2)
LIO
22BR
C169 LG
• L I 18VT/BK—<( LIO I8BR/LG-
C126
•^Y—-LI 18VT/8K—<( L10 18BR/LG
C133
LI
18VT P—110 18BR/L6
BACK-OP
BK
LAMP SWITCH LIO LIO
I SU7 18BR
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8W-70-8 LG LG
LI 8120
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TOM BK
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LI (DAYTIME RUNNING
18VT LAMPS ONLY)
BK
L I 18VT/BK
C128
J958W-9
BR 8W-51 REAR LIGHTING SW - 51 - 5
S313
8W-70-34
LI Li
18VT
18VT BK
BK
C333 C329
C416
(1)4^ C4ii
LEFT RIGHT
BACK-UP BACK-UP
LAMP LAMP
€419 C418
LI
I8VT
BK
S312
C333 8W-7G-34 C329
I Z13 1 8 B K — » Z13 18BK Z13 1 8 B K — ( ( Z13 18BK—(
S401 S402
8W-70-37 8W-70-37
TRAILER
TOW
ONLY FUEL TANK
LEVEL GAUGE
ZI3 16BK SENDING U N I T
(8W-30-48)
TRAILER
TOW
ONLY
VJS58W-9
8W - 51 - 6 - 8W-51 REAR LIGHTING BR
BATTERY
POSITIVE
TERMINAL
| POWER -
AO DISTRIBUTION
6RD CENTER
FUSE 8
40A
X
J
C18Q
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TA3
12RO
L6
A3
12RD SJLJL8
L6 8W-70-8
A3
12RD
L6 S203
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A3 12R0/L6
A3
12RD
LG
C24X
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20 Euai
15A BLOCK
€241
F32
18PK
DB
>K C23I
JOINT
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C23JL CONNECTOR B
F32 20PK/DB (f+^ (NEAR REAR
OF
FUSE BLOCK)
C231
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F32
18PK
DB
C228
C214 I C214
13 L50 18WT/TN
j
im (CENTER ( 2 )
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SWITCH
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(TOP OF BRAKE PEDAL)
REAR WHEEL
ANTI-LOCK
CONTROL
MODULE J958W-9
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C412/^^ \c412
L50 IfWT/TN (f4^^#4^> 23 tBBK/m •
(2) (1)
CENTER HIGH
MOUNTED STOP
LAMP 1
(REAR OF ROOF LINER)
/ S
C413/ ^ \C413
L50 18WT/TN- 23 18BK/0R
C308 (2) v ^ y (d C30B
CENTER HIGH
MOUNTED STOP
LAMP 2 13
L50 (REAR OF ROOF LINER) 18BK
18WT OR
TN
13 18BK/0R
C302
L50 SEAT BELT

18RT SWITCH
TN G301 (8W-44-S)'
8W-15-8
S207
8H-70-26 TURN S I G N A L
L50 T8WT/TN- AND HAZARD
FLASHER SWITCH
(PART OF MULTI-FUNCTION SWITCH)
(8W-52-3)
C183 — ,
SPLICE
S149 Ml 18PK
(8W-70-21)
SPLICE
€133 (1).
S218 — M2 20YL —
M2 18YL —
(8W-70-30)
OPTIONAL
(TAPE TO HARNESS)
SPLICE
S207 - L50 18WT/TN » L50 18WT/TN )l
(8W--7-0-20)
L50
18WT
TN 8W*70-7
(4)
-Zl 18BK- Zl 18BK
Y GIOS
I8W-15-4I
J958W-9
8W - 51 - 8 - 8W-51 REAR LIGHTING B R
BATTERY FENDER AND TAILGATE L A I PS — DUAL REAR WHEELS
POSXTXVE
TERMINAL
AO POWER r ^ -1
6RD DISTRIBUTION F33 20PK/RD
CENTER € 2 4 1 1 1 ,o | C 2 4 1
M/O—v,
PREMIUM
ltL I (4)
A 7
FUSE BLOCK :
C20B
12RD RADIO
BK
b FUSE 1
^ 50A
S2Q4
A7 }
12RD mm \
8W-70-24 BK " OFF
A7
f-1 PARK
CIS© 12RD
A7 BK (9) C206
LORD
YL HEADLAMP
C133 SWITCH
•A7 12RD/BK— L7
S147 20BK
I JOINT YL
BW-70-21 | CONNECTOR A
I Cat? i 1 C217
6 |
L7 18BK/YL )) L7 18BK/YL (f-f^ <
i . \
(NEAR REAR OF
FUSE BLOCK)
C118 C343
L7 I8BK/YL )> L7 18BK/YL • L7 I8BK/YL L7 18BK/YL-
SIPS S3I4
8W-70-3 8W-70-35 •17 IfBf/Yl-
C406
L7
18BK
YL
€424 S407
•213 18BK (f-f^ )— L7 18BK/YL —<
8W-70-38
(1)
LEFT
TAILGATE
LAMP
S408 >
C425/ "^^VC425
8W-70-38 1
Z13 18BK < f 4 - ^ ^ ^ > - - L7 18BK/YL
RIGHT
Z13 TAILGATE
18BK LAMP
C42S C426
C406 >)—L7 18BK/YL
(1) (2)
L I C E N S E LAMP
Z13 18BK-
Z13 18BK-
J958W-9
FENDER AND TAILGATE LAMPS — DUAL REAR WHEELS
LEFT FORWARD
FENDER LAMP
C402 €420 C420 C402

L7 I8BK/YLH«(~L7 188K/YL--(£- ) - Z 1 3 18BK-»—Z13 18BK
(2) (1)
RIGHT FORWARD
FENDER LAMP
C403 C421 C421 C403

| — L7 i 8 B K / Y L - < f - L 7 1 8 B K / Y L — ( f » — Z l 3 18BK-»—Z13 18BK
1 (2) 1)
LEFT REAR
FENDER LAMP
C404 €422 €422 €404

<f-L7 18BK/YL >)-Zi3 18BK-^>-
L7
Z13
18BK
RIGHT REAR 18BK
YL
FENDER LAMP
S405
•L7 18BK/YL- C40S €423 €405
L7 i 8 B K / Y L - < f - L 7 18BK/YL >)-Zl3 18BK-^>— Z13 18BK- 8W-70-38
L7 18BK/YL- S406
8W-70-38 Z13
18BK
^€343
S311 Z13
I8BK
FUEL TANK
LEVEL GAUGE 1 S312
16BK
SENDING U N I T 8W-70-34
(8W-30-48) 12BK
L7
18BK Z13 Z13
-TRAILER 18BK 18BK
YL TOW
ONLY
TRAILER
TOW
ONLY
Z13 18BK-
Z13 18BK
J958W-9
BR 8W-52 TURN SIGNALS 8W - 52 - 1
TURN SIGNALS
TURN SIGNALS Circuit L9 from the hazard flasher fuse supplies
In the ACCESSORY or RUN position, the ignition battery voltage to the hazard warning flasher. Circuit
switch connects circuit Al from fuse 3 in the Power L19 from the flasher connects to the multi-function
Distribution Center (PDC) to circuit A31. Circuit A31 switch.
feeds circuit L5 through fuse 6 in the fuse block. When the operator presses the hazard flasher but
Circuit L5 powers the turn signal flasher. Circuit ton, the multi-function switch connects circuit L19 to
L6 from the flasher connects to the multi-function circuits L60, L61, L62, and L63.
switch to supply power to the turn signals. The Circuit L62 powers the right rear turn signal/stop
multi-function switch connects circuit L6 to the turn lamp. Circuit L63 powers the left rear turn signal/
signal lamps on circuits L60, L61, L62 and L63. stop lamp. Circuit L60 powers the right front lamps
and circuit L61 powers the left front lamps.
RIGHT TURN SIGNAL
Circuit L60 and L61 are double crimped at the
When the operator selects the right turn signal, the
multi-function switch and supply power for the turn
multi-function switch connects power from circuit L6
to circuits L60 and L62. Circuit L62 feeds the right signal indicator lamps in the instrument cluster.
rear turn signal/hazard flasher/stop lamp. GROUND CIRCUIT
Circuit L60 feeds the right front turn signal/hazard Circuit Zl provides a ground for the parking lamps,
flasher lamp and side marker lamp. Circuit L60 also
splices to power the turn signal indicator lamp on the turn/tail/stop lamps, and rear license plate lamps.
instrument cluster. Circuit Zl also provides a ground for the back-up
lamps and Center High Mounted Stop Lamps
LEFT TURN SIGNAL (CHMSL) lamps.
When the operator selects the left turn signal, the
multi-function switch connects power from circuit L6 HELPFUL INFORMATION
to circuits L61 and L63. Circuit L63 feeds the left • Check the fusible link in the A15 circuit
rear turn signal/hazard flasher/stop lamp. • Check the 15 amp fuse located in cavity C of the
Circuit L61 feeds the left front turn signal/hazard PDC
flasher lamp and side marker lamp. Circuit L61 also • Check the ground locations for the lamps
splices to power the turn signal indicator lamp on the
instrument cluster. DIAGRAM INDEX
GROUND CIRCUIT Component Page

:
Circuit Zl provides a ground for the parking lamps, Fuse C (PDC) .". . .8W-52-2
turn/tail/stop lamps, and rear license plate lamps. Fuse 3 (PDC) 8W-52-2
Hazard Flasher 8W-52-3
HELPFUL INFORMATION
• Check the 40 amp fuse located in cavity 3 of the Park/Turn Signal Lamps 8W-52-2
PDC Tail/Stop/Turn Signal Lamps . .8W-52-2
• Check the 15 amp fuse located in cavity 6 of the Turn Signal Flasher .8W-52-3
fuse block Turn Signal/Hazard Flasher Switch 8W-52-3
• Check the lamp filaments
HAZARD FLASHERS
Circuit A15 from the battery positive post supplies
power to the hazard flasher fuse (fuse C) in the
Power Distribution Center (PDC). Circuit 15 has an
in-line fusible link.
SW -12 - 2 8W-52 TURN SIGNALS BR
BATTERY
POSITIVE S148
TERMINAL
8W-70-21 C I 19
A15 16PK ({ A15 16PK-
AO AO 20PK 1 C180
6BK
POWER
I S FUSE 3 FUSE C
| C 40A OISTR1BUT10N
ISA CENTER
L Y
^ C180 C180
C212 - L 9 18BK/VT -
Al A31 12BK/WT•
12p ci33 C212
(2)
I Al 12RD Jfl ÂCC
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I G N I T I O NI 8W-70-2 C101
SWITCH ^-L\ Wnim L60 18LG/TN
"RUN
(3)
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RIGHT PARK
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S I G N A L LAMP
LEFT PARK
AND TURN
S1Q8 S I G N A L LAMP
8W-70-4 Clilf Q N D ~!C123 C112

Zl 12BKy<f-j4 3 j — » — Z1 18BK—<< L61 18LG/TN
I
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12BK MBK GROUND
w/o- C418
HIGH LINE JOINT
LEFT T A I L , L63 18DG/BR
CLUSTER (NEXT
TO PDC) STOP. AND TURN
G101
S I G N A L LAMP
8W-15-2
W/TRAILER TOW W/TRAILER TOW

S11S S311
8W-70-7 8W-70-33
•Z13 12BK Z13 12BK Z13 12BK I J8W-70-34
V -Z13 16BK Z13 16BK- Z13 16BK i 1
Z13
18BK
Zl
16BK Z13
18BK
» S402
8W-70-37
Z13
18BK
G106
(3)^C4H
8W-15-4
RIGHT T A I L .
STOP, AND TURN L62 18DG/BR
S I G N A L LAMP
J958W-9
BR 8W-52 TURN SIGNALS 8W - 52 - 3
FUSE BLOCK
C133 €841 r -
L9 18BK/VT - L9 18BK/VT•
!
A31 12BK/WT •
TURN
SIGNAL 6
HAZARD
FLASHER, ISA WARNING
FLASHER
INSTRUMENT CLUSTER €241

r LEFT RIGHT 1 1
— L5 2 0 B K - J
! FRONT FRONT
I TURN TURN I L19
| SIGNAL SIGNAL | L
L 6 20RD/GY 18BK
l ^ J _ i _ J WT
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L60 HAZARD SWITCH
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TURN S I G N A L
AND HAZARD
L63 18DG/BR• FLASHER SWITCH
(PART OF
L63 L62 MULTI-FUNCTION L50
18DG 18BR SWITCH) 18WT
C333 RD PK TN
— L63 18DG/RD•
L63
S3 I S 18DG
RD
8W-70-35
C128 €133
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SPLICE
S207
(8W-70-2&)
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S315
L62
8W-70-35 I8BR
PK
LB2 18BR/PK-
€328
162 itOG/ff
J958W-9
BR 8W-53 WIPERS 8W - 53 - 1
WIPERS
WIPERS mentarily. When the washer switch closes, voltage
Fuse 8 in the fuse block powers the intermittent from circuit V6 passes through the switch to circuit
wiper system. The intermittent wiper system oper V10. Circuit V10 provides a signal to the intermit
ates at either DELAY, LOW or HIGH speeds. tent wiper control module and supplies voltage for
In the ACCESSORY or RUN position, the ignition the windshield washer pump. When the control mod
switch connects circuit Al from fuse 3, a 40 amp, in ule receives the signal on circuit V10, it cycles the
the Power Distribution Center (PDC) with circuit wipers on circuit V3 while the washer fluid pump op
A31. Circuit A31 supplies voltage to circuit V6 erates.
through fuse 10 in the fuse block. The washer motor operates whenever the washer
Circuit ¥6 splices to supply power to the wiper switch CLOSES and supplies voltage to it on circuit
switch circuitry in the multi-function switch, the in V10. Circuit Zl provides ground for the pump motor.
termittent wiper module and the park switch in the
wiper motor. Ground for the wiper motor is supplied HELPFUL INFORMATION
on circuit Zl. Circuit Z3 provides ground for the in • Circuit V3 is double crimped at the multi-function
termittent wiper control module. switch to allow either the wiper switch or intermit
When the operator moves the wiper switch to the tent wiper control module to power the wiper motor
LOW speed position, the switch passes voltage to cir LOW speed brushes
cuit V3. Circuit V3 feeds the wiper motor LOW speed • Check the 40 amp fuse located in cavity 3 of the
brushes. If the operator selects wiper HIGH speed PDC
operation, the wiper switch passes current to circuit • Check the 20 amp fuse located in cavity 8 of the
V4. Circuit V4 feeds the wiper motor HIGH speed
fuse block
brushes.
If the operator selects wiper DELAY operation, the LOW WASHER FLUID WARNING LAMP
wiper switch provides an input to the intermittent
wiper control module on circuit V9. The DELAY por The low washer fluid warning lamp is located in
tion of the wiper switch contains a variable resistor. the instrument cluster. Circuit G29 connects the
The variable resistor connects to the intermittent warning lamp to the low washer fluid sensor in the
wiper module on circuit V9. Voltage for the resistor is washer fluid reservoir. The switch in the sensor
supplied by circuit V6 through the wiper switch. The CLOSES when the fluid level drops below a cali
amount of delay selected by the operator determines brated level. When the switch CLOSES, voltage flows
the voltage drop through the resistor and the voltage through the warning lamp to ground on circuit Zl.
level received by the intermittent wiper module.
After the intermittent wiper control module deter HELPFUL INFORMATION
mines the amount of delay selected, it cycles the wip • Check the grounding location for the sensor
ers by periodically energizing circuit VI7 which • Check the continuity across the switch
connects to circuit V3 through the wiper switch. Cir
cuit V3 powers the wiper motor LOW speed brushes. DIAGRAM INDEX
As the windshield wiper motor turns, the park
switch, internal to the motor, moves from its Component ^ ^ Page
grounded position (down) to the powered RUN (up) Fuse 3 (PDC) . . . . . 8W-53-2, 3
position. Circuit V7 provides an input to the inter Fuse 8 (Fuse Block) 8W-53-2, 3
mittent wiper control module when the wiper switch Ignition Switch . JW-53-2, 3
is in the OFF position. The intermittent wiper con Intermittent Wiper Control Module .8W-53-2, 3
trol module powers the park switch in the wiper mo Intermittent Wiper Switch 8W-53-2
tor on circuit V5. Low Washer Fluid Level Sensor .8W-53-3
The intermittent windshield wiper system is also Windshield Washer Pump Motor 8W-53-3
equipped with a pulse wipe feature. To activate this Windshield Wiper Motor 8W-53-3
feature, the operator presses the washer switch mo
8W - 53 - 2 - 8W-63 WIPERS BR
BATTERY
POSITIVE r
TERMINAL C212
f POWER C2I2
AO DISTRIBUTION Al 12RD (f- ACC
-)) A31 12BK/WT -
6RD CENTER (1)
OFF (2)
-ir I ^ /RUN
FUSE 3 # START C241
40A :C133 I . . I
IGNITION
SWITCH 2 ® A 'FUSE BLOCK
C180
L I I
•Al 12RD-
C241
V6
16DB
BK
INTERMITTENT WIPER SWITCH

(PART OF MULTI-FUNCTION SWITCH)
i
I /
| OFF DELAY
8
« H I
off>
DELAY
1
J_Z
2 D £JJJY
• HI
^WASHER 1
S W I T C
OFF#
V <ty
( v N I
ON I
#0N JJ
L_7 2 4 3 C210
V6
V3 V9 V3 V8 V10
18BR 18WT 18BR 16DB 18BR
18VT
WT BK WT B K
S202
8W-70-22
V4 V6 V6
V3
18BR 16RD 18DB 16DB
WT YL BK BK
k - -x :i33
^ C O J
T
V4
rV6
V3
18BR 16RD 18DB
WT YL BK
V7 V9 V6
Vi7 V8 V10
18D6 18WT 18DB
18DG 18VT 18BR
WT BK BK
INTERMITTENT INTERMITTENT
WIPER MOTOR WIPER MOTOR
(8W-53-3) (8W-53-3) ViO 18BR
C219 C133
6 7 1 8 3 2
PARK DELAY DELAY DELAY IGN WASH VIO
SWITCH 18BR
OUTPUT
(ACC/RUN)
(TOP REAR CENTER OF I . P . )
INTERMITTENT WIPER CONTROL MODULE J958W-9

B R BATTERY 8W-53 WIPERS 8W - 53 - 3
POSITIVE
TERMINAL m m % j e a
POWER
C212
f DISTRIBUTION Al 12RD
AO CENTER » A 3 ! 12BK/WT
6RD ~
-ir
FUSE
FUSE 3 START BLOCK
40A C133
IGNITION
SWITCH
C180
•Al 12RD-
V6 18DB/BK•
cm i INTERMITTENT
V5 18D6/YL-
PARK
I WIPER CONTROL
INTERMITTENT I MODULE
WIPER SWITCH I (TOP REAR
(8W-53-2) CENTER OF I . P . )
GND |
L.__5-_J
:C2i9
["LOW WASHER"!
FLUID, instrument
I INDICATOR I CLUSTER
i LAMP j
1 1
8
i I
y C21S
G29
22BK
TN
OQ7 -jvcm
629
WINDSHIELD 18BK
WASHER TN
PUMP
MOTOR C108
(BOTTOM
OF
WASHER
INTERMITTENT
n
BOTTLE)
WIPER MOTOR C107
Zl
18BK
i B8W-70-7
US
V10
Zl 18BR
16BK
G106
° |8W-15-4
J958W-9
BR 8W-54 TRAILER TOW 8W - 54 - 1
TRAILER TOW
TRAILER TOW • A6 for a battery feed
The trailer tow package consists of a relay located • L76 for a battery feed from the trailer tow relay
in the Power Distribution Center (PDC), a trailer tow • LI as a reverse lamp input
connector, and an electric brake provision. • L62 for the right turn signal
• L63 for the left turn signal
TRAILER TOW RELAY • Z13 for a ground
The trailer tow relay located in the Power Distribu • B40 for the electric brake provision
tion Center (PDC) is supplied power for the contact
side on circuit A6. This circuit is protected by a 30 HELPFUL INFORMATION
amp fuse located in cavity .7 of the PDC and spliced • Check the 30 amp fuse located in cavity 7 of the
to provide power to the trailer tow connector. PDC
Power for the coil side of the relay is supplied on • Check the grounding location for circuit Z13.
circuit L7. This circuit is HOT when the headlamp
switch is in the PARK or ON position. Ground for the DIAGRAM INDEI
coil side of the relay is supplied on circuit Zl.
When the relay is energized, the contacts in the re Component . Page
lay CLOSE connecting circuits A6 and L76. Circuit
Fuse 7 (PDC) .8W-54-2
L76 connects from the relay to the trailer tow con
Trailer Tow Relay 8W-54-2
nector.
Trailer Tow Connector 8W-54-2
Electric Brake Provision 8W-54-2
TRAILER TOW CONNECTOR
The following circuits connect to the trailer tow
connector:
8W • 54 - 2 8W-54 TRAILER TOW BR
BATTERY
POSITIVE
TERMINAL POWER
AO DISTRIBUTION
6RD
CENTER
30
7 FUSE
30A
7
87
86 85
TRAILER
TOW RELAY
C180
Ai A6 17 176
MRD 20BK Zl
MRD 14BK
TN YL 20BK
TN OR
15111
8W-70-8 Ct29
A6 14RD/TN—)>-
SPLICE SPLICE A6 SPLICE SPLICE

S316 S313 S106 S108
(8W-70-35) (8W-70-34) 14RD (8W-70-3)
TN (8W-70-4)
€331 cm
L76 14BK/0R L76 14BK/0R-
-<f-
L63
18DG ^ ELECTRIC
RD SPLICE S315
(SW-70-35) I BRAKE
I PROVISION
— 1 — ( B O T T O M LEFT
j OF L P . )
B40
14LB SPLICE S 3 1 2
L63 (8W-70-34)
18DG C331 CX29
RD
B40 Z13
14LB 12BK
.£221
140 14LB
TRAILER
TOW
CONNECTOR
Z13 128K-
J958W-9
8W-60 POWER WINDOWS 8W - 60 - 1
POWER WINDOWS
POWER WINDOWS The ground is passed through the switch on a bus
The power window system is supplied power from bar to circuit Q16. Circuit Q16 then connects to the
the 30 amp circuit breaker located behind the fuse master switch. The ground is passed through the
block. Power for the circuit breaker is supplied on switch to ground on the Z3 circuit.
circuit A22 from the ignition switch. This circuit is When window UP operation is selected, the power
HOT when the ignition switch is in the RUN posi and ground circuits are reversed. Circuits Q16 and
tion. Q12 are the feeds and circuits Q22 and Q26 are the
Power for the A22 circuit is supplied by the A2 cir grounds.
cuit which is HOT at all times and protected by a 40
amp fuse located in the Power Distribution Center RIGHT WINDOW SWITCH OPERATION
(PDC), cavity 2. When the window switch is moved to the window
Circuit F21 connects from the circuit breaker to DOWN position, voltage is supplied on the F21 cir
both window switches. Circuit F21 is the feed for the cuit through the closed contacts in the switch to the
switches. Both switches use a bus bar to provide Q22 circuit. The Q22 circuit connects from the switch
power for the different functions of the switch. to the right front window motor. Grounding is pro
The ground path for the system is through the vided on circuit Q12 from the motor back to the
master window switch on the Z3 circuit. switch. The ground is passed through the switch to
the Q16 circuit. The Q16 circuit connects from the
MASTER WINDOW SWITCH (LEFT WINDOW
right switch to the master switch. Ground is passed
OPERATION)
through the master switch to ground on the Z3 cir
When the window switch is moved to the window
DOWN position, voltage is supplied on the F21 cir cuit.
cuit through the closed contacts in the switch to the When window UP operation is selected, the power
Q21 circuit. The Q21 circuit connects from the switch and ground circuits are reversed. Circuit Q12 is the
to the left front window motor. Grounding is provided feed and circuits Q22 and Q26 are the ground.
on circuit Qll from the motor back to the switch.
The ground is passed through the switch to ground HELPFUL INFORMATION
on the Z3 circuit. • Check the 40 amp fuse located cavity 2 of the PDC
When window UP operation is selected, the power • Check the 30 amp circuit breaker located in the
and ground circuits are reversed. Circuit Qll is the fuse block
feed and circuit Q21 is the ground. • Check the ground for the power window system
M A S T E R WINDOW SWITCH (RIGHT WINDOW DIAGRAM INDEX
OPERATION)
When the window switch is moved to the window Component Page
DOWN position, voltage is supplied on the F21 cir
Circuit Breaker 8W-60-2, 3
cuit through the closed contacts in the switch to the
Fuse 2 (PDC) .8W-60-2, 3
Q26 circuit. The Q26 circuit connects from the mas Ignition Switch 8W-60-2, 3
ter switch to the right window switch. A bus bar in Power Window Motor 8W-60-2, 3
ternal to the right switch passes the voltage through Power Window Switch 8W-60-2, 3
the switch to circuit Q22. Circuit Q22 connects from
the switch to the right window motor. Grounding is
provided on circuit Q12 from the motor back to the
right switch.
8W - 60 - 2 8W-60 POWER WINDOWS B R
BATTERY
POSITIVE
TERMINAL
T POWER IGNITION
AG DISTRIBUTION SWITCH
6RD CENTER 1 ' 1
T
I «ACC
I S201
caial I _ôff
C212 BM - 70-22-
FUSE 2
40A A22 12BK/0R-
(4) |
O-x •START !3) A22
12BK
A2 i OR
C180 12PK
BK C241
A2 I
12PK
f
#—— A2 12PK/BK
C133
)}-
FUSE
BLOCK
CB1
30A I
1
S146 S2I4
RIGHT DOOR
8W-70-29
^€241
8W-70-20 POWER WINDOW
SWITCH F21 14TN F21 14TN
(8W-60-3)
F2I
LEFT 14TN
POWER WINDOW
SWITCH
LEFT POWER
C3IS WINDOW MOTOR
) V - — F2i 14TN
,(2)
UP
)i——
(4)
O i l 14LB
LEFT
-# %
^71]— 021 l4WT
# DOWN
UP
C207 C239
) ) — 016 14BR/WT ~(( 016 14BR/WT )) Q16 14BR/WT
(6)
RIGHT
v!
13 1 4 B K / 0 R
%s)— "
2 6 14VT/WT
^77) " ° "~7 ((——026 14VT/WT )) 026 14VT/WT
- # DOWN
S306
8W-70-32
13
14BK
OR
f G3Q2
=±zr 18 W - 1 S - 81
J958W-9
BR 8W-60 POWER WINDOWS 8W - 60 - 3
3ATTERY
POSITIVE
TERMINAL
POWER IGNITION
AO DISTRlBtfTIOH SWITCH
6RD CENTER r
.ACC
C212
S20I
OFF
C212 8W-70-22
-<(" RUN
•A22 12BK/0R
(4)
sM #START (3) A22
12BK
OR
A2
12PK
BK C241
1
FUSE CB1 |
C133
BLOCK 3QA |
A2 12PK/BK ))—
S146 S
8W-70-20 C241
S2I4
LEFT DOOR 8W-70-29
POWER WINDOW
SWITCH F21 14TN- F21 14TN
(8W-60-2)
F21
14TN
C239
F21
14TN
(3)-
C326
R I G H T POWER
WINDOW MOTOR
-#UP
C326 C32S
012 14BR
(4)
I
QJ6 14BR/WT
026 14VT/WT • » 7 — 022 14VT

(5)
- # DOWN
V _ /
RIGHT
POWER WINDOW
SWITCH
J958W-9
BR 8W-61 POWER DOOR LOCKS 8W - 6 1 - 1
POWER DOOR LOCKS

POWER DOOR LOCKS R I G H T D O O R SWITCH O P E R A T I O N (LOCK)
The Power D i s t r i b u t i o n Center (PDC) supplies volt W h e n the switch is moved to the L O C K position,
age to the fuse block f r o m the 50 amp fuse located i n voltage is supplied to the P33 circuit, and t h e n to t h e
cavity 1 on circuit A 7 . Fust 19, located i n the fuse door lock motors. The ground p a t h is provided on t h e
block, supplies battery voltage on the F35 circuit to P34 circuit back to the r i g h t door switch. The ground
both door lock switches. is passed through the switch i n t e r n a l bus bar to t h e
The ground p a t h for the system is t h r o u g h the left P36 circuit. The P36 circuit goes to the left door
door lock switch on the Z3 circuit. switch and through to ground on circuit Z3.
L E F T DOOR SWITCH O P E R A T I O N (LOCK) R I O H T DOOR SWITCH OPERATION (UNLOCK)

W h e n the door lock switch is moved to the L O C K W h e n the switch is moved to the U N L O C K position
position, voltage is supplied on the P35 circuit to the voltage is supplied to the P34 circuit f r o m the switch
bus bar located inside the r i g h t door switch, lock to the door U N L O C K side of the motors. The ground
side. B a t t e r y voltage is passed through the switch to i n g p a t h is through the L O C K side of the motors, cir
the P33 circuit to the door motors. Grounding is pro
cuit P33, back to the switch. The ground continues
vided t h r o u g h the P34 circuit for both door motors
t h r o u g h the i n t e r n a l bus bar of the switch on circuit
back to the r i g h t door switch. The ground is passed
P35 to the left door switch. A t the left door switch,
t h r o u g h the bus bar i n t e r n a l to the switch, U N L O C K
the ground passes t h r o u g h t h a t switches i n t e r n a l bus
side, to the P36 circuit. The P36 circuit goes to the
bar to ground on circuit Z3.
left front switch to a bus bar, i n t e r n a l to the switch,
and t h e n to the Z3 circuit. The Z3 circuit provides
HELPFUL INFORMATION
ground.
• Check the 50 amp fuse i n cavity 1 of the PDC.
LEFT D O O R SWITCH OPERATION (UNLOCK) • Check the 20 amp fuse i n cavity 19 of the fuse
W h e n the switch is moved to the U N L O C K posi block.
tion, voltage is supplied on the P36 circuit to the
r i g h t door switch, unlock side. The battery voltage is DIAGRAM INDEX
passed through the switch i n t e r n a l bus bar to the
P34 circuit. The P34 circuit t h e n goes to the door mo Component Page
tors on the unlock side. Grounding for the U N L O C K Fuse 1 (PDC) .8W-61-2, 3
function is provided by the P33 circuit. Fuse 19 . . . . . . . . .8W-61-2, 3
The P33 circuit goes back to the r i g h t door switch, Lett Door Lock Switch .8W-61-2
L O C K side, and passes through the i n t e r n a l bus bar Right Door Lock Switch .8W-61-2
to the P35 circuit. The P35 circuit goes back to the Door Lock Motors 8W-61-2
left door switch, and passes through the switch to
ground on circuit Z3.
8W - 61 - 2 8W-61 POWER DOOR LOCKS BR
BATTERY
POSITIVE AO 6RD—Hflr^^K^)) A7 10RD/BK • A7 12RD/BK 1
TERMINAL
8W-70-21
I FUSE 1 I
j 50A_ _____ J
POWER
DISTRIBUTION RIGHT DOOR
CENTER LOCK SWITCH
(8W-61-3)
F35
16RD
^cm
F35
IBRD
C207
F35 16RD F35 IBRD
S21G
F35 8W-70-30
MRD
(3) C315
*—# UNLOCK
C315 C315 C20? C239
Z3 14BK/0R
<5)i t ) > — P36 1 6 P K / V T — P 3 6

(4)
I
1 6 P K / V T — » — P36 16PK/VT
S306 1
8W-70-32 1
Z3 14BK/0R— P35 1 6 0 R / V T — ( f - P35 160R/VT - » — P35 160R/VT
<2)
- * LOCK
Z3 LEFT POOf
14BK LOCK SWITCH
OS
f G302
ley- 15-sl
J958W-9
BR 8W-61 POWER DOOR LOCKS 8W - 61 - 3
C180
BATTERY
POSITIVE -AO 6RD—p-<( ^rr$—^ IORD/BK—< A7 12RD/BK
TERMINAL
SI47
, FUSE I , 8W-70-21
SOA J
POWER
•1ST* i t - m e w
CENTER LEFT DOOR
LOCK SWITCH
t
(8W-61-2)
F35
MRD
^ C207
F35
16RD
C239
F35 16RD —(( F35 16RD F35 IBRD
S216
8W-70-30
(3) C325
- # UNLOCK
S310
C325 C32S »W-70-33
P36 16PK/YT ({ »—P34 16PK/BK • - # - P 3 4 16PK/BK—|
|2)l
P34
16PK
BK
I S309
f CT-70-33
P35 160R/VT— ) ) ^ y P33 1B0R/BK — { -P33 1 6 0 R / B K —
LOCK
P33 P34
160R 16PK
BK BK
RIGHT D O S *
LOCK SWITCH
C239
P33 P34
160R 16PK
BK BK
LEFT FRONT
DOOR LOCK MOTOR
C207
UNLK LK
cm
L— P34 1 6 P K / B K —
(2)' O n
— P33 1 6 0 R / B K(—I )r K i r
J958W-9
BR 8W-62 POWER MIRRORS 8W - 62 - 1
POWER MIRRORS
POWER MIRRORS If a RIGHT door mirror movement LEFT is se
The power mirrors use a single switch located in lected, voltage is supplied through the P74 circuit
the left door trim panel. The feed for the system is and the ground is passed through circuit P70. When
supplied on circuit Ml from the 15 amp Ignition-Off the left door mirror RIGHT movement is selected,
Draw (IOD) fuse located in the fuse block cavity 17. the power and ground are reversed.
This fuse also supplies power for the radio, interior
lamps and other components. Grounding for the HELPFUL INFORMATION
power mirrors is provided through the Z3 circuit. • Check the IOD fuse located in the fuse block
• Circuit Ml supplies voltage to the radio, cargo
SWITCH AND mmmom O P E R A T I O N lamp, dome lamp, time delay relay, glove box lamp,
The power mirror switch has a right and a left po and vanity lamps. Check for proper operation of
sition. Moving the switch to either of these positions these items
changes the voltage path internal to the switch • Move the switch to its various positions and listen
(changes polarity at the motors). for the motors to click or try to move. Some move
When the switch is moved to the LEFT position
ment or clicking indicates a poor connection or a me
and mirror movement UP is selected, voltage is sup
plied through the P75 circuit and the ground path is chanical problem with a mirror
through circuit P73. When the DOWN movement is • Check the ground for the power mirror switch
selected, the power and ground are reversed.
If a LEFT door mirror movement LEFT is selected, DIAGRAM INDEX
voltage is supplied through the P71 circuit and the
ground is passed through circuit P73. When the left Component Page
door mirror RIGHT movement is selected, the power Fuse 1 (PDC) 8W-62-2
and ground are reversed. Fuse 17 8W-62-2
When the switch is moved to the RIGHT position Power Mirror Motors 8W-62-2
and mirror movement UP is selected, voltage is sup Power Mirror Switch 8W-62-2
plied through the P72 circuit and the ground path is
through circuit P70. When the DOWN movement is
selected, the power and ground are reversed.
8W - 62 - 2 8W-62 POWER MIRRORS BR
BATTERY
POSITIVE
TERMINAL S147
C180 8W-70-21 C133 S204
-AO 6RD- -»- - » — A7 10RD/BK •A7 12RD/BK ))—A7 12RD/BK + 18W-70-24
FUSE 1
SOA
i . J
POWER
DISTRIBUTION
CENTER
S20S
C201 8W-70-25 C241 R\L .7
15A I BLOCK
Mi 20PK )>- -Ml 20PK- •Ml 18PK — -<f
I I
C31Q POWER MIRROR SWITCH
€310
13
18BK
OR
S306
• 8W-70-32.
1
Z3
14BK
0R C310
i 1 G302 P75 P72

P70 P74
20DB 20YL 20YL
8W-15-8 20WT 20DB
WT ' BK PK
P72
20YL
BK
C201 C201 C201
P72 f?5 P70 F71

20YL 20DB 20WT 20YL 20DB
BK WT P72 20YL/BK-
:C240 VERTICAL C240 C24Q VERTICAL

(2)
C311 P74 (3)f

20DB 1
DN
C322
(3)
PTO
OTI x
LT — ' RT
20WT
£122<f I T
L f V - ^ T 1(2)
P72 HORIZONTAL HORIZONTAL^
20YL P71 k
BK 20YL LEFT POWER RIGHT ROWER

MIRROR MOTORS MIRROR MOTORS
P70 20WT
J958W-9
BR 8W-63 POWER SEAT 8W - 63 - 1
POWER SEAT
GENERAL INFORMATION For HORIZONTAL REARWARD function the cir
The power seat system is protected by a 20 amp cuits are reversed. PI7 is the feed, and P15 is the
circuit breaker located in cavity CB2 of the fuse ground.
block. This circuit breaker is HOT at all times. Cir When the operator selects the REAR VERTICAL
cuit A7 is the power supply for the circuit breaker. UP function, power is passed on the F37 circuit
The A7 circuit originates in the Power Distribution through the closed contacts in the switch to the P l l
Center (PDC) and is protected by a 50 amp fuse lo circuit. The P l l circuit connects to the motor. Ground
cated in cavity 1. is provided on the PI3 circuit back to the switch. A
Circuit F37 is the feed for the switches and the ground BUS bar internal to the switch then connects
seat motors from the circuit breaker. A BUS bar in to the Z3 circuit.
ternal to the switches feeds all the contacts. Ground For VERTICAL DOWN function the circuits are re
ing for the seats is provided on circuit Z3. versed. P13 is the feed, and P l l is the ground.
DRIVER'S SEAT HELPFUL INFORMATION
When the operator selects the FRONT VERTICAL
UP function, power is passed on the F37 circuit • Check the 20 amp circuit breaker in located in
through the closed contacts in the switch to the P19 cavity CB2 of the fuse block
circuit. The P19 circuit connects to the motor. • Check the 50 amp fuse located in cavity 1 of the
Ground is provided on the P21 circuit back to the PDC
switch. A ground BUS bar internal to the switch then
connects it to ground on the Z3 circuit. DIAGRAM INDEX
For FRONT VERTICAL DOWN function the cir
cuits are reversed. P21 is the feed, and P19 is the CompojSjnj_ ^ „ _ _ Page
ground. Circuit Breaker 8W-63-2
When the operator selects the HORIZONTAL FOR Fuse 1 (PDC) 8W-63-2
WARD function, power is passed on the F37 circuit Power Seat Motors . . . . . . . . . . . . . . . . . . . . . . JW-63-2
through the closed contacts in the switch to the P15 Power Seat Switch .8W-63-2
circuit. The P15 circuit connects to the motor.
Ground is provided on the PI7 circuit back to the
switch. A ground BUS bar internal to the switch then
connects to the Z3 circuit.
8 W - 63 - 2 8W-63 POWER SE1T BR
BATTERY POWER
POSITIVE DISTRIBUTION
TERMINAL
f CENTER
S147
iciao 8W-70-21 C133 S204
AO 6RD |H^f#Ay^K)>~f-)>— A7 1 0 R D / B K — # A7 12RD/BK )> A7 12RD/BK - j|8W~70~24
FUSE 1
50A
POWER SEAT SWITCH

C431
—<f
23
14BK J
OR VERT VERT
UP DOWN
:C303
23 L—^h-X
14BK
m R€AR HEAR FRTi FRT
UP UP DOWN
i 6301 DOWN
4 4
AFT f Ifwd
8W-I5-8
t.
C431
P17 P15 Pll P13 PIS P21

14DB 14YL 14YL 14RD 14YL 14RD
RD LB WT WT LG L6
(2) C428 (2) C429 (2) C430
r d REAR/ FRONT
O FORWARD/
VERTICAL
r \ BACKWARD r n UP/DOWN
M
( ) SEAT
V J SEAT
MOTOR
MOTOR
( ) . SEAT
MOTOR
I V
(1) ^ C 4 2 8 J) Y C428 ;i)^C430
J958W-9
BR 8W-70 SPLICE INFORMATION 8W - 7 0 - 1
SPLICE INFORMATION
GENERAL INFORMATION the systems they affect are referenced. For viewing
This section identifies all splices shown in the dia the location of each splice in the vehicle, refer to Sec
grams. It also shows the splices in their entirety. All tion 8W-95.
circuits that are part of the splices are shown, and
SPLICE INDEX
Component Component Page

5101 . .8W-70-2 S201 8W-70-22
5102 8W-70-2 5202 8W-70-22
5103 8W-70-2 5203 8W-70-23
5104 8W-70-2 5204 8W-70-24
5105 8W-70-3 5205 8W-70-25
5106 8W-70-3 5206 8W-70-26
5107 8W-70-3 S207 8W-70-26
5108 8W-70-4 5208 8W-70-27
S109 8W-70-4 5209 8W-70-27
5110 8W-70-5 S210 8W-70-28
5111 8W-70-5 S211 8W-70-28
5112 8W-70-6 S212 8W-70-28
5113 8W-70-6 S213 8W-70-29
5114 8W-70-6 S214 8W-70-29
5115 8W-70-7 S215 . . 8W-70-29
5116 8W-70-7 S216 8W-70-30
5117 8W-70-8 S217 8W-70-30
5118 8W-70-8 S218 8W-70-30
5119 8W-70-8 S301 8W-70-30
5120 8W-70-9 5302 8W-70-30
5121 8W-70-9 5303 8W-70-31
S122 8W-70-10 5304 8W-70-31
S123 8W-70-10 5305 8W-70-31
S124 8W-70-10 5306 8W-70-32
S125 8W-70-10 5307 8W-70-32
S126 8W-70-11 5308 8W-70-32
S127 8W-70-11 5309 8W-70-33
S128 8W-70-11 S310 8W-70-33
S129 8W-70-12 S311 8W-70-33
S130 8W-70-12 S312 8W-70-34
S131 8W-70-13 S313 8W-70-34
S132 8W-70-13 S314 8W-70-35
S133 8W-70-14 S315 8W-70-35
S134 8W-70-14 S316 8W-70-35
S135 8W-70-15 S317 8W-70-36
S136 .8W-70-16 S318 8W-70-36
S137 . .8W-70-17 S319 8W-70-36
S138 8W-70-17 S320 . 8W-70-37
S139 8W-70-18 S401 8W-70-37
S140 8W-70-19 5402 8W-70-37
S141 8W-70-19 5403 8W-70-37
S142 8W-70-19 5404 8W-70-37
S143 8W-70-20 5405 8W-70-38
S144 8W-70-20 5406 8W-70-38
S145 8W-70-20 5407 8W-70-38
S146 8W-70-20 5408 8W-70-38
S147 8W-70-21 5409 8W-70-39
S148 8W-70-21
S149 8W-70-21
8W 70-2 8W-70 SPLICE INFORMATION BR
c p l t c e RIGHT PARI A i l
SlOi * L7 20BK/YL • L7 18BK/YL — T U R N SIGNAL LAMP

S
(8W .7°0-3) (8W-50-5)
S102 TURN SIGNAL

RIGHT PARK AND HAZARD
AMP TURN ~ -L60 18L6/TN I - L 6 0 20TN/BK )>-L60 20TN/BK FLASHER SWITCH
SIGNAL LAMP (8W-52-3)
(8W-50-5) C133
I I GROUND
| GROUND | jam
L _ _ | I
f
Zl
18BK
C123
C106 RIGHT PARK AND

5103 TURN SIGNAL LAMP
PTO OR
4 X 4 SWITCH Zl 18BK )> Zl 20BK- - Z l 18BK- - (8W-50-5)
(8W-31-3)
C1Q5 WINDSHIELD
SPLICE
S409 Zl 1 8 B K — » Z l 20BK- -Zl 20BK- m WASHER
Zl PUMP MOTOR
(8W-70-39)
18BK (8W-53-3)
G102
|8W15-3|
C1Q5
FOG LAMP
RELAY 2 j L39 20LB » L39 20LB •
(8W-50-6) FOG
LAMPS
(8W-50-7)
S104 C1Q5
-L39 20LB- • L39 20LB » L39 20LB •
C133
L39 20LB « L39 20LB
f
FOG LAMP
SWITCH
(8W-50-7)
J958H-9
BR 8W-70 SPLICE INFORMATION 8W - 70 - 3
ANTI-LOCK
BRAKE SYSTEM
CONTROL MODULE
PTO OR C 1 2 1 [~
4X4 S W I T C H 4WD
(8W-31-3) G107 20BK/GY —<f"8 SWITCH
OUTPUT
I
J
G107
18BK
GY
C215
ctos C133
4WD
—(( G107 20BK/GY • • — G 1 0 7 20BK/GY • G107 22BK/GY (f-J 2 SWITCH
OUTPUT
5105
(ABS ONLY)
INSTRUMENT
CLUSTER
JOINT
CONNECTOR A
C133 C217
LEFT PARK PARK I
AND TURN - -L7 18BK/YL -L7 18BK/YL » — L7 18BK/YL —(£—! 4 SWITCH
SIGNAL LAMP | OUTPUT
(8W-50-5) J
C128 S106
SPLICE TRAILER TOW
S314 - * - - L 7 I8BK/YL - ) ) — L 7 18BK/YL L7 20BK/YL RELAY
(8W-70-35) (8W-54-2)
L7 20BK/YL• SPLICE S 1 0 1
(8W-70-2)
C133
FOG LAMP ^ ~
RELAY 1 L7 20BK/YL - » — L 7 20BK/YL
(8W-50-6)
DAYTIME RUNNING
LAMPS MODULE
F
C131 HEADLAMP ~*
I,. SWITCH I
-L4 16VT/WT j t v
OUTPUT j
1 1
(LOW)
i . : i
LEFT S107 RIGHT
HEADLAMP • -L4 16VT/WT L4 16VT/WT HEADLAMP
(8W-50-3) (8W-50-3)
HEADLAMP C133
DIMMER 1 4
SWITCH ^ ~ l^VT/WT — < f - L 4 16VT/WT
(8W-50-2)
J958W-9
-70-4 8W-70 SPLICE INFORMATION BR
LOW TRAILER
WASHER FLUID ASS WARNING TOW RELAY
LEVEL SWITCH LAMP RELAY (8W-11-4,
(8W-53-3) (8W-11-8) 8W-54-2)
Zi 18BK Zl 20BK
VEHICLE SPEED SHI r - - 1

CONTROL S E R V O S Zl 2011 Zi 18BK
(8W-33-2)
I I ~GND I
Zl 18BK- — _ J
I J
DAYTIME RUNNING
GND 4 - » — — - Z l 12BK LAMPS MgPULE
I I
£1M
^ b r [8W-15-21
VACUUM
SENSOR G9 20GY/BK•
(8W-32-5.
8W-32-12)
mmi
BRAKE HSfi CONNECTOR_C
WARNING
SWITCH " •G9 16GY/BK
(8W-32-5. CtlJ C1Q8 f BRAKE 1
W N G
8W-32-12) G9 2QGY/BK )>—G9 22GY/BK—<f-26 yf p M
1
DRIVER '
cm !, BRAKE ,I
WARNING I
69 20GY/BK —<i 1
25 LAMP
DRIVER
I
J
ANTI-LOCK
BRAKE SYSTEM
COMTROL MODULE
J958W-9
BR 8W-70 SPLICE INFORMATION 8W - 70 - S
• H O T AT ALL T I M E S 4
1
4
FUSE BLOCK <s on
20A |
I
^C24I
ANTI-LOCK
BRAKE SYSTEM A20
CONTROL MODULE 18RD
DB
I ~ 1
cm C133
12 -A20 18RD/DB A20 18RD/DB » —
VACUUM SENSOR
FUSED
IGNITION
17 3 -A20 18RD/DB A20 18RD/DB * (8W-32-12)
SWITCH H
OUTPUT
(RUN) -A20 18RD/DB
ABS PUMP RELAY
A20 18RD/DB ^ (8W-U-6.
8W-32-9)
-A20 18RD/DB
21 -A20 18RD/DB
JOINT
CONNECTOR C
C2Q9 T STOP 1
C133
j V40 20WT/PK ((—V40 22WT/PK ( £ - 31 yfjq

$
OUTPUT
H
J
STOP LAMP
SWITCH 9 - ) ) -V40 20WT/PK Sill
OUTPUT POWERTRAIN
l I CONTROL MODULE
C125 C135 STOP

1 L A M P
V40 22WT/PK ((—V40 20WT/PK ( f - 29
SWITCH I
^ OUTPUT J
J958W-9
8W - 70 - 6 8W-70 SPLICE INFORMATION £13
ANTI-LOCK
BRAKE SYSTEM
CONTROL MODULE
£1111 PUMP/MOTOR I
B120 14BR/WT ( f - 34 RELAY
I OUTPUT I
I . J
ANTI-LOCK -B120 12BR/WT
BRAKE SYSTEM S112
PUMP/VALVE REAR ANTI-LOCK
-B120 12BR/WT B120 12BR/WT
ASSEMBLY VALVE
(8W-32-10) (8W-32-9)
-BI20 12BR/WT
ABS PUMP RELAY
B 1 2 0 12BR/WT (8W-11-6)
C125
FUEL SHUT
T40 1 2 B R — » - T40 12BR DOWN RELAY
(8W-30-45)
ENGINE C119
STARTER ENGINE
MOTOR RELAY T40 12BR- T40 1 2 B R — » T 4 0 12BR- STARTER
(8W-11-7) S113 MOTOR
(8W-21-2)
DIESEL ENGINE
ONLY
• HOT AT ALL T I M E S 4
I 1
1
Ys 'FUSE BLOCK
|Ci0A |
L| 1
:
C241 C126
S E
| F 1 8 18LG/BK » — F 1 8 18LG/BK §o|
(8W-70-13)
F 1 8
22LG
BK
S114 FUEL PUMP

- ( { — F 1 8 20LG/BK- F18 20LG/BK RELAY
C133 (8W-11-8)
AUTOMATIC
SHUT DOWN A / C COMPRESSOR
F 1 8 20LG/BK• F 1 8 20LG/BK
RELAY CLUTCH RELAY
(8W-11-4) (8W-11-5)
J958W-9
8W-70 SPLICE INFORMATION 8W - 70 - 7
UNDERHOOD
LAMP
(8W-44-6)
GROUND
JOINT Zl
20BK
C183
Zl 18BK ) NO CONNECTION
GND I
C123
INTERMITTENT
Zl 12BK Zl 18BK- WIPER MOTOR
(8W-53-3)
-DIESEL ENGINE
Z13 12BK
ONLY
Z13 16BK
Zl 14BK-
SilS WITH
Zl 18BK TRAILER
TOW
LEFT
HEADLAMP
(8W-50-3)
Zl Zl Zl Zl Zl
Zl GAS- 14BK 12BK 16BK 12BK
16BK
18BK ENGINE
ONLY
-Zl 20BK
# G104 G105 G106
8W-15-4 8W-15-4 8W-15-4
SPLICE S311
(8W-70-23)
FUEL TANK LEVEL C125

SPLICE
GAUGE SENDING U N I T Zll 16BK/WT Zll 16BK/WT i S140
(8W-30-48) (8W-70-19)
Zll
20BK
WT
C128 C133
S116 SPLICE
Zll 20BK/WT• Zll 18BK/WT^—» Z l l 18BK/WT S208
(8W-70-27)
J958W-9
8W - 70 - i, 8W-70 SPLICE INFORMATION
PARK/NEUTRAL C20S DAY/NIGHT
f
POSITION AUTOMATIC L I 22VT/BK- • L I 22VT/BK- MIRROR
SWITCH TRANSMISSION (8W-44-7)
(8W-31-5) C133
LI
18VT
BK
x C128 | S117 C126
BACK-UP \ " ' I ^ ~ SPLICE
LAMP • - L i 1 8 V T / B K — ~ J \ \ — L I 18VT/BK ®—Li 18VT/BK ))— L I 18VT/BK S313
SWITCH (8W-70-34)
(8W-31-5) TRAILER
I—MANUAL TOW ONLY
TRANSMISSION
DAYTIME RUNNING
LAMPS MODULE
• HOT AT ALL T I M E S ^
1
C131 I 1 1
FUSED e
S
B{+) POWER
SPLICE FUSE 6 I D I S T R I B U T I O N
1
S203 40A | CENTER

(8W-70-23) A3
12RD
LG
C180
C133
A3 12RD/LG ( ( — A 3 12RD/LG A3 12RD/LG
S118
TRAILER TOW TRAILER

CONNECTOR TOW RELAY • HOT AT ALL T I M E S ^
(8W-54-2) (8W-11-4)
POWER
I \ FUSE 7 I D l S T R I B U T I O N
A6 A6 30A CENTER
14RD MRD
TN TN
C18Q
C332 C129 S119
—A6 14RD/TN [(—A6 MRD/TN A6 14RD/TN
J958W-9
BR 8W-70 SPLICE INFORMATION 8W - 70 - S
davtime running
mmmim c LAMPS MODULE '
T FUSED ~j e m | FUSED ,
mm 1
IGNITION
< ^ 29 SWITCH
1
|
IGNITION
SWITCH
1
|
x x
, OUTPUT , OUTPUT I
I (RUN) I I (RUN) J
i
AUTOMATIC-
TRANSMISSION
LIO PARK/NEUTRAL
LIO 18BR
22BR POSITION
LG SWITCH
LG
(8W-31-5)
LIO
18BR
LG
mi -LIO 20BR/LG -LIO 18BR/LG )>^~L10 18BR/LG

BACK-UP
LAMP SWITCH
§U§ cias (8W-31-S)
DRL ONLY
MANUAL-
TRANSMISSION
SPLICE
-634 18RD/GY• S211
M Y T I M E RUNNING (8W-70-28)
LAMPS MODULE
HIGH cm
BEAM
INDICATOR -634 20RD/GY INSTRUMENT
LAMP CLUSTER
DRL ONLY
HEADLAMP cm | HIGH !
SWITCH 0 BEAM I
5
L3 16RD/0R- •634 18RD/GY 2
INDICATOR »
OUTPUT
£133 I LAMP I
634
18RD
GY
S121 HEADLAMP
— L 3 16RD/0R• - ) ) — L3 16RD/0R DIMMER SWITCH
C133 (8W-50-2)
LEFT RIGHT
HEADLAMP L3 16RD/0R L3 16RD/0R HEADLAMP
(8W-50-3) (8W-50-3)
J958W-9
8W - 70 -10 SW-70 SPLICE INFOiiftllON BR
C133
SPLICE S 2 1 2
-Z2 I8BK/LG » — Z2 18BK/LG • ^ (BW-70-S8)
S122
Z2 18BK/LG -Z2 18BK/LG
Z2 Z2
WITH HIGH 18BK I8BK
LINE CLUSTER LG LG
Z2
18BK
LG
Z2 18BK/LG- -Z2 18BK/LG
=
G1Q7
8W-15-4
G103
8W-15-3
C133
T. =•
G202
8W-15-7
LEFT PARK S123 CI33 TURN SIGNAL

AND TURN AND HAZARD
SIGNAL LAMP L61 18LG/TN L61 20LG/YL »—L61 18LG/YL
SWITCH
(8W-50-5) (8W-52-3)
Kl15 18TN INJECTOR # 8

(8W-30-32)
POWERTRAIN
CONTROL MODULE
C135 S124
INJECTOR
# 4 , # 9 15 Kl15 20TN Kl15 18TN- INJECTOR # 4
DRIVER (8W-30-32)
8.0 ENGINE
ONLY
INJECTOR #8
Kl13 18LB/BR (8W-30-31)
S12S
INJECTOR INJECTOR # S
#5, # 8 13 Kl13 20LB/BR- -Kl13 18LB/BR (8W-30-31)
DRIVER
8.0 ENGINE
ONLY
J958W-9
BR 8W-70 SPLICE INFORMATION 8W - 70 -11
INJECTOR # 7
K158 18LG/BK (8W-30-32)
POWERTRAIN
CONTROL MODULE
COS S12G
INJECTOR INJECTOR # 2
02, # 7 58 K158 20L6/BK- K158 18LG/BK (8W-30-32)
DRIVER
8.0 ENGINE
ONLY
INJECTOR #8
Kl14 18YL/WT (8W-30-32)
S127
INJECTOR
#3, #6 14 INJECTOR # 3
Kl14 20YL/WT Kl 14 18YL/WT (8W-30-32)
DRIVER
8.0 ENGINE
ONLY
-Kl16 18WT/DB . INJECTOR #10

(8W-30-31)
S128
INJECTOR
#1, #10 16 INJECTOR # 1
DRIVER
-»- Kl16 20WT/DB -Kl16 18WT/DB (8W-30-31)
8.0 ENGINE
ONLY
J958W-9
8W - 70 - 12 8W-70 SPLICE INFORMATION BR
BR < 8W-7Q SPLICE INFORMATION 8W - 70 -13
C133 C216 VEHICLE

SPEED
67 20WT/0R SENSOR I
' SIGNAL J
INSTRUMENT
CLUSTER
POWERTRAIN
CONTROL MODULE
VEHICLE
SPEED (8W-30-19.
SENSOR 47 8W-30-28.
SIGNAL 8W-30-38,
8W-30-47)
FUSED
IGNITION ,
SWITCH QIv
Y
OUTPUT 77>
(START/RUN)
FUEL SHUT DOWN

SOLENOID
(8W-30-45)
IGNITION
8.0 ENGINE MODULE
ONLY
FUSED I
HEATED INTAKE IGNITION I
AIR SYSTEM SWITCH
RELAY I F18 20LG/BK
OUTPUT I
(8W-30-41) START/RUN) |
HEATED INTAKE
AIR SYSTEM
RELAY 2
(8W-30-42)
ENGINE DATA-LINK
CONNECTOR
FUEL HEATER _ (8W-30-15,
RELAY F18 20LG/BK• 8W-30-24.
(8W-30-45) 8W-30-33.
8W-30-42)
EXHAUST GAS
RECIRCULATION TRANSMISSION
SOLENOID
OVERDRIVE
(8W-30-17. F18 20LG/BK- ' SOLENOID
8W-30-28, (8W-31-2)
8W-30-36)
EVAP/PURGE
SOLENOID
(8W-30-17, ^ SPLICE S I 1 4
F18 18LG/BK (8W-70-6)
8W-30-26.
, 8W-30-36)
J958W-9
-70-14 8W-70 SPLICE INFORMATION BR
INJECTOR #7
(8W-30-22,
8W-30-32)
5 . 2 L . 5 . 9 , AND 8.0L
ENGINES ONLY
INJECTOR #5
(8W-30-13, INJECTOR #8
-A142 16D6/0R A142 14DG/0R
8W-30-22, * (8W-30-32)
8W-30-31)
8.0L ENGINE
ONLY
INJECTOR #3
(8W-30-13,
8W-30-22. * -A 142 16DG/0R
8W-30-32)
S133
INJECTOR # 1 GAS ENGINES ONLY

(8W-30-13. —A142 14DG/0R SPLICE S135
-A142 16DG/0R
8W-30-22, (8W-70-15)
8W-30-31)
A142
14DG
OR
AUTOMATIC
SHUT DOWN C125 RIGHT HEATED
RELAY OXYGEN SENSOR
(8W-11-4. -A142 14DG/0R -A142 14DG/0R > (8W-30-20,
8W-30-20, 8W-30-29
8W-30-29) A142 8W-30-39)
14DG
OR
3 . 9 L . 5 . 2 L , AND 5.9L- - 5 . 2 L . 5 . 9 . AND 8.0L

ENGINES ONLY ENGINES ONLY
LEFT HEATED
OXYGEN SENSOR
(8W-30-29,
8W-30-39)
POWERTRAIN
CONTROL MODULE
I 1
C135
| GENERATOR GENERATOR
FIELD 20 U ) . •K20 18DG K20 18DG (8W-20-2,
CONTROL
S134
iW-20-4)
I
J958W-9
BR 8W-7Q SPLICE INFORMATION 8W - 70 -15
POWERTRAIN
CONTROL MODULE
I 1
INJECTOR #8 C135
(8W-30-23, ASD I
8W-30-31) f » 57 RELAY
I OUTPUT
5 . 2 L . 5 . 9 L . AND 8.0L
I
ENGINES ONLY
INJECTOR # 6
(8W-30-14, ^
8W-30-23, -A142 16DG/0R
8W-30-32) A142 16DG/0R
INJECTOR #4
(8W-30-14. 3 . 9 L . 5 . 2 L , AND 5.9L
8W-30-23, -A142 16DG/0R
ENGINES ONLY
8W-30-32)
S135
INJECTOR #2 GAS ENGINES ONLY
(8W-30-14. „ SPLICE S133
A142 16DG/0R A142 14DG/0R (8W-70-14)
8W-30-23,
8W-30-32)
I G N I T I O N COIL I G N I T I O N COIL
A142 14DG/0R (8W-30-14.
. 4-PACK -A142 14DG/0R 8W-30-23)
(8W-30-34)
IGNITION COIL
6-PACK •A142 14DG/0R
(8W-30-34) GENERATOR
A142 14DG/0R (8W-20-2)
8.0L
ENGINE
ONLY
SPLICE S138
A142 14DG/0R (8W-70-17)
J958W-9
8W - 70 -16 8W-70 SPLICE INFORMATION BR
POWERTRAIN
CONTROL MODULE
VEHICLE
SPEED C135
SENSOR SENSOR
(8W-30-19, !
K4 18BK/LB K4 20BK/LB (f GROUND
8W-30-28,
8W-30-38.
8W-30-47)
WATER-IN-FUEL
THROTTLE SENSOR
POSITION 20BK/LB- (8W-30-46)
SENSOR
(8W-30-18, K4 18BK/LB
8W-30-27, DIESEL
8W-30-37, ENGINE
8W-30-46) ONLY
TRANSMISSION
TEMPERATURE _ ENGINE SPEED
SENSOR ^ K4 18BK/LB 20BK/LB SENSOR
(8W-31-3) (8W-30-47)
K4 16BK/LB
RIGHT HEATED
OXYGEN SENSOR DIESEL ONLY
(8W-30-20, INTAKE AIR
' 8W-30-29, TEMPERATURE
8W-30-39)
t
K4 18BK/LB K4 16BK/LB -« SENSOR
(8W-30-46)
3.9L-
MAP SENSOR ENGINE ONLY N
(8W-30-18, CAMSHAFT
K4 18BK/LB POSITION
8W-30-27, K4 20BK/LB
8W-30-37) SENSOR
GAS- (8W-30-16)
ENGINES
ONLY
LEFT HEATED
SPLICE S 1 2 9 OXYGEN
(8W-70-12) K4 18BK/LB K4 18BK/LB -
SENSOR
(8W-30-29,
5 . 2 L . 5 . 9 L , AND 8.0L- 8W-30-39)
ENGINES ONLY
CAMSHAFT CRANKSHAFT
POSITION POSITION
SENSOR K4 18BK/LB K4 20BK/LB SENSOR
(8W-30-37) (8W-30-18,
8W-30-27)
8.0L ENGINE ONLY- 3 . 9 L . 5 . 2 L , AND 5.9L-
ENGINES ONLY
J958W-9
map S E N S O R
(8W-30-18. KS 18VT/WT-
8W-30-27,
8W-30-37)
POWERTRAIN
CONTROL MODULE
THROTTLE
POSITION cos
SENSOR 5V
K6 18VT/WT K6 20YT/WT OUTPUT
(8W-30-18,
8W-30-27. SQ7
8W-30-37) GAS ENGINES
ONLY
ASD
-A142 16DG/0R 57 RELAY
OUTPUT
SPLICE S133 INJECTOR #10

-A142 14DG/0R A142 16DG/0R- ' (8W-30-31)
(8W-70-14)
aias
8.0L ENGINE
SPLICE S135 ONLY
(8W-70-15) -A142 14DG/0R
A142
I4DG
OR
AUTOMATIC
-A142 I4DG/0R- S H U T DOWN R E L A Y
£12S (8W-30-39)
J958W-9
70-18 8W-70 SPLICE INFORMATION BR
POWERTRAIN
CONTROL MODULE
Zl2 16BK/TN 11 GROUND
Z12 16BK/TN 12 GROUND
MANUAL
TRANSMISSION
IGNITION ONLY
8.0 ENGINE
MODULE ONLY
C137 ZI2 20BK/TN- 30 GROUND
j GROUND
FUEL
HEATER RELAY
Z12 20BK/TN• (8W-30-45)
DIESEL-
ENGINE
ENGINE ONLY
DATA LINK
CONNECTOR FUEL
(8W-30-15. Z12 20BK/TN ^ SHUT DOWN
Z12 18BK/TN RELAY
8W-30-24,
8W-30-33. (8W-30-45)
8W-30-42)
SPLICE S 1 4 2
Z12 14BK/TN (8W-70-14)
ENGINE
COOLANT
ENGINE Z12 20BK/TN TEMPERATURE
STARTER
RELAY
(8W-U-7,
8W-21-2)
-T41 22BK/WT 8.0L
ENGINE
7 SENSOR
(8W-40-5)
ONLY
J958W-9
en 8W-70 SPLICE INFORMATION 8W - 70 - 1 1
LEFT
HEATED
SPLICE sue OXYGEN
Zll 16BK/WT SENSOR
(8W-70-7)
(8W-30-28.
C125 8W-30-39)
5.2L.5.9L,
AND 8.0L
A/C ENGINES
COPRESSOR ONLY
CLUTCH Z t l 18BK/WT Zll 18BK/W
(8M-42-S) GAS
ENGINES
ONLY
• Z l l 16BK/WT Zll 18BK/WT

§ 1 1 1 S14©
3W-I5-5
1
RIGHT
HEATED
OXYGEN
SENSOR
(8W-30-20,
8W-3Q-29.
8W-30-39
ENGINE
STARTER C12S
MOTOR ^_ SPLICE S139
-T41 22BK/WT• -Z12 20BK/TN (8W-70-18)
RELAY
(8W-11-7.
8W-21-2)
T41
20BK
POWERTRAIN WT
CONTROL MODULE
I PARK/NEUTRAL I C135 S141 PARK/NEUTRAL

I POSITION ~ | \ \ POSITION
0 T41 20BK/WT T41 18BK/WT SWITCH
3 0
I SWITCH ri) (8W-31-5)
| SENSE |
i_ . . I
FUEL HEATER
Z12 16BK/TN (8W-30-45)
S142
^ SPLICE S139
Z12 14BK/TN Z12 14BK/TN (8W-70-13)
DIESEL
Gill ONLY
[8W-15-51
J958W-9
8W - 7 0 - 20 8W-70 SPLICE INFORMATION BR
AUTOMATIC
SHUT DOWN
-A142 14DG/0R RELAY
C125 (8W-30-43)
POWERTRAIN A142
CONTROL MODULE 14D6
OR
I ASD | CI3S S143

RELAY 57 GENERATOR
•A142 16DG/0R -A142 14DB-
OUTPUT (8W-20-4)
DIESEL
ONLY
S144
FUEL HEATER
RELAY -A12 14RD/TN •AI2 200R -QO W
HEATER
(8W-30-45) FEED
DIESEL
ONLY
S145
FUEL SHUT rrlFb FUEL SHUT
DOWN RELAY A18 10RD/BK AI8 16DB DOWN FEED
' (8W-30-45)
DIESEL
ONLY
• HOT AT ALL TIMES<^

I 1 1
POWER
TÛ!FUSE 2 I DISTRIBUTION
| * 40A | CENTER
SPLICE
S201
(8W-70-22)
CI80 IGNITION
SWITCH
A22
A2 12BK
12PK ACC OR
BK
S146 OFF
C133 C212 C212
RUN
-A2 12PK/BK )> A2 12PK/BK —«-
(4) (3)
I START
A2
12PK
BK
ENGINE
STARTER
MOTOR
RELAY
(8W-11-7)
J958W-9
8W-70 SPLICE INFORMATION 8W - 70 - 21
FOG LAMP
HORN RELAY
RELAY 1 L38 20LB/BK
(8W-50-6)
(8W-11-5)
C133
L38
F31
20LB
18VT
BK
• HOT AT ALL T I M E S «
POWER
DISTRIBUTION
I C FUSE 1 FUSE A FUSE B l CENTER
I ; soa ISA 2©A I
C180
A7 A7
10RD 12RD
BK BK
| S147
-A7 I2R0/BK
C133
SPLICE S 2 0 4
A7 12RD/BK » A7 12RD/BK • •(8W-70-24)
S148 BATTERY
POSITIVE
•AO 20BK TERMINAL
(8W-20-8. .
8W-20-4)
A15
16BK
POWER
DISTRIBUTION
CENTER
C119 C133
C180 7 U S E ~ C ~ "! C 1 8 0 HAZARD
WARNING
- A 1 5 16BK- -<f#0^^>f)) L9 18BK/TN • -L9 18BK/TN
1 1
\ FLASHER
ISA (8W-52-3)
I l
S149
C183
UNDERHOOD
LAMP - -Ml 20PK- Ml 18PK ~) NO CONNECTION
(8W-44-6)
C133
SPLICE S 2 0 5
Ml 20PK- —» Ml 20PK- (8W-70-25)
J958W-9
8W - 70 - 22 8W-70 SPLICE INFORMATION B R
SPLICE
S146
(8W-70-20)
A2
12PK
BK
C133
IGNITION
SWITCH
FUSE BLOCK
A2
12PK r
A22 12BK/0R
BK
F2
C212 1 OFF
( 30A
Jl C212 S201
-<f I ^RUN
- » — A 2 2 12BK/0R A22 12BK/0R if
(4) CB1
(3)
30A
START
14
20A
-#~—
15
10A
—A22 12BK/0R
C241 16
15A
— J
• HOT IN ACC AND RUN ^

CI33
INTERMITTENT
WIPER MOTOR • V6 18DB/BK <f
FUSE BLOCK l 1
(8W-53-3)
i 20A
20A I
LL C241
1
V6
INTERMITTENT 18DB
WIPER CONTROL BK V6
• ^MilULE 16DB
BK
IGNITION C219
SWITCH S2Q2
OUTPUT 3"))- V6 18DB/BK-
(ACC/RUN)
I
INTERMITTENT
WIPER SWITCH V6 16DB/BK-
(8W-53-2)
J958W-9
8W-70 SPLICE INFORMATION 8W-70-.23
JOINT
CONNECTOR B
C231
FUSED
B + <r»- •F32 18PK/DB-
HEADLAMP
DIMMER SWITCH
(8W-50-2)
F32
18PK
DB
• HOT AT I L L TIMES4 L20

C241 L2
16LG
16LG
FUSE 8 I ^WER WT
( 40 I
A DISTRIBUTION 1
CENTER P 20 FUSE BLOCK
Q , 5 A ^ — -
C180
I 1 :
C206
C241 (7) (2)
r
A3 OFF
12RD A3
12RD i PARK
LG
LG
i
HEAD
C133 C206
•A3 12RD/LG•
8203
-A3 12RD/LG•
—<f
(a)
A3
12RD HEADLAMP
LG SWITCH
A3 12RD/LG SPLICE S118

(8W-70-8)
J958W-9
SW - 71 - 24 8W-70 SPLICE INFORMATION SR
JOINT
CONNECTOR C
FUSED C208 TRANSMISSION POWER

HEADLAMP OVERDRIVE SEAT
SWITCH E2 200R SWITCH SWITCH
OUTPUT (8W-31-2) (8W-63-2)
L I
JOINT
CONNECTOR A
, PARK C217 F37

I LAMP E2
6U>- 14RD
I SWITCH •L7 20BK/YL 200R
1
LB
OUTPUT
I
L7
20BK
HEADLAMP YL
SWITCH
C303
C206 1 OFF
C206 1
PARK 13 FUSE BLOCK
—<f 5A |
(9) F37
(4) HEAD 14RD
C241 LB
- ) > — E l 20TN/0R
(1)
C202
F33
20PK
RD F37
14RD
SPLICE LB
S147
(8W-70-21)
C241 A7
12RD
BK
18 C133
FUSE BLOCK
ISA !
A7
C241 12RD
BK
C241 ,C24A
• A7 12RD/BK A7 12RD/BK F37 14RD/LB-
S204 L CB2 30Aj
FUSE BLOCK
J958W-9
BUZZER JOINT
MODULE CONNECTOR B
£ U B [" "1 C231

// 1 c FUSED 1 ^ J FUSED
(Tj- 6
B(+) |
8
B(+)
I I
1 Ml
if 17 ' FUSE BLOCK

ISA |
I
C241
18PK
SPLICE
S320
(8W-70-37)
* Ml
20PK
Ml
18PK Ml
20PK
Ml 18PK- Ml 18PK-
Ml 20PK- Ml 20PK-
S205
Ml Ml Ml Ml
20PK 20PK 18PK 20PK
Ml
C201 C133 20PK C202 C2Q8
Ml Ml Ml Ml
20PK 20PK 20PK
18PK
POWER SPLICE T I M E DELAY SPLICE OVERHEAD

MIRROR S149 RELAY S303 MAP LAMP
SWITCH (8W-70-21) (8W-44-3) (8W-70-31) (8W-49-4)
(8W-62-2)
J958W-9
SW - 71 - 1 1 8W-70 SPLICE INFORMATION
INTERMITTENT WIPER
COOTiOL. MOOilLE
c m
GND
I
FOG LAMP
SWITCH
(8W-50-7)
•Z3 20BK/0R Z3 20BK/0R
Z3 20BK/0R
ilA§LAHP
SWITCH « Z3 20BK/0R Z3 20BK/0R
(8W-44-3)
SPLICE
S215 i Z3 12BK/0R
(8W-70-29)
L50 18WT/TN
C3Q8
L50 18WT/TN
L50
18WT
TN
C202
L50
18WT
TN
STOP LAMP S2Q7

SWITCH -L50 18WT/TN- L50 18WT/TN
(8W-33-3)
B R - 8W-70 SPLICE INFORMATION —
INSTRUMENT
CLUSTER
GND
OVERHEAP
6
i CONSOLE
C215
zu
20BK
Z l l 20BK/WT-
C338
-«-2 GND j
WT
AIRBAG/ABS
—«s9
DATA L I N K
Z l i 20BK/WT CONNECTOR
(8W-32-11)
C133
Zll 18BK/WT • -<f
Zll
18BK
STOP LAMP. WT
SWITCH 1
Zll 20BK/WT
(8W-33-3)
SPLICE
5118
(8W-70-7)
INSTRUMENT
FUSED CLUSTER
IGNITION
SWITCH r FUSED
OUTPUT
IGNITION I
(START/RUN) 7
«n SWITCH
OUTPUT
I
,
AIRBAG C215 I (START/RUN) I
CONTROL MODULE
FUSED
IGNITION • HOT I N RUN OR START«
SWITCH F14 18LG/YL
F14
OUTPUT | C232 20LG
(START/RUN) YL
FUSE BLOCK
m isA
MESSAGE CENTER C241
FUSED S209
IGNITION
SWITCH 3p»" F14 20LG/YL- F14 18LG/YL
OUTPUT C224
(START/RUN)
J958W-9
8W - 70 - 28 8W-70 SPLICE INFORMATION BR
C133 CI27 SPLICE

-67 22WT/0R -G7 20WT/0R- S131
(8W-70-13)
67
INSTRUMENT 20WT
OR
CLUSTER
VEHICLE j C21B S2tQ
SPEED
SENSOR 4 j-)) 67 20WT/0R
SIGNAL
HIGH i
BEAM , , x SPLICE S 1 2 1
INDICATOR 2 634 18RD/6Y- G34 18RD/6Y- (8W-70-9)
LAMP
634 18RD/6Y-
634 634
18RD 18RD
DAYTIME RUNNING
GY GY
LAMPS MODULE
FOG LAMP S211 cm | mm ~ "!

RELAY 2 BEAM
G34 18RD/6Y •634 18RD/GY
(8W-50-6)
C133
G34 2 0 R D / G Y — < f - 2 TcTT0R
1N0
LAMP
,
I I AMP I
LEFT DOOR RIGHT DOOR SPLICE

SPEAKER ^ Z2 I 8 B K / L G Z2 1 8 B K / L G SPEAKER S122
(PREMIUM) :PREMIUM (8W-70-7)
(8W-47-6) 8W-47
C201
Z2 18BK/L6
RADIO
CHOKE Z2 1 8 B K / L G Z2 18BK/LG
(8W-47-5)
C202 r -Z2 18BK/LG
T
Z2 Z2 1 8 B K / L G
I8BK
LG W/O
PREMIUM
RADIO
SPLICE S 3 0 1
(8W-70-30)
J958W-9
BR 8W-70 SPLICE INFORMATION 8W - 70 - 2S
C202 C201
SPLICE S302 LEFT DOOR
-X13 18BK/RD- -X13 18BK/RD SPEAKER
(8W-70-30)
(8W-47-6)
X13 XI3
18BK 18BK
RD RD
S213 £240
RAOZO CHOKE RIGHT DOOR
(8W-47-5) -X13 18BK/RD X13 1 8 B K / R D — » — X 1 3 18BK/RD SPEAKER
(8W-47-6)
• HOT I N RUN ONLY 4

LEFT DOOR C207
POWER WINDOW
SWITCH
(8W-60-2)
F2I 14TN-
FUSE BLOCK ]T -;C
F21 I m 3M i
14TN I
RIGHT DOOR C241
POWER WINDOW C239 S214
SWITCH F21 14TN F21 14TN- F2t 14TN
(8W-60-3)
CIGAR
LIGHTER i -13 18BK/0R
(8W-41-2)
POWER GLOVE BOX LAMP

OUTLET , • AND SWITCH
(PTO) -23 18BK/0R Z3 16BK/0R
(8W-44-6)
(8W-41-2)
SPLICE
S206 ,
(8W-70-26) 13 12BK/0R Z3 18BK/0R FOG LAMP RELAY 2
(8W-50-6)
TRANSMISSION
OVERDRIVE m
SWITCH Z3 20BK/0R Z3 20BK/0R FOG LAMP SWITCH

(8W-31-2) (8W-50-7)
HEATER SWITCH
OR m Z3 20BK/0R
HVAC SWITCH
(8W-42-3,
8W-42-4)
J958W-9
r
8W - 71 - 3 0 8W-70 SPLICE INFORMATION B R
SPLICE S204
(8W-70-24) " •A7 12RD/BK-
C241
FUSEBLOCK
19
20A I
i
C241
-F35 16RD
C207 C239
LEFT DOOR RIOHT DOOR
LOCK SWITCH •F35 14RD- •F35 16RD- F35 16RD- -F35 16RD- LOCK SWITCH
(8W-61-2) (8W-61-3)
S I 16
BLOWER MOTOR
•C7 12BK/TN . (8W-42-3.
8W-42-4)
HEATER SWITCH
(8W-42-3) S217 BLOWER MOTOR
OR
C7 12BK/TN „ RESISTOR
HVAC SWITCH * C7 12BK/TN (8W-42-3.
(8W-42-4)
8W-42-4)
C202
DOME LAMP
M2 20YL —»~ M2 20YL- (8W-44-3)
JOINT
CONNECTOR A
C183 C133
I COURTESY I
NO CONNECTION f—12 18YL- —« M2 20YL- M2 20YL- —(fHlO LAMP |
| DRIVER j
S218
LEFT REAR
Z2 18BK/LG -*« SPEAKER
(8W-47-6)
C202 S301
SPLICE S 2 1 2 RIGHT REAR
(8W-70-28)' 12 18BK/LG Z2 18BK/LG• Z2 18BK/LG SPEAKER
(8W-47-6)
LEFT REAR
-X13 18BK/RD SPEAKER
(8W-47-6)
C202 S302
SPLICE S 2 1 3 RIGHT REAR
1 X13 18BK/RD » X13 18BK/RD I -X13 18BK/RD• SPEAKER
(8W-70-29)
(8W-47-6)
J958W-9
BR 8W-70 SPLICE INFORMATION 8W-70-31
C201
SPLICE S205 CARGO LAMP 1
(8W-70-17) 1
•Ml 18PK »— Ml 18PK-
(8W-44-3)
Ml Ml
18PK 18PK
DOME LAMP
Ml 18PK -Ml 18PK Ml 18PK CARGO LAMP 2
(8W-44-3)
(8W-44-3)
S303 C308
LEFT DOOR
X53 18DG TWEETER
(8W-47-7)
X53
18DG
C201 S304
RADIO LEFT DOOR
X53 20DG ((— X53 18DG- X53 18DG SPEAKER
(8W-47-5)
(8W-47-6)
LEFT DOOR
-X55 18BR/RD- TWEETER
(8W-47-7)
X55
18BR
RD
C201
RADIO LEFT DOOR
(8W-47-5) X55 18BR/RD »—-X55 18BR/RD X55 18BR/RD- SPEAKER
(8W-47-6)
S305
J958M-9
70-32 8W-70 SPLICE INPOiiAIiON BR
LIFT POWER
WINDOW SWITCH
(aw-60-2)
Z3
14BK
OR
•Z3 14BK/0R
LEFT DOOR POWER
LOCK SWITCH
-Z3 18BK/0R- MIRROR SWITCH
(8W-61-2)
S306 (8W-62-2)
Z3 14BK/0R
Z3
14BK
OR
• 0302
8W-15-8
RIGHT DOOR
X54 18VT- TWEETER
(8W-47-7)
C240 5307
RADIO RIGHT DOOR
(8W-47-5)^ -X54 20VT- X54 18VT X54 18VT SPEAKER
(8W-47-6)
RIGHT DOOR
-X56 18DB/RD- TWEETER
(8W-47-7)
C240 S308
RADIO .JIGHT DOOR
(8W-47-5) -X56 20DB/RD X56 18DB/RD -X56 18DB/RD- SPEAKER
(8W-47-B)
J958W-9
C207 LEFT FRONT

-P33 1 6 0 R / B K — - ) ) P33 160R/BK- DOOR LOCK
MOTOR
(8W-61-3)
C239
P33
160R
BK
RIGHT DOOR S309 RIGHT FRONT

LOCK SWITCH „ DOOR LOCK
(8W-61-3) -P33 160R/BK P33 160R/BK- MOTOR
(8W-61-3)
C207 LEFT FRONT

-P34 16PK/BK- » P34 16PK/BK DOOR LOCK
MOTOR
(8W-61-3)
C239
P34
16PK
BK
RIGHT DOOR S310 RIGHT FRONT

LOCK SWITCH DOOR LOCK
(8W-61-3) -P34 16PK/BK P34 ISPK/BK
MOTOR
(8W-61-3)
WITH
TRAILER
TOW
-Z13 12BK Z13 12BK-
SPLICE /
5311 FUEL TANK
-Z13 16BK Z13 16BK- •Z13 16BK ^ SAU6E SENDING
siis UNIT ( 8 W - 3 0 - 4 8 )
(8W-70-7)
C128
J958W-9
8W - 70 - 34 SW-70 SPLICE INFORMATION B R
SPLICE S4Q5 SPLICE S 3 I I

(8W-70-38) (8W-7Q-33)
DUAL REAR-
WHEELS ONLY
Z13
18BK WITH
TRAILER
TOW
LEFT LICENSE \ £ 1 ^ C332

TRAILER TOW
LAW Z13 I 8 B K — ^ f - — Z 1 3 18BK Z13 12BK—)>—Z13 12BK- I CONNECTOR
(8W-51-2) (8W-54-2)
€342
RIGHT LICENSE — —
C333
LAMP ®*» Z13 18BK -{( Z13 18BK SPLICE 8 4 © i
—)) Z13 18BK-
(3W-51-2) (8W-70-37)
C329
—)>- — Z13 18BK- SPLICE S 4 0 2
(8W-70-37)
PARK/NEUTRAL
CT2S POSITION
SWITCH
Ll 18VT/BK IL
BACK-UP
WITH LAMP SWITCH
TRAILER (8W-31-5)
TOW
SPLICE S I I ? LI 18VT/BK
(8W-70-8)
C128
C331 S313 C329 RIGHT BACK-UP

Li 18VT/BK -—-LI I8VT/BK »— -Li 18VT/BK LAMP
(8W-51-5)
LI
I8VT C333
BK LEFT BACK-UP
-Li 18VT/BK )> L i I8VT/BK LAS3P
(8W-51-5)
TIAILEI TOM
C&NhJECTQR
(8W-54-2)
J958W-9
SR 8W-70 SPLICE INFORMATION 8W - 7 0 - 3 5
LEFT TAIL, C333 C128

STOP AND S P L I C E sioa
TURN SIGNAL L7 18BK/YL —»—L7 18BK/YL
(8W-70-3)
LAPP
(8W-51-3)
L7 L7
18BK 18BK
YL YL
RIGHT T A I L
STOP MB
C329 C342
mm SIGNAL RIGHT LICENSE
LAMP •L7 1 8 B K / Y L — < ( — L 7 18BK/YL— 1
L7 18BK/YL » -L7 18BK/YL LAMP
(8W-S1-3) (8W-51-2)
S314
C343
LEFT LICEWS
L7 18BK/YL L7 18BK/YL LANP
(8W-5I-2)
DUAL REAR-
WHEELS ONLY
SPLICE S40S
-L7 18BK/YL- (8W-70-38)
TURN SIGNAL
€128 C133 AND HAZARD
FLASHER
-)) L62 18BR/PK — ) ) L62 18BR/PK- 1
SWITCH
(8W-52-3)
LS2
18BR
PK
RIGHT T A I L
T R A I L E R TOW C331 S315 C329 STOP AND
CONNECTOR „ TURN S I G N A L
-L82 18BR/PK —<f~ L62 18BR/PK • L62 18BR/PK »—L62 18BR/PK- LAMP
(8W-54-2)
(8W-51-3)
TURN SIGNAL
€128 C133 AND HAZARD
FLASHER
—»—L63 18DG/RD » L63 18DG/RD - i SWITCH
(8W-52-3)
L62
18BR
PK
LEFT T A I L ,
TRAILER TOW C331 S316 C333 STOP AND
CONNECTOR „ TORN S I G N A L
L63 18DG/RD — ( { — L 6 3 18DG/RD L63 18DG/RD )) L63 18DG/RD • LAMP
(8W-54-2)
(8W-51-3)
J958W-9
SW - 71 - 36 8W-7I SPLICE INFOiilliON B R
JOINT
CONNECTOR A
C217 r
PARK ~!
LAMP I
L7 20BK/YL SWITCH " |
LEFT OUTBOARD OUTPUT I
CLEARANCE ^ L7 18BK/YL
LAMP
(8W-50-10)
LEFT OUTBOARD
RIGHT OUTBOARD
IDENTIFICATION _ CLEARANCE LAMP
LAMP L7 18BK/YL L7 I8BK/YL
(8W-50-10)
(8W-50-10)
OVERHEAD CONSOLE RIGHT OUTBOARD

L7 18BK/YL IDENTIFICATION
PARK C338 LAMP
LAMP (8W-50-10)
SWITCH 12 L7 18BK/YL
OUTPUT
CENTER
IDENTIFICATION
GND LAMP
(8W-50-10)
Z4
18BK CENTER
IDENTIFICATION
LAMP
(8W-50-IO)
LEFT OUTBOARD
Z4 -Z4 18BK CLEARANCE LAMP
I8BK (8W-50-10)
RIGHT OUTBOARD
S318 Z4 18BK- CLEARANCE LAMP
(8W-50-10)
LEFT OUTBOARD
Z4 18BK- i IDENTIFICATION
LAMP ( 8 W - 5 0 - 1 0 )
Z4
18BK
Z4
I8BK RIGHT OUTBOARD
•Z4 18BK IDENTIFICATION
DAY/NIGHT LAMP ( 8 W - 5 0 - 1 0 )
MIRROR -Z4 22BK Z4 18BK-
(8W-44-7)
S319
" A , G304
•=±=r 8W-15-8
J958W-9
OVERHEAD CONSOLE
1
~! C338 , S320 C208
' FUSED SPLICE S205
Ml 18PK •Ml 20PK Ml 20PK
| B+ 5 | )) (8W-70-25)
I FUSED
B + Ml 18PK
6 u$
i
SPLICE S312
Zl3 18BK
(8W-70-34)
C333
Z13
18BK
LEFT LEFT T A I L ,
BACK-UP
S4©I STOP AND
LAMP Z13 18BK- Z13 18BK TURN S I G N A L
(8W-51-5) LAMP
(8W-51-3)
SPLICE S 3 1 2
-Z13 18BK-
(8W-70-34)
C329
Z13
18BK
RIGHT RIGHT T A I L ,
S402 STOP AND
BACK-UP
LAMP Zl3 18BK -Z13 18BK- TURN S I G N A L
LAMP
(8W-51-5)
(8W»51°3)
BATTERY S403 HEATED INTAKE

POSITIVE A I R SYSTEM
TERMINAL A19 12BK- A19 6BK •
RELAY 1
(8W-30-41) (8W-30-41)
S404 HEATED INTAKE

A I R SYSTEM
A8 12BK A8 6BK RELAY 2
(8W-30-4I)
J958W-9
8W-70 SPLICE INFORMATION BR
S405
Z13 18BK Z13 18BK
7
Z13 ZI3 Z13 ZI3 ZI3
18BK 18BK 18BK 18BK 18BK
Z13
C405 C404 18BK C343 C402 C403
Z13 Z13 Z13 Z13 Z13

18BK 18BK 18BK 18BK
i i
18BK
LEFT RIGHT
RIGHT REAR LEFT REAR LICENSE SPLICE
FORWARD FORWARD
FENDER LAMP FENDER LAMP LAMP S312 FENDER LAMP FENDER LAMP
(8W-51-9) (8W-51-9) (8W-51-8) (8W-70-34)
(8W-51-9) (8W-51-9)
f SPLICE I
S314
(8W-70-3S)
f
L7 L7 L7 L7 L7
18BK 18BK 18BK 18BK 18BK
YL YL YL YL YL
!L7
C405
L7
+
C404
L7
18BK
YL fL7
C343
+
L7
C402
L7
18BK
C403
18BK 18BK 18BK 18BK

YL YL
YL YL YL
L7 18BK/YL
§406
€406
3 4 0 7
L7 18BK/YL- A
1 1
L7 L7
18BK 18BK
YL YL
if I
RIGHT
f
TAILGATE T A ILEFT
LGATE
LAMP LAMP
(8W-51-8) (8W-51-8)
f1 f
Z13 I
18BK ZI3
18BK
S4Q8
Z13 18BK
J958W-9
C105
SPLICE
S103
-»- Zl 20BK
(8W-70-2)
Zl
20BK
LEFT FOG S409 RIGHT FOG

LAMP , Zl 20BK Z l 20BK • LANP
(8W-50-7) (8W-50-7)
J958W-9
BR 8W-80 CONNECTOR PIN OUTS — - 8W - 80 - 1
CONNECTOR PIN OUTS

GENERAL INFORMATION . circuit occupies. Individual connector numbers are
The pages referenced in this section show the con- referenced on diagram pages throughout Group 8W.
nector, the circuits in the connector, and the pin that
CONNECTOR LOCATIONS
Component Page Component Page

C101 8W-80-3 C146 8W-8n-1 Q
UVV U U 1 %
7
C102 .. . . . . . . . . . . .8W-80-3 C147 . . 8W-8N-1 Q
C103 8W-80-3 C148 . . . . . . .UVV O U I O
C104 8W-80-3 C149 . . . . • • • • • « • . • • 8W-80-P0
UVV U U CO
C105 8W-80-3 C150 . •

8W-80-P0
.UVV U U CO
.UVV O U C u
C106 8W-80-4 C151 . . . . . 88W-8n-?n
W-80-?n
C107 8W-80-4 C152 . . . .UVV U U CO
C108 . ...... .8W-80-4 C153 • 8W-80-P0
.UVV U UCO
C109 8W-80-4 C154 . . . . .uvv u u c i
8W-80-P1
8W-80-P1
C110 . . . . . . . . . . . . . . . . . . . . . .8W-80-4 C155 . . . • • « • • • » . . u v v U U C I
G112 . . . 8W-80-5 C156 .UVV C1

8 W - 8ODU- 9 1
C113 8W-80-5 C157 . . . .UVVU U C 1

8W-80-P1
C114 . . . . . . . . . . . . . . . . . . . . . . . .8W-80-5 C158 .UVV C1
8 W - 8U 0U- P 1
C115 . .8W-80-5 C159 . . . • • » • • • 8W-80-??

.UVV U U CC
U U cc
C116 .8W-80-6 C160 . . .uvv
8W-80-??
8W-80-??
O U CC
C117 .8W-80-6 C161 . . . . . . . . . . . . . . . . . OVV
C118 .8W-80-6 C162 • • • • • cc

8W-80-??
.UVV U U
8W-80-??
C119 8W-80-6 C163 • UVV U U CO
C120 • . .UVV U U Cu
8W-80-6 C164 8W-80-??
8W-80-P?
C121 8W-80-7 C165 UVV U UCO
C122 .8W-80-8 C166 >
8W-8N-9?
.OVV O U CO
C123 O U CO
. . . . . . . . . . .8W-80-8 C167 . . . . . . 8W-8FI--??
U VV
C124 8W-80-8 C168 . 8VW

.O V -8
ON Cr\
U-? 4
• u v v u u
8W-80-P4
C125 8W-80-9 C169 . 8W-80-24
C126 8W-80-9 C170 .uvv u u a
• 8
UWV V- 8
U 0U- T
P4T
C127 8W-80-9 C171 8W-8N-P4
C128 UVV O U a
8W-80-10 C172 . . . . . . . . . . . . ..
8W-80-P5
U U CO
C129 . . . . . . . . . . . . . . . . . . . . . . . .. 8W-80-10 C173 .UVV
C130 8W-80-10 C174 . . . . . . . . . . . . . . U V V U U CO
C131 . 8W-80-10 C175 . . . . .. • • • .UVV U U CO

C132 U V V O U CO
8W-80-P5
8W-80-10 C176 « •
C133 .8W-80-11 C177 • • • • • CO

FLW-RO-PS
.UVV O U
C134 U V V U U CKJ
8W-8f)-?fi
.8W-80-12 C178 • • •
C135 (3.9L Engine) U V V U U CO

8W-8n-?fi
8W-80-13 C179 • •
C135 (5.2L/5.9L Engine) 8W-80-14 C180 • ••>• .v/VV \J\J cu

8W-80-26
C135 (8.0L Engine) U U CO
8W-80-28
. . . . . . . . . .8W-80-15 C181 . . . . ; • .U VV
C135 (Diesel Engine) 8W-80-16 C182 U U CO

8W-80-26
.UVV
C136 . . . . . 8W-80-17 C201 . . . . . . . . . . . . . . • • » • 8W-80-26CO

.UVV U U
C137 > . . .UVV U U CI

8W-8D-P7
8W-80-17 C202
C138 8W-80-17 C203
8 W-8
UVV
0-P7
U U CI
C139 .8W-80-17 C204 . . CI
8W-80-P7
.UVV U U
C140 u v v O U CO
8W-80-P8
.8W-80-18 C205 •
C141 . . . . . . . . . .8W-80-18 C206 • • CO

8W-8D-P8
.uvv U U
C142 U V V U U CO
8W-80-P8
. . . . . . . . . .8W-80-18 C207 . .. »
C143 8W-80-18 C208 . • • • • • • • 8W-8D-P8

O V V O U CO
C144 . . . . . . . . . .8W-80-19 C209 . .. • UVV U UCZJ

8W-8D-PQ
C145 . . 8W-80-19 C210 » C%J
8W-80-PQ
.OVV O U
8W-80-30
8W - 80 - 2 — — 8W-80 CONNECTOR PIN OUTS
?m Component P a n e
2 1 8 W - 8 0 - 3 0 C325 " ~a!

2 * •• 8W-80-30 C326 211 AA
5? 8W-80-31 C327 211 AA
® f 8W-80-31 C328 22 AA
f'l 8W-80-31 C329 2m AA
2 ? 8W-80-32 C330 o ^ l 4 4
2 1 8W-80-32 C331 ^-80-44

2 J 8W-80-32 C332 21It
2 " 8W-80-33 C333 22 a\
™ 8W-80-33 C334 211 A,
C
C %1 8W-80-33 C335 2tt
8 0 4 5
2® 8W-80-33 C336 g^ "
8W-80-34 C337
2111 2-11 aI
3
SL
2 4
2 ? ...8W-80-34 C338
%H 8W-80-34 C339 2 mil
C226 m i m qA n o A n uW-80-46
C229 ; ; 2 l l t °c
4
8W-80-47
C230 2 lit C A M 8 W - 8 0 - 4 7
C234
C235
;;;; 2llf
22?7
. .8W-80-37 7
£L
C405
C A M
04
8 W - 8 0 -
8w- -48
4
80
8
. .8W-80-37 C406
C236 2211
. .8W-80-37 p i n y 8 W - 8 0 - 4 8
C407
C238
C239
2 lit
. .8W-80-37
. .8W-80-38
8
1 80lit 38
C408
C409
cZ
c Z 8 W - 8 0 - 4
8W-80-49
9
. .SW-80-38
8 C410
C240 ^ "
. 8.8W-80-38 %J 8W-80-49
C241 ; ; 2 l l t 8
. .8W-80-38
C411
C412P 4 8 W - 8 0 - 4 9
C301 Zll
. .8W-80-39 11 rio
C413 8W-80-50
. .8W-80-39 C414
, .8W-80-39 C415
C304 . ;; 2 2 1 1 8W-80-50
.8W-80-39 C416
n, n c
.8W-80-39
8W-80-39 C417
C417 a wfin51
° ™
C
^308
C
••
Z 8 W - 8 0 - 4
.8W-80-40
8W-80-40
0
.8W-80-40
.8W-80-40
Q\A/_Qn_/!n
C418
C418
C419
C419
C420
r>,nn
2llt 2tt
.8W-80-51
u>v uu-^ru kjhcu .8W-80-51
.8W-80-40 C421
C309 . . . .8W-80-40 C421 8W-80-51
.8W-80-40 C422
C310 8W-80-40 C422 .8W-80-52
.8W-80-41 C423 .
C311 8W-80-41 C423 8W-80-52
.8W-80-41 C424 .
C312 .8W-80-41 C424 . . . . . . . . . . . .8W-80-52
.8W-80-41 C425 .
C313 .8W-80-41 C425 . . . .8W-80-52
.8W-80-41 C426 .
C314 . .8W-80-41 C426 .8W-80-52
.8W-80-41 C427 .
C315 8W-80-41 C427 .8W-80-53
.8W-80-42 C428 .
C316 8W-80-42 C428 8W-80-53
.8W-80-42 C429 .
C317 8W-80-42 C429 8W-80-53
.8W-80-42 C430 .
C318 8W-80-42 C430 .8W-80-53
.8W-80-42 C431
C319 .8W-80-42 C431. 8W-80-53
.8W-80-42
C320 . .8W-80-42 C432 .
C432 8W-80-54
.8W-80-43
C321 8W-80-43 C433 .
C433 8W-80-54
Q322
.8W-80-43
Q\A/_QH AO
.8W-80-43
C323
.8W-80-43
C324
8W-80 CONNECTOR PIN OUTS 8W - 80 - 3
-BLACK
C101
CAV CIRCUIT FUNCTION

1 Zl 18BK GROUND
2 L7 18BK/YL PARK LAMP SWITCH OUTPUT
3 L60 18LG/TN RIGHT FRONT TURN SIGNAL
RIGHT PARK AND
AND TURN SIGNAL LAMP
C102

1 Zl 20BK GROUND
2 L4 16VT/WT HEAD LAMP SWITCH OUTPUT (LOW-BEAM)
BLUE
3 L3 16RD/0R HEAD LAMP SWITCH OUTPUT (HIGH-BEAM)
RIGHT
HEADLAMP
BLACK
€103
1 R46 18BR/LB RIGHT IMPACT SENSOR L I N E 1
2 R48 18TN RIGHT IMPACT SENSOR L I N E 2
RIGHT AIRBAG
SENSOR
BLACK
£104
1 B7 20WT RIGHT FRONT WHEEL SPEED SENSOR (4-)
2 B6 20WT/DB RIGHT FRONT WHEEL SPEED SENSOR ( - )
RIGHT FRONT
WHEEL S P E E D
SENSOR
C105
-BLACK
CAV CIRCUIT BLACK- CIRCUIT
CAV
1 Zl 20BK 1 Zl 20BK
2 L39 20LB 2 L39 20LB
3 L39 20LB
3 2 1
3 L39 20LB
1 2 3
INDICATES TWISTED P A I R J958W-9

8W - 80 - 4 8W-80 CONNECTOR PIN OUTS BR
C106
BLACK
BLACK
CAV CIRCUIT CAV CIRCUIT
1 6107 20BK/GY 1 G107 18BK/GY
1 6107 20BK/6Y 2 Zl 18BK
2 Zl 20BK
1 2
C107

1 VIO 18BR WINDSHIELD WIPER SWITCH OUTPUT (WASH)
2 Zl 20BK GROUND
BLACK
WINDSHIELD WASHER
PUMP MOTOR
BLACK
€108

1 Zl 18BK GROUND
LOW WASHER FLUID 2 G29 18BK/TN LOW WASHER FLUID INDICATOR LAMP
LEVEL SWITCH
C109
BLACK
1 Zi 20BK GROUND
2 V30 20DB/RD STOP LAMP SWITCH OUTPUT
3 V35 20LG/RD VEHICLE SPEED CONTROL VENT SIGNAL
1 4 4 V36 20TN/RD VEHICLE SPEED CONTROL VACUUM SIGNAL
VEHICLE
SPEED CONTROL
SERVO
BLACK C110

1 R47 18DB/LB LEFT IMPACT SENSOR LINE 1
2 R49 18LB LEFT IMPACT SENSOR LINE 2
LEFT AIRBAG
SENSOR
J958W-9
BR 8W-80 CONNECTOR PIN OUTS 8W - 80 - 5
cua
1 Zl 18BK GROUND
LEFT PARK AND 3 L61 18LG/TN LEFT FRONT TURN SIGNAL
AND TURN SIGNAL LAMP
CIO
1 Zl 20BK GROUND
2 L4 16VT/WT HEADLAMP SWITCH OUTPUT (LOW-BEAM)
3 L3 16RD/0R HEADLAMP SWITCH OUTPUT (HIGH-BEAM)
BLUE
LEFT
HEADLAMP
BLACK £114
JT
1 632 18BK/LB SENSOR 6R0UND
2 631 18VT/L6 AMBIENT AIR TEMP SENSOR SI6NAL
1 2
AMBIENT
AIR TEMPERATURE
SENSOR
BLACK
C115

1 Zl 18BK GROUND
HORN 2 X2 18DG/RD HORN RELAY OUTPUT
(HIGH NOTE)
J958W-9
8W - 80 - 6 8W-80 CONNECTOR PIN OUTS
BLACK
£ C116

l-HMH-2
1 ZI 18BK GROUND
2 X2 18D6/RD HORN RELAY OUTPUT
HORN
(LOW NOTE)
CUT

BLACK 1 BI08 I8WT REAR DECAY SOLENOID CONTROL
/ 2
3
B i l l 18LB/BK
Z8 I6BK/PK
REAR RESET SWITCH SENSE
GROUND
RWAL
ONLY
4 B101 18LG/WT REAR ISOLATION SOLENOID CONTROL

1 4 1 B254 I6DG/0R REAR DECAY VALVE CONTROL
ABS
REAR ANT I-LOCK 2 B I 9 20LB REAR VALVE RESET SWITCH SENSE ONLY
VALVE 3 B120 12BR/WT PUMP/MOTOR RELAY OUTPUT
4 B252 18BR/TN REAR ISOLATION VALVE CONTROL
BLACK
C118

1 B9 20RD LEFT FRONT WHEEL SPEED SENSOR ( + )
2 B8 20RD/GY LEFT FRONT WHEEL SPEED SENSOR (-)
LEFT FRONT
WHEEL SPEED
SENSOR
-BLACK
BLACK
C I 19

1 T40 12BR 1 T40 12BR
2 AI5 I6PK 2 AI5 16PK
/—BLACK
C12Q

1 Z8 10BK/PK GROUND
2 B60 12LB/BK PUMP/MOTOR CONTROL
ABS 2-WAY
POWER FEED
X - INDICATES TWISTED PAIR J958W-9

CAM
1 Bl13 20RD/VT REAR WHEEL SPEED SENSOR-HIGH
2 B7 20WT RIGHT FRONT WHEEL SPEED SENSOR ( + )
3 B9 20RD LEFT FRONT WHEEL SPEED SENSOR (+)
4 Bl16 20GY PUMP RELAY CONTROL
5 B5 20VT/RD LEFT FRONT RESET SWITCH SENSE
6 A20 18R0/0B FUSED IGNITION SWITCH OUTPUT (RUN)
7 A20 18RD/DB FUSED IGNITION SWITCH OUTPUT (RUN)
1 26
8 6107 20BK/6Y 4WD SWITCH OUTPUT
14 BLACK 9 V40 20WT/PK STOP LAMP SWITCH OUTPUT
10 012 200R SCI TRANSMIT
11 Dll 20WT/RD SCI RECEIVE
12 A20 18RD/DB FUSED IGNITION SWITCH OUTPUT (RUN)
a 13 B47 20RD/LB WARNING LAMP RELAY CONTROL
add 14 Bl14 20WT/VT REAR WHEEL SPEED SENSOR - LOW

aaa 15 B6 20WT/DB RIGHT FRONT WHEEL SPEED SENSOR (-)
aaa 16 B8 20RD/6Y LEFT FRONT WHEEL SPEED SENSOR (-)
aaa 17 A20 18RD/DB FUSED IGNITION SWITCH OUTPUT (RUN)
QQQ 18 B18 20VT/L6 RIGHT FRONT RESET SWITCH SENSE
QQQ 19 B19 20LB REAR VALVE RESET SWITCH SENSE
acid 20 11 18BK/RD GROUND
aaa 21 A20 18RD/DB FUSED IGNITION SWITCH OUTPUT (RUN)
aaa 22 -—-
aaa 23
—20LG/RD
aaa 24 619 WARNING LAMP RELAY OUTPUT
gag 25 69 206Y/BK BRAKE WARNING LAMP DRIVER
26 B254 16D6/0R REAR DECAY VALVE CONTROL
27
25
28 B252 18BR/TN REAR ISOLATION VALVE CONTROL
29
13 37 30 B248 16D6/WT RIGHT FRONT DECAY VALVE CONTROL
ANTI-LOCK BRAKE 31
SYSTEM CONTROL 32
MODULE
33 B249 18MT/TN RIGHT FRONT ISOLATION VALVE CONTROL
,34 B120 14BR/WT PUMP/MOTOR RELAY OUTPUT
35 B243 16D6/BK LEFT FRONT DECAY VALVE CONTROL
' 36
37 B245 18WT/L6 LEFT FRONT ISOLATION VALVE CONTROL
X - INDICATES TWISTED PAIRS (B6 I 87, B8 I B9, Bl13 I Bl14) J958W-9

8W - 80 - 8 8W-80 CONNECTOi PIN OUTS
C122

1 B120 12BR/WT PUMP/MOTOR RELAY OUTPUT
2 B18 20VT/L6 RIGHT FRONT RESET SWITCH SENSI
if— 3 B248 1GDG/WT RIGHT FRONT DECAY VALVE CONTROL
1 -
O O O O Q 4 B249 18WT/TN RIGHT FRONT ISOLATION VALVE CONTROL
10- O ooo O 5 B80 12LB/BK PUMP/MOTOR CONTROL
n 6 B120 12BR/WT PUMP/MOTOR RELAY OUTPUT
DARK 7 B245 18WT/LG LEFT FRONT ISOLATION VALVE CONTROL
GRAY 8 B243 16DG/BK LEFT FRONT DECAY VALVE CONTROL
FRONT ANTI-LOCK 9 B5 20VT/RD LEFT FRONT RESET SWITCH SENSE
VALVE
10 B120 12BR/WT PUMP/MOTOR RELAY OUTPUT
C123

BLACK 1 Zl 18BK GROUND
1 Zl 18BK GROUND
2 Zl 12BK GROUND
2 Zl 14BK GROUND
3 Zl 18BK GROUND
3 Zl 18BK GROUND
4 Zl 14BK GROUND
GROUND
JOINT 4 Zl 12BK GROUND
5 Zl 18BK GROUND
C124

BLACK 1 V4 18RD/YL WINDSHIELD WIPER SWITCH OUTPUT (HIGH)
2 V5 18DG/YL WINDSHIELD WIPER PARK SWITCH
3 VS 18DB/BK FUSED IGNITION SWITCH OUTPUT (ACC/RUN)
4 V3 18BR/WT WINDSHIELD WIPER SWITCH OUTPUT (LOW)
INTERMITTENT
WIPER MOTOR
J958W-9
C125

1 Zll 16BK/WT 1 Zll 16BK/WT
LT GRAY -LT GRAY
2 T41 22BK/WT 2 Z12 20BK/TN
3 T18 22LG/0R 2 T41 20BK/WT
4 TS 220R/WT 3 T18 20LG/0R
1 - •O o o o O 5 C90 18LG 3 654 200R/BK
10- 6 A142 14DG/0R 4 T6 200R/WT

•O o o o O
7 CI3 22DB/0R 5 C90 18LG
n
8 K51 22DB/YL 6 A142 14DG/0R
9 V40 22WT/PK 7 C13 20DB/0R
9 V40 22WT/PK 8 K51 20DB/YL
10 T40 12BR 9 V40 20WT/PK
10 T40 12BR
C126

-DARK -DARK 1 A14 16RD/WT
1 A14 16RD/WT
GRAY GRAY
2 V33 20WT/LG 2 V33 20WT/LG
3 V32 20YL/RD 3 V32 20YL/RD
4 V31 20BR/RD 4 V31 20BR/RD
5 F18 18LG/BK 5 F18 18LG/BK
6 LI 18VT/BK 6 Li 18VT/BK
6 LI 18VT/BK 6 LI 18VT/BK
7 V35 20LG/RD 7 V35 20LG/RD
8 G3 22BK/PK 8 G3 20BK/PK
9 V36 20TN/RD 9 V3S 20TN/RD
10 L10 18BR/LG 10 L10 18BR/LG
10 L10 18BR/LG 10 L10 18BR/LG
C127

-BLACK 1 G85 180R/BK 1 G85 180R/BK
2 G21 22GY/LB 2 G21 20GY/LB
3 G24 22GY/PK 3 G24 20GY/PK
4 G60 22GY/YL 4 G60 18GY/YL
5 G6 22GY 4 G60 16GY/YL
6 G20 22VT/YL 5 66 18GY
7 C3 18DB/BK 5 66 16GY
8 G14 18PK/BK 6 G20 18VT/YL
9 G7 22WT/0R 7 C3 18DB/BK
10 G86 18TN/0R 8 G14 18PK/BK
11 D21 20PK/DB 9 67 20WT/0R
12 D20 20DG 9 G7 18WT/0R
10 G86 18TN/0R
11 021 20PK
12 D20 20LG
INDICATES TWISTED PAIR
8W - 80 -10 — — 8W-80 CONNECTOR PIN OUTS ~™™ B i t
CAV CIRCUIT C128 CAV CIRCUIT

1 L7 18BK/YL BLACK 1 L7 J8BK/YL
xx 2 B113 20RD/VT 2 Bi13 20RD/VT
-rr
o o o
x 2 B113 20RD/VT Or
O O O •1
3 L63 18DG/RD
->
L63 18DG/RD 4 L62 18BR/PK
10- o o o Of-- 6 4 L62 18BR/PK > o o o c / •10 5 A61 16DG/BK
n
5 A61 16DG/BK 6 Z13 16BK
6 Z13 166K 6 Z13 12BK
-BLACK
G Z13 12BK 7 Zll 20BK/WT
7 Zll 20BK/WT 8 B114 20WT/VT
X 8 Bl14 20WT/VT 9 G4 20DB
XX 8 Bl 14 20MT/VT 10 LI 18VT/BK
9 G4 22DB
10 Li 18VT/BK
BLACK C129 BLACK
CAV CIRCUIT CAV CIRCU:;

1 A6 14RD/TN 1 A6 14RD/TN
2 B40 H L B 2 B40 H L B
3 L76 14BK/0R 3 L76 14BK/0R
£13©
BLACK CAV CIRCUIT FUNCTION
1 Ml 20PK FUSED B +
2 Zl 20BK GROUND
UNDERHOOD
LAMP
C131

BLACK 1 L10 18BR/LG FUSED IGNITION SWITCH OUTPUT (RUN)
2 G34 20RD/GY
;•! 1 CM BEAM INDICATOR LAMP
3 G i l 20WT/BK PARK BRAKE SWITCH SENSE
4 — —
5 L3 I6RD/0R HEADLAMP SWITCH OUTPUT (HIGH-BEAM)
6 A3 12RD/LG FUSED B -;-
7 — —
DAYTIME RUNNING
LAMPS MODULE 8 Zl 18BK GROUND
9 Zl 18BK GROUND
10 L4 16VT/WT HEADLAMP SWITCH OUTPUT (LOW-BEAM)
GREEN
GREEN
C132
CAV CIRCUIT FUNCTION CAV ::rcuit

1 A41 DB/YL CLUTCH SAFTEY SWITCH SENSE 1 A41 20YL
CLUTCH 2 A41 14YL CLUTCH SAFTEY SWITCH SENSE CLUTCH 2 A41 20YL
PEDAL POSITION PEDAL POSITION
SWITCH BYPASS JUMPER
X AND X X - INDICATES TWISTED PAIR J958W-9

B R 8W-80 CONNECTOR PIN OUTS 8W - 80 -11
C133
(CONTINUED ON 8W-80-12)

1 R47 18DB/LB 1 R47 180B/LB
2 L50 18WT/TN 2 L50 18WT/TN
3 G4 22DB 3 64 22DB
4 L62 18BR/PK 4 L62 18BR/PK
5 L63 180G/RD 5 L63 1806/RO
6 T6 220R/WT 6 T6 220R/WT
7 T18 22LG/0R 7 T18 22L6/0R
8 620 22VT/YL 8 G20 22VT/YL
9 621 22GY/LB 9 621 22GY/LB
10 624 226Y/PK 10 624 226Y/PK
11 — 11 M2 20YL
12 R48 18TN 12 R48 18TN
13 L38 20LB/BK 13 L38 20LB/BK
14 C90 18LG 14 C90 22L6
15 63 22BK/PK 15 63 22BK/PK
16 X3 22BK/RD 16 X3 22BK/RD
BLACK -BLACK
17 — 16 X3 20BK/RD
18 68 226Y 17 —
19 660 226Y/YL 18 G6 226Y
JCZL
20 67 22WT/0R 19 660 226Y/YL
i—fUUIJUUU UUUUUUH-12 12--4JUUUUU UUUUULJH-i
21 — 20 67 20WT/0R
i 3 — • • • • • • •QDDDD-24 22 L I 18VT/BK 24-OD0000 0 D D 0 D D - I 3 21 —
25-HODQDDD ••mDDhhe 23 A4I I80B/YL 36-H0DQDQ0. ••••••1+25 22 L i 22VT/BK
24 L39 20LB 23 A41 18DB/YL
37- •40 40 37
25 139 20LB 24 L39 20LB
41-
45-
•44
•48
26
27
27
6107 20BK/GY
634 18RD/6Y
634 20RD/GY
44-
48-
O •41
•45
25
26
26
L39 20LB
6107 20BK/6Y
6107 22BK/6Y
28 69 186Y/BK 27 634 18RD/6Y
28 69 20GY/BK
60-HODDDDD0000001+49 28 69 226Y/BK
ei-OOODDO • • • • • • - 7 2 29 629 18BK/TN 72-OOODDD 000000-61 29 629 22BK/TN
73-Hnnnnnn nnnnnnl4-84 30 F18 20L6/BK 8444nnnnnn nnnnnnl-73 30 F18 22LG/BK
31 V30 20DB/RD 31 V30 20DB/RD
32 611 20WT/BK 32 611 22WT/BK
33 Z l l 18BK/WT 33 Z l l 18BK/WT
34 m 20PK 34 Ml 20PK
35 V40 22WT/PK 35 V40 22WT/PK
35 V40 20WT/PK 36 Z6 18BK/0R
36 Z6 18BK/0R 37 V3 18BR/WT
37 V3 18BR/WT 38 L3 16RD/0R
38 L3 16RD/0R 39 L4 16VT/WT
39 L4 16VT/WT 40 L7 18BK/YL
40 L7 18BK/YL 41 A20 18RD/DB
41 A20 18RD/DB 41 A20 18RD/DB
42 Al 12RD 42 Ai 12RD
43 A2 12PK/BK 43 A2 12PK/BK
44 L9 18BK/VT 44 L9 18BK/VT
45 V4 18RD/YL 45 V4 16RD/YL
46 B108 18WT 46 B108 18WT
47 A3 12RD/LG 47 A3 12RD/L6
48 A7 12R0/BK 48 A7 12RD/BK
49 Z2 18BK/LG 49 Z2 18BK/L6
50 619 20LG/RD 50 619 22LG/R0
J958W-9
8W - 80 -12 8W-80 CONNECTOR PIN OUTS BR
C133
(CONTINUED FROM 8 H - 8 0 - H )

5i 8101 18LG/WT 51 B101 18L6/WT
52 B i l l I8LB/BK 52 B i l l 22LB/BK
53 B113 20RD/VT 53 Bl13 22RD/VT
54 Bl14 20WT/VT 54 Bl14 22WT/VT
55 R46 18BR/LB 55 R46 18BR/LB
58 56
57 57
58 R49 18LB 58 R49 18LB
59 631 18VT/LG 59 631 22VT/L6
60 632 18BK/LB 60 632 22BK/LB
61 12 18BK/LG 61 12 18BK/L6
62 LIO 20BR/LG 62 LIO 22BR/LG
62 LIO 18BR/LG 63
63 . 64 V6 18DB/BK
64 V6 18DB/BK 65 V5 18DG/YL
65 V5 18DG/YL 66 VIO 18BR
BLACK 66 VIO 18BR BLACK 67 614 20PK/BK
A
84--4JUUUUU UUUUUUf--73
67
68
69
70
614 18PK/BK
686 18TN/0R
L61 20LG/YL
L60 20TN/BK 73-MUUUUUU UUUUUUI+84
I 1.
68
69
70
71
686 20TN/0R
L61 18LG/YL
L60 18TN/BK
685 200R/BK
72—•••••• •••••D~6 71 685 180R/BK 6 1 • • • • • D ~ 7 2 72 L7 20BK/YL
60-HODDQDD • • • • • • + « 72 L7 20BK/YL 49 — • • • • • • ••••••--60 73 020 20D6
73 020 20DG 74 021 20PK/DB
"•I
o
48 45 45- -48
74 D21 20PK/DB 75
44- -41 75 41- 44 76 012 220R
76 012 200R 77 D l l 22WT/RD
40-
•I
36--00DDDD ••••••—25
-37 77
78
79
D l l 20WT/RD
V31 20BR/RD
37-
2 5 - a m r a
-40
• • • • • d - 3 6
78
79
80
V31 22BR/RD
V32 22YL/RD
24-ODDODD • • • • • • - i 3 80 V32 20YL/RD 13--ODDDDD • • • • • • - 2 4 81 V33 22WT/L6
81 V33 20WT/L6 i-Hnnnnnn nnnnnnl-12 82
12-Hnnnnnn nnnnnnH-i 82 83
83 84
84
-BLACK
C134

1 Zi 18BK 6R0UND
2 G9 206Y/BK BRAKE WARNING LAMP DRIVER
3 A20 18RD/DB FUSED B +
VACUUM SENSOR
X - INDICATES TWISTED PAIRS ( Bl13 I B l 1 4 . D20 I 021) J958W-9

8W-80 CONNECTOR PIN OUTS 8W - 80 -13

1 Kl 18D6/RD MAP SENSOR SIGNAL
2 K2 18TN/BK EN6INE COOLANT TEMPERATURE SENSOR SIGNAL
3 A14 16RD/WT FUSED B +
4 K4 20BK/LB SENSOR 6R0UND
5 — —
6 K6 20VT/MT 5V OUTPUT
7 K7 200R 8V SUPPLY
8 — —
9 F18 20L6/BK FUSED IGNITION SWITCH OUTPUT (START/RUN)
10 T6 200R/WT TRANSMISSION OVERDRIVE SWITCH OUTPUT
11 Z12 16BK/TN GROUND
13 K14 18LB/BR INJECTOR #4 DRIVER
14 K13 18YL/WT INJECTOR #3 DRIVER
15 K12 18TN INJECTOR #2 DRIVER
16 K l l 18WT/DB INJECTOR # 1 DRIVER
17 — —
18 — —
19 K19 16BK/GY IGNITION COIL DRIVER
20 K20 18D6 GENERATOR FIELD CONTROL
21 K21 18BK/RD INTAKE AIR TEMPERATURE SENSOR SIGNAL
22 K22 180R/DB THROTTLE POSITION SENSOR
23 — —
24 K24 20GY/BK CRANKSHAFT POSITION SENSOR SIGNAL
25 021 20PK SCI TRANSMIT
26 — —
27 C20 18BR A/C REQUEST SIGNAL
28 — —
29 V40 20WT/PK STOP LAMP SWITCH OUTPUT
30 T41 20BK/WT PARK/NEUTRAL POSITION SWITCH SENSE
31 614 18PK/BK TRANSMISSION TEMP LAMP DRIVER
32 63 20BK/PK MALFUNCTION INDICATOR LAMP
33 V36 20TN/RD VEHICLE SPEED CONTROL-VACUUM SIGNAL
34 C13 200B/0R A/C COMPRESSOR CLUTCH RELAY CONTROL
35 K35 206Y/YL EGR SOLENOID CONTROL
36
37
—
T18 20LG/0R
—
TRANSMISSION CONTROL MODULE
38 K38 186Y INJECTOR # 5 DRIVER
39 K39 186Y/RD IDLE AIR CONTROL MOTOR DRIVER
40 K40 18BR/WT IDLE AIR CONTROL MOTOR DRIVER
41 K41 18BK/DG HEATED OXYGEN SENSOR
42 T54 18VT TRANSMISSION TEMPERATURE SENSOR
43 621 20GY/LB TACHOMETER SIGNAL
44 K44 20TN/YL CAMSHAFT POSITION SENSOR SIGNAL
45 D20 20L6 SCI RECEIVE
46 — —
47 67 20WT/0R VEHICLE SPEED SENSOR SIGNAL
48 V31 20BR/RD VSC SWITCH - SET
49 V32 20YL/RD VSC SWITCH OUTPUT (ON)
50 V33 20WT/LG VSC SWITCH RESUME/ACCEL
51 K51 20DB/YL ASD/FUEL PUMP RELAY CONTROL
52 K52 20PK/BK EVAP/PURGE SOLENOID CONTROL
53 V35 20LG/RD VEHICLE SPEED CONTROL-VENT
54 654 200R/BK UP SHIFT LAMP
54 K54 200R/BK TCC SOLENOID CONTROL
55 T60 20BR OVERDRIVE SOLENOID CONTROL
56 — ~—
57 A142 16D6/0R ASD RELAY OUTPUT

58 K58 18BR/DB INJECTOR #6 DRIVER
59 K59 18VT/BK IDLE AIR CONTROL MOTOR DRIVER
60 K60 18YL/BK IDLE AIR CONTROL MOTOR DRIVER
J958W-9
8W - 80 -14 8W-80 CONNECTOR Pil OUTS

C135 : Kl 18D6/RD MAP SENSOR SIGNAL
2 K2 18TN/BK ENGINE COOLANT TEMP SENSOR SIGNAL
5.2L S S.SL 3 A14 16RD/WT FUSED B +
ENGINES 4 K4 20BK/LB SENSOR GROUND
5 —
6 K6 20VT/WT 5V OUTPUT
7 K7 200R 8V SUPPLY
8 — —
9 F18 20L6/BK FUSED IGN SW OUTPUT (START/RUN)
10 T6 200R/WT TRANS OD SWITCH OUTPUT
13 K14 18LB/BR INJECTOR #4 DRIVER
14 K13 18YL/WT INJECTOR #3 DRIVER
15 K12 18TN INJECTOR #2 DRIVER
16 K l l 18WT/DB INJECTOR #1 DRIVER
17 K17 18DB/TN INJECTOR M l DRIVER
18 K18 18RD/YL INJECTOR #8 DRIVER
19 K19 16BK/6Y IGNITION COIL DRIVER
BLACK 20 K20 18D6 GENERATOR FIELD CONTROL
23 K141 18TN/WT LEFT HEATED OXYGEN SENSOR
24 K24 206Y/BK CRANKSHAFT POSITION SENSOR SIGNAL
26 —• —-
27 C20 18BR A/C REQUEST SIGNAL
28 — —
31 G14 18PK/BK TRANSMISSION TEMP LAMP DRIVER
32 63 20BK/PK MALFUCTION INDICATOR LAMP
34 C13 20DB/0R A/C COMPRESSOR CLUTCH RELAY CONTROL
....
36 —
37 T18 20L6/0R TRANSMISSION CONTROL MODULI-
38 K38 186Y FUEL INJECTOR U 5 DRIVER
39 K39 186Y/RD IDLE AIR CONTROL MOTOR DRIVER
41 K41 18BK/D6 RIGHT HEATED OXYGEN SENSOR
42 T54 18VT TRANSMISSION TEMPERATURE SENSGH
43 621 20GY/LB TACHOMETER SIGNAL
45 020 20L6 SCI RECEIVE
46 —
49 V32 20YL/RD VSC SWITCH OUTPUT fON)
POWERTRAIN 50 V33 20WT/L6 VSC SWITCH RESUME/ACCEL
CONTROL 51 K51 20DB/YL AUTOMATIC SHUT DOWN SIGNAL
MODULE 52 K52 20PK/BK EVAP/PURGE SOLENOID SIGNAL CONTROL
53 V35 20L6/RD VEHICLE SPEED CONTROL VENT SIGNAL
54 654 200R/BK UP SHIFT LAMP DRIVER
56 624 20GY/PK SERVICE REMINDER INDICATOR DRIVER
57 A142 16DG/0R ASD RELAY OUTPUT
58 K58 18BR/DB INJECTOR #6
J958W-9
BR 8W-80 CONNECTOR PIN OUTS 8W - 80 - 1 5

C135 I Kl 18D6/RD MAP SENSOR SI6NAL
8.0LTH6INE 2 K2 18TN/BK EN6INE COOLANT TEMP SENSOR SI6NAL
3 A14 16RD/WT FUSED B+
4 K4 20BK/LB SENSOR GROUND
5
6
—
K6 20VT/WT
—
5V OUTPUT
7 K7 200R 8V SUPPLY
8
9
—
F18 20L6/BK
—
FUSED IGNITION SW OUTPUT (START/RUN)
13 Kl13 20LB/BR INJECTOR # 5 . * 8 DRIVER
14 K l t 4 20YL/WT INJECTOR #3. # 6 DRIVER
15 Kl 15 20TN INJECTOR # 4 , # 9 DRIVER
16 Kl16 20WT/DB INJECTOR # 1 , # 10 DRIVER
17 K18 18RD/YL IGNITION COIL DRIVER
18 K43 20D6/6Y IGNITION COIL DRIVER
BLACK 19 K19 20BK/6Y IGNITION COIL DRIVER
24 K24 206Y/BK CRANKSHAFT POSITION SENSOR SIGNAL
25 D21 20PK SCI TRANSMIT
26
27
—
C20 18BR
—
A/C REQUEST SIGNAL
28
29
—
V40 20WT/PK
—
STOP LAMP SWITCH OUTPUT
31 T18 20L6/0R TRANSMISSION OVERDRIVE LAMP
34 C13 20DB/0R A/C COMPRESSOR CLUTCH RELAY CONTROL
36 614 18PK/BK TRANSMISSION TEMP LAMP
37 K137 20WT/BK DWELL SIGNAL
38 K138 20BR/0R DWELL SIGNAL
39 K39 18GY/RD IDLE AIR CONTROL MOTOR DRIVER
41 K41 18BK/D6 RIGHT HEATED OXYGEN SENSOR
41 K41 18BK/DG RIGHT HEATED OXYGEN SENSOR
42 T54 18VT TRANSMISSION TEMP SENSOR
43 621 206Y/LB TACHOMETER SIGNAL
45 020 20L6 SCI RECEIVE
46
47
—
67 20WT/0R
—-
VEHICLE SPEED SENSOR SIGNAL
POWERTRAIN
CONTROL 48 V31 20BR/RD VSC SWITCH - SET
MODULE 49 V32 20YL/RD VSC SWITCH OUTPUT (ON)
50 V33 20WT/LG VSC SWITCH RESUME/ACCEL
51 K51 20DB/YL ASD/FUEL PUMP RELAY CONTROL
52 K52 20PK/BK EVAP/PURGE SOLENOID CONTROL
53 V35 20LG/RD VEHICLE SPEED CONTROL-VENT SIGNAL
56 624 206Y/PK SERVICE REMINDER INDICATOR DRIVER
58 K158 20L6/BK INJECTOR M l , M l DRIVER
J958W-9
8W - 80 -18 8W-80 CONNECTOR PIN OUTS mm

1 Kl 20DG/RD WATER-IN-FUEL
CI3S 2 — —
DIESEL ENGINE 3 A14 16RD/WT FUSED B+
5
6
—
K6 20VT/WT
—
5V OUTPUT
7 K7 200R 8V SUPPLY
8 —
9 F18 18L6/BK FUSED IGN SW OUTPUT (START/RUN)
13 — —
14
15
—
S22 200R/BK
—
HEATED INTAKE AIR RELAY 2
16 S21 20YL/BK HEATED INTAKE AIR RELAY 1
17 —
18 — —
BLACK
19 — —
21 K21 16BK/RD INTAKE AIR TEMPERATURE SENSOR
23 —
24 K24 206Y/BK ENGINE SPEED SENSOR
26 —
27 C20 18BR A/C REQUST SIGNAL
28
29
—
V40 20WT/PK
—
30 T41 20BK/WT PARK/NEUTRAL POSITION SW SENSE
31 614 18PK/BK TRANSMISSION TEMP LAMP DRIVER
33 V36 20TN/RD VEHICLE SPEED CONTROL-VACUUM SIG
34 C13 20DB/0R A/C COMPRESSOR CLUTCH RLY CONTROL
35 686 18TN/0R WATER-IN-FUEL
36 685 180R/BK WAIT-TO-START
37 T18 20L6/0R TRANSMISSION CONTROL MODULF
38 — i
39 —
40 — —
41 — —
42 T54 16VT TRANSMISSION TEMPERATURE SENSOR
43 621 206Y/LB TACHOMETER SIGNAL
44 —
45 D20 20L6 SCI RECEIVE
46 — —
POWERTRAIN 49 V32 20YL/RD VSC SWITCH OUTPUT (ON)
CONTROL 50 V33 20WT/LG VSC SWITCH RESUME/ACCEL
MODULE 51 K51 20DB/YL ASD/FUEL PUMP RELAY CONTROL
52 — —
53 V35 20L6/RD VEHICLE SPEED CONTROL VENT SIGNAL
54 K54 20OR/BK TCC SOLENOID CONTROL
56 — —
58 — —
59 — —
60 — —
J958W-9
BR 8W-80 CONNECTOR PIN OUTS 8W - 80 - 1 7
C136
c BLACK 1
2
2
F18 20LG/BK
D2i 20PK
D21 20PK
IGN SW OUTPUT (START/RUN)
SCI TRANSMIT
SCI TRANSMIT
EEje 3 ZI2 20BK/TN GROUND
4 — —
ENGINE 5 D20 20LG SCI RECEIVE
DATA LINK
CONNECTOR 5 D20 20LG SCI RECEIVE
6 — —
C137

BLACK I K32 18YL/GY IGNITION COIL DRIVER
2 — — .
3 — —
1 - O ooo O - 5 4 — —
» =3 5 K17 18DB/TN IGNITION COIL DRIVER
10- O o o o O - 6
n.
7 K138 20BR/0R DWELL SIGNAL
IGNITION
8 K137 20WT/BK DWELL SIGNAL
MODULE
9 F18 20LG/BK FUSED I6N SW OUTPUT (START/RUN)
10 K7 180R 8V SUPPLY
C138

1 K24 20GY/BK CRANKSHAFT POSITION SENSOR SIGNAL
3 K7 200R 8V SUPPLY
BLACK
CRANKSHAFT
POSITION
SENSOR
•BLACK C139
CAV CIRCUIT FUNCTION 3.9L.5.2L

1 G60 16GY/YL OIL PRESSURE GAUGE SENDING UNIT AND 5.9L
ENGINE
2 G6 16GY OIL PRESSURE WARNING LAMP SWITCH
ENGINE CAV CIRCUIT FUNCTION 8.0L AND

OIL PRESSURE 1 G60 18GY/YL OIL PRESSURE GAUGE SENDING UNIT DIESEL
SENSOR ENGINE
2 GS 18GY OIL PRESSURE WARNING LAMP SWITCH
*- INDICATES TWISTED PAIR

J958W-9
8W 80 -18 8W-80 CONNECTOR PIN OUTS B R
BLACK CI4P
1 Ki16 18WT/DB INJECTOR #10 DRIVER
INJECTOR #10
BLACK C141
LOJ CAV CIRCUIT FUNCTION

1 K18 18RD/YL IGNITION COIL DRIVER
3 K17 18DB/TN IGNITION COIL DRIVER
IGNITION COIL
4-PACK
C142

1 Kl13 18LB/BR INJECTOR #8 DRIVER 8.0L ENGINE
ONLY

5.2L AND 5.9L
1 K18 18RD/YL INJECTOR #8 DRIVER
ENGINES ONLY
INJECTOR #8 2 A142 16DG/0R ASD RELAY OUTPUT
£143
1 Kl14 18YL/WT INJECTOR #6 DRIVER 8.0L ENGINE
ONLY
CAV CIRCUIT FUNCTION 3.9L. 5.2L

1 K58 18BR/DB INJECTOR #G DRIVER AND 5.9L
2 A142 16DG/0R ASD RELAY OUTPUT ENGINES ONLY
INJECTOR #6
J958W-9
BR 8W-80 CONNECTOR PIN OOTS 8W - 80 -19
C144

2 - K32 18YL/GY IGNITION COIL DRIVER
3 K43 200G/GY IGNITION COIL DRIVER
4 A142 140G/0R ASD RELAY OUTPUT
BLACK-
IGNITION
COIL
6-PACK
C145

1 Kl15 18TN INJECTOR #4 DRIVER 8.0L ENGINE
ONLY
CAV CIRCUIT FUNCTION 3.9L.

1 K14 18LB/BR INJECTOR #4 DRIVER 5.2L AND 5.9L
INJECTOR #4
BLACK €146
1 F18 20LG/BK FUSED IGN SW OUTPUT (START/RUN)
2 K35 20GY/YL EGR SOLENOID CONTROL
EXHAUST
GAS RECIRCULATION
SOLENOID
C147

1 K158 18LG/BK INJECTOR #2 DRIVER 8.0L ENGINE
ONLY

1 K12 18TN INJECTOR #2 DRIVER AND 5.9L
INJECTOR #2
J958W-9
C148

Hoi 1 K4 18BK/LB SENSOR GROUND
2 Kl 18D6/RD MAP SENSOR SIGNAL
3 KB 18VT/WT 5V OUTPUT
( 3 . 9 L . 5.2L
(8.0L ENGINE ONLY) AND 5.9L ENGINE)
MAP SENSOR
C149

3 K6 18VT/WT 5V OUTPUT
BLACK-
THROTTLE
POSITION
SENSOR
C150
BLACK
J L CAV
1
CIRCUIT
K39 18GY/RD
FUNCTION
IDLE AIR CONTROL MOTOR DRIVER
IDLE AIR
CONTROL MOTOR
C151
BLACK
I K20 18DG GENERATOR FIELD CONTROL
q> 3
2
3
A142
Zl 6BK
14DB ASD RELAY OUTPUT
GROUND
1 2
GENERATOR
-BLACK C152

1 K2 18TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
2
ENGINE
COOLANT
TEMPERATURE
SENSOR
J958W-9
8W-80 CONNECIOi PIN OUTS 8W - 80 - 21
CIS3
i F18 20LG/BK FUSED IGN SW OUTPUT (START/RUN)
BLACK 2 K52 20PK/BK EVAP/PURGE SOLENOID CONTROL
EVAP/
PURGE
SOLENOID
BLACK CIS4

1 Kl15 18TN INJECTOR m DRIVER
INJECTOR #9
C155

1 K158 18LG/BK INJECTOR #7 DRIVER 8
ONLY
i 2
CAV
I
A142 16DG/0R
CIRCUIT
K!7 18DB/TN
ASD RELAY OUTPUT
FUNCTION
INJECTOR M l DRIVER
5.2L
AND 5.9L
ENGINES ONLY
INJECTOR #7 2 A142 16DG/0R ASD RELAY OUTPUT
C1SS

1 Kl13 18LB/BR INJECTOR #5 DRIVER S.OL ENGINE
ONLY

i K38 18GY INJECTOR #5 DRIVER AND 5.9L
ASD RELAY OUTPUT ENGINES ONLY
INJECTOR #5 2 A142 16DG/0R
BLACK
CIS?
CAV CIRCUIT FUNCTION 8.0L AND

1 K21 1GBK/RD INTAKE AIR TEMPERATURE SENSOR SIGNAL DIESEL
ENGINE
INTAKE AIR 2 K4 16BK/LB SENSOR GROUND
TEMPERATURE
SENSOR
1 K21 18BK/RD INTAKE AIR TEMPERATURE SENSOR SIGNAL AND 5.9L
ENGINES
2 K4 18BK/LB SENSOR GROUND j
J958W-9
80-22 8W-80 CONNECTOR PIN OUTS BR
C158

1 Kl14 18YL/WT INJECTOR #3 DRIVER S.OL ENGINE
ONLY
ti
3.9L, 5.2L
1 K13 18YL/WT INJECTOR #3 DRIVER AND 5.9L
A142 16DG/0R ENGINES ONLY
2 ASD RELAY OUTPUT
INJECTOR #3
CliS

1 Kl16 18WT/DB INJECTOR #1 DRIVER 8.0L ENGINE
ONLY
CAV CIRCUIT FUNCTION 3.9L, 5.2L

1 Kll 18WT/DB INJECTOR #1 DRIVER AND 5.9L
INJECTOR # 1
CI60
BLACK
2 K41 18BK/DG RIGHT HEATED OXYGEN SENSOR SIGNAL
3 Zll 18BR/WT GROUND
RIGHT HEATED
OXYGEN SENSOR
cist

1 LI 18VT/BK BACK-UP LAMPS SWITCH OUTPUT
^=*=*fy ^BLACK 2 LIO 18BR/LG FUSED IGNITION SWITCH OUTPUT (RUN)
BACK-UP
LAMP SWITCH
J958W-9
8W - 80 - 23
C162
CAV CIRCUIT FACTION

2 K!4! 18TN/HT LEFT HEATED OXYGEN SENSOR SIGNAL
3 Zll 18BK/MT GROUND
BLACK
LEFT HEATED
OXYGEN SENSOR
BLACK € £63
El CAV CIRCUIT FUNCTION
1 G7 18MT/0R VEHICLE SPEED SENSOR SIGNAL
3 K7 180R 8V SUPPLY
VEHICLE
SPEED
SENSOR
BLACK C164

LH-i 1 C3 18DB/BK A/C COMPRESSOR CLUTCH RELAY OUTPUT
2 Zll 18BK/WT GROUND
A/C COMPRESSOR
CLUTCH
C165
BLACK
CAV CIRCUIT FUMCTIGri

1 C90 18LG/WT A/C SELECT SiSMAL
2 C90 18LG A/C SELECT SISMAL
A/C HIGH PRESSURE

SWITCH
CliS
BLACK
CAMSHAFT 3 K7 180R 8V SUPPLY

POSITION
SENSOR
J958W-9
8W - 80 - 24 3W-80 CONNECTOR PIN OUTS B R
CIS?

2 F18 20LG/BK FUSED IGNITION SWITCH OUTPUT (START/RUN)
BLACK 3 K54 200R/BK TCC SOLENOID CONTROL
TRANSMISSION
OVERDRIVE
SOLENOID
C1SS
1 T54 18VT TRANSMISSION TEMPERATURE SENSOR SIGNAL GAS
BLACK' CAV CIRCUIT FUNCTION

TRANSMISSION 1 T54 IGVT TRANSMISSION TEMPERATURE SENSOR SIGNAL DIESEL
TEMPERATURE
SENSOR 2 K4 16BK/LB SENSOR GROUND
BLACK
cisi
1 LIO I8BR/LG FUSED IGNITION SWITCH OUTPUT (RUN)
2 T41 18BK/WT PARK/NEUTRAL POSITION SWITCH SENSOR
3 LI 18VT/BK BACK-UP LAMPS SWITCH OUTPUT
PARK/NEUTRAL
POSITION SWITCH
C170
I A142 14DG/0R ASD RELAY OUTPUT
IGNITION COIL
BLACK Ctf I

3 K7 200R 8V SUPPLY
CAMSHAFT
POSITION
SENSOR
J958W-9
2 C172
-BLACK CAV CIRCUIT FUNCTION

i A12 14RD/TN FUSED B +
2 F18 20LG/BK FUSED IGNITION SWITCH OUTPUT (START/RUN)
3
4 A93 14RD/BK FUEL HEATER RELAY OUTPUT
FUEL HEATER
RELAY
t C173
BLACK
1 A18 10RD/BK FUSED B +
4—i 0-2
2 T40 12BR ENGINE STARTER MOTOR RELAY OUTPUT
3 A123 10RD/VT FUEL SHUT DOWN RELAY OUTPUT
3 4 Z12 18BK/TN GROUND
FUEL SHUT
DOWN RELAY
C174
BLACK
2 Kl 20DG/RD W A T E R - I N - F U E L SIGNAL
1 2
WATER-IN-
FUEL SENSOR
C17S
1 2 3 ^ BLACK
< 1
2
Z12 10BK/TN
A123 10RD/VT
GROUND
FUEL SHUT DOWN RELAY OUTPUT
FUEL SHUT DOWN
SOLENOID 3 F18 20LG/BK FUSED IGNITION SWITCH OUTPUT (START/RUN)
BLACK C176

I K6 20VT/WT 5V OUTPUT
2 K22 200R/DB THROTTLE POSITION SENSOR SIGNAL
THROTTLE POSITION
SENSOR
J958W-9
C204
to BLACK
CAV
1 M2
CIRCUIT
20YL COURTESY LAMP

. .ACTION
DRIVER
2 Z3 20BK/OR GROUND
HEADLAMP
SWITCH
cats
BLACK BLACK
X 1 R43 18BK/LB 1 R43 18BK/LB
t 2 R45 18DG/LB E • • 2 R45 18DG/LB
C206

1 El 20TN/0R HEADLAMP SWITCH OUTPUT
2 L2 1 6 L G HEADLAMP SWITCH OUTPUT
BLACK
3 M3 22PK/DB GROUND
4 F33 20PK/RD FUSED 8 4-
5 G26 1 8 L B K E Y - I N IGNITION SWITCH SENSE
6 G16 22BK/LB DOOR JAMB SWITCH SENSE
7 L20 16LG/WT FUSED B +
Br 8
9
A3
L7
12RD/LG
20BK/YL
FUSED
PARK
B +
LAMP SWITCH OUTPUT
HEADLAMP
SWITCH
C207

1 F35 16RD 1 F35 1 6 R D
BLACK- B LL AACI R
K—y
2 F21 1 4 T N 2 F2I HTM
3 016 14BR/WT 3 Q16 14BR/WT
4 026 14VT/WT 4 Q26 14VT/WT
5 P36 16PK/VT Q OlQi-8 5 P36 16PK/VT
6 P35 160R/VT 6 P35 160R/VT

7 P34 16PK/BK 7 P34 ISPK/BK
8 P33 160R/BK 8 P33 160R/BK
INDICATES TWISTED PAIR J958W-9

CAV CIRCUIT
C208 I E2 220R
2 F12 22DB/WT
CAV CIRCUIT 3 L7 18BK/YL
1 E2 220R 3 L7 20BK/YL
2 F I 2 22DB/WT 4 Ml 20PK
BLACK-
3 L7 20BK/YL 4 Ml 20PK
BLACK
4 Mi 20PK 5 M2 22YL
5 M2 22YL 5 M2 22YL
6 Zll 20BK/WT G Zll 20BK/WT
7 632 22BK/LB 7 G32 22BK/LB
8 G31 22VT/LG 8 G31 22VT/LG
9 LIO 22BR/LG 9 LIO 22BR/LG
C209

E2 220R FUSED HEADLAMP SWITCH OUTPUT
Gil 20WT/BK PARK BRAKE SWITCH SENSE

Gil 22WT/BK PARK BRAKE SWITCH SENSE
10 Gil 22WT/BK PARK BRAKE SWITCH SENSE
11 Gil 22WT/BK PARK BRAKE SWITCH SENSE
BLACK 12 616 22BK/LB BUZZER
11 13 G16 22BK/LB BUZZER
14 616 22BK/LB BUZZER
f
15 V32 22YL/RD VEHICLE SPEED CONTROL
2 2 - ^ -12
33
23 18
JOINT 19 F12 22DB/WT FUSED IGNITION SWITCH OUTPUT START/RUN
CONNECTOR C 20 F12 22DB/WT FUSED IGNITION SWITCH OUTPUT (START/RUN)
21 F12 20DB/WT FUSED IGNITION SWITCH OUTPUT (START/RUN)
22 F12 22DB/WT FUSED IGNITION SWITCH OUTPUT (START/RUN)
23 G9 22GY/BK BRAKE WARNING LAMP DRIVER
27
28 LIO 22BR/LG BACK- UP LAMP SWITCH OUTPUT
29 LIO 22BR/LG BACK-UP LAMP SWITCH OUTPUT
30 LIO 22BR/LG BACK- UP LAMP SWITCH OUTPUT
J958W-9
C210

1 V9 18WT/BK WINDSHIELD WIPER SWITCH OUTPUT (DELAY)
2 V8 18VT WINDSHIELD WIPER SWITCH OUTPUT (DELAY)
3 VIO 18BR WINDSHIELD WIPER SWITCH OUTPUT (WASH)
4 V6 16DB/BK FUSED IGNITION SWITCH OUTPUT (ACC/RUN)
5 V4 16RD/YL WINDSHIELD WIPER SWITCH OUTPUT (HIGH)
BLACK 6 V3 18BR/HT WINDSHIELD WIPER SWITCH OUTPUT (LOW)
17
7 V7 18DG/WT WINDSHIELD WIPER SWITCH OUTPUT (PARK)
8 V17 18DG WINDSHIELD WIPER SWITCH OUTPUT (DELAY)
• •
• • u
10 L6 20RD/6Y TURN SIGNAL FLASHER OUTPUT
• 11 L61 20LG/YL LEFT FRONT TURN SIGNAL
• 11 L61 18LG/YL LEFT FRONT TURN SIGNAL
• • D 12
13
L63
L50
18DG/RD
18WT/TN
LEFT REAR TURN SIGNAL
• • •
9-a • • 14 L19 18PK/WT HAZARD FLASHER OUTPUT
15 L62 18BR/PK RIGHT REAR TURN SIGNAL
16 L60 20TN/BK RIGHT FRONT TURN SIGNAL
10 16 L60 18TN/BK RIGHT FRONT TURN SIGNAL
MULTI-FUNCTION 17 — —
SWITCH 18 L4 16VT/WT HEADLAMP SWITCH OUTPUT (LOW)
19 L2 16LG HEADLAMP SWITCH OUTPUT
20 L3 16RD/0R HEADLAMP SWITCH OUTPUT (HIGH)
21 L20 16LG/WT FUSED B +
22 —
23 — —
24 — —
€111

BLACK 1 X3 22BK/RD HORN RELAY OUTPUT
1 X3 20BK/RD • HORN RELAY CONTROL
• • • 2 V33 22WT/LG VEHICLE CONTROL SWITCH - RESUME/ACCEL
3 V34 22WT/RD FUSED IGNITION SWITCH OUTPUT (START/RUN)
I 5
VEHICLE SPEED 4 V31 22BR/RD VEHICLE SPEED CONTROL SWITCH - SET
CONTROL SWITCH 5 V32 22YL/RD VEHICLE SPEED CONTROL SWITCH OUTPUT (ON)
C212
CAV CIRCUIT FUNCTION-

1 Al J.2RD FUSED 3-:-
BLACK 2 A3! 12BK/WT VV?YlVy\ SWITCH OUTPUT (ACC/R-/L;
3 A22 12BK/0R ISKITICi! SWITCH OUTPUT (RUii;
4 A2 12PK/BK FUSED 3v-
7 5 69 22GY/BK BRAKE WARNING LAMP DRIVER
6 A21 12DB IGNITION SWITCH OUTPUT (START/RUN)
IGNITION SWITCH 7 A41 18DB/YL IGMiTiGM SWITCH OUTPUT (STAir/;
J958W-9
BLACK C213
jf
• ~ 1
1 GIB 22BK/LB BUZZER
2 G26 18LB KEY-IN BUZZER SWITCH
3 Z3 20BK/0R GROUND
>-4
4 M50 22YL/RD KEY-IN LAMP DRIVER
KEY-IN SWITCH AND

IGNITION SWITCH
LAMP
C214

BLACK 1 F32 18PK/DB FUSED B +
2 L50 18WT/TN STOP LAMP SWITCH OUTPUT
3 V30 20DB/RD STOP LAMP SWITCH OUTPUT
4 V32 20YL/RD FUSED IGNITION SWITCH OUTPUT (RUN)
STOP LAMP
SWITCH
C215

1 G19 22LG/RD WARNING LAMP DRIVER
1 14
2 G107 22BK/GY 4WD SWITCH OUTPUT
i
UUUUULn 0 Li 2 G107 20BK/GY 4WD SWITCH OUTPUT
JULUUUULL 1 — —
3
TEdJ 4 G4 22DB FUEL LEVEL SENSOR SIGNAL
5 G60 22GY/YL OIL PRESSURE GAUGE SENDING UNIT
7 F14 20LG/YL FUSED IGNITION SWITCH OUTPUT (START/RUN)
8 G29 22BK/TN LOW WASHER FLUID INDICATOR LAMP
9 G3 22BK/PK MALFUNCTION INDICATION LAMP
10 G24 22GY/PK SRI DRIVER
INSTRUMENT 11 G6 22GY OIL PRESSURE WARNING LAMP SWITCH
CLUSTER
12 G21 22GY/LB TACHOMETER SIGNAL
13 — —
14 E2 220R FUSED HEADLAMP SWITCH OUTPUT
J958W-9
8W - 80 - 32 8W-80 CONNECTOR PIN
C216

1 L60 20TN/BK RIGHT FRONT TURN SIGNAL
2 634 18RD/GY HIGH-BEAM INDICATOR LAMP
BLACK 2 634 18RD/6Y HI6H-BEAM INDICATOR LAMP
•tULJUUL-l pULULULy
L 3
4
L61 20LG/YL
67 20WT/0R
LEFT FRONT TURN SI6NAL
VEHICLE SPEED SENSOR SIGNAL
5 Z3 20BK/0R GROUND
JhdJ 6 R41 18BK/TN AIRBAG SYSTEM WARNING LAMP DRIVER
14 7 — —
8 620 22VT/YL ENGINE COOLANT TEMPERATURE SENDING UNIT
INSTRUMENT
CLUSTER 9 Z l l 20BK/WT GROUND
10 611 22WT/BK PARK BRAKE SWITCH SENSE
11 69 226Y/BK BRAKE WARNING LAMP DRIVER
13 — —
14 613 20DB/RD SEAT BELT LAMP DRIVER
C217

1 M2 20YL COURTESY LAMP DRIVER
JOINT 8 M2 22YL COURTESY LAMP DRIVER
CONNECTOR A
10 12 20YL COURTESY LAMP DRIVER
€218

BLACK 1 F12 20DB/MT FUSED IGNITION SWITCH OUTPUT (START/RUN)
2 613 20DB/RD SEAT BELT LAMP DRIVER
3 Z3 20BK/0R GROUND
(ZD 4 610 22L6/RD SEAT BELT WARNING SWITCI-;
l t d nm 5 — —
6 Ml 20PK FUSED B~:-
7 626 18LB KEY-IN BUZZER SWITCH
7 626 18LB KEY-IN BUZZER SWITCH
BUZZER 8 — —
MODULE
J958W-9
C219

i V9 I8WT/BK WINDSHIELD WIPER SW OUTPUT (DELAY)
2 VIO 18BR WINDSHIELD WIPER SW OUTPUT (WASH)
2 VIO 18BR WINDSHIELD WIPER SW OUTPUT (WASH)
3 V6 18DB/BK IGN SW OUTPUT (ACC/RUN)
4 V5 18DG/YL WINDSHIELD WIPER PARK SWITCH
5 23 18BK/0R GROUND
i
L 6 V7 18DG/WT WINDSHIELD WIPER SW OUTPUT (PARK)
BLACK
7 VI7 18DG WINDSHIELD WIPER SW OUTPUT (DELAY)
8 V8 18VT WINDSHIELD WIPER SW OUTPUT (DELAY)
INTERMITTENT MIRER
CONTROL MODULE
C220

* 1 Bl13 22RD/VT REAR WHEEL SPEED SENSOR - HIGH
** I Bl13 22RD/VT REAR WHEEL SPEED SENSOR - HIGH
• v V
ROLLSBLACK
*
**
2
2
Bl14 22WT/VT
Bl14 22WT/VT
REAR WHEEL SPEED SENSOR - LOW
REAR WHEEL SPEED SENSOR - iM
TEST
CONNECTOR
C221
874 87
a BLACK
CAV
30
CIRCUIT
L38 20LB/BK FUSED B +
FUNCTION
85 L72 22BK/RD GROUND

87 L139 20LG/BK FOG LAMP RELAY Ml OUTPUT
87A
FOG LAMP
RELAY 1
C222
87A 87
a BLACK
CAV
30
CIRCUIT
L139 20LG/BK
FUNCTION
FOG LAMP RELAY Ml OUTPUT
85 Z3 18BK/0R GROUND
86 G34 18RD/GY HIGH BEAM INDICATOR LAMP DRIVER
87A L39 20LB FOG LAMP RELAY Ml OUTPUT
87
FOG LAMP
RELAY 2
* AND * * - INDICATES TWISTED PAIRS J958W-9

C223
BLACK CAV
1
CIRCUIT FUNCTION
1 02 18WT/BK CCD BUS (--}
2 Ml 20PK FUSED (H~
3 D l l 22WT/RD SCI RECEIVE
4 D20 2006 SCI RECEIVE
ErTJTJTh 5 D21 20PK/DB SCI TRANSMIT
6 Dl 18VT/BR CCD BUS (+)
T_j=Er
7 012 220R SCI TRANSMIT
8
AIRBAG/ABS
DATA LINK
CONNECTOR
C224
BLACK —i
1 —
2 686 20TN/0R WATER-IN-FUEL
3 F14 20L6/YL FUSED ION SW OUTPUT (START/RUN)
•••• 4 685 200R/BK WAIT-TO-START
•••• 5 614 20PK/BK TRANS WARNIN6 LAMP DRIVER
6 — —
8 7 —
MESSAGE 8 —
CENTER
C225

BLACK
1 1
2
3
T6 220R/WT
Z3 20BK/0R
F12 22DB/WT
TRANSMISSION OVERDRIVE SWITCH OUTPUT
6R0UND
FUSED ION SW OUTPUT (START/RUN)
4 — —
5 T18 22L6/0R OVERDRIVE SWITCH LAMP DRIVER
TRANSMISSION 6 E2 200R FUSED HEADLAMP SWITCH OUTPUT
OVERDRIVE
SWITCH 6 E2 220R FUSED HEADLAMP SWITCH OUTPUT
C226
GRAY CAV CIRCUIT FUNCTION

I L72 22BK/RD GROUND
2 Z3 20BK/0R 6R0UND
3 Z3 20BK/0R 6R0UND
4 L39 20LB FOG LAMP RELAY # 2 OUTPUT
F06 LAMP 6 —
SWITCH
X - INDICATES TWISTED PAIRS (Dl I 02, 020 t 021) J958W-9

C227

v^BLACK
ill 2
3
C90 22LG
C5 16LG/YL
A/C SELECT SIGNAL
BLOWER MOTOR SWITCH OUTPUT (Mi)
4 C4 1GTN BLOWER MOTOR SWITCH OUTPUT (LOW)
5 C6 H L B BLOWER MOTOR SWITCH OUTPUT (M2)
HVAC SWITCH S C7 12BK/TN BLOWER MOTOR SWITCH OUTPUT (HIGH)
AND 7 Z3 12BK/OR GROUND
HEATER SWITCH
€228
i B101 18LG/WT REAR ISOLATION SOLENOID CONTROL
3 A20 18RD/DB FUSED 84-
BLACK
3 A20 18RD/DB FUSED B 4 -
0 0 0 0 0 0 - 7
5 G i l 22WT/BK PARK BRAKE SWITCH SENSE
14—OOOO OOO— 8 6 G9 22GY/WT BRAKE WARNING LAMP DRIVER
REAR WHEEL
ANTI-LOCK 8 Bl13 22RD/VT REAR WHEEL SPEED SENSOR - HIGH
CONTROL MODULE
9 Bl 14 22WT/VT REAR WHEEL SPEED SENSOR - LOW
10 Bl 12 20BK SERVICE TEST
11 B i l l 22LB/BK REAR RESET SWITCH SENSE
13 F32 20PK/DB FUSED B +
14 B108 18WT RWAL DECAY SOLENOID CONTROL
C229

1 — —
2 X55 20BR/RD LEFT FRONT DOOR SPEAKER B ( - )
-db• • • • • b 3 X56 20DB/RD RIGHT FRONT DOOR SPEAKER B ( - )
BLACK
G X12 18RD/WT FUSED IGN SW OUTPUT (RUN/START)
STEREO
RADIO 7 Ml 20PK FUSED 8 4-
J958W-9
C230

1 X60 22DG/RD RADIO 12 VOLT OUTPUT
i <
2 X51 20BR/YL LEFT REAR SPEAKER (+)
3 X52 20DB/WT RIGHT REAR SPEAKER (+)
"LT 4 X53 20DG LEFT FRONT DOOR SPEAKER (+)
BLACK 5 X54 20VT RIGHT FRONT DOOR SPEAKER (+)
STERO 6 X57 20BR/LB LEFT REAR SPEAKER R
RADIO
7 X58 20DB/0R RIGHT REAR SPEAKER (—) 1
C?31

1 Ml 20PK FUSED B 4-
2 Ml 20PK FUSED B 4 -
3 —
6 — —
7 BLACK
7
8
9
F32 20PK/DB
Mi 18PK
Ml 20PK
FUSED B +
FUSED B +
FUSED B +
JOINT 10 Ml 18PK FUSED B -f
CONNECTOR B
C232

BLACK 1 R47 18DB/LB LEFT IMPACT SENSOR LINE 1
2 R49 18LB LEFT IMPACT SENSOR LINE 2
3 D2 18WT/BK CCD BUS ( - }
4 Dl 18VT/BR CCD BUS (4-)
5 F23 18DB/YL FUSED IGN SW OUTPUT (RUN)
6 F14 18LG/YL FUSED IGN SW OUTPUT (START/RUN)
7 R41 18BK/TN AIRBAG SYSTEM WARNING LAMP DRIVER
8 — —
......
9 —
10 — —
AIRBAG
CONTROL MODULE 12 R48 18TN RIGHT IMPACT SENSOR LINE 2
13 R46 18BR/LB RIGHT IMPACT SENSOR LINE 1
INDICATES TWISTED PAIR

J958W-9
C133
£ BLACK 1
3 2
3 —
R43 18BK/LB AIRBAG LINE 1 —
I 4 4 R45 18DG/LB AIRBAG LINE 2
AIRBAG CONTROL
MODULE
€234
BLACK
1 Z2 18BK/LG GROUND
2 X60 22DG/RD RADIO 12 VOLT OUTPUT
3 XI3 I8BK/RD INFINITY SPEAKER AMPLIFIER
4 Ml I8PK FUSED B +
RADIO
CHOKE
C235

1 F30 18RD/0R FUSED IGN SW OUTPUT (ACC/RUN)
2 Z3 18BK/0R GROUND
POWER
OUTLET
€238
BLACK
1 Z3 18BK/0R GROUND
CIGAR
LIGHTER
C237
BLACK
1 C7 12BK/TN 1 C7 12BK/TN
2 C6 H L B 2 C6 H L B
3 C4 16TN 3 C4 16TN
4 C5 16LG/YL 4 _ C5 16LG/YL
INDICATES TWISTED PAIR J958W-9

8W - 81 - 38 8W-80 C0I1ECT0I P i l OUTS BR
C238
-BLACK
1 -—
cs J D L ^ f •2
CAV
1 CI
CIRCUIT
12DG
FUNCTION
FUSED IGNITION SWITCH OUTPUT (RUN)
( jet. y 2 C7 12BK/TN GROUND
BLOWER
MOTOR
C13S

BLACK
BLACK I 026 14VT/WT 1 026 14VT/WT
5^ L
u±=n *
2 016 14BR/WT 2 016 14BR/WT
3 F2I NTN 3 F2! 14TN
~a~B, 4 4
5 5
'10
10 6 P36 16PK/VT 6 P36 16PK/VT
7 F35 16RD 7 F35 IBRD
8 P33 160R/BK 8 P33 160R/BK
9 P34 16PK/BK 9 P34 16PK/BK
10 P35 160R/VT 10 P35 160R/VT
C24Q
BLACK CAV CIRCUIT CAV CIRCUIT
\
L /
1
2
P72 20YL/BK
P70 20WT L
BLACK
1
2
P72 20YL/BK
P70 20WT
3 X54 20VT 3 X54 20VT
a 4 X13 18BK/RD 3 X54 18VT
5 Z2 18BK/LG 4 X13 18BK/RD
6 X56 20DB/RD 5 Z2 18BK/L6
7 M2 22YL 6 X56 18DB/RD
8 P74 20DB 6 X56 20DB/RD
7 M2 18YL
8 P74 20DB
C241
F U S E BLOCK
(SEE 8W-10-2)
J958W-9
C301
BLACK
1 22 18BK/LG GROUND
2 X58 18DB/0R RIGHT REAR SPEAKER (-)
3 X52 180B/WT RIGHT REAR SPEAKER (+)
4 X13 18BK/RD AMPLIFIED AMPLIFIER
RIGHT REAR
PREMIUM SPEAKER
BLACK-\ C302

I X58 18DB/0R RIGHT REAR SPEAKER ( - )
2 X52 18DB/WT RIGHT REAR SPEAKER {+)
RIGHT REAR
STANDARD SPEAKER
C303
BLACK CAV CIRCUIT BLACK CAV CIRCUIT

I Z3 HBK/OR i Z3 14BK/0R
2 F37 14RD/LB 2 F37 14RD/LB
2 1
C3§4
BLACK
1 Ml 18PK FUSED 0 4-
DOME
LAMP
C305

1 Z2 18BK/LG GROUND
4M n 3 2 X57 18BR/LB
X51 18BR/YL
LEFT REAR SPEAKER
LEFT REAR SPEAKER
(-)
(+)
3
1 4 4 X13 18BK/RD AMPLIFIED SPEAKER
LEFT REAR
PREMIUM SPEAKER
J958W-9
-80-40 8W-80 CONNECTOR PIN OUTS BR
C306
1 X57 18BR/LB LEFT REAR SPEAKER (-)

2 X51 18BR/YL LEFT REAR SPEAKER (+)
BLACK
1 2
LEFT REAR
STANDARD
SPEAKER
C307
BLACK
1 Z3 18BK/0R mom:-
i Z3 18BK/0R GROUND
SEAT BELT 2 G10 20LG/RD SEAT BELT WARNING SWITCH
SWITCH
C308
CAV CIRCUIT
BLACK I m I8PK
BLACK
CAV ciRcun 1 Ml 18PK
i !8PK 2 Z3 18BK/0R
2 Z3 18BK/QR 2 Z3 18BK/0R
3 L50 18WT/TN 3 L50 18WT/TN
4 M3 20PK/DB 3 L50 18WT/TN
5 — 4 M3 18PK/DB
6 4 M3 18PK/DB
5 —
6
C309
BLACK
1 Z3 18BK/0R GROUND
Z GIG 18BK/LB DOOR JAMB SWITCH SENSE
3 • M2 18YL COURTESY LAMP DRIVER
LEFT DOOR
JAMB SWITCH
BLACK C3io

i P74 20DB POWER MIRROR UP/DOWN CONTROL
2 P72 20YL/BK POWER MIRROR LT/RT CONTROL
3 P70 20WT POWER MIRROR UP/DOWN CONTROL
4 Ml 20PK FUSED 8 4
8 P75 20DB/WT POWER MIRROR LT/RT CONTROL
7 P71 20YL POWER MIRROR LT/RT CONTROL
POWER 6 P73 20YL/PK POWER MIRROR UP/DOWN CONTROL
MIRROR
SWITCH 5 Z3 18BK/0R GROUND
5 Z3 18BK/0R GROUND
J958W-9
-BLACK C311
1 P75 20M/WT POWER MIRROR L E F T / R I G H T CONTROL
2 P73 20YL/PK POWER MIRROR UP/DOWN CONTROL

3 P71 20YL POWER MIRROR LEFT/RIGHT CONTROL
c~zr
LEFT POWER
MIRROR MOTORS
BLACK C3I2
1 — CAV CIRCUIT FUNCTION

1 X55 20BR/RD LEFT DOOR SPEAKER ( - )
2 X53 20DG LEFT DOOR SPEAKER (+)
2 —
LEFT DOOR
STANDARD
SPEAKER
C313
1 12 18BK/LG GROUND
2 X55 18BR/RD LEFT DOOR SPEAKER (-)
3 X53 18DG LEFT DOOR SPEAKER (+)
BLACK
4 X13 I8BK/RD AMPLIFIED SPEAKER
LEFT DOOR
PREMIUM
SPEAKER
£314
1 • X53 18DG LEFT DOOR SPEAKER (+)
2 X55 18BR/RD LEFT DOOR SPEAKER (-)
LEFT DOOR '

TWEETER
C315

1 P35 160R/VT DOOR LOCK SWITCH OUTPUT (LOCK)
O 2 Z3 14BK/0R GROUND
3 F35 14RD FUSED B +
4 P36 16PK/VT DOOR LOCK SWITCH OUTPUT (UNLOCK)
5 Z3 14BK/0R GROUND
-BLACK
LEFT DOOR
LOCK SWITCH
J958W-9
C316
1 2 3
I 026 14VT/WT RIGHT PWR WINDOW SW, RIGHT UP/DOWN CONTROL
2 F21 14TN FUSED IGNITION SWITCH OUTPUT (RUN)
3 021 14WT LEFT PWR WINDOW SW, LEFT UP/DOWN CONTROL
4 Qll HLB LEFT PWR WINDOW SW, LEFT UP/DOWN CONTROL
5 13 14BK/0R GROUND
6 016 HBR/WT RIGHT PWR WINDOW SW, RIGHT UP/DOWN CONTROL
WHITE
LEFT POWER
WINDOW SWITCH
€317
BLACK
1 P33 160R/BK DOOR LOCK DRIVER
2 P34 16PK/BK DOOR UNLOCK DRIVER
LEFT DOOR
LOCK MOTOR
€318

1 Oil HLB LEFT PWR WINDOW SW. LEFT UP/DOWN CONTROL
2 021 HWT LEFT PWR WINDOW SW LEFT UP/DOWN CONTROL
t
BLACK
LEFT POWER
WINDOW MOTOR
€319
BLACK
1 13 18BK/0R 6R0UND
RI6HT DOOR
JAMB SWITCH
/—BLACK
/ €320

1 X56 20DB/RD RIGHT DOOR SPEAKER+
2 X54 20VT RI6HT DOOR SPEAKER-
RIGHT DOOR
STANDARD SPEAKER
J958W-9
B R 8W-80 CONNECTOR PIN OUTS 8W - 80 - 43
o n
1 012 14BR RIGHT PWR WINDOW SW, RIGHT UP/DOWN CONTROL
2 022 HVT RIGHT PWR WINDOW SW. RIGHT UP/DOWN CONTROL
BLACK
RIGHT POWER
WINDOW MOTOR
C322
i 2 3
GRAY- CAV CIRCUIT FUNCTION
i P74 2001 POWER MIRROR UP/DOWN CONTROL
2 P70 20WT POWER MIRROR UP/DOWN CONTROL
It,
3 P72 20YL/BK POWER MIRROR LEFT/RIGHT CONTROL
RIGHT
POWER MIRROR
MOTORS
C323

I 12 I8BK/LG GROUND
2 X56 18DB/RD RIGHT DOOR SPEAKER R
3 X54 18VT RIGHT DOOR SPEAKER (+)
BLACK- 4 X13 18BK/RD AMPLIFIED SPEAKER
RIGHT DOOR
PREMIUM SPEAKER
C324

1 X54 18VT RIGHT DOOR SPEAKER R
2 X56 18DB/RD RIGHT DOOR SPEAKER R
BLACK
RIGHT DOOR
TWEETER
1 2 C32S
1
O CAV CIRCUIT FUNCTION
o 1 P33 160R/BK DOOR LOCK DRIVER

2 P36 16PK/VT DOOR LOCK SWITCH OUTPUT (UNLOCK)
3 F35 IBRD FUSED B
5 P35 I60R/VT DOOR LOCK SWITCH OUTPUT (LOCK)
-BLACK
RIGHT DOOR
LOCK SWITCH
J958W-9
8W - 80 - 4 4 8W-80 CONNECTOR PIN OUTS
C326
i
1 Q22 14VT RIGHT PWR WINDOW SWITCH, UP/DOWN CONTROL
BLACK- 2 016 14BR/WT RIGHT PWR WINDOW SWITCH. UP/DOWN CONTROL
5-=k) OH" 4 3
4
F21
012 14BR
14TN FUSED IGNITION SWITCH OUTPUT (RUN)
RIGHT PWR WINDOW SWITCH. UP/DOWN CONTROL
5 026 14VT/WT RIGHT PWR WINDOW SWITCH. UP/DOWN CONTROL
RIGHT POWER
WINDOW SWITCH
C327
BLACK
1 P33 160R/BK DOOR LOCK DRIVER
RIGHT DOOR
LOCK MOTOR
C328
BLACK
1 A61 16D6/BK FUEL PUMP RELAY OUTPUT
2 64 20DB FUEL LEVEL SENSOR SI6NAL
3 Zll 20BK/WT 6R0UND
FUEL TANK LEVEL 4 Z13 16BK GROUND
GAUGE SENDING UNIT
BLACK C329
CAV CIRCUIT BLACK CAV CIRCUIT

1 L7 18BK/YL 1 L7 18BK/YL
2 Z13 18BK 2 Z13 18BK
4 L62 18BR/PK 4 L62 18D6/BR
4 L62 18BR/PK
1 2 C330
BLACK BLACK

1 B l 14 20WT/VT 1 Bl14 20WT/VT
2 B113 20RD/VT 2 Bl13 20RD/VT
* - INDICATES TWISTED PAIR J958W-9

C331
BLACK- 3 2 1
I Li I8VT/BK 1 LI 18VT/BK
n a
2 L62 18BR/PK 2 L62 I8BR/PK
3 L63 18DG/RD BLACK 3 L63 18DG/RD
C332
BLACK CAV CIRCUIT /-BLACK CAV CIRCUIT
1 A6 I4RD/TN -JrTLi 1 A6 14RD/TN
2 B40 H L B 2 - - 1 2 B40 H L B
3 L7B 14BK/0R 3— -4 3 L76 HBK/OR
4 ZI3 12BK M 4 ZI3 I2BK
C333
-BLACK BLACK

i L7 18BK/YL I L7 183K/YL
2 Z13 18BK 2 Z13 18BK
3 Li 18VT/BK 3 LI 18VT/V
4 L63 18DG/RD 4 L63 18DG/BR
C334
BLACK
£ CAV
i
CIRCUIT
LiO 22BR/LG
FUNCTION
FUSED IGNITION SWITCH OUTPUT (RUN)
--3
2 Z4 22BK GROUND
3 Li 22VT/BK BACK-UP LAMP SWITCH OUTPUT
DAY/NIGHT
MIRROR
BLACK C335

1 Z4 18BK GROUND
LEFT OUTBOARD
CLEARANCE LAMP
J958W-9
-BLACK
C336

I Z4 18BK GROUND
I 2
LEFT OUTBOARD
IDENTIFICATION
LAMP
£33?
J U L CAV CIRCUIT FACTION
-TAAArj- 3 1 Z4 I8BK GROUND
3 Ml 20PK FUSED B +
BLACK-
OVERHEAD
MAP LAMP
C338

1 —
BLACK
3 — —
4 1A 18BK 6R0UND
5 Ml 18PK FUSED B +
f ' es a a a a
8 Mi 18PK FUSED B +
! • • • • • 7 F12 22DB/WT FUSED IGN SWITCH OUTPUT (START/RUN)
—q a a o—q
9 631 22VT/LG SENSOR RETURN
10 632 22BK/LB AMBIENT AIR TEMPERATURE SENSOR
11 —
OVERHEAD
CONSOLE 12 L7 20BK/YL PARK LAMP SWITCH OUTPUT
-BLACK C339

1 Z4 18BK GROUND
1
CENTER
IDENTIFICATION
LAMP
J958W-9
•BLACK C340

1 Z4 18BK GROUND
1 2
RIGHT OUTBOARD
IDENTIFICATION
LAMP
BLACK
C34I
1 Z4 I8BK GROUND
1 2
RIGHT OUTBOARD
CLEARANCE
LAMP
C342

1 Z13 18BK 1 Z13 18BK
2 L7 18BK/YL 2 L7 1.8BK/YL
BLACK BLACK
2 I
C343

1 Z13 18BK 1 Z13 18BK
2 L7 18BK/YL 2 L7 18BK/YL
BLACK BLACK
1 2
C40I
-BLACK

1 C7 12BK/TN BLOWER MOTOR SWITCH OUTPUT - HIGH
-ESI& 2 2 C5 16LG BLOWER MOTOR SWITCH OUTPUT - Ml
Q - 3 3 C4 16TN BLOWER MOTOR SWITCH OUTPUT - LOW
4 CB H L B BLOWER MOTOR SWITCH OUTPUT - M2
BLOWER
MOTOR
RESISTOR
J958W-9
C402
-BLACK BLACK-

i DEE
1 zi3 tsetc 1
a m 2 2 L7 18BK/YL 2 L7 18BK/YL
C403
BLACK BLACK

1 113 IBBK 1 Z13 18BK
H 2
2 L7 I8BK/YL 2 L7 18BK/YL
C404
BLACK BLACK
I
CAV CIRCUIT | CAV CIRCUIT
i u r n
1 111 18BK | 1 Z13 18BK
u n i 2
2 17 18BK/YL | 2 L7 18BK/YL
C405
BLACK
CAV CIRCUIT
i
BLACK
I E
z CAV CIRCUIT
1 Z13 18BK 1 Z13 18BK
H 2
2 L7 I8BK/YL 2 L7 18BK/YL
CIRCUIT
Z13 18BK
L7 18BK/YL
J958W-9
-BLACK
C407

2 ZI I8BK GROUND
PTO OR
4X4 SWITCH
C409

1 Bl14 20WT/VT REAR WHEEL SPEED SENSOR - LOW
2 Bl13 20RD/WT REAR WHEEL SPEED SENSOR - HIGH
REAR WHEEL
ANTI-LOCK
BRAKE SENSOR
C410
BLACK
1 13 18PK/DB GROUND
2 Ml 18PK FUSED B +
CARGO
LAMP 1
€411
BLACK
1 M3 18PK/DB GROUND
2 Ml 18PK FUSED B +
CARGO
LAMP 2
J958W-9
8W - 80 - 50 — — 8W-80 CONNECTOR PIN OUTS — — _ — BR
C4I2
BLACK
1 13 I8BK/0R GROUND
2 L50 I8WT/TN STOP LAMP SWITCH OUTPUT
CENTER HIGH
MOUNTED
STOP LAMP I
C413
BLACK
I Z3 18BK/0R GROUND
2 L50 18WT/TN STOP LAiP SWITCH OUTPUT
CENTER HIGH
MOUNTED
STOP LAMP 2
C414
I 2
1 Z13 18BK GROUND
RIGHT
LICENSE
LAMP
-BLACK
C415

1 L62 18DG/BR RIGHT REAR TURN SIGNAL
3H 3 ZI3 18BK GROUND
RIGHT TAIL. STOP. AND

TURN SIGNAL LAMP
GRAY
C4i§
1 Li 18VT/BK BACK-UP LAMPS SWITCH OUTPUT
2 Z13 18BK GROUND
RIGHT BACK-UP LAMP

U958W-9
BR 8W-80 CONNECTOR PIN OUTS 8W - 80 -11
C417
1 2
1 Z13 18BK GROUND
2 L? 18BK/YL PARK LAMP SWITCH OUTPUT
LEFT
LICENSE
LAMP
-BLACK
€418

1 L63 18DG/BR LEFT REAR TURN SIGNAL
3 Z13 I8BK GROUND
LEFT TAIL, STOP. AND

TURN SIGNAL LAMP
GRAY
€419

I LI 18VT/BK BACK-UP LAMPS SWITCH OUTPUT
2 Zl3 18BK GROUND
LEFT BACK-UP LAMP
BLACK C420
CAV CIRCUIT
DUAL REAR
1 Z13 18BK GROUND WHEELS
LEFT FORWARD
FENDER LAMP
BLACK £411

Z13 18BK GROUND DUAL REAR
I
WHEELS
RIGHT FORWARD
FENDER LAMP
J958W-9
8W - 80 - §2 8W-80 CONNECTOR PIN OUTS B R
BLACK C422

DUAL REAR
1 2
LEFT REAR
FENDER LAMP
BLACK C423

DUAL REAR
1 2
RIGHT REAR
FENDER LAiP
C424
BLACK

DUAL REAR
1 2
LEFT
TAILGATE
LAMP
C425
BLACK

DUAL REAR
1 2
RIGHT
TAILGATE
LAMP
C426
BLACK' CAV CIRCUIT FUNCTION

DUAL REAR
LICENSE
LAMP
J958W-9
BLACK C427

i Z13 I2BK GROUND
2 B40 H L B TRAILER TOW ELECTRIC BRAKE OUTPUT
3 L76 HBK/OR TRAILER TOW RELAY OUTPUT
4 A6 HRD/TN FUSED B +
5 L63 18DG/RD LEFT REAR TURN SIGNAL
6 L62 18BR/PK RIGHT REAR TURN SIGNAL
7 Li 18VT/BK BACK-UP LAMPS SWITCH OUTPUT
TRAILER
TOW CONNECTOR
C428
BLACK

JL 1 P15 14YL/LB LEFT POWER SEAT HORIZONTAL FORWARD
2 P17 HDB/RD LEFT POWER SEAT HORIZONTAL REARWARD
FORWARD/BACKWARD
SEAT MOTOR
C429
r
J3L
RED

1 Pil 14YL/WT LEFT POWER SEAT REAR UP
dGGEH 2 P i 3 14RD/WT LEFT POWER SEAT REAR DOWN
REAR/VERTICAL
SEAT MOTOR
C430
r -RED

1 PIS HYL/LG LEFT POWER SEAT FRONT UP
2 P21 14RD/LG LEFT POWER 5>AT FRONT DOWN
FRONT UP/DOWN
SEAT MOTOR
C431
C CIRCUIT FUNCTION
BLACK
1 F37 14RD/LB FUSED HEADLAMP SWITCH OUTPUT
2 Z3 HBK/OR GROUND
3 — —
4 — —
5 Pll 14YL/WT LEFT POWER SEAT REAR UP
6 —
7 —
8 — —
9 P13 14RD/WT LEFT POWER SEAT REAR DOWN
10 P17 HDB/RD LEFT POWER SEAT HORIZONTAL REARWARD
POWER SEAT SWITCH 11 P15 HYL/LB LEFT POWER SEAT HORIZONTAL FORWARD
12 P19 HYL/LG LEFT POWER SEAT FRONT UP
13 P21 HRD/LG LEFT POWER SEAT FRONT DOWN
J958W-9
BLACK C431

1 L39 20LB FOG LAMP RELAY #2 OUTPUT
2 Zl 20BK GROUND
RIGHT FOG
LAMP
BLACK C433

1 L39 20LB FOG LAMP RELAY #2 OUTPUT
2 Zl 20BK GROUND
LEFT FOG
LAMP
J958W-9
8W-90 CONNECTOR LOCATIONS sw - s i -1
SENERil INFORMATION nector index is provided. Use the wiring diagrams in

This section provides illustrations identifying com each section for connector number identification. Re
ponent and connector locations in the vehicle. A con fer to the index for the proper figure number.
Connector # Color Location Fig. Connector # Color Location Fig.

C101 BK . . At Lamp 1 CMS BK . Injector #4 6, 7, 8
C102 . . . . . . BL . . At Headlamp . 1 C146 RD . On EGR Solenoid 6, 7, 8
C103 . . . . . . G Y . . Right Fender Shield .1 C147 . . . . . . BK . Injector #2 . .6, 7, 8
C104 . . . . . . . 6N . . Right Fender Shield .1 C148 BK . On Throttle Body 6, 7, 8
C105 BK . . Rear of Right Fog Lamp C149 BK . On Throttle Body .6, 7, 8
C106 RD . . On Front Axle . . 23 C150 BK . On Throttle Body 6, 7, 8
C107 . . . . . . BK . . Bottom of Washer Bottle . . . . . . ...2 C151 . . . . . . BK . Front of Engine 6, 7, 8,
C108 BK . . Side of Washer Bottle . . . . . . . . . .2 C152 BK . Near Thermostat (Except Diesel) .6, 7, 8
C109 . . . . . . BK . . Below Battery 4 C152 BK . Left Rear of Cylinder Head (Diesel) . .9
C110 GY . . Left Side Shield . . . . . . . . . . . . . .1 C153 BK . Rear of Intake Manifold .6, 7
C111 . . . . . . BK' . . Rear of Left Fog Lamp C154 . . . . . . BK . V-10, injector #9 .8
C112 BK . . At Lamp 2 C155 BK . injector #7 7, 8
C113 . . . . . . BL . . At Headlamp . . . . . . . . . . . . . . . .2 C156 BK . Injector #5 .6, 7, 8
C114 RD . . Radiator Left Support 4 C157 . . . . . . GY . . Right Side of Intake Manifold
C115 . . . . . . BK . . Front Bumper Left Support 2 (V-6, V-8) 6, 7,
C116 BK . . Front Bumper Left Support .2 C157 . . GY . Below Left Side of Intake
C117 BK . . Below Brake Master Cylinder . . . . . .3 Manifold (V-10) .8
C118 .. DG . . Left Fender Side Shield 3 C157 . . GY . . Rear of Intake Manifold (Diesel) . . . .9
C119 BK . . Below PDC 3 C158 , BK . , Injector #3 . 6, 7, 8
C120 BK . . At ABS Module 3 C159 BK . , Injector #1 6, 7, 8
C121 . . . . . . BK . . At ABS Module .3 C160 BK . , Right Exhaust Pipe 10, 11
C122 GY . . Rear of ABS Pump 3 C161 . . BK . , Top of Manual Transmission 10
C123 . . . . . . BK . . Left Side Shield, Next to PDC C162 BK . , Left Exhaust Pipe . . .10, 11
C124 . . . . . . BK . . Wiper Motor . . . . . . . . . . . . . . . . . C163 . . . . . . B K . , Rear of Transmission (2WD) . .10, 11
C125 GY . . Left Side of Dash Panel . . . . . . .3, 4 C163 . . . . . . BK . , Rear of Transfer Case (4WD) . .10, 11
C126 . . . . . . GY . . Left Side of Dash Panel 3, 4 C164 . . BK . . V-6, V-8, Diesel Rear of A/C
C127 . BK . . Left Side of Dash Panel . . . . . . .3, 4 Compressor
C128 . . BK . . Above Left Front Body Cushion .2, 20 C164 . . BK . . V-10, Rear of A/C Compressor . . . .8
C129 BK . . Above Left Front Body Cushion .2, 20 C165 BK . , On A/C Compressor
C130 . . . . . . BL .. . At Underhood Lamp 4 C166 . . BK . . V-10, Side of Engine Block 8
C131 .. BK . . Left Fender Side Shield 2 C167 . . . . . . BK . . Left Side of Transmission 11
C132 . . GN . . Top of Clutch Pedal C168 BK . . Left Side of Transmission 11
C133 . . . . . . BK . . Bottom of LP., Near Steering C169 BK . . Left Side of Transmission 11
Column . . . . . . . . . . . . . . . . .12 C170 . . BK . . Front Right of Engine 6, 7
C134 . . . . . . BK . . Left Fender Side Shield 4 C171 BK . . Rear of Distributor 6, 7
C135 BK . . Right Side of Dash Panel 1 C172 BK . . On Dash Panel, Near Master Cylinder .
C136 . . . . . . BK . . Cowl Panel, Above PCM 3 C173 BK . . On Dash Panel, Near Master Cylinder .
C137 . . GY .. . Behind Coolant Reservoir 1 C174 BK . . Bottom of Fuel Filter/Water Separator .9
C138 BK . . V-6, V-8, Rear of Block 6, 7 C175 . . BK . . Near Rear of Injection Pump 9
C138 . . . . . . BK . . V-10, Right Side of Block 8 C176 BK . . Diesel, On Injection Pump . 9
C139 . . . . . . BK . . V-6, V-8, Near Distributor. 6, 7 C177 . . BK . . Above Starter Motor 9
C139 . . . . . . BK . .V-10, Near Oil Filter .8 C178 BK . . Front of Engine 9
C139 BK . . Diesel, Left Side of Engine 9 C179 BK . . Rear of Generator 9
C140 . . . . . . BK . . V-10, Injector #10 7, 8 C180 . . BK . . Power Distribution Center, Near
C141 . . . . . . BK . . V-10, Right Side of Engine. 8 Battery 5
C142 BK . . Injector #8 7, 8 C181 . . . . . . BK . . Starter Motor .5
C143 BK . . Injector #6 6, 7, 8 C182 . . BK . . A/C Low Pressure Cut-Out Switch
C144 . . . . . . BK . . V-10, Right Side of Engine . .8 C183 BK . . Near PDC
Hi -90-2_ _ — _ — - 8W-90 CONNECTOR LOCATIONS — — BK
Connector # Color Location Fit^ Connector # Color Location Fig^

C201 BK . .Left Kick Panel 19 C314 BK . . Left Door .19
C202. . . . . . . BK . .Bottom Left of LP. . . . . . . . . . . . .14 C315 . . BK . . Left Door 19
C203 BK . .Bottom of LP., Drivers Side 13 C316 . . . . . . WT . . Left Door 19
C204 . .....BK . .Near Headlamp Switch 14 C317 BK . . Left Door 19
C205 BK . .Rear of Airbag 14, 15 C318 . . BK . . Left Door 19
C206 BK . .Rear of Headlamp Switch 14 C319 BK . . Rear of Right Door Jamb Switch
C207 . .....BK . .Left Kick Panel 19 C320 ......BK . . Right Door .19
C208 . .....BK . .Near Fuse Block 13 C321 BK . , . Right Door .19
C209 . GN . .Behind Knee Bolster C322 GY . . Right Door 19
C210 BK . .Multi-Function Switch, On Steering C323 BK . . Right Door 19
Column 13, 15 C324 BK . , . Right Door .19
C211 . . . . . . BK . . On Steering Column 15 C325 BK . , . Right Door 19
C212 BK . . At Ignition Switch 13, 15 C326 ......BK . , . Right Door .19
C213 - BK . . At Ignition Switch 13, 15 C327 BK . , . Right Door .19
C214 BK . . Top of Brake Pedal Arm 13 C328 BK . . . Top of Fuel Tank 20
C215 BK . . Rear of Instrument Cluster 12 C329 BK . , . Below Right Tail Lamp 20, 22
C216 BK . . Instrument Cluster 12 C330 BK . . . On Frame, Near Rear of Fuel Tank .20
C217 . . BK . . Near Rear of Fuse Block C331 . . . . . . BK . . . Rear Frame . .20
C218 BK . . In Fuse Block C332 BK . . . Rear Frame 20
C219 BK . . Top Rear Center of LP. .12 C333 .. BK . . . Below Left Tail Lamp 20, 22
C220 BK . . Bottom Left of LP. . .13 C334 BK . . . Day/Night Rear View Mirror 16
C221 . . . . . . BK . . On Stop Lamp Switch Bracket C335 ......BK . . . Above Front of Headliner 16
C222 BK . . On Stop Lamp Switch Bracket C336 BK . . . Above Front of Headliner . 16
C223 BK . . Center Bottom of LP. . .13 C337 BK . . . In Overhead Console
C224 BK . . Behind Center of LP 13 C338 BK . . . Above Front of Headliner 16
C225 BK . ! . Behind O/D Switch 13 C339 ......BK . . . Above Front of Headliner 16
C226 . . GY . . . Behind Fog Lamp Switch C340 BK . . . Above Front of Headliner . 16
C227 BK . . . Rear of HVAC Switch . .12 C341 .. BK . . . Above Front of Headliner .16
C228 BK . , . Center of LP. 12 C342 BK . . . Right Rear of Frame 20
C229 BK . , . Rear of Radio .14 C343 .. BK . . . Right Rear of Frame .20
C230 .. BK . , . Rear of Radio .14 C401 BK . . . Below LP., Right Side
C231 BK . , . Near Rear of Fuse Block C402 BK . . . At Forward Lamp on Left Fender
C232 ......YL . . . Center of LP. at Airbag Module . . .12 C403 BK . . . At Forward Lamp on Right Fender
C233 YL . . . Center of LP. at Airbag Module . . .12 C404 BK . . . At Rear Lamp on Left Fender
C234 ......BK . . . LP. Center Support 12 C405 BK . . . At Rear Lamp on Right Fender
C235 . . . . . . BK . , . Center of LP. 13 C406 BK . . . In Tailgate 22
C236 . . BK . . . Rear of Cigar Lighter .12 C407 BK . . . On Front Left of Frame, Near Sway
C237 BK . . . Bottom Right of LP . .13 Bar Cushion .23
C238 BK . . . Bottom Right of LP. 13 C409 BK . . . Left Frame Rail, Near Fuel Tank . . .20
C239 ......BK . . . Right Side of Dash, Near Right C410 .. BK . . . Rear of Lamp .21
Kick Panel . . . . . 12 C411 BK . . . Rear of Lamp 21
C240 . . BK . . . Right Side of Dash, Near Right C412 ......BK . . . Rear of Lamp 21
Kick Panel 12 C413 BK . . . Rear of Lamp 21
C241 BK . . . At Fuse Block 17 C414 BK . . . At Rear Bumper 22
C301 BK . . . At Right Rear Speaker 17, 18 C415 BK . . . Rear of Lamp 22
C302 BK . . . At Right Rear Speaker 17, 18 C416 BK . . . Rear of Lamp 22
C303 . . . . . . B K . . . Below Drivers Seat 17, 18 C417 BK . . . At Rear Bumper . 22
C304 GY . . . Behind Dome Lamp . .17, 18 C418 BK . . . Rear of Lamp 22
C305 . . BK . . . At Left Rear Speaker 17, 18 C419 BK . . . Rear of Lamp 22
C306 BK . . . At Left Rear Speaker 17, 18 C420 BK . . . Rear of Lamp
C307 . . . . . . B K . . . In Body, Behind LT Door C421 BK . . . Rear of Lamp
Opening . . . . . . . . . . . . . .17, 18 C422 BK . . . Rear of Lamp
C308 BK . . . Center Rear of Headliner 17, 18 C423 BK . . . Rear of Lamp
C309 BK . . . Rear of Left Door Jamb Switch C424 BK . . . Rear of Lamp
C310 BK . . . Left Door . .19 C425 ......BK . . . Rear of Lamp
C311 . . . . . . GY . . . Left Door . 19 C426 ......BK . . . Rear of Lamp
C312 . . . . . . BK . . . Left Door 19 C427 BK . . . On Tailer Hitch
C313 BK . . . Left Door 19 C428 BK . . . Below Drivers Seat
BR 8W-90 CONNECTOR LOCATIONS 8W - 90 - 3
Connector # Color Location Fig. Connector # Color Location Fig.

C429 RD . . . Below Drivers Seat G112 Diesel, Front of Cylinder Head 9
C430 RD . . . Below Drivers Seat G113 Below A/C Compressor 6, 7
C431 . . BK . . . Left Side of Seat G113 Rear of A/C Compressor (V-10) . . . .8
G101 Left Fender Side Shield .2 G113 . . . . . . . . . . . . Near Thermostat Housing (Diesel) . .9
G102 Left Fender Side Shield 2 G114 . Left Side of Engine Block (Diesel)
G103 Right Fender Side Shield .1 G115 Near Left Battery (Diesel) 5
G104 At Brake Master Cylinder .3 G116 Right Side of Engine Block (Diesel)
G105 Left Fender Side Shield, Near PDC . .3 G117 Near Right Battery (Diesel) 5
G106 . . . . . . . . . . . . Near Horns 2 G201 LP Right Center Support .14
G107 Left Fender Side Shield, Near PDC . .3 G202 LP Right Center Support 14
G108 . . Left Fender Side Shield, Near PDC . .3 G203 LP. Left Center Support 14
G109 Left Fender Side Shield .8 G301 Below Left Rear Speaker 17, 18
G110 Below A/C Compressor .8 G302 Left Kick Panel . .19
G111 V-6, V-8, V-10, Below A/C G303 Left Kick Panel 19
Compressor 6, 7, 8 G304 Front Center of Headliner 16
G111 Diesel, Front Top of Cylinder Head . .9
CI49 (BLACK) CI56 (BLACK)
CI58 (BLACK) THROTTLE POSITION FUEL
FUEL SENSOR INJECTOR 5
CI50 (BLACK)
INJECTOR 3 IDLE AIR CONTROL
MOTOR
CI59 (BLACK)
FUEL
INJECTOR CI39 (BLACK)
ENGINE OIL PRESSURE
SENDING UNIT/SWITCH
TO BATTERY
GROUND
CI43 (BLACK)
FUEL
CI47 (BLACK)
INJECTOR 6 FUEL
CI46 (RED) INJECTOR 2 C I 71 (BLACK)
EGR SOLENOID/ EVAP/PURGE CAMSHAFT
TRANSDUCER SOLENOID
C153 (BLACK) POSITION
CI57 (GRAY) SENSOR
INTAKE AIR
TEMPERATURE SENSOR CI52 (BLACK)
ENGINE COOLANT
TEMPERATURE SENSOR CRANKSHAFT
POSITION
A / C COMPRESSOR SENSOR
G111, G l 13
EGR
TUBE
CI70 (BLACK)
DISTRIBUTOR C I 51 (BLACK)
IGNITION COIL GENERATOR
C I 3 8 (BLACK)
ENGINE COOOLANT
TEMPERATURE
SENDING UNIT
VIEW IN DIRECTION
OF ARROW Y VIEW IN DIRECTION
OF ARROW X J958W-31
Fig. 6 Engine Connectors—V-6

GO
CI59 (BLACK) CI58 (BLACK)

FUEL FUEL CI49 (BLACK) CI48 (BLACK)
INJECTOR 1 INJECTOR 3 THROTTLE POSTION MAP SENSOR
SENSOR
CI42 (BLACK)
FUEL
INJECTOR 8
CI50 (BLACK)
IDLE AIR CONTROL
MOTOR
CI39 (BLACK)
ENGINE OIL
PRESSURE SENDING
UNIT/SWITCH
CI46 (RED)
EGR SOLENOID/ GO
TRANSDUCER
ASSEMBLY
€§
O
o
z
m
o
o
o
CI45 (BLACK) EGR

FUEL o
INJECTOR 4 TUBE m
CI47 (BLACK)
FUEL
INJECTOR 2
C170 (BLACK)
DISTRIBUTOR VIEW IN DIRECTION
IGNITION COIL
CI 51 (BLACK) OF ARROW X
GENERATOR
OF ARROW Z CI38 (BLACK)
J958W-32
m
Fig. 7 Engine Connectors—¥-8 as
C I 4 5 (BLACK) C I 5 6 (BLACK) m
C I 51 (BLACK) INJECTOR #5 3D
INJECTOR # 4 GENERATOR C I 5 4 (BLACK)
COOLANT C I 5 7 (BLACK) INJECTOR #9
CI46 (RED) INTAKE AIR C I 5 5 (BLACK)
TEMPERATURE INJECTOR # 7
EGR SOLENOID TEMPERATURE
SENDING UNIT
SENSOR
C I 4 3 (BLACK) C152(BLACK)
C I 4 7 (BLACK)
INJECTOR #6 ENGINE
INJECTOR #2
COOLANT
TEMPERATURE
C I 4 2 (BLACK) SENSOR
INJECTOR #8
C I 6 4 (BLACK)
C I 4 0 (BLACK) A / C COMPRESSOR
INJECTOR # 1 0 CLUTCH
OO
C I 3 9 (BLACK)
OIL PRESSURE C I 5 8 (BLACK) i
SENDING UNIT INJECTOR #3 m
o
o
C I 6 6 (BLACK)
CAMSHAFT G109
POSITION
SENSOR o
C I 3 8 (BLACK) 39
C I 6 5 (BLACK) C I 5 9 (BLACK)
CRANKSHAFT 1™
A / C HIGH INJECTOR #1 o
POSITION
SEE VIEW C PRESSURE o
SENSOR G l 10
SEE VIEW C SWITCH (2 WAY)
CI 41 (BLACK)
3
o
IGNITION COIL C I 5 0 (BLACK) z
C I 4 8 (BLACK) m
PACK (4) MAP SENSOR IDLE AIR CONTROL
MOTOR
C I 4 9 (BLACK)
TPS SENSOR
VIEWC
C I 5 3 (BLACK)
C I 4 4 (BLACK) EVAP/PURGE
IGNITION COIL SOLENOID
PACK
(6)
J958W-33
CO
Fig. 8 Engine Connectors—V-10

GO
CI39 (BLACK)
ENGINE WIRING ENGINE OIL PRESSURE CI76 (BLACK) CO
HARNESS SENDING UNIT THROTTLE
X POSITION
GENERATOR (SENSOR)
POWER STEERING
PUMP
FUEL
HEATER
C I 7 7 (BLACK)
VIEW IN DIRECTION
OF ARROW X
m
VIEW IN DIRECTION o
/ OF ARROW Z o
VIEW IN DIRECTION
CI 79 OF ARROW T
o
(BLACK)
m
0111,0112 o
o
G l 13 CI74 (BLACK) CI57 (GRAY) 39

AIR HEATER WATER-IN INTAKE AIR
ASSEMBLY FUEL SENSOR TEMPERATURE SENSOR €3
CI52 (BLACK)
ENGINE COOLANT
C I 7 5 (BLACK) TEMPERATURE SENSOR
FUEL SHUT-OFF
SOLENOID VIEW IN DIRECTION
CI78 (BLACK) OF ARROW Y
ENGINE SPEED VIEW IN DIRECTION
SENSOR OF ARROW T VIEW IN DIRECTION
OF ARROW X J958W-34
CONNECTOR
Fig. 9 Engine Connectors—Diesel

m
CI 61 (BLACK) n
TO ENGINE BACK-UP LAMP
WIRING SWITCH
HEATED OXYGEN Cl63 (BLACK)

SENSOR VEHICLE SPEED
SENSOR
CI63 (BLACK)
VEHICLE SPEED
SENSOR
TRANSFER
CASE
CO
3.9L5.2L AND 5.91

o
o
o
TO ENGINE
WIRING o
CI60 (BLACK) o
39
r*
CI 61 (BLACK) C161 (BLACK) o
CI63 (BLACK) TO ENGINE BACK-UP LAMP o
BACK-UP VEHICLE SPEED :£§
WIRING SWITCH
LAMP SWITCH SENSOR o
z
C163 (BLACK)
m
VEHICLE SPEED
SENSOR
C162 (BLACK) DIESEL ENGINE

5.9L HD
HEATED OXYGEN
HEATED oo
J958W-30
m
Fig. 10 Manual Transmission Connectors

oo
C I 6 0 (BLACK)
C I 6 9 (BLACK)
PARK N E U T R A L
HEATED O X Y G E N
POSITION SWITCH
TO ENGINE SENSOR
WIRING C I 6 7 (BLACK)
TRANSMISSION TO ENGINE
OVERDRIVE SOLENOID WIRING
C I 6 8 (BLACK)
TRANSMISSION
TEMPERATURE
SENSOR
C I 6 3 (BLACK)
VEHICLE SPEED
SENSOR
C I 6 8 (BLACK) C I 6 3 (BLACK)
TRANSMISSION VEHICLE SPEED
TEMPERATURE SENSOR
SENSOR
C I 6 9 (BLACK)
PARK/NEUTRAL
3.9L. 5.2LAND5.9L
POSITION SWITCH
C I 6 0 (BLACK)
HEATED O X Y G E N
SENSOR HEATED O X Y G E N
SENSOR
C I 6 9 (BLACK)
TRANSFER
PARK/NEUTRAL
POSITION SWITCH CASE
C I 6 7 (BLACK)
TRANSMISSION
OVERDRIVE
SOLENOID
C I 6 8 (BLACK)
TRANSMISSION
TEMPERATURE
SENSOR
C162(BLACK) C I 6 3 (BLACK)
VEHICLE SPEED C I 6 3 (BLACK)
HEATED O X Y G E N SENSOR VEHICLE
SENSOR
5.2LAND5.9L HEAVY DUTY SPEED S E N S O R J958W-29
Fig. 11 Automatic Transmission Connectors

C 2 1 9 (BLACK)
INTERMITTENT
WIPER MODULE
INSTRUMENT C215 (BLACK)

PANEL INSTRUMENT CLUSTER
C 2 1 6 (BLACK)
I N S T R U M E N T CLUSTER
T O INTERMITTENT
i WIPER MODULE
(SEE V I E W Y )
FUSE B L O C K
A N D RELAY B A N K
I N S T R U M E N T PANEL
ASSEMBLY
V
C I 3 3 (BLACK)
I N S T R U M E N T PANEL T O
HEADLAMP A N D DASH
C 2 0 1 (BLACK)
WIRING CONNECTOR
C 2 0 7 (BLACK) V I E W I N DIRECTION
DOOR WIRING OF A R R O W X
C239(BLACK)
/ RADIO CHOKE
DOOR WIRING
A N D RELAY
ASSEMBLY
INSTRUMENT
T O HEADLAMP A N D
PANEL
DASH W I R I N G
SUPPORT
(SEE V I E W X)
C 2 3 3 (YELLOW)
AIRBAG CONTROL T O RWAL MODULE
C234 (BLACK)
MODULE INSTRUMENT
(SEE V I E W Y )
C 2 3 6 (BLACK) PANEL W I R I N G
C I G A R LIGHTER
C 2 3 2 (YELLOW)
AIRBAG C O N T R O L V I E W I N DIRECTION
MODULE OF A R R O W Z
J958W-21
Fig. 12 Instrument Panel Connectors

I N S T R U M E N T PANEL
HARNESS
C 2 2 0 (BLACK)
ROLLS TEST C O N N E C T O R
ASSEMBLY P L A N T USE
C 2 3 5 (BLACK) ONLY
AUXILIARY P O W E R
OUTLET C O N N E C T O R
V I E W IN DIRECTION C 2 2 3 (BLACK)
C 2 2 4 (BLACK) OF A R R O W Y AIRBAG/ABS
M E S S A G E CENTER DATA LINK C O N N E C T O R
C 2 2 5 (BLACK)
TRANSMISSION
OVERDRIVE S W I T C H
C 2 0 8 (BLACK)
ROOF WIRING I N S T R U M E N T PANEL
CONNECTOR HARNESS
T O PARK BRAKE
SWITCH
^ C 2 1 4 (BLACK)
STOP LAMP SWITCH
V I F W I N DIRECTION
C 2 3 8 (BLACK) C 2 1 0 (BLACK) OF A R R O W X
BLOWER M O T O R MULTI-FUNCTION
SWITCH
TO CLOCKSPRING
T O FUSE B L O C K
C 2 1 3 (BLACK)
C212 (BLACK)
IGNITION
IGNITION SWITCH
SWITCH I N S T R U M E N T PANEL
HARNESS
C 2 0 3 (BLACK)
R W A L TEST
CONNECTOR
V I F W I N DIRECTION
OF A R R O W Z J958W-22
Fig. 13 instrument Panel Connectors

Fig. 14 instrument Panel Ground Connections
C308 (BLACK)
CHMSL
C301 (BLACK)
OR C302 (BLACK) VIEW IN DIRECTION
REAR SPEAKER OF ARROW X
J958W-18
Fig. 17 Cab Connectors

POWER MIRROR
C311 (GRAY) LEFT DOOR
C322 (GRAY) RIGHT DOOR
DOOR LOCK SWITCH
C315 (BLACK) LEFT DOOR POWER MIRROR SWITCH
C310 (BLACK)
C325 (BLACK) RIGHT DOOR
MIDRANGE DOOR SPEAKER

LEFT DOOR: C314 (BLACK)
RIGHT DOOR: C324 (BLACK)
TO INSTRUMENT
PANEL WIRING
DOOR SPEAKER
LEFT DOOR: C312 (BLACK)
OR
C313 (BLACK)
RIGHT DOOR: C320 (BLACK)
OR
C323 (BLACK)
(BLACK)
POWER WINDOW SWITCH

C316 (WHITE) LEFT DOOR
C326 (BLACK) RIGHT DOOR POWER WINDOW
MOTOR
C318 (BLACK) LEFT DOOR (BLACK)
C321 (BLACK) RIGHT DOOR
DOOR AJAR
POWER DOOR SWITCH G302 (LEFT)
LOCK MOTOR G303 (RIGHT)
C317 (BLACK) LEFT DOOR VIEW IN DIRECTION
C327 (BLACK) RIGHT DOOR OF ARROW X
J958W-20
Fig. If Door Connectors

C330 (BLACK)
C331 (BLACK) REAR WHEEL
OR C332 (BLACK) SPEED SENSOR
CHASSIS
WIRING (TO C409 BLACK)
HARNESS
FUEL TANK
X-MEMBER
FRAME
ASSEMBLY
C333 (BLACK)
LEFT TAIL
LAMP
CHASSIS WIRING
HARNESS
C I 2 8 (BLACK)
C328 (BLACK)
FUEL
TANK
MODULE J958W-17
Fig* 20 Frame Connectors

90 - 24 8W-90 CONNECTOR LOCATIONS
J958W-236
Fig. 21 Center High Mounted Stop Lamps and Cargo Lamps

C414 (BLACK) RIGHT
C417 (BLACK) LEFT
LICENSE LAMPS
C416 (BLACK) RIGHT
i
CO
o
!
Fig. 22 Rear Lamps m
BR 8W-95 SPLICE LOCATIONS 8W - 9 5 - 1
SPLICE LOCATIONS
GENERAL INFORMATION index is provided. Use the wiring diagrams in each
This section provides illustrations identifying the section for splice number identification. Refer to the
general location of the splices in this vehicle. A splice index for proper splice number.
SPLICE LOCATIONS
Splice Splice
Number Locations Fig. limber Locations Fig.
S101 In T/0 for Right Turn Signal Lamp S134 Near Branch to Throttle Position Sensor
S102 In T/0 for Right Turn Signal Lamp . . . . . . (Diesel) 5
S103 Before T/0 for Right Headlamp 5135 . . . . . . Between T/Os for Injectors 2 and 4 (V-6, V-8) .3
S104 Near Horn T/0 S135 Between T/Os for Injectors 2 and 4 (V-10) . . .4
S105 In Branch for Horn T/0 5136 . . . . . . After Branch to Injectors 2, 4, 6, 8 (V-6, V-8) .2
S106 After Branch for Horn T/0 S136 . . . . . . After Branch to Injectors 2, 4, 6, 8, 10 (V-10) .2
5107 . . . . . . Before Branch for ABS Control Module . . . . .2 S136 . . . . . . Between T/Os for Intake Air Heaters and
5108 . . . . . . Before Branch for ABS Control Module 2 Fuel Heater (Diesel) .5
5109 . . . . . . Before Branch for ABS Control Module 2 S137 Near T/0 to Distributor (V-6, V-8) 3
S110 In Branch to ABS Control Module . .2 S137 In T/0 to Idle Air Control Motor (V-10) .4
5111 In Branch to ABS Control Module 2 S138 Between T/Os for Injectors 7 and 9 (V-10) . . .4
5112 . . . . . . In T/0 for to ABS Control Module . . . . . . . .2 S139 Before Dash T/Os for Headlamp and Dash Har
S113 Before T/0 for PDC ............. .2 ness Connectors (V-6, V-8 and Diesel) . . . . .2
S114 Before Branch to Engine Harness Connectors .2 5139 After Branch to Injectors 1, 3, 5, 7, 9 (V-10) .2
S115 Before Branch to Engine Harness Connectors .2 5140 . . . . . . Before Dash T/Os for Headlamp and Dash
S116 In Branch to Engine Harness Connectors . . . .2 Harness Connectors (V-6, V-8) 2
S117 In Branch to Engine Harness Connectors . . . .2 S140 . . . . . . After Branch to Injectors 1, 3, 5, 7, 9 (V-10) .2
S118 In T/0 to Chassis Connector (C128) 1 5140 . . . . . . Between T/Os for Intake Air Heaters and
S119 In T/0 to Chassis Connector (C128) .1 Fuel Heater (Diesel) 5
5120 . . In T/0 to Chassis Connector (C128) . . . . . . .1 5141 In Branch to Transmission Wiring (V-6, V-8) .3
5121 In Branch to LP. Harness, On LP. Side S141 After T/0 for Left Heated Oxygen
of Grommet .2 Sensor (V-10) .6
5122 . . . . . . In Branch to LP. Harness, On LP. Side of 5141 Before PCM (Diesel) . .2
Grommet .2 5142 . . . . . . Near T/0 for Fuel Shut-Off Solenoid 5
S123 In T/0 for Left Turn Signal Lamp . . . . . . . . .1 5143 . . . . . . Between T/Os for Intake Air Heaters and
5124 . . . . . .After PCM .2 Fuel Heater (Diesel) 5
5125 . . After PCM . .2 S144 At Fuse Link, In Harness to Left Battery
Positive Terminal .Not Shown
S126 After PCM .2
S145 At Fuse Link, In Harness to Left Battery
S127 After A/C Low Pressure Switch T/0 2
Positive Terminal .Not Shown
5128 . . . . . . Before Branch to Injectors 2, 4, 6, 8, 10 . . . .2
5146 . . . . . . Inside PDC Not Shown
S129 After PCM ... .2
5147 Inside PDC Not Shown
5129 . . . . . . Before Branch to Injectors 2, 4, 6, 8,
5148 Battery Positive Harness . . . . . . . .Not Shown
10 (V-10) . . . . . . . . . . . . . . .2
5201 In Fuse Block . . . . . . . . . . . . . . .Not Shown
S130 After Branch to Injectors 2, 4, 6, 8 (V-6, 10) .2
5202 In Fuse Block . . . . . . . . . . . . . . .Not Shown
S130 After Branch to Injectors 2, 4, 6, 8, 10 (V-10) .2
5203 In T/0 to Headlamp Switch . 7
S130 Near T/0 for Fuel Shut-Off Solenoid (Diesel) .5
5204 In T/0 to Headlamp Switch .7
S131 After Branch to Injectors 2, 4, 6, 8 (V-6, V-8) .2
5205 Before T/0 for Headlamp and Dash Harness
S131 . . . . . . After Branch to Injectors 2, 4, 6, 8, 10 (V-10) .2
Connector 7
5131 Before PCM (Diesel) 2
5206 In T/0 to Fuse Block 7
5132 . . . . . . After Branch to Injectors 2, 4, 6, 8, (V-6, V-8) .2
5207 Between T/Os for Cluster Connectors 7
5132 . . After Branch to Injectors 2, 4, 6, 8, 10 (V-10) .2
5208 . . . . . . Between T/Os for Cluster Connectors 7
S132 Rear of Engine, In Branch to PCM (Diesel) . .5
5209 . . . . . . After T/Os for Cluster Connectors 7
5133 . . After T/0 for Idle Air Control Motor (V-6, V-8) .3
S210 After T/O to Wiper Module . .7
S133 After T/0 for Injector 10 (V-10) 4
S211 After T/0 for RWAL Module 7
5134 . . . . . . . Between T/Os for Injectors 4 and 6 (V-6, V-8) .3
S212 Before Airbag Control Module T/O's 7
S134 Between T/Os for Injectors 4 and 6 (V-10) . . .4
S213 In T/0 to Radio Choke Relay 7
S214 . . After T/0 for Cigar Lighter 7
8W - II - 2 8W-95 SPLICE LOCATIONS
Splice Splice
Number Locations Fig. lumber Locations Fig.
S215 After T/O for Cigar Lighter . . . . 7 S315 In T/O to Trailer Tow Harness Connectors . .11
S218 . . . . . .
Before T/O for Glove Box 7 S316 In T/O to Trailer Tow Harness Connectors . .11
S217 . . . . . .
After T/O for Glove Box .7 5317 . . . . . . After T/O for Left Outboard Clearance Lamp . .8
5301 . . . . . .
Near T/O for Body Ground (G301) 9 5318 . . . . . . After T/O for Left Outboard Clearance Lamp . .8
5302 . . . . . .
Near T/O for Left Rear Speaker .9 5319 . . . . . . Before T/O for Center Identification Lamp
5303 Near T/O for Body Ground (G301) . . . . . . . .9 5320 . . . . . . Before T/O for Center Identification Lamp
5304 In T/0 to Left Door Speaker 10 5401 In Tail Lamp Jumper Harness Not Shown
5305 In T/0 to Left Power Window Motor 10 5402 In Tail Lamp Jumper Harness Not Shown
5306 . . . . . . Before Grommet to Left Door 10 5403 In Air Intake Heater Feed . . . . . . . .Not Shown
5307 In T/O to Right Door Speaker 10 5404 In Air Intake Heater Feed Not Shown
5308 In T/O to Right Power Window Motor 10 5405 In Fender Lamps Harness Not Shown
5309 . . . . . . Before Door Switch 10 5406 In Fender Lamps Harness . Not Shown
S310 Before Door Switch . . 10 5407 In Tailgate Harness Not Shown
5311 Near T/O for Fuel Pump Module . .11 5408 In Tailgate Harness Not Shown
5312 . . . . . . After Branch to Right Rear Lamps .11
S313 After Branch to Right Rear Lamps 11
S314 After Branch to Right Rear Lamps 11
SEE
to
cn
S112-
VIEW IN DIRECTION
VIEW IN DIRECTION OF ARROW Z
OF ARROW Y
oo
CO
S I 3 6 (V/10)
cn
SI 3
(V/6, V / 8
>
VIEW IN DIRECTION
OF ARROW W 140
SI 31 (DIESEL) J958W-245
Fig. 2 Engine Compartment Wiring Splices

m
30
Fig. 3 V-6, V-8 Engine Wiring Splices
.S134 m
CO
m
m
o
VIEW IN DIRECTION m
OF ARROW X
S132
o
m
VIEW IN DIRECTION
OF ARROW Y J958W-243
CO
cn
Fig. 5 Diesel Engine Wiring Splices
8W - 95 - 8 8W-95 SPLICE LOCATIONS
J958W-237
Fig. 6 Transmission Wiring Splices

S309
RT/DOOR
J958W-240
Fig. 10 Door Wiring Splices

ENGINES
CONTENTS
page page
3.9L ENGINE SERVICE PROCEDURES .. 20 LUBRICATION SYSTEM 37

5.2L ENGINE SERVICE PROCEDURES .. 52 LUBRICATION SYSTEM 68
5.9L (DIESEL) ENGINE SERVICE LUBRICATION SYSTEM 97
PROCEDURES . . . . 146 LUBRICATION SYSTEM . . . . 132
5.9L ENGINE SERVICE PROCEDURES . . . . . . . 81 LUBRICATION SYSTEM . . . . 185
8.0L ENGINE SERVICE PROCEDURES . . . . . . 113 SPECIFICATIONS—5.9L ENGINE . . . . . . . . . 108
ENGINE DIAGNOSIS ...... 5 STANDARD SERVICE PROCEDURES .. 1
STANDARD SBRWICE PROCEDURES
INDEX
page . page
Engine Performance—Gasoline Engines 2 Hydrostatic Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Form-ln-Place Gaskets—Gasoline Engines . . . . . . . 1 Measuring with Plastigage 3
Honing Cylinder Bores . . . . . . . . . . . . . . . . . . . . . . 2 Repair Damaged or Worn Threads . . . . . . . . . . . . . 4
FORM-IN-PLACE GASKETS—GASOLINE ENGINES

There are several places where form-in-place gas Mopar® Gasket Maker, normally red in color, is
kets are used on the engine. DO NOT use form-in- available in 6 cc tubes. This anaerobic type gasket
place gasket material unless specified. Care material cures in the absence of air when squeezed
must be taken when applying form-in-place gaskets. between smooth machined metallic surfaces. It will
Bead size, continuity and location are of great impor not cure if left in the uncovered tube. DO NOT use
tance. Too thin a bead can result in leakage while too on flexible metal flanges.
much can result in spill-over. A continuous bead of
SURFACE PREPARATION
the proper width is essential to obtain a leak-free
Parts assembled with form-in-place gaskets may be
joint.
disassembled without unusual effort. In some in
Two types of form-in-place gasket materials are
stances, it may be necessary to lightly tap the part
used in the engine area (Mopar® Silicone Rubber Ad
with a mallet or other suitable tool to break the seal
hesive Sealant and Mopar® Gasket Maker). Each
between the mating surfaces. A flat gasket scraper
have different properties and cannot be used inter
may also be lightly tapped into the joint but' care
changeably.
must be taken not to damage the mating surfaces.
MOPAR® SILICONE RUBBER MBMB8IWB Scrape or wire brush all gasket surfaces to remove
SEALANT all loose material. Inspect stamped parts to ensure
Mopar® Silicone Rubber Adhesive Sealant, nor gasket rails are flat. Flatten rails with a hammer on
mally black in color, is available in 3 ounce tubes. a flat plate, if required. Gasket surfaces must be free
Moisture in the air causes the sealant material to of oil and dirt. Make sure the old gasket material is
cure. This material is normally used on flexible metal removed from blind attaching holes.
flanges. It has a shelf life of 1 year and will not prop
erly cure if over aged. Always inspect the package for GASKET APPLICATION
the expiration date before use. Assembling parts using a form-in-place gasket re
quires care.
Mopar® Silicone Rubber Adhesive Sealant should
be applied in a continuous bead approximately 3 mm
9 -2 ENGINES BR
(0.12 inch) in diameter. All mounting holes must be (h) Repeat Step 3g for all remaining cylinders.
circled. For comer sealing, a 8 or 6 mm (1/8 or 1/4 (i) Compression should not be less than 689 kPa
inch) drop is placed in the center of the gasket con (100 psi) and not vary more than 172 kPa (25 psi)
tact area. Uncured sealant may be removed with a from cylinder to cylinder.
shop towel. Components should be torqued in place (j) If cylinder(s) have abnormally low compres
while the sealant is still wet to the touch (within 10 sion pressures, repeat steps 3a through 3h.
minutes). The use of a locating dowel is recom (k) If the same cylinder(s) repeat an abnormally
mended during assembly to prevent smearing the low reading, it could indicate the existence of a
material off location. problem in the cylinder.
Mopar® Gasket Maker should be applied sparingly The recommended compression pressures are
to one gasket surface. The sealant diameter should to be used only as a guide to diagnosing engine
be 1.00 mm (0.04 inch) or less. Be certain the mate problems. An engine should NOT be disassem
rial surrounds each mounting hole. Excess material bled to determine the cause of low compression
can easily be wiped off. Components should be unless some malfunction is present.
torqued in place within 15 minutes. The use of a lo (4) Clean or replace spark plugs as necessary. Ad
cating dowel is recommended during assembly to pre just gap (refer to Group 8D, Ignition System for gap
vent smearing the material off location. adjustment and torque).
ENGINE PERFORMANCE—GASOLINE ENGINES (5) Test resistance of spark plug cables (refer to
Group 8D, Ignition System).
lb provide best vehicle performance and lowest ve
hicle emissions, it is most important that the tune-up (6) Inspect the primary wire. Test coil output volt
be done accurately. Use the specifications listed on age, primary and secondary resistance. Replace parts
the Vehicle Emission Control Information label found as necessary (refer to Group 8D, Ignition System and
on the engine compartment hood. make necessary adjustment).
(1) Test cranking amperage draw (refer to Group (7) Set ignition timing to specifications (refer to
8B, Battery/Starter/Generator Service for the proper Specification Label on engine compartment hood).
procedures). This step does not apply to 8.0L engine.
(2) Tighten the intake manifold bolts (refer to (8) Perform a combustion analysis.
Group 11, Exhaust System and Intake Manifold for (9) Test fuel pump for pressure and vacuum (refer
the proper specifications). to Group 14, Fuel System for the proper specifica
(3) Perform cylinder compression test: tions).
(a) Check engine oil level and add oil, if neces (10) Inspect air filter element (refer to Group 0,
sary. Lubrication and Maintenance for the proper proce
(b) Drive the vehicle until engine reaches normal dure).
operating temperature. (11) Inspect crankcase ventilation system (refer to
(c) Select a route free from traffic and other Group 0, Lubrication and Maintenance for the proper
forms of congestion, observe all traffic laws and procedure).
briskly accelerate through the gears several times. (12) For emission controls, refer to Group 25,
The higher engine speed may help clean out valve Emission Controls System for service procedures.
seat deposits which can prevent accurate compres (13) Inspect and adjust accessory belt drives (refer
sion readings. to Group 7, Cooling System for the proper adjust
ments).
CAUTION: DO NOT overspeed the engine. (14) Road test vehicle as a final test.
(d) Remove all spark plugs from engine. As spark HONING CYLINDER BORES
plugs are being removed, check electrodes for ab Before honing, stuff plenty of clean shop towels un
normal firing indicators—fouled, hot, oily, etc. der the bores and over the crankshaft to keep abra
Record cylinder number of spark plug for future sive materials from entering the crankshaft area.
reference. (1) Used carefully, the Cylinder Bore Sizing Hone
(e) Disconnect coil wire from distributor or from C-823 equipped with 220 grit stones, is the best tool
both coil packs (V-10) and secure to good ground to for this job. In addition to deglazing, it will reduce
prevent a spark from starting a fire. taper and out-of-round as well as removing light
(f) Be sure throttle blades are fully open during scuffing, scoring or scratches. Usually a few strokes
the compression check. will clean up a bore and maintain the required lim
(g) Insert compression gage adaptor into the its.
No.l spark plug hole. Crank engine until maximum
pressure is reached on gauge. Record this pressure CAUTION: DO NOT use- rigid type hones to remove
as No.l cylinder pressure. cylinder wall glaze.
BR ENGINES 9- 3
(2) Deglazing of the cylinder walls may be done if (2) The total clearance of the main bearings can
the cylinder bore is straight and round. Use a cylin only be determined by removing the weight of the
der surfacing hone, Honing Tool C-3501, equipped crankshaft. This can be accomplished by either of two
with 280 grit stones (C-3501-3810). 20-60 strokes, de methods:
pending on the bore condition, will be sufficient to METHOD - 1 (PREFERRED)—Shim the bear
provide a satisfactory surface. Using honing oil ings adjacent to the bearing to be checked. This will
C-3501-3880 o r a light honing oil available from m a remove the clearance between upper bearing shell
j o r oil distributors. and the crankshaft. Place a minimum of 0.254 mm
(0.010 inch) shim between the bearing shell and the
CAUTION: DO NOT use engine or transmission oil, adjacent bearing cap. Tighten the bolts to 18 N-m (13
mineral spirits or kerosene. ft. lbs.) torque.
• CHECK NO.l BEARING: Shim No.2 main bear
(3) Honing should be done by moving the hone up ing.
and down fast enough to get a C r o s s h a t c h pattern. o CHECK NOo2 BEARING: Shim No.l and No.3
The hone marks should INTERSECT at 50° to 60° main bearing.
f o r proper seating of rings (Fig. 1). • CHECK NO.3 BEARING: Shim No.2 and No.4
main bearing.
• CHECK NOc4 BEARING: Shim No.3 main bear
ing (3.9L). Shim No.3 and No.5 main bearing (5.2L,
5.9L, 8.0L and 5.9L-Diesel).
• CHECK NO.5 BEARING: Shim No.4 main bear
ing (5.2L and 5.9L). Shim No.4 and No.6 main bear
ing (8.0L and 5.9L-Diesel).
ing (8.0L). Shim No.5 and No.7 main bearing (5.9L-
Diesel).
ing (5.9L-Diesel).
Remove all shims before assembling engine.
METHOD - 2 (ALTERNATIVE)—The weight of
the crankshaft is supported by a jack under the coun
terweight adjacent to the bearing being checked.
(3) Place a piece of Plastigage across the entire
Fig. 1 Cylinder Bore Crosshatch Pattern
width of the bearing cap shell (Fig. 2). Position the
(4) A controlled hone motor speed between 200 and Plastigage approximately 6.35 mm (1/4 inch) off cen
300 RPM is necessary to obtain the proper cross- ter and away from the oil holes. In addition, suspect
hatch angle. The number of up and down strokes per areas can be checked by placing the Plastigage in
minute can be regulated to get the desired 50° to 60° that area. Tighten the bearing cap bolts of the bear
angle. Faster up and down strokes increase the crossing being checked to 115 N-m (85 ft. lbs.) torque. DO
hatch angle. NOT rotate the crankshaft or the Plastigage
(5) After honing, it is necessary that the block be may be smeared, giving inaccurate results.
cleaned to remove all traces of abrasive. Use a brush
to wash parts with a solution of hot water and deter
gent. Dry parts thoroughly. Use a clean, white, lint-
free cloth to check that the bore is clean. Oil the
bores after cleaning to prevent rusting.
MEASURING WITH PLASTiGAGE
CRANKSHAFT MAIN BEARING CLEARANCE

Engine crankshaft bearing clearances can be deter
mined by use of Plastigage, or equivalent. The follow
ing is the recommended procedures for the use of
Plastigage: Fig. 2 Placement of Plastigage in Bearing Shell
(1) Remove oil film from surface to be checked. (4) Remove the bearing cap and compare the width
Plastigage is soluble in oil of the flattened Plastigage with the scale provided on
the package (Fig. 3). Plastigage generally comes in 2
scales (one scale is in inches and the other is a met REPAIR DAMAGED OR WORM THREADS
ric scale). Locate the band closest to the same width. Damaged or worn threads can be repaired. Essen
This band shows the amount of clearance. Differ tially, this repair consists of:
ences in readings between the ends indicate the • Drilling out worn or damaged threads.
amount of taper present. Record all readings taken • Tapping the hole with a special Heli-Coil Tap, or
(refer to Engine Specifications), equivalent.
• Installing an insert into the tapped hole.
This brings the hole back to its original thread
size.
CAUTION: B e sure that the tapped holes maintain
the original center line.
-,-TV Heli-Coil tools and inserts are readily available

from automotive parts jobbers.
"Ml RN861 HYDiQSTATiC LOCI

When an engine is suspected of hydrostatic lock
'. 3 Cleaia,iCo, •nt (regardless of what caused the problem),' follow the
(5) Plastigage is available in a variety of clearance steps below.
ranges. The 0.025-0.076 mm (0.001-0.003 inch) range (1) Perform the Fuel Pressure Release Procedure
is usually the most appropriate for checking engine (refer to Group 14, Fuel System).
bearing clearances. (2) Disconnect the negative cable from the battery.
(3) Inspect air cleaner, induction system and in
CQMNECTING MOD BEARING CLEARANCE take manifold to ensure system is dry and clear of
Engine connecting rod bearing clearances can be foreign material.
determined by use of Plastigage, or equivalent. The (4) Place a shop towel around the spark plugs or
fuel injectors (diesel engine) to catch any fluid that
following is the recommended procedures for the use may possibly be under pressure in the cylinder head.
of Plastigage: Remove the spark plugs or fuel injectors (diesel en
(1) Remove oil film from surface to be checked. gines).
Plastigage is soluble in oil.
(2) Place a piece of Plastigage across the entire CAUTION: DO MOT use the starter motor to rotate
width of the bearing cap shell (Fig. 2). Position the the c r a n k s h a f t Severe damage could occur.
Plastigage approximately 6.85 mm (1/4 inch) off cen
ter and away from the oil holes. In addition, suspect (5) With all spark plugs and injectors (diesel en
areas can be checked by placing the Plastigage in the gine) removed, rotate the crankshaft using a breaker
suspect area. bar and socket.
(3) The crankshaft must be turned until the con (6) Identify the fluid in the cylinders (coolant, fuel,
necting rod to be checked starts moving toward the oil, etc.).
top of the engine. Only then should the rod cap with (7) Make sure all fluid has been removed from the
Plastigage in place be assembled. Tighten the rod cap cylinders.
nut to 6 1 N-m (45 ft. lbs.) torque. BO NOT rotate (8) Repair engine or components as necessary to
the crankshaft or the Plastigage may be prevent this problem from occurring again.
smeared, giving inaccurate results. (9) Squirt engine oil into the cylinders to lubricate
the walls. This will prevent damage on restart.
(4) Remove the bearing cap and compare the width (10) Install new spark plugs or fuel injectors (die
of the flattened Plastigage with the scale provided on sel engine). Tighten the spark plugs to 41 N-m (30 ft.
the package (Fig. 3). Plastigage generally comes in 2 lbs.) torque. Tighten the fuel injector nuts to 60 N-m
scales (one scale is in inches and the other is a met (44 ft. lbs.) torque.
ric scale). Locate the band closest to the same width. (11) Drain engine oil. Remove and discard the oil
This band shows the amount of clearance. Differ filter.
ences in readings between the ends indicate the (12) Install the drain plug. Tighten the plug to 34
amount of taper present. Record all readings taken N-m (25 ft. lbs.) torque.
(refer to Engine Specifications). (13) Install a new oil filter.
(5) Plastigage is available in a variety of clearance (14) Fill engine crankcase with the specified
ranges. The 0.025-0.076 mm (0.001-0.003 inch) range amount and grade of oil (refer to Group 0, Lubrica
is usually the most appropriate for checking engine tion and Maintenance).
bearing clearances. (15) Connect the negative cable to the battery.
(16) Start the engine and check for any leaks.
BR ~ — _ ENGINES I -5
EUGIHE DIAGNOSIS
Engine diagnosis is helpful in determining the Ensure the battery is completely charged and the
causes of malfunctions not detected and remedied by engine starter motor is in good operating condition.
routine tune-ups. Otherwise the indicated compression pressures may
These malfunctions may be classified as either per not be valid for diagnosis purposes.
formance (engine idles rough and stalls) or mechani (1) Clean the spark plug recesses with compressed
cal (a strange noise). air.
Refer to the Service Diagnosis—Performance chart (2) Remove the spark plugs.
and the Service Diagnosis—Mechanical chart for pos (3) Secure the throttle in the wide-open position.
sible causes and corrections of malfunctions. Refer to (4) Disconnect the ignition coil.
Group 14, Fuel System for the fuel system diagnosis. (5) Insert a compression pressure gauge and rotate
the engine with the engine starter motor for three
GENERAL INFORMATION revolutions.
Engine diagnosis is helpful in determining the (6) Record the compression pressure on the 3rd
causes of malfunctions not detected and remedied by revolution. Continue the test for the remaining cylin
routine tune-ups. ders.
These malfunctions may be classified as either me Refer to Engine Specifications for the correct en
chanical (a strange noise), or performance (engine gine compression pressures.
idles rough and stalls).
Refer to the Service Diagnosis—Mechanical Chart ENGINE CYLINDER HEAD GASKET FAILURE
and the Service Diagnosis—Performance Chart for DIAGNOSIS
possible causes and corrections of malfunctions. Refer A leaking engine cylinder head gasket usually re
to Group 14, Fuel System for the fuel system diagno sults in loss of power, loss of coolant and engine mis
sis. firing.
Additional tests and diagnostic procedures may be An engine cylinder head gasket leak can be located
necessary for specific engine malfunctions that can between adjacent cylinders or between a cylinder and
not be isolated with the Service Diagnosis charts. In the adjacent water jacket.
formation concerning additional tests and diagnosis • An engine cylinder head gasket leaking between
is provided within the following diagnosis: adjacent cylinders is indicated by a loss of power
• Cylinder Compression Pressure Test. and/or engine misfire.
• Cylinder Combustion Pressure Leakage Test. • An engine cylinder head gasket leaking between a
• Engine Cylinder Head Gasket Failure Diagnosis. cylinder and an adjacent water jacket is indicated by
• Intake Manifold Leakage Diagnosis. coolant foaming or overheating and loss of coolant.
INTAKE MANIFOLD LEAKAGE DIAGNOSIS CYLMfDER-TO-CYLINDER L E l I i i E TEST
An intake manifold air leak is characterized by To determine if an engine cylinder head gasket is
lower than normal manifold vacuum. Also, one or leaking between adjacent cylinders; follow the proce
more cylinders may not be functioning. dures outlined in Cylinder Compression Pressure
Test. An engine cylinder head gasket leaking between
WARNING; U S E E X T R E M E CAUTION W H E N THE adjacent cylinders will result in approximately a 50-
ENGINE IS OPERATING. DO WOT STAND IN A DI 70% reduction in compression pressure.
RECT LINE WITH THE FAN. DO MOT PUT YOUR
HANDS NEAR THE P U L L E Y S , B E L T S OR THE FAN. CYUNDm-TO-WATER JACKET LEAKAGE
DO NOT W E A R LOOSE CLOTHING. TEST
(1) Start the engine. WARNING: U S E E X T R E M E CAUTION WHEN THE
(2) Spray a small stream of water at the suspected ENGINE IS OPERATING. DO NOT STAND SN A DI
leak area. RECT LINE WITH THE F A N . DO NOT PUT YOUR
(3) If a change in RPM'S, the area of the suspected HANDS NEAR THE P U L L E Y S , B E L T S OR THE FAN.
leak has been found. DO MOT W E A R LOOSE CLOTHING.
(4) Repair as required.
Remove the radiator cap.
CYLINDER COMPRESSION PRESSURE TEST Start the engine and allow it to warm up until the
The results of a cylinder compression pressure test engine thermostat opens.
can be utilized to diagnose several engine malfunc If a large combustion/compression pressure leak ex
tions. ists, bubbles will be visible in the coolant.
9-6 ENGINES BR
If bubbles are not visible, install a radiator pres (2) Add an oil soluble dye (use as recommended by
sure tester and pressurize the coolant system. manufacturer). Start the engine and let idle for ap
If a cylinder is leaking combustion pressure into proximately 15 minutes. Check the oil dipstick to
the water jacket, the tester pointer will pulsate with make sure the dye is thoroughly mixed as indicated
every combustion stroke of the cylinder. with a bright yellow color under a black light.
(3) Using a black light, inspect the entire engine
CYLINDER COMBUSTION PRESSURE LEAKAGE for fluorescent dye, particularly at the suspected area
TEST of oil leak. If the oil leak is found and identified, re
The combustion pressure leakage test provides an pair per service manual instructions.
accurate means for determining engine condition. (4) If dye is not observed, drive the vehicle at var
Combustion pressure leakage testing will detect: ious speeds for approximately 24km (15 miles), and
© Exhaust and intake valve leaks (improper seat repeat step (3).
ing). If the oil leak source is not positively identi
® Leaks between adjacent cylinders or into water fied at this time, proceed with the air leak detec
jacket. tion test method as follows:
• Any causes for combustion/compression pressure (1) Disconnect the breather cap to air cleaner hose
at the breather cap end. Cap or plug breather cap
loss.
nipple.
WARNING: DO NOT R E M O V E THE RADIATOR C A P (2) Remove the PCV valve from the cylinder head
WITH THE S Y S T E M HOT AND UNDER P R E S S U R E cover. Cap or plug the PCV valve grommet.
B E C A U S E S E R I O U S B U R N S FROM COOLANT CAN (3) Attach an air hose with pressure gauge and
OCCUR. regulator to the dipstick tube.
CAUTION: Do not subject the engine assembly to
Check the coolant level and fill as required. DO
more than 20.6 kpa (3 PSI) of test pressure.
NOT install the radiator cap.
Start and operate the engine until it attains nor (4) Gradually apply air pressure from 1 psi to 2.5
mal operating temperature, then turn the engine psi maximum while applying soapy water at the sus
OFF pected source. Adjust the regulator to the suitable
Remove the spark plugs. test pressure that provide the best bubbles which
Remove the oil filler cap. will pinpoint the leak source. If the oil leak is de
Remove the air cleaner. tected and identified, repair per service manual pro
Calibrate the tester according to the manufactur cedures.
er's instructions. The shop air source for testing (5) If the leakage occurs at the rear oil seal area,
should maintain 483 kPa (70 psi) minimum, 1 379 refer to the section, Inspection for Rear Seal Area
kPa (200 psi) maximum and 552 kPa (80 psi) recom Leak. :
mended. (6) If no leaks are detected, turn off the air supply
Perform the test procedures on each cylinder ac and remove the air hose and all plugs and caps. In
cording to the tester manufacturer's instructions. stall the PCV valve and breather cap hose. Proceed
While testing, listen for pressurized air escaping to step 7.
through the throttle body, tailpipe and oil filler cap (7) Clean the oil off the suspect oil leak area using
opening. Check for bubbles in the radiator coolant. a suitable solvent. Drive the vehicle at various
All gauge pressure indications should be equal, speeds approximately 24 km (15 miles). Inspect the
with no more than 25% leakage. engine for signs of an oil leak by using a black light.
FOR EXAMPLE: At 552 kPa (80 psi) input pres
sure, a minimum of 414 kPa (60 psi) should be main INSPECTION FOR REAR SEAL AREA LEAKS
tained in the cylinder. Since it is sometimes difficult to determine the
Refer to the Cylinder Combustion Pressure Leak source of an oil leak in the rear seal area of the en
age Test Diagnosis chart. gine, a more involved inspection is necessary. The fol
lowing steps should be followed to help pinpoint the
INSPECTION (ENGINE OIL LEAKS IN GENERAL) source of the leak.
Begin with a through visual inspection of the en If the leakage occurs at the crankshaft rear oil seal
gine, particularly at the area of the suspected leak. If area:
an oil leak source is not readily identifiable, the fol (1) Disconnect the battery.
lowing steps should be followed: (2) Raise the vehicle.
(1) Do not clean or degrease the engine at this (3) Remove torque converter or clutch housing
time because some solvents may cause rubber to cover and inspect rear of block for evidence of oil.
swell, temporarily stopping the leak. Use a black light to check for the oil leak:
Hit — — — — — — _ ENGINES I -7
(a) Circular spray pattern generally indicates scratches. The crankshaft sea! flange is especially
seal leakage or crankshaft damage. machined to complement the function of the rear oil
(b) Where leakage tends to run straight down, seal.
possible causes are a porous block, distributor seal,
camshaft bore cup plugs oil galley pipe plugs, oil (6) For bubbles that remain steady with shaft ro
filter runoff, and main bearing cap to cylinder tation, no further inspection can be done until disas
block mating surfaces. See Group 9, Engines for sembled. Refer to the service Diagnosis—Mechanical,
proper repair procedures of these items. under the Oil Leak row for components inspections
(4) If no leaks are detected, pressurized the crank on possible causes and corrections.
case as outlined in the, Inspection (Engine oil Leaks (7) After the oil leak root cause and appropriate
in general) corrective action have been identified, Refer to Group
9, Engines—Crankshaft Rear Oil Seals, for proper re
CAUTION: Do not exceed 20.6 kPa (3 psi).
placement procedures.
(5) If the leak is not detected, very slowly turn the
crankshaft and watch for leakage. If a leak is de ENGINE OIL PRESSURE
tected between the crankshaft and seal while slowly (1) Remove oil pressure sending unit.
turning the crankshaft, it is possible the crankshaft (2) Install Oil Pressure Line and Gauge Tool
seal surface is damaged. The seal area on the crank C-3292. Start engine and record pressure. Refer to
shaft could have minor nicks or scratches that can be Oii Pressure in Engine Specifications for the proper
polished out with emery cloth. pressures.
CAUTION: Use extreme caution when crankshaft

polishing is necessary to remove minor nicks and
ENGINE DIAGN&&8&-GASOLINE—PERFORMANCE
ENGINE WILL NOT START 1. Weak battery. 1. Test battery specific gravity. Charge or replace os necessary,
2. Corroded or loose battery 2. Clean and tighten battery connections. Apply a coat of light
connections. mineral grease to the terminals.
3. Faulty starter. 3. Refer to Group 8A, Battery/Starter/Charging System
Diagnostics.
4. Moisture on ignition wires and 4. Wipe wires and cap clean and dry.
distributor cap.
5. Faulty ignition cables. . 5. Replace any cracked or shorted cables.
6. Faulty coil or control unit. 6 . Test and replace, if necessary (refer to Group 8D, Ignition
System).
7. Incorrect spark plug gap. 7. Set gap {refer to Group 8D, Ignition System).
8. Incorrect ignition timing. 8. Refer to Group 8D, Ignition System.
9. Dirt or water in fuel system. 9. Clean system and replace fuel filter.
10. Faulty fuel pump, relay or wiring. 10. Refer to Group 14, Fuel System.
ENGINE STALLS OR 1. Idle speed set too low. 1. Refer to Group 14, Fuel System.
ROUGH IDE 2. idle mixture too lean or too rich. 2. Refer to Group 14, Fuel System.
3. Leak in intake manifold. 3. inspect intake manifold gasket and vacuum hoses. Replace, if
necessary (refer to Group 11, Exhaust System & Intake
Man i fold).
4. Worn or burned distributor rotor. 4. Install new distributor rotor.
5. Incorrect ignition wiring. 5 . Install correct wiring.
6. Faulty coil. 6. Test and replace, if necessary (refer to Group 8D, Ignition
System).
7. EGR valve leaking. 7. Test and replace, if necessary {refer to Group 25, Emissions
8. Incorrect cam timing. Control System).
8. Refer to Timing Belt Service.
ENGINE LOSS OF POWER 1. Incorrect ignition timing. - 1. Refer to Group 8D, Ignition System.
2. Worn or burned distributor rotor. 2. install new distributor rotor.
3. Worn distributor shaft. 3. Remove and repair distributor (refer to Group 8D, Ignition
System).
4. Dirty or incorrectly gapped spark
plugs. 4. Clean plugs and set gap (refer to Group 8D, Ignition System).
5. Dirt or water in fuel system. 5 . Clean system and replace fuel filter.
6. Faulty fuel pump. 6 . Install new fuel pump.
7. Incorrect valve timing. 7. Correct valve timing.
8. Blown cylinder head gasket. 8. Install new cylinder head gasket.
9. Low compression. 9. Test compression of each cylinder.
10. Burned, warped or pitted valves. 10. Install new valves.
11. Plugged or restricted exhaust 11. Install new parts, as necessary.
system. 12. Replace any cracked or shorted cables.
12. Faulty ignition cables. 13. Test and replace, as necessary (refer to Group 8D, Ignition
13. Faulty coil. System).
14. Incorrect cam timing. 14. Refer to Timing Belt Service.
ENGINE MISSES O N 1. Dirty or gap set too wide in spark 1. Clean spark plugs and set gap (refer to Group 8D, Ignition
ACCELERATION plug. System).
3. Dirt in fuel system. 3. Clean fuel system.
4. Burned, warped or pitted valves. 4. Install new valves.
5. Faulty coil. 5 . Test and replace, if necessary, (refer to Group 8D, Ignition
6. Incorrect cam timing. „ System).
r
6. f?«fe* r. Timing Belt Service.
ENGINE MISSES AT HIGH 1. Dirty or gap set too wide in spark 1. Clean spark plugs and set gap (refer to Group 8D, Ignition
SPEED System).
plug.
2. Remove and repair distributor (refer to Group 8D, Ignition
2. Worn distributor shaft. System).
3. Install new distributor rotor.
3. Worn or burned distributor rotor.
4. Test and replace, as necessary {refer to Group 8D, Ignition
4. Faulty coil. System).
6. Dirty injector in throttle body. 6. Clean injector.
7. Dirt or water in fuel system. 7. Clean system and replace fuel filter.
8. Incorrect cam timing. 8. Refer to Timing Belt Service.
9309-227
BR ENGINES 9-9
ENGINE DIAGNOSIS—GASOLINE—MECHANICAL

NOISY VALVES 1. High or low oil level in crankcase. 1. Check for correct oil level (refer to
Group 0, Lubrication and Maintenance.
2. Thin or diluted oil. 2. Change oil (refer to Group 0,
Lubrication and Maintenance).
3. Low oil pressure. 3. Check engine oil level.
4. Dirt in tappets/lash adjusters. 4. Clean hydraulic tappets/hydraulic
lash adjusters.
5. Bent push rods. 5. Install new push rods.
6. Worn rocker arms. 6. Inspect oil supply to rocker arms.
7. Worn tappets/lash adjusters. 7. Install new hydraulic tappets/
hydraulic lash adjusters.
8. Worn valve guides. 8. Ream and install new valves with
oversize stems.
9. Excessive runout of valve seats 9. Grind valve seats and valves.
on valve faces.
CONNECTING ROD NOISE 1. Insufficient oil supply. 1. Check engine oil level (refer to
Group 0, Lubrication and Maintenance).
2. Low oil pressure. 2. Check engine oil level. Inspect oil
pump relief valve and spring.
3. Thin or diluted oil. 3. Change oil to correct viscosity.
4. Excessive bearing clearance. 4. Measure bearings for correct
clearance. Repair as necessary.
5. Connecting rod journal out-of- 5. Replace crankshaft or grind journals.
round.
6. Misaligned connecting rods. 6. Replace bent connecting rods.
MAIN BEARING NOISE 1. Insufficient oil supply. 1. Check engine oil level (refer to
. Group 0, Lubrication and Maintenance).
2. Low oil pressure. 2. Check engine oil level. Inspect oil
pump relief valve and spring.
4. Excessive bearing clearance. 4. Measure bearings for correct
clearance. Repair as necessary.
5. Excessive end play. 5. Check No. 3 main bearing for wear
on flanges.
6. Crankshaft journal out-of-round, 6. Grind journals or replace crankshaft.
worn.
7. Loose flywheel or torque converter. 7. Tighten to correct torque.
J9509-62
9 -10 ENGINES — • —— BR
SERVICE DIAGNOSIS—GASOLINE—LUBRICATION
OIL LEAKS 1. Gaskets and O-Rings. 1.

(a) Misaligned, deteriorated or torn. (a) Replace the part.
(b) Loose fastener, broken or porous (b) Tighten, repair or replace the part.
metal part.
2. Crankshaft Rear Seal 2.
(a) Misinstalled, inverted or torn lip (a) Replace the seal. *
(b) Torn, cut or shaved seal back bead. (b) Replace the seal.
3. Crankshaft Seal Flange. 3.
Scratched, nicked or grooved. Replace or polish if necessary.
4. Cylinder block to Cap Mating Surface. 4.
(a) Inadequate Loctite sealant. (a) Apply sealant per sealant per service
manual.
(b) Oil hole burr. (b) Carefully stone or chamfer hole.
5. Oil Pan to Rear Main Cap Sealant 5.
(Slots 3.9-5.2 only).
(a) Inadequate or mislocated sealant. (a) Apply sealant per service manual
procedures.
(b) Torn, cut or misinstalled oil pan. (b) Replace the gasket.
(c) Cracked or damaged oil pan flange. (c) Replace the oil pan.
6. Chain Case Cover Seal. 6.
(a) Misinstalled, cocked or misaligned. (a) Replace per service manual procedures.
(b) Torn, cut or damaged seal lips. (b) Replace the seal.
(c) Scratched or damaged seal casing (c) Replace the seal.
or cover bore.
(d) Scratched or damaged vibration (d) Minor damage can be polished out;
damper hub. otherwise replace the part.
OIL PRESSURE DROP 1. Low oil level. 1. Check engine oil level.
2. Faulty oil pressure sending unit. 2. Install new sending unit.
3. Low oil pressure. 3. Check sending unit and check main bearing
oil clearance.
4. Clogged oil filter. 4. Install new oil filter.
5. Worn parts in oil pump. 5. Replace worn parts or pump.
7. Excessive bearing clearance. 7. Measure bearings for correct clearance.
8. Oil pump relief valve stuck. 8. Remove valve and inspect, clean and install.
9. Oil pump suction tube loose; bent or 9. Remove oil pan and install new tube, if
cracked. necessary.
10. Oil pump cover warped or cracked. 10. Install new oil pump.
OIL PUMPING AT RINGS; 1. Worn, scuffed or broken rings. 1. Hone cylinder bores and install new rings.
SPARK PLUGS FOULING 2. Carbon in oil ring slot. 2. Install new rings.
3. Rings fitted too tightly in grooves. 3. Remove the rings. Check grooves. If
grooves are not proper width, replace piston.
4 Worn valve guides. 4. Ream guides and replace valves with
oversize valves and seals.
5. Leaking intake gasket (3.9L & 5. Replace gasket and tighten intake manifold
5.2L engines). to proper torque.
6. Leaking valve guide seals (3.9L & 6. Replace seals.
5.2L engines).
7. Dislodged valve guide seals (3.9L & 7. Seat valve guide seals or replace, as
5.2L engines). n 6 e d e d
J9509-61
BR ENGINES 9 -11
SERVICE DIAGNOSIS—DIESEL—PERFORMANCE
ENGINE WILL NOT CRANK 1. Starting motor operating, but 1. Remove the starter motor. Check for
OR CRANKS SLOWLY not cranking the engine. broken flywheel teeth or a broken
starting motor spring.
2. Crankshaft rotation restricted. 2. Rotate the engine to check for rotational
resistance.
3. Starting circuit connections 3. Clean and tighten connections.
' loose or corroded.
4. Neutral safety switch or starter 4 Check starter relay supply voltage and
relay inoperative. proper operation of neutral safety switcn •'
1
if equipped. Replace defective parts.
5. Battery charge low. 5. Check battery voltage. Replace battery
if a charge cannot be held.
6. No voltage to starter solenoid. 6. Check voltage to solenoid. If necessa *
replace the solenoid.
7... Solenoid or starter motor 7. Replace starter motor.
inoperative.
ENGINE CRANKS, BUT 1. No fuel in supply tank. 1. Fill fuel supply.
WILL NOT S T A R T - 2. Electrical fuel shutdown 2. Check for loose wires and verify that the
NO SMOKE FROM solenoid not operating. ' fuel shutdown solenoid and fuel
EXHAUST shutdown solenoid relay are functioning
3. Air intake or exhaust plugged. 3. Remove the obstruction.
4. Fuel filter plugged. 4. Drain fuel/water separator and replace
fuel filter.
5. Excessive fuel inlet restriction. 5. Check fuel inlet restriction. Correct
cause.
6. Injection pump not getting fuel 6. Check fuel flow/bleed fuel system.
or fuel is aerated.
7. Inoperative fuel transfer (Lift) . 7. Check fuel line for restrictions and fuel
pump. pressure.
8. One or more injectors worn or 8. Check/replace bad or improperly
not operating properly. operating injectors.
9. Worn or inoperative injection 9. Visually check delivery with externally
pump. connected injector to one of the pump
outlets. Repair or replace the pump if
fuel is not being delivered.
10. Internal pump timing incorrect. 10. Time the pump (refer to Group 14, Fuel
System).
11. Camshaft out of time. 11. Check/correct gear train timing
alignment.
J9509-145
9 -12 ENGINES Bit
SERVICE DIAGNOSIS—DIESElr-PERFORMANCE-CONr.
ENGINE HARD TO START, 1. Incorrect starting procedure. 1. The fuel shutoff solenoid control must
OR WILL NOT S T A R T - • be in the run position. Ensure proper
SMOKE FROM EXHAUST procedure is being used.
2. Cranking speed too slow. 2. A. Verify that the transmission is not
engaged.
B. Check the battery, starting motor and
look for loose or corroded wiring
connections.
C. Rotate the engine with barring tool
(Snap-on Tool SP371, MTE No.
3377462, or equivalent) to check for
external rotational resistance.
3. Intake heater system not 3. Verify system is working. Repair/replace
working. inoperative parts.
4. Insufficient intake air. 4. Inspect or replace filter and check for
obstructions to the air supply tube.
5. Air in fuel system or the fuel 5. Check the flow through the filter and
supply is inadequate. bleed the system. Locate and eliminate
the air source.
6. Fuel transfer (lift) pump. 6. Measure transfer pump outlet pressure.
If needed, repair or replace pump.
7. Injection pump throttle linkage 7. Visually check the linkage.
loose or damaged. Adjust/replace linkage.
8. Contaminated fuel. 8. Verify by operating the engine with
clean fuel from a temporary tank. Check
for presence of gasoline. Drain and
flush fuel supply tank. Replace
fuel/water separator filter.
9. Fuel screen plugged. 9. Check fuel screen.
10. One or more injectors worn or 10. Check/replace improperly operating
not operating properly. injectors.
11. Worn or inoperative injection 11. Visually check fuel delivery with an
pump. externally connected injector to one of
the pump outlets. Repair or replace the
. pump if fuel is not being delivered.
12. Injection pump out of time. 12. Check/Time the pump (refer to Group
14, Fuel System).
13. Valves incorrectly adjusted. 13. Adjust valves.
14. Engine compression low. 14. Check compression to identify the
problem.
J9509^148
BR ENGINES 9 -13
SERVICE DIAGNOSIS—DIESEL—PERFORMANCE—CONT.
CONDITION POSSIBLE C A U S E S
ENGINE STARTS, BUT WILL 1. Idle speed too low for the 1 Adjust the idle speed.
NOT KEEP RUNNING accessories.
2. Intake air or exhaust system 2. Visually check for exhaust restriction a . .
restricted. inspect the air intake. Repair/replace
restricting parts.
3. Air in the fuel system or the fuel 3. Check flow through the filter and bleed
supply is inadequate. the system. Locate and eliminate the air
source.
4. Fuel waxing due to extremely 4. Verify by inspecting the fuel filter. Clean
cold weather. the system and use climatized fuel.
Replace fuel/water separator filter. Check
fuel heater for proper operation.
5. Contaminated fuel. 5. Verify by operating the engine with cle<
fuel from a temporary supply tank. Check
for presence of gasoline. Replace
SURGING (SPEED 1. If the condition occurs at idle, 1. Adjust the idle speed.
CHANGE) • the idle speed is set too low for
the accessories.
2. Improperly operating injection 2. Replace the injector pump.
pump.
ROUGH IDLE 1. If engine is cold, intake heater 1. Refer to intake heater system (see Group
(IRREGULARLY FIRING OR system defective. 14, Fuel System).
ENGINE SHAKING) 2. Adjust idle speed.
2. Idle speed too low for the
accessories. 3. Repair or replace mounts.
3. Engine mounts damaged or
lose. 4. Correct leaks in the high pressure lines,
4. High pressure fuel leaks. fittings or delivery valves.
5. Bleed the fuel system and eliminate the j
5. Air in the fuel system. source of the air.
6. Check and replace the injector with the
6. Sticking needle valve in an sticking needle valve.
injector.
ENGINE RUNS ROUGH 1. Fuel injection lines leaking. 1. Correct leaks in the high pressure lines
fittings, injectors sealing washers or
delivery valves.
2. Air in the fuel or the fuel supply 2. Check the flow through the filter and
is inadequate. bleed the system. Locate and eliminate
the air source.
3. Contaminated fuel. 3. Verify by operating the engine with clean
fuel from a temporary supply tank. Check
for presence of gasoline. Replace
J9509-147
P CONDITION POSSIBLE CAUSES CORRECTION
ENGINE RUNS ROUGH 4. Incorrect valve operation. 4. Check for a bent push rod and adjust
CONT. valves. Replace push rod, if necessary.
5. Injection pump timing incorrect. 5. Check/time pump (refer to Group 14,
Fuel System).
6. Improperly operating injectors. 6. Replace inoperative injectors.
7. Defective injection pump 7. Repair or replace injection pump.
(delivery valve).
8. Camshaft out of time. 8. Check/correct gear train timing
alignment.
9. Damaged camshaft or tappets. 9. Inspect camshaft valve lift. Replace
camshaft and tappets.
ENGINE R P M WILL NOT 1. Engine overload. 1. Verify high idle speed without load.
REACH RATED S P E E D Investigate operation to be sure correct
gear is being used.
2. Improperly operating 2. Verify engine speed with hand
tachometer. tachometer, correct as required.
3. Throttle linkage worn or 3. Adjust linkage for stop-to-stop fuel
incorrectly adjusted. control lever travel. Replace linkage if
necessary.
4. Inadequate fuel supply. 4. Check the fuel flow through the system
to locate the reason for inadequate fuel
supply, correct as required.
5. Air/fuel controls leak. 5. Check and repair leak. Check AFC
tubing for obstruction.
6. Improperly operating injection 6. Repair or replace injection pump.
pump.
LOW POWER 1. Fuel control lever not moving 1. Check/correct for stop-to-stop travel.
to full throttle.
2. High oil level. 2. Check/correct oil level.
3. Engine overloaded. 3. Check for added loading from
accessories or driven units, brakes
dragging and other changes in vehicle
loading. Repair/replace as needed.
4. Slow throttle response caused 4. Check for leaks and obstructions.
by leaking or obstructed air Tighten the fittings. Repair or replace
control tube or improperly the pump if the controls are not
operating control in the pump. functioning.
5. Inadequate intake air flow. 5. Inspect/replace air cleaner element.
Look for other restrictions.
6. Inadequate fuel supply. Air in 6. Inspect/correct leaks in the high
the fuel. pressure lines, fittings injectors sealing
washers or delivery valve seals.
7. Excessive exhaust restriction. 7. Check/correct the restriction in the
exhaust system.
J9509-148
BR ENGINES 9 • 15
LOW POWER CONT. 8. High fuel temperature, 8. Verify that fuel heater is off when engine
is warm. Check for restricted fuel drain
tube. Repair/replace as needed.
9. Poor quality fuel or fuel 9. Verify by operating from a temporary
contaminated with gasoline. tank with good fuel. Check for presence
of gasoline. Replace fuel/water
separator filter.
10. Air leak between the 10. Check/correct leaks in hoses, gaskets,
turbocharger and the intake charge air cooler and around mounting
manifold. capscrews or through holes in the
manifold cover.
11. Exhaust leak at the manifold or 11. Check/correct leaks in the manifold or
turbocharger. turbocharger gaskets. If manifold is
cracked, replace manifold.
12. Improperly operating 12. Inspect/replace turbocharger.
turbocharger.
13. Wastegate operation. 13. Check waste gate operation.
14. Valve not operating. 14. Check for bent push rod, replace if
necessary.
15. Worn or improperly operating 15. Check/replace injectors.
injectors.
16. Incorrect injection pump timing. 16. Verify injection pump timing (see Group
14, Fuel System).
17. Improperly operating injection 17. Repair or replace injection pump.
pump.
EXCESSIVE EXHAUST 1 . Engine running too cold (white 1. Refer to troubleshooting for coolant
SMOKE smoke). temperature below normal (refer to
Group 7, Cooling System). Inspect
intake manifold heater system for
proper operation.
2. Improper starting procedure 2. Use proper starting procedures.
(white smoke).
3. Check fuel supply pressure and inlet
3. Fuel supply inadequate. restriction.
4. Check and time pump (refer to Group
4. Injection pump timing. 14, Fuel System).
5. Inspect/change air filter. Look for other
5. Inadequate intake air. restriction. Check charge air cooler for
obstructions.
6. Air leak between turbocharger 6. Check/correct leaks in the air crossover
and intake manifold. tube, hoses, gaskets, mounting
capscrews or through holes in the
manifold cover.
7. Exhaust leak at the manifold or 7. Check/correct leaks in the manifold or
turbocharger. turbocharger gaskets. If cracked,
replace manifold.
8. Improperly operating 8. Inspect/replace turbocharger.
turbocharger,
9. Improperly operating injectors. 9. Check and replace inoperative injectors.
J9509-149
9 -16 ENGINES mm

EXCESSIVE EXHAUST 10. improperly operating or 10. Repair or replace injection pump,
SMOKE CONT. overfuelecf injector pump.
11 . Piston rings not sealing (blue 11. Perform blow-by check. Correct as
smoke). required.
ENGINE WILL NOT SHUT 1. Fuel shutoff solenoid or 1. Check/replace fuel shutoff solenoid or
OFF solenoid relay inoperative. relay.
2. Engine running on fumes 2. Check the air intake ducts for the source
drawn into the air intake. of fumes.
WARNING: In case of engine runaway
due to flammable fumes from gasoline
spills or turbocharger oil leaks being
sucked into the mglm. Shut off engine
ignition switch first then use a C 0 2 fire
extinguisher and direct the spray under
the front bumper to remove oxygen
supply. The engine air intake is on the
passenger side behind the bumper. The
fire extinguisher must be directed at this
location for emergency shutdown
conditions.
3. Fuel injection pump 3. Repair or replace fuel injection pump.
malfunction.
COOLANT T E M P E R A T U R E 1. Low coolant level. 1. Check coolant level. Add coolant, if
ABOVE NORMAL necessary. Locate and correct the
source of the coolant loss, (refer to
Group 7, Cooling).
2. Incorrect/improperly operating 2. Replace cap with the correct rating for
pressure cap. the system.
3. Loose drive belt on water 3. Check/replace belt or belt tensioner.
pump/fan.
4. Inadequate air flow to the 4. Check/repair radiator core, fan shroud
radiator. and viscous fan drive as required.
5. Radiator fins plugged. 5. Blow debris from fins.
6. Collapsed radiator hose. 6. Replace the hose. Check cap operation,
(refer to Group 7, Cooling System).
7. Improperly operating 7. Verify that the gauge and temperatur
temperature sensor/gauge. sensor are,accurate. Replace
gauge/sensor, if bad.
8. Improperly operating, incorrect 8. Check and replace the thermostat.
or no thermostat.
9. Air in the cooling system. 9. A. Make sure the fill rate is not being
exceeded and the correct vented
thermostat is installed.
B. Check for loose hose clamps.
Tighten if loose.
C. If aeration continued, check for a
compression leak through the head
gasket.
J9509-150
BR ENGINES 9 -17
COOLANT T E M P E R A T U R E 10. Inoperative water pump. 10. Check and replace the water pump.
ABOVE NORMAL C O N T . , 11. Incorrect injection pump timing. 11. Check/time the injector pump (refer to !
Group 14, Fuel System).
12. Overfueled injection pump. 12. Repair or replace the injection pump.
13. Plugged cooling passages in 13. Flush the system and fill with clean
radiator, head, head gasket or coolant.
block.
14. Engine overloaded. 14. Verify that the engine load rating is not
being exceeded.
COOLANT TEMPERATURE 1. Too much air flow across the ' 1. Check/repair viscous fan drive as
BELOW NORMAL radiator. required.
2. Incorrect thermostat or 2. Check and replace thermostat.
contamination in thermostat.
3. Temperature sensor or gauge 3. Verify that the gauge and sensor are
inoperative. accurate. If not, replace gauge/sensor.
4. Coolant not flowing by 4. Check and clean coolant passages.
temperature sensor.
J9509-151
9 - 18 ENGINES BR
SERVICE DIAGNOSIS—DIESEL—MECHANICAL
common POSSIBLE CAUSES CORRECTION

LUBRICATING OIL 1. Low oil level. 1. A. Check and fill with clean engine oil
PRESSURE LOW B. Check for a severe external oil leak
that could reduce the pressure.
2. Oil viscosity thin, diluted or 2. Verify the correct oil is being used.
wrong specification. Check for oil dilution. Refer to
Contaminated Lube Oil (Engine
Diagnosis Mechanical).
3. Improperly operating pressure 3. Verify the pressure switch is functioning
switch/gauge. correctly. If not, replace switch/gauge.
4. Relief valve stuck open. 4. Check/replace valve.
5. Plugged oil filter. 5. Change oil filter. Oil filter change
interval may need to be revised.
6. If cooler was replaced, 6. Check/remove shipping plugs.
shipping plugs left in cooler.
7. Worn oil pump. 7. Check and replace oil pump.
8. Suction tube loose or seal 8. Check and replace seal.
leaking.
9. Loose main bearing cap. 9. Check and install new bearing and
tighten cap to proper torque.
10. Worn bearings or wrong 10. Inspect and replace connecting rod or
bearings installed. main bearings. Check and replace
piston cooling nozzles.
11. Oil jet under piston bad fit into 11. Check oil jet position.
main carrier.
LUBRICATING OIL 1. Pressure switch/gauge not 1. Verify the pressure switch is functioning
PRESSURE TOO HIGH operating properly. correctly. If not, replace switch/gauge.
2. Engine running to cold. 2. Refer to Coolant Temperature Below
Normal (Engine Diagnosis Performance).
3. Oil viscosity too thick. 3. Make sure the correct oil being used,
(Refer to Group 0, Lubrication and
Maintenance).
4. Oil pressure relief valve stuck 4. Check and replace valve.
closed or binding.
LUBRICATING OIL L O S S 1. External leaks. 1. Visually inspect for oil leaks. Repair as
required.
2. Crankcase being overfilled. 2. Verify that the correct dipstick is being used.
3. Incorrect oil specification or 3. A. Make sure the correct oil is being
viscosity. used.
B. Look for reduced viscosity from
dilution with fuel.
C. Review/reduce the oil change
intervals.
4. Oil cooler leak. 4. Check and replace the oil cooler.
5. High blow-by forcing oil out the 5. Check the breather tube area for signs of
breather. oil loss. Perform the required repairs.
8. Turbocharger leaking oil to the 6. Inspect the air ducts for evidence of oil
air intake. transfer. Repair as required.
7. Piston rings not sealing (oil 7. Perform blow-by check. Repair as
being consumed by the engine). required.
J9509-152
BR ENGINES 9 -19
SERVICE DIAGNOSIS—DIESEL—MECHANICAL—CONT.

COMPRESSION KNOCKS 1 . Air in the fuel system. 1. Bleed the fuel system (refer to Group 14,
Fuel System).
2. Poor quality fuel or water/ 2. Verify by operating from a temporary tank
gasoline contaminated fuel. with good fuel. Clean and flush the fuel
supply tanks. Replace fuel/water
separator filter.
3. Engine overloaded. 3. Verify the engine load rating is not being
exceeded.
4. Incorrect injection pump timing. 4. Check and time injection pump (refer to
Group 14, Fuel System).
5. Improperly operating injectors. 5. Check and replace inoperative injectors.
EXCESSIVE VIBRATION 1. Loose or broken engine mounts. 1. Replace engine mounts.

2. Damaged fan or improperly 2. Check and replace the vibrating
operating accessories. components.
3. Improperly operating vibration
damper. 3. Inspect/replace the vibration damper.
4. Improperly operating viscous fan
drive. 4. Inspect/replace the fan drive.
5. Worn or damaged generator
bearing. 5. Check/replace the generator.
6. Flywheel housing misaligned.
6. Check/correct flywheel alignment.
7. Loose or broken power
component. 7. Inspect the crankshaft and rods for
damage that causes an unbalance,
repair/replace as required.
8. Worn or unbalanced driveline
8. Check/repair driveline components.
components.
EXCESSIVE ENGINE 1. Drive belt squeal, insufficient 1. Check the automatic tensioner and
NOISES tension or abnormally high inspect the drive belt. Make sure water
loading. pump, tensioner pulley, fan hub and
generator turn freely.
2. Intake air or exhaust leaks. 2. Refer to Excessive Exhaust smoke
(Engine Diagnosis Performance).
3. Excessive valve lash. 3. Adjust valves. Make sure the push rods
are not bent and rocker levers or
adjusting screws are not severely worn.
Replace bent or severely worn pads.
4. Turbocharger noise. 4. Check turbocharger impeller and turbine
wheel for housing contact. Repair/replace
as required.
5. Gear train noise. 5. Visually inspect and measure gear
backlash. Replace gears as required.
6. Power function knock. 6. Check/replace rod and main bearings.
GENERATOR NOT 1 . Loose or corroded battery. 1. Clean/tighten battery connection.

CHARGING OR 2. Generator belt slipping. 2. Check/replace automatic belt tensioner.
INSUFFICIENT CHARGING Check/replace drive belt.
3. Generator pulley loose on shaft. 3. Tighten pulley.
4. Improperly operating generator. 4. Check/replace generator.
J9509-153
9 - 20 3 . 9 L ENGINE BR
3.9L ENGINE SERVICE PROCEDURES
INDEX
page page
Camshaft ..... . 32 Oil Pan 35

Cylinder Block . . 46 Rocker Arms and Push Rods . . . . . . . . . . . . . . . . 24
Cylinder Head Cover . . 24 Specifications—3.9L Engine .. 48
Cylinder Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Timing Chain Cover 30
Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Valve Components Replace—Cylinder Head Not
Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 21 Removed . . . . . . . . . . . . . . . . . . . . 24
Engine Front Mounts . 20 Valve Stem Seal and Spring Replacement . . . . . . . 24
Engine Rear Mount .. 21 Valve Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Front Crankshaft Oil Seal Replacement . . . . . . . . . 32 Valves and Valve Springs 26
General Information 20
Vibration Damper 30
Hydraulic Tappets .. 28
GENERAL INFORMATION
The 3.9 Liter (238 C1D) six-cylinder engine is a V-
Type, lightweight, single cam, overhead valve engine
with hydraulic roller tappets (Fig. 1).
Engine Type ...90* V-6 OHV

Bore and Stroke ..99.3 x 84.0 mm (3.9! x 3.31 in.)
Displacement 3.911238 cu. in.)
Compression Ratio 9.1:1
Torque.... 312 N*m |230 ft. Ihs.| @ 3,200 rpm
Firing Order . 1 -6-5-4-3-2
Lubrication Pressure Feed - Full Fbw Filtration
Engine Oil Capacity ...3.8L (4.0 Qts) with Filter
Cooling System Liquid Cooled - Forced Circulation J9309-26
Coding Capacity 14.31 {15.1 Qts)

Fig. 2 Firing Order
Grinder Block... Cast Iron
Crankshaft. .Modular t i r o
Cylinder Head ..........Cast Iron X M 3.9L T XXXX xxxxxxxx
Combustion Chambers... "Fast Burn*' Design
Camshaft ............. Nodular Cast iron
Pistons .Aluminum Alby w/Sfrof X = Last Digit of Model Year
Connecting Rods .....Forged Ste®! M = Plant - M Mound Road
S Sahillo
T Trenton
J9409-9 K Toluca
3.9L - Engine Displacement
Fig. 1 Engine Description T a Usage - T Truck
XXM = Month/Day
This engine is designed for unleaded fuel. XDQ0QOOC - Serial Code - Last 8 Digits of VIN No.
Engine lubrication system consists of a rotor type
oil pump and a full flow oil filter.
The cylinders are numbered from front to rear; 1 , J9209-72
3, 5 on the left bank and 2, 4, 6 on the right bank. Fig. 3 Engine Identification Number
The firing order is 1-6-5-4-3-2 (Fig. 2).
The engine serial number is stamped into a ma ENGINE FRONT MOUNTS
chined pad located on the left, front corner of the cyl
REMOVAL
inder block. When component part replacement is
(1) Disconnect the negative cable from the battery.
necessary, use the engine type and serial number for
(2) Position fan to assure clearance for radiator top
reference (Fig. 3).
tank and hose.
BR 3 J L ENGINE I - 21
CAUTION: DO NOT lift the engine by the Intake

manifold.
(3) Install engine support/lifting fixture.

(5) Lift the engine SLIGHTLY and remove the
thru-bolt and nut (Fig. 4).
(6) Remove engine support bracket/cushion bolts
(Fig. 4). Remove the support. bracket/cushion and
heat shields.
!-BOLT
CUSHION
J9409-54
Fig. 5 Positioning Engine Front Mounts

RESTRICTION PADS INSTALLATION
J9409-144 (1) If removed, position the transmission support
bracket to the transmission. Install new attaching
Fig. 4 Engine Front Mounts bolts and tighten to 88 N-m (65 ft. lbs.) torque.
INSTALLATION (2) Position support cushion to transmission sup
(1) With engine raised SLIGHTLY, position the en port bracket. Install stud nuts and tighten to 41 N-m
gine support bracket/cushion and heat shields to the (30 ft. lbs.) torque.
block. Install new bolts and tighten to 81 N-m (60 ft. (3) Using the transmission jack, lower the trans
lbs.) torque. mission and support cushion onto the crossmember
(2) Install the thru-bolt into the engine support (Fig. 6).
bracket/cushion. (4) Install the support cushion bolts and tighten to
(3) Lower engine with support/lifting fixture while 41 N°m (30 ft. lbs.) torque.
guiding the engine bracket/cushion and thru-bolt into (5) Remove the transmission jack.
support cushion brackets (Fig. 5). (6) Lower the vehicle.
(4) Install thru-bolt nuts and tighten the nuts to
102 N*m (75 ft. lbs.) torque. ENGINE ASSEMBLY
(5) Lower the vehicle.
REMOVAL
(6) Remove lifting fixture.
(1) Remove the battery.
ENGINE REAR MOUNT (2) Drain cooling system (refer to Group 7, Cooling
System for the proper procedure).
REMOVAL (3) Remove the upper crossmember and top core
(1) Raise the vehicle on a hoist. support.
(2) Position a transmission jack in place. (4) Remove the transmission oil cooler.
(3) Remove support cushion stud nuts (Fig. 6). (5) Discharge the air conditioning system, if
(4) Raise rear of transmission and engine equipped (refer to Group 24, Heating and Air Condi
SLIGHTLY. tioning for service procedures).
(5) Remove the bolts holding the support cushion (6) Remove the serpentine belt (refer to Group 7,
to the transmission support bracket. Remove the sup Cooling System).
port cushion. (7) Remove the A/C compressor with the lines at
(6) If necessary, remove the bolts holding the tached. Set aside.
transmission support bracket to the transmission.
9 - 22 3.9L ENGINE
J9509-126
Fig. 6 Engine Rear Support Cushion Assemblies

(8) If equipped, remove the condenser. (5) Install the prop shaft (refer to Group 16, Pro
(9) Remove the washer bottle. peller Shaft).
(10) Disconnect the top radiator hose. (6) Install the dust.shield and transmission cover.
(11) Remove the fan. (7) Install the starter and connect the starter wires
(12) Remove the fan shroud. (refer to Group 8B, Battery/Starter/Generator Ser
(13) Disconnect the lower radiator hose. vice).
(14) Remove radiator (refer to Group 7, Cooling (8) Install exhaust pipe to manifold.
System). (9) Install the transmission cooler line brackets
(15) Remove the generator with the wire connec from oil pan.
tions (refer to Group 8B, Battery/Starter/Generator (10) Install engine front mount thru-bolt nuts.
Service). Tighten the nuts.
(16) Remove the air cleaner box. (11) Install the drain plug and tighten to 34 N-m
(17) Disconnect the throttle linkage. (25 ft. lbs.) torque.
(18) Remove throttle body. (12) Lower the vehicle.
(19) Remove the intake manifold (refer to Group (13) Remove engine lifting fixture.
11, Exhaust System and Intake Manifold). (14) On Manual Transmission vehicles, install the
(20) Remove the distributor cap and wiring. shift lever (refer to Group 21, Transmissions).
(21) Disconnect the heater hoses. (15) Connect the fuel lines.
(22) Disconnect the power steering hoses, if (16) Connect the transmission cooler lines.
equipped. (17) Connect the power steering hoses, if equipped.
(23) Disconnect the transmission cooler lines. (18) Connect the heater hoses.
(24) Perform the Fuel System Pressure ' release (19) Install the distributor cap and wiring.
procedure (refer to group 14, Fuel system). Discon ' (20) Install the intake manifold (refer to Group 11,
nect the fuel lines. Exhaust System and Intake Manifold).
(25) On Manual Transmission vehicles, remove the (21) Using a new gasket, install throttle body.
shift lever (refer to Group 21, Transmissions). Tighten the throttle body bolts to 23 N-m (200 in.
(26) Raise and support the vehicle on a hoist. lbs.) torque.
(27) Remove the drain plug and drain the engine (22) Connect the throttle linkage.
oil (23) Install the air cleaner box.
(28) Remove engine front mount thru-bolt nuts. (24) Install the generator and wire connections (re
(29) Remove the transmission cooler line brackets fer to Group 8B, Battery/Starter/Generator Service).
from oil pan. (25) Install radiator (refer to Group 7, Cooling Sys
(30) Disconnect exhaust pipe at manifold. tem).
(31) Disconnect the starter wires. Remove starter (26) Connect the lower radiator hose.
motor (refer to Group 8B, Battery/Starter/Generator (27) Install the fan shroud.
Service). (28) Install the fan.
(32) Remove the dust shield and transmission (29) Connect the top radiator hose.
cover. (30) Install the washer bottle.
(33) Refer to Group 21, Transmissions for trans (31) If equipped, install the condenser.
mission removal. (32) Install the A/C compressor with the lines at
(34) Lower the vehicle. tached.
(33) Install the serpentine belt (refer to Group 7,
CAUTION: DO NOT lift the engine by the intake
Cooling System).
manifold,
(34) Evacuate and charge the air conditioning sys
(35) Install an engine lifting fixture. tem, if equipped (refer to Group 24, Heating and Air
(36) Remove engine from vehicle and install engine Conditioning for service procedures).
assembly on a repair stand. (35) Install the transmission oil cooler.
(36) Install the upper crossmember and top core
INSTALLATION support.
(1) Remove engine from the repair stand and posi (37) Add coolant to the cooling system (refer to
tion in the engine compartment. Position the thru- Group 7, Cooling System for the proper procedure).
bolt into the support cushion brackets. (38) Install the battery.
(2) Install an engine support fixture. (39) Warm engine and adjust.
(3) Raise and support the vehicle on a hoist. (40) Road test vehicle.
(4) Refer to Group 21, Transmissions for transmis
sion installation.
I - 24 3 J L ENGINE — * — — — — — ^ BR
CYLINDER HEAD COWER ROCKER

ARMS
A steel backed silicon gasket is used with the cyl
inder head cover (Fig. 1). This gasket can be used
again.
CYLINDER H E A D
COVER G A S K E T V
J9209-104
Fig. 1 Cylinder Head Cower Gasket

REMOVAL
(2) Disconnect closed ventilation system and evap J9209-66
oration control system from cylinder head cover.
(3) Remove cylinder head cover and gasket. The Fig. 2 Rocker Arms
gasket may be used again. INSTALLATION
(1) Rotate the crankshaft until the V6 mark lines
CLEANING
up with the TDC mark on the timing chain case
Clean cylinder head cover gasket surface.
cover. This mark is located 147° ATDC from the No.l
Clean head rail, if necessary.
firing position.
INSPECTION
CAUTION: DO NOT rotate or crank the engine dur
Inspect cover for distortion and straighten, if nec ing or immediately after rocker arm installation. Al
essary. low the hydraulic roller tappets adequate time to
Check the gasket for use in head cover installation. bleed down (about 5 minutes).
If damaged, use a new gasket.
(2) Install the push rods in the same order as re
INSTALLATION moved.
(1) The cylinder head cover gasket can be used (3) Install rocker arm and pivot assemblies in the
again. Install the gasket onto the head rail. same order as removed. Tighten the rocker arm bolts
(2) Position the cylinder head cover onto the gas to 28 N-m (21 ft. lbs.) torque.
ket. Tighten the bolts to 11 N°m (95 in. lbs.) torque. (4) Install cylinder head cover.
(3) Install closed crankcase ventilation system and (5) Connect spark plug wires.
evaporation control system.
(4) Connect the negative cable to the battery. VALVE STEM SEAL AND SPRING REPLACEMENT
This procedure is done with the cylinder head in
VILVE COMPONENTS REPLACE—CYLINDER HEAD stalled.
NOT REMOVED (1) Set engine basic timing to Top Dead Center
(TDC).
ROCKER ARMS AND PUSH RODS (2) Remove the air cleaner.
(3) Remove cylinder head covers and spark plugs.
REMOVAL (4) Remove coil wire from distributor and secure to
(1) Disconnect spark plug wires by pulling on the good ground to prevent engine from starting.
boot straight out in line with plug. (5) Using suitable socket and flex handle at crank
(2) Remove cylinder head cover and gasket. shaft retaining bolt, turn engine so the No.l piston is
(8) Remove the rocker arm bolts and pivots (Fig. at TDC on the compression stroke.
2). Place them on a bench in the same order as re (6) Remove rocker arms.
moved. (7) With air hose attached to an adapter installed
(4) Remove the push rods and place them on a in No.l spark plug hole, apply 620-689 kPa (90-100
bench in the same order as removed. psi) air pressure.
en 3.9L ENGINE 9 - 25
(8) Using Valve Spring Compressor Tool (9) Disconnect accelerator linkage and if so
MD-998772A, compress valve spring and remove re equipped, the speed control and transmission kick-
tainer valve locks and valve spring. down cables.
(9) Install seals on the exhaust valve stem and po (10) Remove the return spring.
sition down against valve guides. (11) Remove distributor cap and wires.
(10) The intake valve stem seals should be pushed (12) Disconnect the coil wires.
firmly and squarely over the valve guide using the (13) Disconnect heat indicator sending unit wire.
valve stem as a guide. DO NOT force seal against top (14) Disconnect heater hoses and bypass hose.
of guide. When installing the valve retainer locks, (15) Remove cylinder head covers and gaskets.
compress the spring only enough to install the locks. (16) Remove intake manifold and throttle body as
(11) Follow the same procedure on the remaining 5 an assembly. Discard the flange side gaskets and the
cylinders using the firing sequence 1-6-5-4-3-2. Make front and rear cross-over gaskets.
sure piston in cylinder is at TDC on the valve spring (17) Remove exhaust manifolds.
that is being removed. (18) Remove rocker arm assemblies and push rods.
(12) Remove adapter from the No.l spark plug Identify to ensure installation in original locations.
hole. (19) Remove the head bolts from each cylinder
(13) Install rocker arms. head and remove cylinder heads. Discard the cylin
(14) Install covers and coil wire to distributor. der head gasket.
(15) Install air cleaner. (20) Remove spark plugs.
(16) Road test vehicle.
CLEANING
CYLINDER H E 1 D S Clean all surfaces of cylinder block and cylinder
The alloy cast iron cylinder heads (Fig. 3) are held heads.
in place by 8 bolts. The spark plugs are located in Clean cylinder block front and rear gasket surfaces
the peak of the wedge between the valves. using a suitable solvent.
SPARK SPARK INTAKE INSPECTION

PLUGS PLUG VALVE Inspect all surfaces with a straightedge if there is
any reason to suspect leakage. If out-of-flatness ex
ceeds 0.00075 mm/mm (0.00075 inch/inch) times the
span length in any direction, either replace head or
lightly machine the head surface.
FOR EXAMPLE:—A 305 mm (12 inch) span is
0.102 mm (0.004 inch) out-of-flat. The allowable out-
of-flat is 305 x 0.00075 (12 x 0.00075) equals 0.23
mm (0.009 inch). This amount of out-of-flat is accept
able.
The cylinder head surface finish should be
1.78-3.00 microns (70-125 microinches).
EXHAUST INTAKE EXHAUST
VALVE VALVES VALVES J9309-35 Inspect push rods. Replace worn or bent rods.
INSTALLATION
Fig. 3 Cylinder Head Assembly
(1) Position the new cylinder head gaskets onto the
REMOVAL cylinder block.
(1) Disconnect the negative cable from the battery. (2) Position the cylinder heads onto head gaskets
(2) Drain cooling system (refer to Group 7, Cooling and cylinder block.
System for the proper procedures). (3) Starting at top center, tighten all cylinder head
(3) Remove the intake manifold-to-generator bolts, in sequence, to 68 N-m (50 ft. lbs.) torque (Fig.
bracket support rod. Remove the generator. 4). Repeat procedure, tighten all cylinder head bolts
(4) Remove closed crankcase ventilation system. to 143 N-m (105 ft. lbs.) torque. Repeat procedure to
(5) Disconnect the evaporation control system. confirm that all bolts are at 143 N-m (105 ft. lbs.)
(6) Remove the air cleaner. torque.
(7) Perform fuel system pressure release procedure
CAUTION: When tightening the rocker arm bolts,
(before attempting any repairs Refer to Group 14, make sure the piston in that cylinder is NOT at
Fuel Systems). TDC. Contact between the valves and piston could
(8) Disconnect the fuel lines. occur.
i - 26 3 J L ENGINE — ^ ^ ^ ^ — ^ ^ ^ — ^ ^ ^ ^ BR
/ALVES AND VALVE SPRINGS

The valves are arranged in-line and inclined 18°.
The rocker pivot support and the valve guides are
cast integral with the heads.
This procedure requires the removal of the cylinder
head.
REMOVAL
(1) Remove the cylinder head.
(2) Compress valve springs using Valve Spring
Compressor Tool MD-998772A.
(3) Remove valve retaining locks, valve spring re
tainers, valve stem seals and valve springs.
(4) Before removing valves, remove any burrs from
valve stem lock grooves to prevent damage to the
valve guides. Identify valves to ensure installation in
Fig. 4 Cylinder Head Bolt Tightening Sequence original location.
(4) Install push rods and rocker arm assemblies in
their original position. Tighten the bolts to 28 N-m VALVE CLEANIMQ
(21 ft. lbs.) torque. Clean valves thoroughly. Discard burned, warped
(5) Install the Intake manifold and throttle body and cracked valves.
assembly (refer to Group 11, Exhaust System and In Remove carbon and varnish deposits from inside of
take Manifold). valve guides with a reliable guide cleaner.
(6) Install exhaust manifolds. Tighten the bolts
VALVE INSPECTION
and nuts to 84 N-m (25 ft. lbs.) torque.
Measure valve stems for wear. If wear exceeds
(7) Adjust spark plugs to specifications (refer to
0.051 mm (0.002 inch), replace the valve.
Group 8D, Ignition System). Install the plugs and
tighten to 41 N-m (30 ft. lbs.) torque. VALVE GUIDES
(8) Install coil wires. Measure valve stem guide clearance as follows:
(9) Connect heat Indicator sending unit wire. (a) Install Valve Guide Sleeve Tool C-3973 over
(10) Connect the heater hoses and bypass hose. valve stem and install valve (Fig. 5). The special
(11) Install distributor cap and wires. sleeve places the valve at the correct height for
(12) Hook up the return spring. checking with a dial indicator.
(13) Connect the accelerator linkage and if so
equipped, the speed control and transmission kick-
down cables.
(14) Install the fuel lines.
(15) Install the generator and drive belt. Tighten
generator mounting bolt to 41 N-m (30 ft. lbs.)
torque. Tighten the adjusting strap bolt to 23 N-m
(200 in. lbs.) torque. Refer to Group 7, Cooling Sys
tem for adjusting the belt tension.
(16) Install the intake manifold-to-generator
bracket support rod. Tighten the bolts.
(17) Place the cylinder head cover gaskets in posi
tion and install cylinder head covers. Tighten the Fig. 5 Positioning Valve with Tool C-3973
bolts to 11 N-m (95 in. lbs.) torque. (b) Attach dial indicator Tool C-3339 to cylinder
(18) Install closed crankcase ventilation system. head and set it at right angle of valve stem being
(19) Connect the evaporation control system. measured (Fig. 6).
(20) Install the air cleaner. (c) Move valve to and from the indicator. The to
(21) Install the heat shields. Tighten the bolts to tal dial indicator reading should not exceed 0.432
41 N-m (80 ft. lbs.) torque. mm (0.017 inch). Ream the guides for valves with
(22) Fill cooling system (refer to Group 7, Cooling oversize stems if dial indicator reading is excessive
System for proper procedure). or if the stems are scuffed or scored.
(23) Connect the negative cable to the battery. Service valves with oversize stems are available
(Fig. 7).
BUS - 3 J L ENGINE I • 27
CONTACT
i * •
Fig. S Measuring Valve Guide Wear A - SEAT WIDTH - INTAKE 1.016 - 1.524 mm (0.040 - 0.060 in.)
- EXHAUST 1.524 - 2.032 mm (0.060 - 0.080 in.)
S - FACE ANGLE (INTAKE & EXHAUST) 4374° - 43V.°
Reamer 0 / S Volve Guide Size C - SEAT ANGLE (INTAKE & EXHAUST) 447.° - 44%°
D - CONTACT SURFACE
0.076 ram 8.026 - 8.052 mm J9309-95
(0.003 in.) (0.316-0,317 In.)
0.381 mm 8.331 -8.357 mm Fig. 8 Valve Face and Seat Angles
(0.015 in,) (0.328 -0.329 in.)
J9309-30
Fig. 7 Reamer Sizes

Slowly turn reamer by hand and clean guide thor
oughly before installing new valve. Ream the valve
guides from standard to 0.381 mm (0.015 inch).
Use a 2 step procedure so the valve guides are
reamed t r u e in relation to the valve seat:
• Step 1—Ream to 0.0763 m m (0.003 inch).
REFACING VALVES AND VALVE SEATS

The intake and exhaust valves have a 43-1/4° to
43-3/4° face angle and a 44-1/4° to 44-3/4° seat angle
(Fig. 8). Fig. 9 Intake and Exhaust Valves
(2) Measure the concentricity of valve seat using a
VALVES dial indicator. Total r u n o u t should not exceed 0.051
Inspect t h e remaining m a r g i n after the valves are m m (0.002 inch) total indicator reading.
refaced (Fig. 9). Valves w i t h less t h a n 1.190 m m (3) Inspect the valve seat w i t h Prussian blue to de
(0.047 inch) margin should be discarded. termine where the valve contacts the seat. To do this,
coat valve seat L I G H T L Y w i t h Prussian blue then set
VALVE SEATS valve i n place. Rotate the valve w i t h l i g h t pressure.
I f the blue is transferred to the center of valve face,
CAUTION: DO NOT un-shroud valves during valve
contact is satisfactory. I f the blue is transferred to
seat refacing (Fig. 10).
the top edge of valve face, lower valve seat w i t h a 15°
stone. I f the blue is transferred to bottom edge of
(1) When refacing valve seats, i t is important t h a t
valve face raise valve seat w i t h a 60° stone.
the correct size valve guide pilot be used for reseat
(4) When seat is properly positioned the w i d t h of
ing stones. A true and complete surface must be ob
intake seats should be 1.016-1.524 m m (0.040-0.060
tained.
INSTALLATION
(1) Coat valve stems with lubrication oil and insert
them in cylinder head.
(2) If valves or seats are reground, check valve
stem height. If valve is too long, replace cylinder
head.
(3) Install new seals on all valve guides. Install
valve springs and valve retainers.
(4) Compress valve springs with Valve Spring
Compressor Tool MD-998772A, install locks and re
lease tool. If valves and/or seats are ground, measure
the installed height of springs. Make sure the mea
surement is taken from bottom of spring seat in cyl
inder head to the bottom surface of spring retainer. If
spacers are installed, measure from the top of spacer.
If height is greater than 42.86 mm (1-11/16 inches),
Fig. 10 Refacing Waive Seats install a 1.587 mm (1/16 inch) spacer in head coun-
inch). The width of the exhaust seats should be terbore. This should bring spring height back to nor
1.524-2.082 mm (0.060^0.080 inch). mal 41.27 to 42.86 mm (1-5/8 to 1-11/16 inch).
WALWE SPMING INSPECTION HYDRAULIC TAPPETS

Whenever valves have been removed for inspection, Before disassembling any part of the engine to cor
reconditioning or replacement, valve springs should rect tappet noise, check the oil pressure. If vehicle
be tested. As an example the compression length of has no oil pressure gauge, install a reliable gauge at
the spring to be tested is 1-5/16 inch. Turn table of the pressure sending unit. The pressure should be
Universal Valve Spring Tester Tool until surface is in between 207-552 kPa (30-80 psi) at 3,000 RPM.
line with the 1-5/16 inch mark on the threaded stud. Check the oil level after the engine reaches normal
Be sure the zero mark is to the front (Fig. 11). Place operating temperature. Allow 5 minutes to stabilize
spring over stud on the table and lift compressing le oil level, check dipstick.
ver to set tone device. Pull on torque wrench until The oil level in the pan should never be above the
ping is heard. Take reading on torque wrench at this FULL mark or below the ADD OIL mark on dipstick.
instant. Multiply this reading by 2. This will give the Either of these 2 conditions could be responsible for
noisy tappets.
spring load at test length. Fractional measurements
are indicated on the table for finer adjustments. Re OIL LEVEL
fer to specifications to obtain specified height and al
lowable tensions. Discard the springs that do not HIGH
meet specifications. If oil level is above the FULL mark, it is possible
for the connecting rods to dip into the oil. With the
engine running, this condition could create foam in
the oil pan. Foam in oil pan would be fed to the hy
draulic tappets by the oil pump causing them to lose
length and allow valves to seat noisily.
LOW
Low oil level may allow oil pump to take in air.
When air is fed to the tappets, they lose length which
allows valves to seat noisily. Any leaks on intake side
of oil pump through which air can be drawn will cre
ate the same tappet action. Check the lubrication
system from the intake strainer to the pump cover,
including the relief valve retainer cap. When tappet
noise is due to aeration, it may be intermittent or
constant, and usually more than 1 tappet will be
noisy. When oil level and leaks have been corrected,
Fig. 11 Testing Valve Spring for Compressed Length operate the engine at fast idle. Run engine for a suf
ficient time to allow all of the air inside the tappets
to be bled out.
BR 8 J L ENGINE S - 21
TAPPET MOISE DIAGNOSIS DISASSEMBLE

(1) To determine source of tappet noise, operate en (1) Pry out plunger retainer spring clip (Fig. 12).
gine at idle with cylinder head covers removed. (2) Clean varnish deposits from inside of tappet
(2) Feel each valve spring or rocker arm to detect body above plunger cap.
noisy tappet. The noisy tappet will cause the affected (3) Invert tappet body and remove plunger cap,
spring and/or rocker arm to vibrate or feel rough in plunger, check valve, check valve spring, check valve
operation. retainer and plunger spring (Fig. 12). Check valve
Worm valve guides or cocked springs are could be flat or ball.
sometimes mistaken for noisy tappets* If such is
the case, noise may be dampened by applying
side thrust on t h e valve spring. If noise is not (1) Clean all tappet parts in a solvent that will re
appreciably reduced, it can be assumed t h e move all varnish and carbon.
noise is in the tappet. Inspect the rocker arm (2) Replace tappets that are unfit for further ser
push rod sockets and push rod ends for wear, vice with new assemblies.
(3) Valve tappet noise ranges from light noise to a (3) If plunger shows signs of scoring or wear, in
heavy click. A light noise is usually caused by exces stall a new tappet assembly. If valve is pitted, or
sive leak down around the unit plunger or by the valve seat on end of plunger is prevented from seat
plunger partially sticking in the tappet body cylinder. ing, install a new tappet assembly.
The tappet should be replaced. A heavy click is (4) Assemble tappets (Fig. 12).
caused by a tappet check valve not seating or by for PLUNGER PLUNGER
eign particles becoming wedged between the plunger SPRING CHECK RETAINER
and the tappet body. This will cause the plunger to BALL SPRING CLIP
stick in the down position. This heavy click will be
accompanied by excessive clearance between the
valve stem and rocker arm as valve closes. In either LER
TAPPET RETAINER
I PLUNGER
case, tappet assembly should be removed for inspec BODY

tion and cleaning. CHECK VALVE PLUNGER
The valve train generates a noise very much like a SPRING
CAP J91G9 220
light tappet noise during normal operation. Care
must be taken to ensure that tappets are making the Fig. 12 Hydraulic Tappet Assembly
noise. In general, if more than one tappet seems to INSTALLATION
be noisy, its probably not the tappets. (1) Lubricate tappets.
(2) Install tappets and push rods in their original
REMOVAL positions. Ensure that the oil feed hole in the side of
(1) Remove the air cleaner. the tappet body faces up (away from the crankshaft).
(2) Remove cylinder head cover. (3) Install aligning yokes with ARROW toward
(3) Remove rocker assembly and push rods. Iden
camshaft.
tify push rods to ensure installation in original loca
tion. (4) Install yoke retainer. Tighten the bolts to 23
(4) Remove intake manifold. N-m (200 in. lbs.) torque. Install intake manifold.
(5) Remove yoke retainer and aligning yokes. (5) Install push rods in original positions.
(6) Slide Hydraulic Tappet Remover/Installer Tool (6) Install rocker arms.
C-4129-A through opening in cylinder head and seat (7) Install cylinder head cover.
tool firmly in the head of tappet. (8) Start and operate engine. Warm up to normal
(7) Pull tappet out of bore with a twisting motion. operating temperature.
If all tappets are to be removed, identify tappets to
ensure installation in original location. CAUTION: To prevent damage to valve mechanism,
(8) If the tappet or bore in cylinder block is scored, engine must not be run above fast idle until all hy
scuffed, or shows signs of sticking, ream the bore to draulic tappets have filled with oil and have become
next oversize. Replace with oversize tappet. quiet.
CAUTION: The plunger and tappet bodies are not

interchangeable. The plunger and valve must al WALfE THING
ways be fitted to the original body. It is advisable to (1) Turn crankshaft until the No.6 exhaust valve is
work on one tappet at a time to avoid mixing of closing and No.6 intake valve is opening.
parts. Mixed parts are not compatible. DO MOT dis
assemble a tappet ©FT a dirty work bench.
(2) Insert a 6.850 mm (1/4 inch) spacer between (2) Place installing tool, part of Puller Tool Set
rocker arm pad and stem tip of No.l intake valve. Al C-3688 in position and press the vibration damper
low spring load to bleed tappet down giving in effect onto the crankshaft (Fig. 2).
a solid tappet.
(3) Install a dial indicator so plunger contacts'
valve spring retainer as nearly perpendicular as pos
sible. Zero the indicator.
(4) Rotate the crankshaft clockwise (normal run
ning direction) until the valve has lifted 0.254 mm
(0.010 inch). The timing of the crankshaft should
now read from 10° before top dead center to 2° after
top dead center. Remove spacer.
CAUTION: DO NOT turn crankshaft any further
clockwise as valve spring might bottom and result
in serious damage. Fig. 2 Installing Vibration Damper
(3) Install the crankshaft bolt and washer. Tighten
(5) If reading is not within specified limits: the bolt to 183 N-m (135 ft. lbs.) torque.
(a) Check sprocket index marks. (4) Install the crankshaft pulley. Tighten the pul
(b) Inspect timing chain for wear. ley bolts to 23 N-m (200 in. lbs.) torque.
(c) Check accuracy of DC mark on timing indica (5) Install the serpentine belt (refer to Group 7,
tor. Cooling System).
(6) Install the cooling system fan. Tighten the bolts
VIBRATION DAMPER to 23 N-m (17 ft. lbs.) torque.
(7) Position the fan shroud and install the bolts.
REMOVAL
Tighten the retainer bolts to 11 N-m (95 in. lbs.)
(1) Disconnect the negative cable from the battery. torque.
(2) Remove fan shroud retainer bolts and set
shroud back over engine. (8) Connect the negative cable to the battery.
(8) Remove the cooling system fan.
(4) Remove the serpentine belt (refer to Group 7, TIMING CHAIN COVER
Cooling System). REMOVAL
(5) Remove the vibration damper pulley. (1) Disconnect the negative cable from the battery.
(6) Remove vibration damper bolt and washer from (2) Drain cooling system (refer to Group 7, Cooling
end of crankshaft. System).
(7) Install bar and screw from Puller Tool Set (3) Remove the serpentine belt (refer to Group 7,
C-3688. Install 2 bolts with washers through the Cooling System).
puller tool and into the vibration damper (Fig. 1). (4) Remove water pump (refer to Group 7, Cooling
System).
(5) Remove power steering pump (refer to Group
19, Steering).
(6) Remove vibration damper.
(7) Loosen oil pan bolts and remove the front bolt
at each side.
(8) Remove the cover bolts.
(9) Remove chain case cover and gasket using ex
treme caution to avoid damaging oil pan gasket.
(10) Place a suitable tool behind the lips of the oil
seal to pry the oil seal outward. Be careful not to
damage the crankshaft seal surface of cover (Fig. 3).
Fig. 1 Vibration Damper Assembly
(8) Pull vibration damper off of the crankshaft. TIMING CHAIN STRETCH
(1) Place a scale next to the timing chain so that
INSTALLATION any movement of the chain may be measured.
(1) Position the vibration damper onto the crank (2) Place a torque wrench and socket over cam
shaft. shaft sprocket attaching bolt. Apply torque in the di
rection of crankshaft rotation to take up slack; 41
Fig. 3 Removal of Front Crankshaft OH Seal Fig. 5 Alignment of Timing Marks
N-m (30 ft, lbs.) torque with cylinder head installed (11) Install the camshaft bolt. Tighten the bolt to
or 20 N-m (15 ft. lbs.) torque with cylinder head re 68 N-m (50 ft. lbs.) torque.
moved. - With a torque applied to the camshaft (12) Check camshaft end play. The end play should
sprocket bolt, crankshaft should not be permitted to be 0.051-0.152 mm (0.002-0.006 inch) with a new
move. It may be necessary to block the crankshaft to thrust plate and up to 0.254 mm (0.010 inch) with a
prevent rotation. used thrust plate. If not within these limits install a
(8) Hold a scale with dimensional reading even new thrust plate.
with the edge of a chain link. With cylinder heads in
stalled, apply 14 N-m (30 ft. lbs.) torque in the re CLEANING
verse direction. With the cylinder heads removed, Be sure mating surfaces of chain case cover and
apply 20 N-m (15 ft. lbs.) torque in the reverse direc cylinder block are clean and free from burrs.
tion. Note the amount of chain movement (Fig. 4). The water pump mounting surface must be
cleaned.
INSTALLATION
(1) Using a new cover gasket, carefully install
chain case cover to avoid damaging oil pan gasket.
Use a small amount of Mopar® Silicone Rubber Ad
hesive Sealant, or equivalent, at the joint between
timing chain cover gasket and the oil pan gasket.
Finger tighten the timing chain cover bolts at this
TORQUE time.
J9409-96 W R E N C H
(2) Place the smaller diameter of the oil seal over
Front Oil Seal Installation Tool 6635 (Fig. 6). Seat
Fig. 4 Measuring Timing Chain Wear and SireMi the oil seal in the groove of the tool.
(4) Install a new timing chain, if its movement ex CRANKSHAFT. INSTALL THIS
ceeds 3.175 mm (1/8 inch). B'OiTOIL N END INTO
(5) If chain is not satisfactory, remove camshaft SEAL SPECIAL TOOL
sprocket attaching bolt and remove timing chain with 6635
crankshaft and camshaft sprockets.
(6) Place both camshaft sprocket and crankshaft
sprocket on the bench with timing marks on exact
imaginary center line through both camshaft and
crankshaft bores.
(7) Place timing chain around both sprockets.
(8) Turn crankshaft and camshaft to line up with
keyway location in crankshaft sprocket and in cam
shaft sprocket.
(9) Lift sprockets and chain (keep sprockets tight
J9309-44
against the chain in position as described).
(10) Slide both sprockets evenly over their respec Fig, 3 Placing Oil Seal on Installation Tool 6635
tive shafts and use a straightedge to check alignment
of timing marks (Fig. 5). (3) Position the seal and tool onto the crankshaft
(Fig. 7).
i - 82 3.IL ENGINE
(8) Remove the vibration damper bolt and seal in

stallation tool.
(9) Inspect the seal flange on the vibration damper.
(10) Install vibration damper.
(11) Install water pump and housing assembly us
ing new gaskets (refer to Group 7, Cooling System).
Tighten bolts to 41 N-m (30 ft. lbs.) torque.
(12) Install power steering pump (refer to Group
19, Steering).
Cooling System).
(14) Install the cooling system fan. Tighten the
bolts to 23 N-m (17 ft. lbs.) torque.
Tighten the bolts to 11 N-m (95 in. lbs.) torque.
(16) Fill cooling system (refer to Group 7, Cooling
(17) Connect the negative cable to the battery.
CHAIN 'X FROMT CRANKSHAFT OIL SEAL REPLACEMENT

6
COVER J93G9-45 *- The oil seal can be replaced without removing the
timing chain cover provided the cover is not mis
Fig. 7 Position Tool and Seal onto Crankshaft aligned.
(4) Tighten the 4 lower chain case cover bolts to (1) Disconnect the negative cable from the battery.
13 N#m (10 ft. lbs.)to•prevent the cover from tipping (2) Remove vibration damper.
during seal installation. (3) If front seal is suspected of leaking, check front
(5) Using the vibration damper bolt, tighten the oil seal alignment to crankshaft. The Seal Installa
bolt to draw the seal into position on the crankshaft tion/Alignment Tool 6635, should fit with minimum
(Fig. 8). interference. If tool does not fit, the cover must be re
moved and installed properly.
damage the crankshaft seal surface of cover.
the oil seal in the groove of the tool.
(6) Position the seal and tool onto the crankshaft
(Fig. 7).
(7) Using the vibration damper bolt, tighten the
bolt to draw the seal into position on the crankshaft
(Fig. 8).
stallation tool.
(10) Install the vibration damper.
CAMSH*ri'
This procedure requires that the engine is removed
from the vehicle.
J9309-46 The camshaft has an integral oil pump and distrib
Fig. 8 Installing Oil Seal utor drive gear (Fig. 9).
(6) Loosen the 4 bolts tightened in step 4 to allow REMOWAL
realignment of front cover assembly. (1) Remove intake manifold.
(7) Tighten chain case cover bolts to 41 N-m (80 ft. (2) Remove cylinder head covers.
lbs.) torque. Tighten oil pan bolts to 24 N-m (215 in. (3) Remove timing case cover and timing chain.
lbs.) torque. (4) Remove rocker arms.
Bit — — — — — — 3.9L ENGINE 9 - 33
CHAIN
SPROCKET
Fig. 9 Camshaft and Sprocket Assembly Fig, 11 Camshaft Bearings Removal and Installation
(5) Remove push rods and tappets. Identify each with Tool C-3132-A
part so it can be installed in the original location. INSTALLATION—BEARING
(8) Remove distributor and lift out the oil pump (1) Install new camshaft bearings with Camshaft
and distributor drive shaft. Bearing Remover/Installer Tool C-3132-A by sliding
(7) Remove camshaft thrust plate; note location of the new camshaft bearing shell over proper adapter.
oil tab (Fig. 10). (2) Position rear bearing in the tool. Install horse
shoe lock and by reversing removal procedure, care
fully drive bearing shell into place.
(3) Install remaining bearings in the same manner.
Bearings must be carefully aligned to bring oil holes
into full register with oil passages from the main
bearing. If the camshaft bearing shell oil holes are
not in exact alignment, remove and install them cor
rectly. Install a new core hole plug at the rear of
camshaft. Be sure this plug does not leak.
INSTALLATION
(1) Lubricate camshaft lobes and camshaft bearing
journals and insert the camshaft to within 51 mm (2
inches) of its final position in cylinder block.
Whenever an engine has been rebuilt, a new
camshaft and/or new tappets installed, add 1
pint of Mopar® Crankcase Conditioner, or
equivalent. The oil mixture should be left in en
gine for a minimum of 805 km (500 miles).
Drain at the next normal oil change.
(2) Install Camshaft Gear Installer Tool C-3509
with tongue back of distributor drive gear (Fig. 12).
Fig. 10 Timing Chain Oil Tab Installation
(8) Install a long bolt into front of camshaft to fa
cilitate removal of the camshaft. Remove camshaft,
being careful not to damage cam bearings with the
cam lobes.
REMOVAL—BEARING
(1) With engine completely disassembled, drive out
rear cam bearing core hole plug.
(2) Install proper size adapters and horseshoe
washers (part of Camshaft Bearing Remover/Installer
Tool C-3132-A) at back of each bearing shell. Drive
Fig. 12 Camshaft Holding Tool C-3509 (Installed
out bearing shells (Fig. 11).
Position)
(3) Hold tool in position with a distributor lock-
plate bolt. This tool will restrict camshaft from being
pushed In too far and prevent knocking out the welch
plug in rear of cylinder block. Tool should remain
installed: until t h e camshaft and crankshaft
sprockets a n d timing chain have been installed.
(4) Install camshaft thrust plate and chain oil tab.
Make sure tang enters lower right hole in
thrust plate. Tighten bolts to 24 N-m (210 in. lbs.)
torque. Top edge of tab should be flat against thrust
plate in order to catch oil for chain lubrication.
imaginary center line through both camshaft and Fig, 14 Distributor Driveshaft Bushing Removal
crankshaft bores.
(6) Place timing chain around both sprockets. (1) Slide new bushing ever burnishing end of Dis
(7) Turn crankshaft and camshaft to line up with tributor Drive Shaft Bushing Driver/Burnisher Tool
keyway location in crankshaft sprocket and in cam C-3053. Insert the tool and bushing Into the bore.
shaft sprocket. (2) Drive bushing and tool Into position, using a
(8) Lift sprockets and chain (keep sprockets tight hammer (Fig. 15),
(9) Slide both sprockets evenly over their respec
of timing marks (Fig. 18).
Fig. 15 Distributor Driveshaft Bushing Installation

(3) As the burnisher Is pulled through the bushing,
the bushing Is expanded tight in the block and bur
Fig. 13 Alignment of Timing Marks nished to correct size (Fig. 16). DO NOT ream this
bushing.
(10) Install the camshaft bolt/cup washer. Tighten
bolt to 88 N-m (50 ft. lbs.) torque. CAUTION: This procedure MUST be followed when
(11) Measure camshaft end play. Refer to Specifica Installing a new bushing or seizure to shaft may oc
tions for proper clearance. If not within limits install cur.
a new thrust plate.
(12) Each tappet reused must be installed in the
same position from which it was removed. When
camshaft is replaced, all of t h e tappets must b e
replaced.
DISTRIBUTOR
Refer to Group 3D, Ignition Systems for the proper

procedure.
(1) Insert Distributor Drive Shaft Bushing Puller Fig. 16 Burnishing Distributor Driveshaft Bushing
Tool C-3052 Into old bushing and thread down until a DISTRIBUTOR INSTALLATION
tight fit is obtained (Fig. 14). Refer to the Component Removal/Installation sec
(2) Hold puller screw and tighten puller nut until tion of Group 8D, Ignition Systems for the proper
bushing is removed. procedure. See Distributor. After the distributor has
mm — — g . 9 ? - ENGINE § - as
been installed, its rotational position must be set us If present, trim excess sealant from inside the en
ing the SET SYNC mode of the DEB scan tool. Refer gine.
to Checking Distributor Position following the Dis • Clean oil pan in solvent and wipe dry with a clean
tributor Installation section in Group 8D, Ignition cloth.
system. Do not attempt to adjust ignition timing Clean oil screen and pipe thoroughly in clean sol
by rotating t h e distributor. It h a s no effect on vent. Inspect condition of screen.
ignition - timing. Adjusting distributor position
INSPECTION
will effect fuel synchronization only.
Inspect oil drain plug and plug hole for stripped or
Before Installing the distributor, the oil pump drive damaged threads. Repair as necessary.
shaft must be aligned to number one cylinder. Inspect oil pan mounting flange for bends or distor
(1) Eotate crankshaft until No.l cylinder Is at top tion. Straighten flange, if necessary.
dead center on the firing stroke.
(2) When In this position, the timing mark on vi II„
bration damper should be under 0 on the timing in (1) Fabricate 4 alignment dowels from 5/16 X 1 1/2
dicator. inch bolts. Cut the head off the bolts and cut a slot
(3) Install the shaft so that after the gear spirals into the top of the dowel. This will allow easier in
Into place, it will Index with the oil pump shaft. The stallation and removal with a screwdriver (Fig. 1).
slot on top of oil pump shaft should be aligned to 5/16" x 17/ BOLT
wards left front Intake manifold attaching bolt hole
(Fig. 17).
DOWEL
•
SLOT J9509-163
Fig. 1 Fabrication of Alignment Dowels

(2) Install the dowels in the cylinder block (Fig. 2).
(3) Apply small amount of Mopar® Silicone Rubber
DOWEL DOWEL
J9209-133
Pig. 17 Position of Oii Pump Shaft Slot

OIL P l l
REMOVAL
(2) Remove engine oil dipstick.
(3) Raise vehicle.
(4) Drain engine oil.
(5) Remove exhaust pipe.
(6) Remove left engine to transmission strut.
(7) Loosen the right side engine support bracket
cushion thru-bolt nut and raise the engine slightly.
Remove oil pan by sliding backward and out.
DOWEL J9309-7S
(8) Remove the one-piece gasket.
GLEAMING Fig. 2 Position of Dowels in Cylinder Block
Clean the block and pan gasket surfaces. Adhesive Sealant, or equivalent in the corner of the
Trim or remove excess sealant film in the rear cap and the cylinder block.
main cap oil pan gasket groove. DO NOT remove (4) Slide the one-piece gasket over the dowels and
the sealant inside the rear main cap slots. onto the block.
I - 38 3 J L ENGINE BR
(5) Position the oil pan over the dowels and onto (9) Install the drain plug. Tighten drain plug to 34
the gasket. N-m (27 ft. lbs.) torque.
(6) Install the oil pan bolts. Tighten the bolts to 24 (10) Install the engine to transmission strut.
N-m (215 in. lbs.) torque. (11) Install exhaust pipe.
(7) Remove the dowels. Install the remaining oil (12) Lower vehicle.
pan bolts. Tighten these bolts to 24 N-m (215 In. lbs.) (13) Install dipstick.
torque. (14) Connect the negative cable to the battery.
(8) Lower the engine into the support cushion (15) Fill crankcase with oil to proper level.
brackets and tighten the thru-bolt nut to the proper
torque.
BR 3 J L ENGINE 9 - 37
LUBRICATION S Y S T E M
A gear—type positive displacement pump is passes through the hole when the rods rotate and the
mounted at the underside of the rear main bearing hole lines up, oil is then thrown off as the rod ro
cap. The pump draws oil through the screen and in tates. This oil throwoff lubricates the camshaft lobes,
let tube from the sump at the rear of the oil pan. The distributor drive gear, cylinder walls, and piston
oil is driven between the drive and Idler gears and pins.
pump body, then forced through the outlet to the The hydraulic valve tappets receive oil directly
block. An. oil gallery In the block channels the oil to from the main oil gallery. The camshaft bearings re
the Inlet side of the full flow oil filter. After passing ceive oil from the main bearing galleries. The front
through the filter 'element, the oil passes from the camshaft bearing journal passes oil through the cam
center outlet of the filter through an oil gallery that shaft sprocket to the timing chain. Oil drains back to
channels the oil up to the main gallery which ex the oil pan under the number one main bearing cap.
tends the entire length on the right side of the block. The oil supply for the rocker arms and bridged
The oil then goes down to the No. 1 main bearing, pivot assemblies is provided by the hydraulic valve
back up to the left side of the block and Into the oil tappets which pass oil through hollow push rods to a
gallery on the left side of the engine. hole In the corresponding rocker arm. Oil from the
Galleries extend downward from the main oil gal rocker arm lubricates the valve train components.
lery to the upper shell of each main bearing. The The oil then passes down through the push rod guide
crankshaft is drilled Internally to pass oil from the holes, and the oil drain back passages in the cylinder
main bearing journals to the connecting rod journals. head past the valve tappet area, and returns to the
Each connecting rod bearing has half a hole in it, oil oil pan.
Fig. 3 Oil Lubrication System
(
The MINIMUM oil pump pressure Is 41.4 ki'-a G
psi) at curb idle. The MAXIMUM oil pump pressure
Is 207-552 kPa (80-80 psi) at 3,000 EPM or more.
CAUTION: if oil pressure Is ZERO at curb idle, DO
NOT run engine at 3,000 RPM.
REMOVAL
(1) Remove the oil pan,
(2) Remove the oil pump from rear main bearing
cap.
DISASSEMBLE
(1) Remove the relief valve as follows:
(a) Remove cotter pin. Drill a 3.175 mm (1/8
Inch) hole Into the relief valve retainer cap and in
sert a self-threading sheet metal screw into cap.
(b) Clamp screw Into a vise and while supporting
oil pump, remove cap b j tapping pump body using
a soft hammer. Discard retainer cap and remove
spring and relief valve (Fig. 4).
OIL PUMP ASSEMrr* ~ *.
r
Fig. § 'OhBGkmg Jii Pump Oover Flatness
Measure thickness and diameter of outer rotor. If
outer rotor thickness measures 20.9 mm (0.825 inch)
or less or If the diameter Is 62.7 mm (2.469 Inches) or
less, replace outer rotor (Fig. 7).
Fig, 4 Oil Prmsum Relief Valve

(2) Remove oil pump cover (Fig. 5).
(3) Remove pump outer rotor and inner rotor with
shaft (Fig. 5).
(4) Wash all parts In a suitable solvent and Inspect
carefully for damage or wear.
INSPECTION Fig. 7 Measuring Outer Rotor Thickness
Mating surface of the oil pump cover should be If inner rotor measures 20.9 mm (0.825 Inch) or
smooth. Replace pump assembly If cover Is scratched less, replace Inner rotor and shaft assembly (Fig. 8).
-or grooved. Slide outer rotor Into pump body. Press rotor to the
Lay a straightedge across the pump cover surface side with your fingers and measure clearance be
(Fig. 8). If a 0.038 mm (0,0015 Inch) feeler gauge can tween rotor and pump body (Fig. 9). If clearance is
be Inserted between cover and straightedge, pump 0.356 mm (0,014 Inch) or more, replace oil pump as
assembly should be replaced. sembly
9 - 41 3 J L ENGINE
Fig. 11 Measuring Clearance Over Rotors
Fig. 8 Measuring inner Rotor Thickness Inspect oil pressure relief valve plunger for scoring
and free operation In its bore. Small marks may be
removed with 400-grit wet or dry sandpaper.
The relief valve spring has a free length of approx
imately 49.5 mm (1.95 Inches). The spring should
test between 19.5 and 20.5 pounds when compressed
to 84 mm (1-11/82 inches). Replace spring that fails
to meet these specifications (Fig. 12).
If oil pressure was low and pump is within specifi
cations, inspect for worn engine bearings or other
reasons for oil pressure loss.
Fig, 9 Measuring Outer Rotor Clearance in Housing

Install Inner rotor and shaft Into pump body. If
clearance between Inner and outer rotors is 0.208
mm (0.008 Inch) or more, replace shaft and both ro
tors (Fig. 10).
RN98
Fig. 12 Proper Installation of Retainer Cap

INSTALLATION
(1) Install oil pump. During installation slowly ro
tate pump body to ensure driveshaft-to-pump rotor
shaft engagement.
(2) Hold the oil pump base flush against mating
surface on No.4 main bearing cap. Finger tighten
pump attaching bolts. Tighten attaching bolts to 41
Fig. 10 Measuring Clearance Between Rotors (8) Install the oil pan.
Place a straightedge across the face of the pump,
between bolt holes. If a feeler gauge of 0.102 mm PiSTiN ftNi CONNECTING ROD ASSEMBLY
(0.004 inch) or more can be Inserted between rotors The pistons are elliptically turned so that the di
and the straightedge, replace pump assembly (Fig. ameter at the pin boss is less than Its diameter
11). across the thrust face. This allows for expansion un
der normal operating conditions. Under operating
temperatures, expansion forces the pin bosses away
from each other, causing the piston to assume a more PISTON PIN BORE DIAMETER
nearly-round shape. 25.007- 25.015 mm
.9848 IN.]
All pistons are machined to the same weight, re
gardless of size, to maintain piston balance.
The piston pin rotates In the piston only and is re
tained by the press interference fit of the piston pin 62.230 mm
|2.45 I N :
In the connecting rod. I
REMOVAL
(1) Remove the engine from the vehicle.
(3) Remove the oil pan. RING GROOVE HEIGHT
(4) Remove top ridge of cylinder bores with a reli OIL RAIL GROOVE 4.0309 - 4.0538 mrn^
able ridge reamer before removing pistons from cyl (.1587- .1596 IN.)
inder block. Be sure to keep tops of pistons covered COMPRESSION RAIL GROOVE -
during this operation. 2.0294-2.0548 mm
(.0799 - .0809 IN.)
(5) Be sure the connecting rod and connecting rod
cap are Identified with the cylinder number. Remove TOTAL WEIGHT (FINISHED)
594.6 ±2 GRAMS
connecting rod cap. Install connecting rod bolt guide
set on connecting rod bolts.
PISTON ADMUP1STCM WAMETCR BORED AMBER
(6) Pistons and connecting rods must be removed SIZE WIN. mm (IN.) MAX. mm (IN.) MIN. mm (IN.) MAX. mm (IN.)
from top of cylinder block. When removing piston and A 99.280 (3.9087) 99.294(3.9092) 99.306(3.9097) 99.319(3.9102)
connecting rod assemblies, rotate crankshaft to cen B 99.294 (3,9092) 99.306 (3.9097) 99.319(3.9102) 99.332 (3.9107)
C 99.306 (3.9097) 99.319(3.9102) 99.332 (3.9107) 99.344(3.9112)
ter the connecting rod in the cylinder bore and at D 99.319(3.9102) 99.332 (3.9107) 99.344 (3.9112) 99.357(3.9117)
BDC. Be careful not to nick crankshaft journals. E 99.332 (3.9107) 99.344(3.9112) 99.357(3.9117) 99.370(3.9122)
(7) After removal, install bearing cap on the mat J9509-80
ing rod.
Fig. 13 Piston Measurements
INSPECTION
ring gap should be between 0.508-0.762 mm (0.020-
Check the crankshaft connecting rod journalforex
0.030 inch). The oil ring gap should be 0.254-1.270
cessive wear, taper and scoring.
mm (0.010-0,050 inch).
Check the cylinder block bore for out-of-round,
(c) Rings with insufficient end gap may be prop
taper, scoring and scuffing..
erly filed to the correct dimension. Rings with ex
Check the pistons for taper and elliptical shape be
cess gaps should not be used.
fore they are fitted into the cylinder bore (Fig. 18).
(2) Install rings and confirm ring side clearance:
FiTTiffs pmwmm (a) Install oil rings being careful not to nick or
Piston and cylinder wall must be clean and dry. scratch the piston. Install the oil control rings ac
Specified clearance between the piston and the cylin cording to instructions in the package. It is not nec
der wall Is 0.018-0.038 mm (0.0005-0.0015 Inch). essary to use a tool to install the upper and lower
Piston diameter should be measured at the top of rails. Insert oil rail spacer first, then side rails.
skirt, 90° to piston pin axis. Cylinder bores should be (b) Install the second compression rings using In
measured halfway down the cylinder bore and trans stallation Tool C-4184. The compression rings must
verse to the engine crankshaft center line. be installed with the identification mark face up
Pistons and cylinder bores should be measured at (toward top of piston) and chamfer facing down. An
normal room temperature, 2PC (70°F). identification mark on the ring is a drill point, a
stamped letter O, an oval depression or the word
FITTING mmm TOP Figs. 14 and 16.
(1) Measurement of end gaps: (c) Using a ring installer, install the top compres
(a) Measure piston ring gap 2 Inches from bot sion ring with the chamfer facing up (Fig. 16). An
tom of cylinder bore. An inverted piston can be identification mark on the ring is a drill point, a
used to push the rings down to ensure positioning stamped letter O, an oval depression or the word
rings squarely In the cylinder bore before measur TOP facing up.
ing. (d) Measure side clearance between piston ring
(b) Insert feeler gauge In the gap. The top com and ring land. Clearance should be 0.074-0.097 mm
pression ring gap should be between 0.254-0.508 (0.0029-0.0038 inch) for the compression rings. The
mm (0.010-0.020 Inch). The second compression
S - 41 3 J L ENGINE
SECOND C O M P R E S S I O N mm CHAMFSi
(BLACK CAST IROHf i
^ SECOND
COMPRESSION
TOP
RING GAP
COMPRESSION
OIL RING RAIL
RING GAP
GAP (TOP)
DOTS ?00f-46
Fig, 14 Second Compression Ring identification
OIL R I N G RAIL
(Typical) GAP (BOTTOM) J9309-80
TOP COMPRESSION R I N G Fig. 17 Proper Ring Installation

(GRAY IN COLOI)
The bearing caps are not Interchangeable and
should be marked at removal to ensure correct as
sembly.
Each bearing cap has. a small V-groove across the
parting face. When installing the lower bearing shell,
ONE
DOT make certain that the V-groove In the shell Is In line
with the V-groove in the cap. This provides lubrica
tion of the cylinder wall In the opposite bank.
The bearing shells must be Installed so that the
. J9009-48
tangs are In the machined grooves In the rods and
Fig, 15 Top Compression Ring Identification caps.
(Typical) Limits of taper or out-of-round on any crankshaft
ryAMPPi TOP COMPRESSION
journals should be held to 0.025 mm (0.001 inch).
CHAMFER ^ ! N G Bearings are available in 0.025 mm (0.001 Inch),
0.051 mm (0.002 inch), 0.078 mm (0.003 inch), 0.254
mm (0.010 inch) and 0.305 mm (0.012 inch) under-
size. Install the bearings in pairs. DO NOT use a
new bearing half with, a n old bearing half. BO
SECOND NOT file the rods or bearing caps*
-COMPRESSION
RING
(1) Be sure that compression ring gaps are stag
gered so that neither is in-line with oil ring rail gap.
, "PISTON J9409-37 (2) Before installing the ring compressor, make
i Compression Ring Chamfer Location sure the oil ring expander ends are butted and the
(Typical) rail gaps located properly (Fig. 17).
steel rail oil ring should be free in groove, but (3) Immerse the piston head and rings In clean en
should not exceed 0.248 mm (0.0097 Inch) side gine oil. Slide Piston Ring Compressor Tool 0-885
clearance. over the piston and tighten with the special wrench
(e) Pistons with Insufficient or excessive side (part of Tool C-385). Be sure position of rings
clearance should be replaced. does not change during this operation.
(8) Arrange ring gaps 130° apart as shown in Fig. (4) Install connecting rod bolt protectors on rod
17. bolts, the long protector should be installed on the
numbered side of the connecting rod.
CONNECTING R O D BEARINGS (5) Rotate crankshaft so that the connecting rod
Fit all rods on a bank until completed. DO NOT al journal is on the center of the cylinder bore. Be sure
ternate from one bank to another, because connecting connecting rod and cylinder bore number are the
rods and pistons are not Interchangeable from one same. Insert rod and piston into cylinder bore and
bank to another. guide rod over the crankshaft journal.
— — — — — 3 J L ENGINE I - 43
(6) Tap the piston down in cylinder bore, using a (6) Lift the crankshaft out of the block.
hammer handle. At the same time, guide connecting (7) Remove and discard the crankshaft rear oil
rod into position on crankshaft journal. seals.
(7) The notch or groove on top of piston must be (8) Remove and discard the front crankshaft oil
pointing toward front of engine. The larger chamfer seal.
of the connecting rod bore must be installed toward
crankshaft journal fillet. INSPECTION OP JOUMMALS
(8) Install rod caps. Be sure connecting rod, con The crankshaft connecting rod and main journals
necting rod cap and cylinder bore number are the should be checked for excessive wear, taper and scor
same. Install nuts on cleaned and oiled rod bolts and ing. The maximum taper or out-of-round on any
tighten nuts to 81 N-m (45 ft. lbs.) torque. crankshaft journal is 0.025 mm (0.001 inch).
(9) Install the oil pan. Journal grinding should not exceed 0.305 mm
(10) Install the cylinder head. (0.012 inch) under the standard journal diameter. DO
(11) Install the engine into the vehicle. NOT grind thrust faces of No.2 main bearing. DO
NOT nick crank pin or bearing fillets. After grinding,
CRANKSHAFT
remove rough edges from crankshaft oil holes and
A crankshaft which has undersize journals will be
clean out all oil passages.
stamped with 1/4 Inch letters near the notch of the
No.6 crankshaft counterweight (Fig. 1). CAUTION: After any journal grind, it is important
FOB EXAMPLE: E2 stamped on the No.6 crank that the final paper or cloth polish be in the same
shaft counterweight indicates that the No.2 rod jour direction a s the engine rotates.
nal is 0.025 mm (0.001 in) undersize. M4 Indicates
that the No.4 main journal is 0.025 mm (0.001 In)
undersize. R3 M2 Indicates that the No.3 rod journal
and the .No.2 main journal are 0.025 mm (0.001 in) Clean Loctite 518 residue and sealant from the cyl
undersize. inder block and rear cap mating surface. Do this be
fore applying the Loctite drop and the installation of
Undersize Journal Identification Stamp rear cap.
ROD - 0.025mm (0.001 in.) Rl-R2-R3-Etc.
MAIN - 0.025mm (0.001 in.) M1-M2-M3 or M4 (1) Lightly oil the new upper seal lips with engine
oil.
STEEL STAMP IDENTIFICATION (2) Install the new upper rear bearing oil seal with
R (ROD) AND/OR M (MAIN) FOLLOWED
BY THE ROD OR MAIN NUMBER the white paint facing towards the rear of the engine.
(3) Position the crankshaft into the cylinder block.
(4) Lightly oil the new lower seal lips with engine
oil
(5) Install the new lower rear bearing oil seal into
the bearing cap with the white paint facing towards
the rear of the engine.
(6) Apply 5 mm (0.20 in) drop of Loctite 518, or
equivalent, on each side of the rear main bearing cap
(Fig. 2). DO NOT over apply sealant or allow the
Fig. 1 Location of Crankshaft Identification sealant to contact the rubber seal. Assemble bearing
When a crankshaft is replaced, all main and con cap to cylinder block immediately after sealant appli
necting rod bearings should be replaced with new cation.
bearings. Therefore, selective fitting of the bearings (7) To align the bearing cap, use cap slot, align
is not required when a crankshaft and bearings are ment dowel and cap bolts. DO NOT remove excess
replaced. material after assembly. DO NOT strike rear cap
more than 2 times for proper engagement.
REMOVAL (8) Clean and oil all cap bolts. Install all main
(1) Remove the oil pan. bearing caps. Install all cap bolts and alternately
(2) Remove the oil pump from the rear main bear tighten to 115 N-m (85 ft. lbs.) torque.
ing cap. (9) Install oil pump.
(3) Remove the vibration damper. (10) Install the timing chain cover.
(4) Remove the timing chain cover. (11) Install the vibration damper.
(5) Identify bearing caps before removal. Remove (12) Apply Mopar® Silicone Rubber Adhesive Seal
bearing caps and bearings one at a time. ant, or equivalent, at bearing cap to block joint to
„ REAR MAIN Fig, 4 Main Bearing Identification
BEARING CAP J9309-72
REMOVAL
Fig. 2 Sealant Application to Bearing Cap (1) Remove the oil pan.
provide cap to block and oil pan sealing (Fig. 2). Ap (2) Remove the oil pump from the rear main bear
ply enough sealant until a small amount Is squeezed ing cap.
out. Withdraw nozzle and wipe excess sealant off the (3) Identify bearing caps before removal. Remove
oil pan seal groove. bearing caps one at a time.
(18) Install new front crankshaft oil seal. (4) Remove upper half of bearing by inserting
(14) Immediately Install the oil pan. Crankshaft Main Bearing Remover/Installer Tool
C-3059 into the oil hole of crankshaft (Fig. 5).
MOPAR SILICONE SEALANT (5) Slowly rotate crankshaft clockwise, forcing out
RUBBER ADHESIVE APPLIED
SEALANT upper half of bearing shell.
NOZZLE TIP
SPECIAL ' BEARING
TOOL C-3059
REAR MAIN
•BEARING CAP J9309-87
Fig, 3 Apply Sealant to Bearing Cap to Block Joint

CRANKSHAFT IAIN BEARINGS
9209-59
Bearing caps are not interchangeable and should
be marked at removal to ensure correct assembly. Fig. 5 Upper Main Bearing Removal and Installation
Upper and lower bearing halves are NOT inter with Tool C-3059
changeable. Lower main bearing halves of No.l and 8
are Interchangeable. imswMLLAwmm
Upper and lower No.2 bearing halves are flanged Only one main bearing should be selectively fitted
to carry the crankshaft thrust loads. They are NOT while all other main bearing caps are properly tight
Interchangeable with any other bearing halves in the ened. All bearing capbolts removed during service
engine (Fig. 4). Bearing shells are available In stan procedures are to be cleaned and oiled before instal
dard and the following undersizes: 0.25 mm (0.001 lation.
Inch), 0.051 mm (0.002 inch), 0.076 mm (0.003 inch),
CAUTION: DO NOT use a new bearing half with old
0.254 mm (0.010 inch) and 0.305 mm (0.012 inch).
bearing half.
Never install an undersize bearing that will reduce
clearance below specifications. When installing a new upper bearing shell, slightly
chamfer the sharp edges from the plain side.
(1) Start bearing in place, and Insert Crankshaft
Main Bearing Remover/Installer Too! C-3059 Into oil
hole of crankshaft (Fig. 5). (1) Remove the oil pan.
(2) Slowly rotate crankshaft counterclockwise slid (2) Remove the oil pump from the rear main bear
ing the bearing into position. Remove Tool C-3059. ing cap.
(8) Install the bearing caps. Clean and oil the (3) Remove the rear main bearing cap. Remove
bolts. Tighten the capbolts to 115 N-m (85 ft. lbs.) and discard the old lower oil seal.
torque. (4) Carefully remove and discard the old upper oil
(4) Install the oil pump. seal.
(5) Install the oil pan. (5) Clean the cylinder block mating surfaces before
oil seal installation.
CRANKSHAFT REAR OIL SEALS (6) Lightly oil the new upper seal lips with engine
oil. To allow ease of installation of the seal, loosen at
The service seal Is a 2 piece, viton seal. The upper least the 2 main bearing caps forward of the rear
seal half can be Installed with crankshaft removed bearing cap.
from engine or with crankshaft Installed. When a (7) Rotate the new upper seal into the cylinder
new upper seal Is Installed, Install a new lower seal. block being careful not to shave or cut the outer sur
The lower seal half can only be Installed with the face of the seal. To assure proper installation, use the
rear main bearing cap removed. installation tool provided with the kit. Install the
new seal with the white paint facing towards the
njppsm SL. _ ^^mm^mMEWrmMA^T
rear of the engine.
mmmmmm (8) Install the new lower rear bearing oil seal into
(1) Remove the crankshaft. Discard the old upper the bearing cap with the white paint facing towards
seal. the rear of the engine.
(2) Clean the cylinder block rear cap mating sur (9) Apply 5 mm (0.20 in) drop of Loctite 518, or
face. Make sure the seal groove Is free of debris. equivalent, on each side of the rear main bearing cap
(8) Lightly oil the new upper seal lips with engine (Fig. 2). DO NOT over apply sealant or allow the
oil. sealant to contact the rubber seal. Assemble bearing
(4) Install the new upper rear bearing oil seal with cap to cylinder block immediately after sealant appli
the white paint facing towards the rear of the engine. cation. Be sure the white paint faces toward the rear
(5) Position the crankshaft into the cylinder block. of the engine.
(6) Lightly oil the new lower seal lips with engine (10) To align the bearing cap, use cap slot, align
oil. ment dowel and cap bolts. DO NOT remove excess
• (7) Install the new lower rear bearing oil seal into material after assembly. DO NOT strike rear cap
the bearing cap with the white paint facing towards more than 2 times for proper engagement.
the rear of the engine. (11) Install the rear main bearing cap with cleaned
(8) Apply 5 mm (0.20 In) drop of Loctite 518, or and oiled cap bolts. Alternately tighten ALL cap bolts
equivalent, on each side of the rear main bearing cap to 115 N-m (85 ft. lbs.) torque.
(Fig. 2). DO NOT over apply sealant or allow the (12) Install oil pump.
sealant to contact the rubber seal. Assemble bearing (13) Apply Mopar® Silicone Rubber Adhesive Seal
cap to cylinder block immediately after sealant appli ant, or equivalent, at bearing cap to block joint to
cation. provide cap to block and oil pan sealing (Fig. 3). Ap
(9) To align the bearing cap, use cap slot, align ply enough sealant until a small amount is squeezed
ment dowel and cap bolts. DO NOT remove excess out. Withdraw nozzle and wipe excess sealant off the
material after assembly. DO NOT strike rear cap oil pan seal groove.
more than 2 times for proper engagement. (14) Immediately install the oil pan.
(10) Clean and oil all cap bolts. Install all main
bearing caps. Install all cap bolts and alternately
tighten to 115 N-m (85 ft. lbs.) torque. (1) P.emovs the oil pan.
(11) Install oil pump. (2) Remove the oil pump from the rear main bear
(12) Apply Mopar® Silicone Rubber Adhesive Seal ing cap.
ant, or equivalent, at bearing cap to block joint to (3) Remove the rear main bearing cap and discard
provide cap to block and oil pan sealing (Fig. 3). Ap the old lower seal.
ply enough sealant until a small amount is squeezed (4) Clean the rear main cap mating surfaces in
out. Withdraw nozzle and wipe excess sealant off the cluding the oil pan seal grooves.
oil pan seal groove. (5) Carefully install a new upper seal (refer to Up
(13) Install new front crankshaft oil seal. per Seal Replacement - Crankshaft Installed proce
(14) Immediately install the oil pan. dure above).
(8) Lightly oil the new lower seal Hps with engine OIL LIMB* PLtm
oil. The oil line plug is located in the vertical passage
(7) Install a new lower seal In bearing cap with at the rear of the block between the Oil-Ib-Filter and
yellow paint facing the rear of engine. Oil-From-Filter passages (Fig. 6). Improper Installa
(8) Apply 8 mm (0.20 In) drop of Loctite 518, or tion or plug missing could cause erratic, low or no oil
equivalent, on each side of the rear main bearing cap pressure.
(Fig. 2). DO NOT over apply sealant or allow the (1) Remove oil pressure sending unit from back of
sealant to contact the rubber seal. Assemble bearing block.
cap to cylinder block Immediately after sealant appli (2) Insert a 8.175 mm (1/8 Inch) finish wire or
cation. equivalent Into passage.
(9) To align the bearing cap, use cap slot, align (8) Plug should be 192.0 to 195.2 mm (7-1/2 to
ment dowel and cap bolts. DO NOT remove excess 7-11/16 Inches) from machined surface of block (Fig.
material after assembly. DO NOT strike rear cap 6). If plug is too high, use a suitable flat dowel to po
more than 2 times for proper engagement. sition properly.
(10) Install the rear main bearing cap with cleaned RIGHT OIL GALLERY
and oiled cap bolts. Alternately tighten the cap bolts
(11) Install oil pump.
(12) Apply Mopar® Silicone Rubber Adhesive Seal
ant, or equivalent, at bearing cap to block joint to
provide cap to block and oil pan sealing (Fig. 4). Ap
ply enough sealant until a small amount Is squeezed
out. Withdraw nozzle and wipe excess sealant off the
oil pan seal groove.
(18) Immediately install the oil pan.
CYLINDER B L I C I
Remove the engine assembly from the vehicle.
msMmssiMBLS
(2) Remove the oil pan.
(8) Remove the piston/connecting rod assembly.
CRANKSHAFT FROM OIL PUMP J9209-147
CLEANING
Fig. 8 Oil Lin® Plug
Clean cylinder block thoroughly and check all core
hole plugs for evidence of leaking. , (4) If plug is too low, remove oil pan and rear main
bearing cap. Use suitable flat dowel to position prop
Examine block for cracks or fractures. erly. Coat outside diameter of new plug with Mopar®
The cylinder walls should be checked for out-of- (Stud and Bearing Mount Adhesive), or equivalent.
round and taper with Cylinder Bore Indicator Tool Plug should be 54.0 to 57.7 mm (2-1/8 to 2-5/16
6879. The cylinder block should be bored and honed inches) from bottom of the block.
with new pistons and rings fitted If: (5) Assemble engine and check oil pressure.
© The cylinder bores show more than 0.127 mm
(0.005 Inch) out-of-round. ENGINE COME &IL AND CAMSHAFT PLUGS
© The cylinder bores show a taper of more than Engine core plugs have been pressed into the oil
0.254 mm (0.010 inch). galleries behind the camshaft thrust plate (Fig. 7).
• The cylinder walls are badly scuffed or scored. This will reduce internal leakage and help maintain
higher oil pressure at idle.
Boring and honing operation should be closely co
ordinated with the fitting of pistons and rings so REMOVAL
specified clearances may be maintained. (1) Using a blunt tool such as a drift or a screw
Refer to Standard Service Procedures In the begin driver and a hammer, strike the bottom edge of the
ning of this Group for the proper honing of cylinder cup plug (Fig. 8).
bores. (2) With the cup plug rotated, grasp firmly with
pliers or other suitable tool and remove plug (Fig. 8).
BR 3J L IlillE 9 - 47
DRIFT 9209-41
Fig, 3 Core Hole Plug Removal

(2) Using proper plug driver, drive cup plug into
Fig. 7 Location of Cup Plugs in Oil Galleries
hole. The sharp edge of the plug should be at least
0.50 mm (0.020 inch) inside the lead-in chamfer.
CLEANING It is not necessary to wait for curing of the sealant.
Thoroughly clean inside of cup plug hole in cylinder The cooling system can be filled and the vehicle
block or head. Be sure to remove old sealer. placed in service immediately.
Make certain the new plug is cleaned of all oil or
grease. mmmmm
(1) Install the piston/connecting rod assembly.
INSTALLATION
(2) Install the oil pan.
(1) Coat edges of plug and core hole with Mopar® (3) Install the cylinder head.
Gasket Maker, or equivalent. (4) Install the engine into the vehicle.
CAUTION: DO NOT drive cup plug into the casting
as restricted coolant flow can result and cause se
rious engine problems.
9 - 48 3 J L ENGINE
SPECIFICATIONS—3 J L ENGINE
ENGINE SPECIFICATIONS
Camshaft
Bearing Diameter End Play . . . . . . . . . . . . . . . . . . . . . . . 0,051-0.178 mm
No. 1 . . . . . . . . . . . . . . . . . . . . . . . . 50.800-50.825 mm (0.002-0.007 in)
' (2.000-2.001 in) Max. Allowable . . . . . . . . . . . . . . . . 0.254 mm
No. 2 . 50.394-50.419 mm (0.010 In)
(1.984-1.985 in)
Main Bearing Journals
No. 3 49.606-49.632 mm
Diameter .. 63.487-63.513 mm
(1.953-1.954 In)
(2.4995-2.5005 in)
No. 4 . . . . . . . . . . . . . . . . . . . . . . . . . 39.688-39.713 mm
Out-of-Round (Max.) . 0.0254 mm
(1.5625-1.5635 In)
Diametrical Clearance . . . 0,0254-0.0762 mm (0.001 in)
(0.001-0.003 in) Taper (Max.) . . . . .. 0.0254 mm .
Max. Allowable . . 0.127 mm (0.001 in)
(0.005 in) Cylinder Block
End P l a y . . . . 0.051-0.254 mm Cylinder lor©
(0.002-0.010 In) Diameter . . 99.314-99,365 mm
Bearing Journal Diameter (3.910-3.912 in)
No. 1 . . . . . . . . . . . . . . . . . . . . . . . . 50.749-50.775 mm Out-of-Round (Max.) . . . . 0.127 mm
(1.998-1.999 In) (0.005 in)
No. 2 . . . . . 50.343-50.368 mm Taper (Max.) 0.254 mm
(1.982-1.983 In) (0.010 in)
No. 3 . . . . . . . . . . . . . . . . . . . . . . . . 49.555-49.581 mm Oversize (Max.) . . . . . . . . . . . . . . . . 1.016 mm
(1.951-1.952 in) ' (0,040 in)
No. 4 , . . . . . . . . . . . . . . . . . . . . . . . -39.637-39.662 mm Distributor Lower Drive Shaft
(1.5605-1.5615 in) Bushing (Press Fit in Block) 0.0127-0.3556 mm
(0.0005-0.0140 in)
Connecting Rods . Shaft-to-Bushing Clearance . . 0.0178-0.0686 mm
Bearing Clearance.................................... 0.013-0.056 mm (0.0007-0.0027 in)
(0.0005-0.0022 In) Tappet lore Diameter 22.99-23.01 mm
Max. Allowable................ 0,08 mm (0.003 in) (0.9051-0.9059 in)
Piston Pin Bore Diameter 24.940-24.978 mm

Cylinder H e a d
(0.9819-0.9834 in)
Compression Pressure 689 kPa
Side Clearance (Two Rods) . . . 0.152-0.356 mm
(100 psi)
(0.006-0.014 in)
Gasket Thickness (Compressed) . . . . . . 1.2065 mm
Total Weight (Less Bearing) . . . . . . . . . 726 grams
(0.0475 in)
(25.61 oz)
Valve Seat
Angle, . .' 44,25° - 44.75°
Crankshaft
Runout (Max.) 0,0762 mm
Connect Rod Journal
(0.003 in)
Diameter . . . . . . . . . . . . . . . . . . 53.950-53.975 mm
Width (Finish) - intake . . . . . . . . . . . 1.016-1.542mm
(2.124-2.125 in)
(0.040-0.060 in)
Out-of-Round (Max.) 0.0254 mm
Width (finish) - Exhaust. 1.524-2.032 mm
(0.001 in)
(0.060-0.080 In)
Taper (Max.) 0,0254 mm
(0.001 in)
Hydraulic Tappets
Body Diameter . . . . . . . . . . . . . . . . . . 22.949-22.962 mm
Diametrical Clearance (0.9035-0.9040 In)
No. 1 0.013-0.038 mm Clearance in Block. 0.0279-0.0610 mm
(0.0005-0.0015 in) (0.0011-0.0024 in)
Nos. 2, 3, and 4 0.013-0.051 mm Dry Lash . . . . . . . . . . . . . . . . . . . . . . . 1.524-5,334 mm
(0.0005-0.0020 in) (0.060-0.210 in)
Max. Allowable (Nos. 2, 3, & 4) 0.064 mm
(0.0025 in) Push Rod length . . . . . . . . . . . . . . . . . 175.64-176.15 mm
(6.915-6.935 In)
J9509-65
ENGINE SPECIFICATIONS~CONT.
Oil Pump Piston Pins

Clearance Over Rotors (Max.). . . . . 0.1016 mm Clearance
(0.004 In) In Piston . . . . . . . . . . . . . . . . 0.00635-0.01905 mm
Cover Out-of-Flat (Max.) . . . . . . . . . . 0.0381 mm (0.00025-0.00075 in)
(0.0015 In) In Rod (Interference) . . . . . . 0.0178-0.0356 mm
Inner Rotor Thickness (Min.) . . . . . . 20.955 mm (0.0007-0.0014 in)
(0.825 in) Diameter. . . . . . . . . . . . . . . . . . . 24.996-25.001 mm
Outer Rotor (0.9841-0.9843 in)
Clearance (Max.) 0.3556 mm End P l a y . . . . . . . . . . . . . . . . . . . . . NONE
(0.014 in) Length 75.946-76.454 mm
Diameter (Min.) . . . . . . . . . . . . . . 62.7126 mm
(2.990-3.010 in)
|2.469 in)
Thickness (Min.) . . . . . . . . . . . . . . 20.955 mm Piston Rings
(0.825 in) Ring G a p
Tip Clearance Between Rotors (Max). . 0.2032 mm Compression Rings 0.254-0.508 mm
(0.008 in) (0.010-0.020 in)
Oil Control (Steel Rails) . . . . . . . . 0.254-1.270 mm
O i l Pressure (0.010-0.050 in)
At Curb Idle Speed (Minimum)*. 41.4 kPa Ring Side Clearance
(6 psi) Compression Rings 0.038-0.076 mm
At 3000 rpm . . . . 207-552 kPa (0.0015-0.0030 in)
(30-80 psi) Oil Ring (Steel Rails) . . . . . . 0.06-0.21 mm
Oil Pressure Switch (0.002-0.008 in)
Actuating Pressure (Min.) 34.5-48.3 kPa Ring Width
(5^7 psi) Compression Rings . . . . . . . . . . . . 1.971-1.989 mm
(0.0776-0.0783 in)
* CAUTION: If pressure is Z E R O at curb idle, Oil Ring (Steel Rails) 3.848-3.975 mm
DO NOT run engine at 3,000 rpm. (0.1515-0.1565 in)
Oii Fllter Y B I V M -
Bypass Valve Setting 62-103 kPa Fac© Angle e
43.25 -43.75°
(9-15 psi) Head Diameter
Intake 48.666 mm
Pistons (1.916 in) .
Clearance at Top of Skirt . . . . . . . . 0.0127-0.0381 mm Exhaust ............ 41.250 mm
(0.0005-0.0015 in) (1.624 in)
Land Clearance (Diametrical) . . . . . 0.635-1.016 mm Length (Overall)
(0.025-0.040 in) Intake . . 124.28-125.92 mm
Piston Length 86.360 mm (4.893-4.918 in)
(3.40 in) Exhaust . . . . . . 124.64-125.27 mm
Piston Ring Groove Depth (4.907-4.932 in)
Nos. 1 and 2 4.572-4.826 mm Lift (Zero Lash) . . . . . . . . . . . • 10.973 mm
(0.180-0.190 in)
(0.432 in)
No. 3 3.810-4.064 mm
(0.150-0.160 in) Stem Diameter . . . . . . . . . . . . . . . . 7.899-7.925 mm
Weight 592.6-596.6 grams (0.311-0.312 in)
(20.90-21.04 oz) Stem-to-Guide Clearance. . . . 0.0254-0.0762 mm
(0.001-0.003 in)
Max. Allowable (Rocking Method). . 0.4318 mm
(0.017 in)
Guide Bore Diameter (Std) 7.950-7.976 mm
(0.313-0.314 in)
J9509-67
_ —.
9 - 50 3.9L ENGINE
ENGINESPECIFICATIONS-CONT.
V a l v e Springs Valve FILING

Free Length ( A p p r o x . ) . . . . . . . . . . . 49.962 mm Exhaust Valve
FL.967 in) Closes (ATC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25°
Spring Tension . . . . . . . . . . @ 41.66 mm = 378 N Opens (BBC) 56°
(Valve Closed) {# 1.64 in = 85 lbs) Duration . . . . , 264°
Spring Tension . . . . . . . . . . . @ 30.89 mm = 890 N Intake Valve
(Valve Open) (@ 1.212 in = 200 lbs) Closes (ABC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65°
Number of Coils . . . . . . . . . 6.8 Opens (BTC) 8°
installed Height. 41.66 mm Duration 250°
(Spring Seat to Retainer) (1.64 in) Valve Overlap 31 °
Wire Diameter 4.50 mm
(0,177 In)
J9409-98
OVERSIZE AND U N D E R S I Z E ENGINE COMPONENT MARKINGS
CONDITION IDENTIFICATION LOCATION OF IDENTIFICATION
CRANKSHAFT JOURNALS R or M Steel stamped (near notch) on no. 6 crankshaft

(UNDERSIZE) M-2-3 etc. (indicating no. 2 and 3 main bearing counterweight.
0.0254 mm (0.001 in.) journal)
and/or
R-l-4 etc. (indicating no. 1 and 4 connecting rod
journal)
HYDRAULIC TAPPETS ; Diamond-shaped stamp

(OVERSIZE) Top pad - front of engine and flat ground on
0.2032 mm (0.008 in.) outside surface of each O / S tappet bore.
VALVE STEMS (OVERSIZE) X Milled pad adjacent to two tapped holes

0.127 mm (0.005 in.) (3/8 in.) on each end of cylinder head.
J9309-81
Adjusting Strap Bolt 23 N*m (200 in. lbs.) Rear Mount - Support Cushion-to-
Crossmember Nut 47 N*»m (35 ft. lbs.)
Camshaft Bolt 68 N»m (50 ft. lbs.) Rear Mount - Support Cushion-to-
Camshaft Thrust Plate Bolts 24 N*m (210 in. lbs.) Trans. Support Bracket Nuts 47 N®m (35 ft. lbs.)
Chain Case Cover Bolts 41 N»m (30 ft. lbs.) Rear Mount - Transmission Support
Connecting Rod Cap Bolts 61 N«m (45 ft. lbs.) Bracket Bolts 102 N*m (75ft.lbs.)
Crankshaft Main Bearing Cap Bolts .... 115N«m (85 ft. lbs.) Rear Support Plate-to-Transfer
Cylinder Head Bolts Case Bolts 41 N*m (30 ft. lbs.)
1 st Step 68 N*m (50 ft. lbs.) Rocker Arm Bolts 23 N-m (200 in. lbs.)
2nd Step 143 N*m (105 ft. lbs.)
Cylinder Head Cover Bolts 11 N«m (95 in. lbs.) Spark Plugs 41 IM*m (30 ft. lbs.)
Starter Mounting Bolts 68 N*m (50 ft. lbs.)
Exhaust Manifold-to-Cylinder
Head Bolts/Nuts 34 N»m (25 ft. lbs.) Throttle Body Bolts 23 N-m (200 in. lbs.)
Torque Converter Drive Plate
68 N»m (50 ft. lbs.) Bolts 31 N-m (270 in. lbs.)
Front Mount - Engine Support Transfer Case-to-lnsulator
81 N»m (60 ft. lbs.) Mounting Plate Nuts 204 N-m (150 ft. lbs.)
41 N»m (30 ft. lbs.) Vibration Damper Retainer

Bolt 183 N*m(135 ft. lbs.)
Intake Manifold Bolts Refer to Procedure
in Service Manual. Water Pump-to-Chain Case
Cover Bolt 41 N-m (30 ft. lbs.)
Oil Pan Bolts 23 N*m (200 in. lbs.)
Oil Pan Drain Plug 34 N»m (25 ft. lbs.)
Oil Pump Attaching Bolts 41 N»m (30 ft. lbs.)
Oil Pump Cover Bolts 11 N®m (95 in. lbs.) J9509-140
9 - 52 5.2L ENGINE
5.2L engine SERVICE PROCEDURES
INDEX
PAGE PAGE
Camshaft . . . . . . . . . . . . . 64 OIL PAN ... . 67

Cylinder HEAD C o ^ a r . . . . . . . . . . 58 Rocker ARMS AND PUSH Rods 56
Cylinder HEADS . . . . . . . . . . . . . . . 57 Specifications—5.2L Engine . . . . . . . . . . . . . . . . . 77
Distributor BUSHING .....66 Timing Chain Cover . . . . . . . . . . . . . . . . . . . . . . . 62
Engine Assembly ......................... 53 Valve Components Replace—Cylinder Head Not
Engine Front Mounts 52 Removed 56
Engine Rear MOUNT 53 Valve Stem Seal and Spring Replacement 56
Front CRANKSHAFT OIL SEAL Replacement . . . . . . . . . 64 Valve Timing . . . 61
General INFORMATION . . . . . . . . . . . . . . . . . . . . . . . 52 Valves and valve Springs . . . . . . . . . . . . . . . . . . . 58
HYDRAULIC TAPPETS . . . . . . . . . . . . 60 Vibration Damper 62
GENERAL INFORMATION
The 5.2 Liter (318 CID) eight-cylinder engine is a
V-Type lightweight, single cam, overhead valve en
gine with hydraulic roller tappets (Fig. 1).
Engine Type
Bore and Stroke....
Displacement.........
Compression Ratio .....................
Torque
...90° V-S OHV
.........99.3 x 84.0 mm {3.91 n 3.31 in.)
....5.21 (318 cu. in.)
..............407 Mm (300ft.lbs.) @ 3,200 rpm

....9J :1
o
FRONT
OF
CLOCKWISE ROTATION
1-8-4-3-6-5-7-2
ENGINE
Firing Order 1 -8-4-3-6-5-7-2
lubrication ............>.....<......Pressure fed - Full few Filtration
Engine Oil Capacity. 4.7L {5.0 Gte) wsA Filter
Cooling System ......Liquid Cooled - Forced Circulation
Cooling Canity . ...........16.U (17.0 Qts) J908D-49
Cylinder Block .Gas* to
Crankshaft . hbcbfar Iron Fig. 2 Firing Order
Cylinder Heed ................... , .......Cost Smn
Combustion Chambers .....Wedge-High Swirl Valve Shrouding
1 M 5.2L T XXXX XXXXXXXX
Camshaft ..................... ..Nodular Cast Iran
Pistons...... .... ..........................Alluminum Alby w / S W
Connecting Rods..............................................
X = Last Digit of Model Year
M * Plant - AA Mound Road
S Saltillo
J9409-10 T Trenton
K Toluca
5.2L = Engine Displacement
Ffef. f Engine Description
T = Usage - T Truck
This engine is designed for unleaded fuel. XXXX = Month/Day
Engine lubrication system consists of a rotor type XXXXXXXX = Serial Code - Last 8 Digits of VIN No.
The cylinders are numbered from front to rear; 1 ,
3, 5, 7 on the left bank and 2, 4, 6, 8 on the right J9209-73
bank. The firing order i s 1-8-4-3-6-5-7-2 (Fig. 2). Fig. 3 Engine Identification Number
The engine serial number is stamped into a ma
chined pad located on the left, front corner of the cyl ENGINE FRONT iitJNfS
inder block. When component part replacement is
REMOVAL
necessary, use the engine type and serial number for
reference (Fig. 3).
(2) Position fan to assure clearance for radiator top
tank and hose.
B R — — — — 5.2L ENGINE S -13
CAUTION: DO NOT Sift the engine by the Intake

manifo!&

(4) Eaise vehicle on hoist.
(Fig. 4). Remove the support. bracket/cushion and
heat shields.
CUSHION
BRACKET
Jf409-54
Fig. 4 Engine Front Mounts bolts and tighten to 102 N-m (75 ft. lbs.) torque.
(3) Lower engine with support/lifting fixture while 47 N-m (35 ft. lbs.) torque.
(4) Install thru-bolt nuts and tighten the nuts to E N G I N E ASSEMBLY
(5) Lower the vehicle. REMOVAL
(6) Remove lifting fixture. (1) Remove the battery.
(2) Drain cooling system (refer to Group 7, Cooling
ENGINE REAR MOUNT System for the proper procedure).
(3) Remove the upper crossmember and top core
MEBM&WAL support.
(1) Raise the vehicle on a hoist. (4) Remove the transmission oil cooler.
(2) Position a transmission jack in place. (5) Discharge the air conditioning system, if
(3) Remove support cushion stud nuts (Fig. 6). equipped (refer to Group 24, Heating and Air Condi
(4) Raise rear of transmission and engine tioning for service procedures).
SLIGHTLY (6) Remove the serpentine belt (refer to Group 7,
(5) Remove the bolts holding the support cushion Cooling System).
to the transmission support bracket. Remove the sup (7) Remove the A/C compressor with the lines at
port cushion. tached. Set aside.
(6) If necessary, remove the bolts holding the (8) If equipped, remove the condenser.
transmission support bracket to the transmission. (9) Remove the washer bottle.
(10) Disconnect the top radiator hose.
9 - 54 5.2L ENGINE
Fig. $ Engine Rear Support Cushion Assemblies

BR 5.2L ENGINE S - 55
(11) Remove the fan. (6) Install the prop shaft (refer to Group 16, Pro
(12) Remove the fan shroud. peller Shaft).
(13) Disconnect the lower radiator hose. (7) Install the dust shield and transmission cover.
(14) Remove radiator (refer to Group 7, Cooling (8) Install the starter and connect the starter wires
System). (refer to Group 8B, Battery/Starter/Generator Ser
(15) Remove the generator with the wire connec vice).
tions (refer to Group 8B, Battery/Starter/Generator (9) Install exhaust pipe to manifold.
Service). (10) Install the transmission cooler line brackets
(16) Remove the air cleaner box. from oil pan.
(17) Disconnect the throttle linkage. - (11) Install engine front mount thru-bolt nuts.
(18) Remove throttle body. Tighten the nuts.
(19) Remove the intake manifold (refer to Group (12) Install the drain plug and tighten to 34 N-m
11, Exhaust System and Intake Manifold). (25 ft. lbs.) torque.
(20) Remove the distributor cap and wiring. (13) Lower the vehicle.
(21) Disconnect the heater hoses. (14) Remove engine lifting fixture.
(22) Disconnect the power steering hoses, if (15) On Manual Transmission vehicles, install the
equipped. shift lever (refer to Group 21, Transmissions).
(23) Disconnect the transmission cooler lines. (16) Connect the fuel lines.
(24) Perform the Fuel System Pressure Release (17) Connect the transmission cooler lines.
procedure (refer to Group 14, Fuel System). (18) Connect the power steering hoses, if equipped.
(25) Disconnect the fuel lines. (19) Connect the heater hoses.
(26) On Manual Transmission vehicles, remove the (20) Install the distributor cap and wiring.
shift lever (refer to Group 21, Transmissions). (21) Install the intake manifold (refer to Group 11,
(27) Raise and support the vehicle on a hoist. Exhaust System and Intake Manifold).
(28) Remove the drain plug and drain the engine (22) Using a new gasket, install throttle body.
oil. Tighten the throttle body bolts to 23 N-m (200 in.
(29) Remove engine front mount thru-bolt nuts. lbs.) torque.
(80) Remove the transmission cooler line brackets (23) Connect the throttle linkage.
from oil pan. (24) Install the air cleaner box.
(81) Disconnect exhaust pipe at manifold. (25) Install the generator and wire connections (re
(82) Disconnect the starter wires. Remove starter fer to Group 8B, Battery/Starter/Generator Service).
motor (refer to Group 8B, Battery/Starter/Generator (26) Install radiator (refer to Group 7, Cooling Sys
Service). tem).
(33) Remove the dust shield and transmission (27) Connect the lower radiator hose.
cover. (28) Install the fan shroud.
(34) Refer to group 21, Transmissions for transmis (29) Install the fan.
sion removal. (30) Connect the top radiator hose.
(35) Remove the prop shaft (refer to Group 16, Pro (31) Install the washer bottle.
peller Shaft). (32) If equipped, install the condenser.
(36) Lower the vehicle. (33) Install the A/C compressor with the lines at
tached.
manifold.
Cooling System).
(37) Install an engine lifting fixture. (35) Evacuate and charge the air conditioning sys
(38) Remove engine from vehicle and install engine tem, if equipped (refer to Group 24, Heating and Air
assembly on a repair stand. Conditioning for service procedures).
(36) Install the transmission oil cooler.
INSTALLATION (37) Install the upper crossmember and top core
(1) Remove engine from the repair stand and posi support.
tion in the engine compartment. Position the thru- (38) Add coolant to the cooling system (refer to
bolt into the support cushion brackets. Group 7, Cooling System for the proper procedure).
(2) Install an engine support fixture. (39) Install the battery.
(3) Raise and support the vehicle on a hoist. (40) Warm engine and adjust.
(4) Refer to Group, 21 Transmissions for transmis (41) Road test vehicle.
sion installation
(5) Install rear transmission support.
9 - 56 5.2L ENGINE — — BR
CYLINDER HEAD COVER ROCKER CYLINDER

again.
CYLINDER HEAD
C O V E R GASKET V
J9209-65
Fig. 2 Rocker Arms

INSTALLATION
J9209-105
Fig. 1 Cylinder Head Cower Gasket cover. This mark is located 147° ATDC from the No.l
firing position.
(1) Disconnect the negative cable from the battery. CAUTION: DO NOT rotate or crank the engine dur
(2) Disconnect closed ventilation system and evap ing or immediately after rocker arm installation. Al
oration control system from cylinder head cover. low the hydraulic roller tappets adequate time to
(3) Remove cylinder head cover and gasket. The bleed down (about 5 minutes).
gasket may be used again.
CLEMMING moved.
Clean cylinder head cover gasket surface. (3) Install rocker arm and pivot assemblies in the
Clean head rail, if necessary. same order as removed. Tighten the rocker arm bolts
INSPECTION
(4) Install cylinder head cover.
Inspect cover for distortion and straighten, if nec
(5) Connect spark plug wires.
essary.
Check the gasket for use in head cover installation. VALVE STEM SEAL AND SPRING REPLACEMENT
If damaged, use a new gasket. This procedure is done with the cylinder head in
INSTALLATION
stalled.
(1) Set engine basic timing to Top Dead Center
(1) The cylinder head cover gasket can be used
(TDC).
again. Install the gasket onto the head rail.
(2) Remove the air cleaner.
(2) Position the cylinder head cover onto the gas (3) Remove cylinder head covers and spark plugs.
ket. Tighten the bolts to 11 N-m (95 in. lbs.) torque. (4) Remove coil wire from distributor and secure to
(3) Install closed crankcase ventilation system and good ground to prevent engine from starting.
evaporation control system. (5) Using suitable socket and flex handle at crank
(4) Connect the negative cable to the battery. shaft retaining bolt, turn engine so the No.l piston is
at TDC on the compression stroke.
VALVE COMPONENTS REPLACE—CYLINDER HEAD (6). Remove rocker arms.
NOT REMOVED (7) With air hose attached to an adapter installed
in No.l spark plug hole, apply 620-689 kPa (90-100
ROCKER ARMS AND PUSH RODS psi) air pressure.
(8) Using Valve Spring Compressor Tool
REMOVAL MD-998772A, compress valve spring and remove re
(1) Disconnect spark plug wires by pulling on the tainer valve locks and valve spring.
boot straight out in line with plug. (9) Install seals on the exhaust valve stem and po
(2) Remove cylinder head cover and gasket. sition down against valve guides.
(3) Remove the rocker arm bolts and pivots (Fig. (10) The intake valve stem seals should be pushed
2). Place them on a bench in the same order as re firmly and squarely over the valve guide using the
moved. valve stem as a guide. DO NOT force seal against top
(4) Remove the push rods and place them on a of guide. When installing the valve retainer locks,
bench in the same order as removed. compress the spring only enough to install the locks.
BR 5.2L ENGINE 9 - 57
(11) Follow the same procedure on the remaining 1 (15) Remove intake manifold and throttle body as
cylinders using the firing sequence 1-8-4=8-6-5-7-2. an assembly. Discard the flange side gaskets and the
Make sure piston in cylinder is at TDC on the valve front and rear cross-over gaskets.
spring that is being removed. (16) Remove exhaust manifolds.
(12) Remove adapter from the No.l spark plug (17) Remove rocker arm assemblies and push rods.
hole. Identify to ensure installation in original locations.
(18) Install rocker arms. (18) Remove the head bolts from each cylinder
(14) Install covers and coil wire to distributor. head and remove cylinder heads. Discard the cylin
(15) Install air cleaner. der head, gasket.
(16) Road test vehicle. (19) Remove spark plugs.
CYLINDER HEADS GLEAMING

The alloy cast iron- cylinder heads (Fig. 8) are held Clean all surfaces of cylinder block and cylinder
in place by 10 bolts. The spark plugs are located in heads.
the peak of the wedge between the valves. Clean cylinder block front and rear gasket surfaces
The 5.2L cylinder head is identified by the foundry using a suitable solvent.
mark NH.
INSPECTION
EXHAUST SPARK EXHAUST SPARK EXHAUST Inspect all surfaces with a straightedge if there is
VALVE PLUGS VALVES PLUGS VALVE
any reason to suspect leakage. If out-of-flatness ex
ceeds 0.00075 mm/mm (0.00075 inch/inch) times the
span length in inches in any direction, either replace
head or lightly machine the head surface.
FOR EXAMPLE: A 305 mm (12 inch) span is
able.
INTAKE INTAKE Inspect push rods. Replace worn or bent rods.
VALVES VALVES J9309-37
INSTALLATION
Fig. 8 Cylinder Head Assembly (1) Position the new cylinder head gaskets onto the
REMOVAL cylinder block.
(1) Disconnect the negative cable from the battery. (2) - Position * the cylinder heads onto head gaskets
(2) Drain cooling system (refer to Group 7, Cooling and cylinder block.
System for the proper procedures). (3) Starting at top center, tighten all cylinder head
(3) Remove the intake manifold-to-generator bolts, in sequence, to 68 N-m (50 ft. lbs.) torque (Fig.
bracket support rod. Remove the generator. 4). Repeat procedure, tighten all cylinder head bolts
(4) Remove closed crankcase ventilation system. to 143 N-m (105 ft. lbs.) torque. Repeat procedure to
(5) Disconnect the evaporation control system. confirm that all bolts are at 143 N-m (105 ft. lbs.)
(6) Remove the air cleaner. torque.
(7) Perform the Fuel System Pressure Release pro
CAUTION: When tightening the rocker arm bolts,
cedure (refer to Group 14, Fuel System). Disconnect
make sure the piston in that cylinder is NOT at
the fuel lines.
TDC, Contact between the valves and piston could
(8) Disconnect accelerator linkage and if so
occur.
down cables. (5) Install push rods and rocker arm assemblies in
(9) Remove the return spring. their original position. Tighten the bolts to 28 N-m
(10) Remove distributor cap and wires. (21 ft. lbs.) torque.
(11) Disconnect the coil wires. (6) Install the intake manifold and throttle body
(12) Disconnect heat indicator sending unit wire. assembly (refer to Group 11, Exhaust System and In
(13) Disconnect heater hoses and bypass hose. take Manifold).
(14) Remove cylinder head covers and gaskets. (7) Install exhaust manifolds. Tighten the bolts
(2) Compress valve springs using Valve Spring
Compressor Tool MD-998772A.
tainers, valve stem seals and valve springs.
(4) Before removing valves, remove any burrs from
valve guides. Identify valves to ensure installation in
original location.
VALVE ©LEAKING
Clean valves thoroughly. Discard burned, warped
and cracked valves.
Remove carbon and varnish deposits from inside of
valve guides with a reliable guide cleaner.
VALVE INSPECTION
Fig. 4 Cylinder Head Bolt Tightening Sequence Measure valve stems for wear. If wear exceeds
(8) Adjust spark plugs to specifications (refer to 0.051 mm (0.002 inch), replace the valve.
Group 8D, Ignition System). Install the plugs and
tighten to 41 N-m (30 ft. lbs.) torque. valwe oumss
(9) Install coil wires. Measure valve stem guide clearance as follows:
(10) Connect heat indicator sending unit wire. (a) Install Valve Guide Sleeve Tool C-3973 over
(11) Connect the heater hoses and bypass hose. valve stem and install valve (Fig. 5). The special
(12) Install distributor cap and wires. sleeve places the valve at the correct height for
(18) Hook up the return spring. checking with a dial indicator.
(14) Connect the accelerator linkage and If so
down cables.
(17) Install the Intake manifold-to-generator
(18) Place the cylinder head cover gaskets In posi
tion and Install cylinder head covers. Tighten the Fig. 5 Positioning Valve with Tool C-3973
bolts to 11 N-m (95 in. lbs.) torque. (b) Attach Dial Indicator Tool C-3339 to cylinder
(19) Install closed crankcase ventilation system. head and set it at right angle of valve stem being
(20) Connect the evaporation control system. measured (Fig. 6).
(21) Install the air cleaner. (c) Move valve to and from the indicator. The to
(22) Install the heat shields. Tighten the bolts to tal dial indicator reading should not exceed 0.432
41 N-m (30 ft. lbs.) torque. mm (0.017 inch). Ream the guides for valves with
(23) Fill cooling system (refer to Group 7, Cooling oversize stems if dial indicator reading is excessive
System for proper procedure). or if the stems are scuffed or scored.
(24) Connect the negative cable to the battery. Service valves with oversize stems are available
(Fig. 7).
VALVES AND VALVE SPRINGS
Slowly turn reamer by hand and clean guide thor
The valves are arranged in-line and inclined 18°. oughly before installing new valve. Ream the valve
The rocker pivot support and the valve guides are guides f r & W L standard to 0.381 mm (0.015 inch).
cast integral with the heads. Use a 2 step procedure so the valve guides are
This procedure requires the removal of the cylinder reamed true in relation to the valve seat:
head.
© Step 1—Ream to 0.0763 mm (0.003 inch),
REMOVAL o Step 2—Ream to 0.381 mm (0.015 inch).
A - SEAT WIDTH - INTAKE 1.016-1.524 mm (0.040 - 0.060 In.]
Fig. S Measuring Waiwe Guide Wear EXHAUST 1.524 - 2.032 mm (0.060 - 0.080 in.)
B - FACE ANGLE (INTAKE & EXHAUST) 4374° - 43V.°
Mmwmf 0 / S Welwe Gmi® Size C - SEAT ANGLE (INTAKE & EXHAUST) mh - 44 // 3
D - CONTACT SURFACE
0.076 mm 8.026 - 8.052 mm J9309-95
(0.003 In.) (0.316-0.317 in.}
Fig, 8 Value Face and Seat Angles
0.381 mm 8.331-8.357 mm
(0.0151a) (0.328-0.329 in.)
iNXAKI EXHAUST
¥AL¥i VALVE
J9309-30
Fig. 7 Reamer Sims

REFACING WAIVES AND WAIVE SEATS
The intake and exhaust valves have a 48-1/4° to
(Fig. 8).
V A L V E SPRING
WALWES RETAINER LOCK
Inspect the remaining margin after the valves are GROOVE
refaced (Fig. 9). Valves with less than 1.190 mm
(0.047 Inch) margin should be discarded.
J9209-127
VALVE SEATS
Fig. 3 Intake and Exhaust Valves
CAUTlONs DO NOT uti-shrouel waives during waiwe contact Is satisfactory. If the blue is transferred-to
seat refacing (Fig. 10). the top edge of valve face, lower valve seat with a 15°
stone. If the blue is transferred to bottom edge of
(1) When refacing valve seats, it is important that valve face raise valve seat with a 80° stone.
the correct size valve guide pilot be used for reseat (4) When seat Is properly positioned the width of
ing stones. A true and complete surface must be ob intake seats should be 1.016-1.524 mm (0.040-0.060
tained. Inch). The width of the exhaust seats should be
(2) Measure the concentricity of valve seat using a 1.524-2.032 mm (0.060-0.080 inch).
dial Indicator. Total runout should not exceed 0.051
mm (0.002 inch) total indicator reading. WALWE SPRING IN8PE&FION
(8) Inspect the valve seat with Prussian blue to de Whenever valves have been removed for Inspection,
termine where the valve contacts the seat. To do this, reconditioning or replacement, valve springs should
coat valve seat LIGHTLY with Prussian blue then set be tested. As an example the compression length of
valve In place. Rotate the valve with light pressure. the spring to be tested is 1-5/16 Inch. Turn table of
If the blue Is transferred to the center of valve face, Universals Valve Spring Tester Tool until surface is
« BR
the Installed height of springs. Make sure the mea

surement is taken from bottom of spring seat In cyl
inder head to the bottom surface of spring retainer. If
spacers are installed, measure from the top of spacer.
If height Is greater than 42.86 mm (1-11/16 Inches),
Install a 1.587 mm (1/16 Inch) spacer in head coun-
terbore. This should bring spring height back to nor
mal 41.27 to 42.86 mm (1-5/8 to I-11/16 Inch).
HYDRAULIC TAPPETS
Before disassembling any part of the engine to cor
rect tappet noise, check the oil pressure. If vehicle
has no oil pressure gauge, install a reliable gauge at
the pressure sending unit. The pressure should be
between 207-552 kPa (80-80 psi) at 8,000 RPM.
Check the oil level after the engine reaches normal
Fig. 10 Refacing Valve Seats operating temperature. Allow 5 minutes to stabilize
in line with the 1-5/16 Inch mark on the threaded oil level, check dipstick.
stud. Be sure the zero mark Is to the front (Fig. 11). The oil level In the pan should never be above the
Place spring over stud on the table and lift compress FULL mark or below the ADD OIL mark on dipstick.
ing lever to set tone device. Pull on torque wrench Either of these 2 conditions could be responsible for
until ping Is heard. Take reading on torque wrench noisy tappets.
at this instant. Multiply this reading by 2. This will
OIL LMWEL
give the spring load at test length. Fractional mea
surements are Indicated on the table for finer adjust HiSH
ments. Refer to specifications to obtain specified If oil level is above the FULL mark, it is possible
height and allowable tensions. Discard the springs for the connecting rods to dip into the oil. With the
that do not meet specifications. engine running this condition could create foam in
LOW
Low oil level may allow oil pump to take In air.
When air Is fed to the tappets, they lose length which
allows valves to seat noisily. Any leaks on intake side
of oil pump through which air can be drawn will cre
ate the same tappet action. Check the lubrication
system from the intake strainer to the pump cover,
including the relief valve retainer cap. When tappet
noise is due to aeration, It may be Intermittent or
operate the engine at fast Idle. Run engine for a suf
Fig, 11 Testing \Mwe Spfmg for Gompm&sedl Length ficient time to allow all of the air inside the tappets
to be bled out.
(1) Coat valve stems with lubrication oil and Insert TAPPET moim DIAGNOSIS
them, in cylinder bead. (1) To determine source of tappet noise, operate en
(2) If valves or seats are reground, check valve gine at Idle with cylinder head covers removed.
stem height. If valve is too long, replace cylinder (2) Feel each valve spring or rocker arm to detect
head. noisy tappet. The noisy tappet will cause the affected
(8) Install new seals on all valve guides. Install spring and/or rocker arm to vibrate or feel rough in
valve springs and valve retainers. operation.
(4) Compress valve springs with Valve Spring Worn, valve guides or cocked springs are
Compressor Tool MD-998772A, install locks and re sometimes mistaken for noisy tappets* If such is
lease tool If valves and/or seats are ground, measure the case, noise may b e dampened by applying
side thrust on the valve spring* If noise is mot MmsmmtE
appreciably reduced, it can be assumed t h e (1) Clean all tappet parts in a solvent that will re
noise is in t h e tappet. Inspect t h e rocker a r m move all varnish and carbon.
p u s h rod sockets a n d push rod ends for wear. (2) Replace tappets that are unfit for further ser
(8) Valve tappet noise ranges from light noise to a vice with new assemblies.
heavy click. A light noise is usually caused by exces (3) If plunger shows signs of scoring or wear, in
sive leak-down around the unit plunger or by the stall a new tappet assembly. If valve is pitted, or
plunger partially sticking in the tappet body cylinder. valve seat on end of plunger is prevented from seat
The tappet should be replaced. A heavy click is ing, install a new tappet assembly.
caused by a tappet check valve not seating or by for (4) Assemble tappets (Fig. 12).
eign particles becoming wedged between the plunger
and the tappet body. This will cause •the plunger to
valve stem and rocker arm as valve closes. In either
case, tappet assembly should be removed for Inspec
tion and cleaning.
The valve train generates a noise very much like a
light tappet noise during normal operation. Care SPRING CAP J9109-22Q
must be taken to ensure that tappets are making the
noise. In general, if more than one tappet seems to Fig. 12 Hydraulic Tappet Assembly
be noisy, its probably not the tappets. INSTALLATION
(1) Lubricate tappets.
REMO . ,
(2) Install tappets and push rods in their original
(1) Remove the air cleaner. positions. Ensure that the oil feed hole in the side of
(2) Remove cylinder head cover. the tappet body faces up (away from the crankshaft).
(3) Remove rocker assembly and push rods. Iden (3) Install aligning yokes with ARROW toward
tify push rods to ensure Installation in original loca camshaft.
tion. (4) Install yoke retainer. Tighten the bolts to 23
(4) Remove Intake manifold. N-m (200 in. lbs.) torque. Install intake manifold.
(5) Remove yoke retainer and aligning yokes. (5) Install push rods in original positions.
(8) Slide Hydraulic Tappet Remover/Installer Tool ' (6) Install rocker arm.
C-4129-A through opening in cylinder head and seat (7) Install cylinder head cover.
tool firmly in the head of tappet. (8) Start and operate engine. Warm up to normal
(7) Pull tappet out of bore with a twisting motion. operating temperature.
If all tappets are to be removed, identify tappets to
ensure installation in original location. CAUTION: To prevent damage to valve mechanism,
(8) If the tappet or bore in cylinder block is scored, engine must not be run above fast idle until all hy
scuffed, or shows signs of sticking, ream the bore to draulic tappets have filled with oil and have become
next oversize. Replace with oversize tappet. quiet.
CAUTION: The plunger esic3 tappet bodies are not

interchangeable. The plunger and waive must al
VALVE TIMING
ways be fitted to the ©rlglnai bo£y. St is advisable to (1) Turn crankshaft until the No.6 exhaust valve is
work on one tappet at a time to avoid mixing of closing and No.6 intake valve is opening.
parts. Mixed parts are noi compatible. DO NOT dis (2) Insert a 6.350 mm (1/4 inch) spacer between
assemble a tappet on a dirty work bench. rocker arm pad and stem tip of No. 1 intake valve. Al
low spring load to bleed tappet down giving in effect
a solid tappet.
(3) Install a dial indicator so plunger contacts
(1) Pry out plunger retainer spring clip (Fig. 12). valve spring retainer as nearly perpendicular as pos
(2) Clean varnish deposits from inside of tappet sible. Zero the indicator.
body above plunger cap. (4) Rotate the crankshaft clockwise (normal run
(3) Invert tappet body and remove plunger cap, ning direction) until the valve has lifted 0.254 mm
plunger, check valve, check valve spring, check valve (0.010 inch). The timing of the crankshaft should
retainer and plunger spring (Fig. 12). Check valve now read from 10° before top dead center to 2° after
could be flat or ball. top dead center. Remove spacer.
I~ m I.2L ENGINE —- ---
OAUTICKs DQ E'lOT turn crankshaft am? f o r t l w

clockwise a s v&Jyfc spring might bottom and result
in serioys damage.
(5) If reading is not within specified limits:

(a) Check sprocket index marks.
(b) Inspect timing chain for wear.
(c) Check accuracy of DC mark on timing indica
tor.
VIBRATION DAMPER
Fig. 2 Installing Vibration Damper
(1) Disconnect the negative cable from the battery. THING CHAIN COVER
shroud back over engine. REMOVAL
(8) Remove the cooling system fan. (1) Disconnect the negative cable from the battery.
(4) Remove the serpentine belt (refer to Group 7, (2) Drain cooling system (refer to Group 7, Cooling
Cooling System). System).
(5) Remove the vibration damper pulley. (3) Remove the serpentine belt (refer to Group 7,
(6) Remove vibration damper bolt and washer from Cooling System).
end of crankshaft.
(4) Remove water pump (refer to Group 7, Cooling
(7) Install bar and screw from Puller Tool Set
C-3688. Install 2 bolts with washers through the System).
puller tool and Into the vibration damper (Fig. 1). (5) Remove power steering pump (refer to Group
19, Steering).
at each side.
damage the crankshaft seal surface of cover (Fig. 3).

(8) Pull vibration damper off of the crankshaft.
(1) Position the vibration damper onto the crank

shaft.
(2) Place Installing tool, part of Puller Tool Set
C-3688 In position and press the vibration damper
onto the crankshaft (Fig. 2).
(3) Install the crankshaft bolt and washer. Tighten
the bolt to 183 N-m (135 ft. lbs.) torque. Fig. 8 Removal of Front Crankshaft Oil Seal
(*•; Install the crankshaft pulley. Tighten the pul rmm® mmim mmEw^m
ley bolts to 23 N-m (200 In. lbs.) torque. (1) Place a scale next to the timing chain so that
(5) Install the serpentine belt (refer to Group 7, any movement of the chain may be measured.
jailing System). (2) Place a torque wrench and socket over cam
('?} Install the cooling system fan. Tighten the bolts shaft sprocket attaching bolt. Apply torque in the di
to' 23 N-m (17 ft lbs.) torque. rection of crankshaft rotation to take up slack; 41
(7) Position the fan shroud and install the bolts. N-m (30 ft. lbs.) torque with cylinder head installed
Tighten the retainer bolts to II N-m (95 in. lbs.)
or 20 N-m (15 ft. lbs.) torque with cylinder head re
torque.
(8) Connect the negative cable to the battery. moved. With a torque applied to the camshaft
5.2L ENGINE 9 - 63
sprocket bolt, crankshaft should not be permitted to thrust plate and up to 0.254 mm (0.010 inch) with a
move. It may be necessary to block the crankshaft to used thrust plate. If not within these limits install a
prevent rotation. new thrust plate.
(8) Hold a scale with dimensional reading even
with the edge of a chain link. With cylinder heads In ©LEMMING
stalled, apply 14 N-m (80 ft. lbs.) torque in the re Be sure mating surfaces of chain case cover and
verse direction. With the cylinder heads removed, cylinder block are clean and free from burrs.
apply 20 N-m (15 ft. lbs.) torque In the reverse direc The water pump mounting surface must be
tion. Note the amount of chain movement (Fig. 4). cleaned.
INSTALLATION
time*
Pig, 4 Measuring Timing Chain Wear and Stretch
CRANKSHAFT
(4) Install a new timing chain, If its movement ex FRONT OIL
ceeds 3.175 mm (1/8 Inch). SEAL
(5) If chain is not satisfactory, remove camshaft
sprocket attaching bolt and remove timing chain with
crankshaft bores.
shaft sprocket.
(9) Lift sprockets and chain (keep sprockets tight J9309-44
(10) Slide both sprockets evenly over their respec Fig. 6 Placing Oil Seal on Installation Tool 6635
tive shafts and use a straightedge to check alignment (3) Position the seal and tool onto the crankshaft
of timing marks (Fig. 5). (Fig. 7).
(4) Tighten the 4 lower chain case cover bolts to
13N-m (10 ft.lbs.) to prevent the cover from tipping
during seal installation.
(Fig. 8).
(6) Loosen the 4 bolts tightened in step 4 to allow
realignment of front cover assembly.
(7) Tighten chain case cover bolts to 41 N-m (30
ft.lbs.) torque. Tighten oil pan bolts to 24 N-m (215
in. lbs.) torque.
Fig 5 Alignment of Timing Marka
D
(11) Install the camshaft bolt. Tighten the bolt to stallation tool.
68 N-m (50 ft. lbs.) torque. (9) Inspect the seal flange on the vibration damper.
(12) Check camshaft end play. The end play should (10) Install vibration damper.
be 0.051-0.152 mm (0.002-0.006 inch) with a new
fROOT CRANKSHAFT OIL SEAL REPLACEMENT

The oil seal can be replaced without removing the
timing chain cover provided the cover is not mis
aligned.
(3) If front seal is suspected of leaking, check front
oil seal alignment to crankshaft. The seal installa
tion/alignment tool 6635, should fit with minimum
interference. If tool does not fit, the cover must be re
moved and installed properly.
damage the crankshaft seal bore of cover.
COVER J930SM5 ** 8 Front Oil Seal Installation Tool 6635 (Fig. 6). Seat
Fig. 7 Position Tool and Seal onto Crankshaft (6) Position the seal and tool onto the crankshaft
(Fig. 7).
(7) Using the vibration damper bolt, tighten the bolt to
draw the seal into position on the crankshaft (Fig. 8).
stallation tool.
GliSHAPI
The camshaft has an integral oil pump and distrib
utor drive gear (Fig. 9).
J9309-46
J9309-71
Fig. 8 Installing Oil Seal

Fig. 9 Camshaft and Sprocket Assembly
ing new gaskets (refer to Group 7, Cooling System), EMOVAL
Tighten bolts to 41 N-m (30 ft. lbs.) torque. (1) Remove intake manifold.
(12) Install power steering pump (refer to Group (2) Remove cylinder head covers.
IS, Steering). (3) Remove timing case cover and timing chain.
(13) Install the serpentine belt (refer to Group 7, (4) Remove rocker arms.
(5) Remove push rods and tappets. Identify each
Cooling System).
part so it can be installed in its original location.
(14) Install the cooling system fan. Tighten the (6) Remove distributor and lift out the oil pump
bolts to 23 N-m (17 ft. lbs.) torque. and distributor drive shaft.
(15) Position the fan shroud and install the bolts. (7) Remove camshaft thrust plate, note location of
Tighten the bolts to 11 N-m (95 in. lbs.) torque. oil tab (Fig. 10).
BR ^ — — 5.2L ENGINE 9 - 65
(2) Position rear bearing in the tool. Install horse

shoe lock and by reversing removal procedure, care
rectly. Install a new core hole plug at the rear of
camshaft. Be sure this plug does not leak.
INSTALLATION
gine for a minimum of 805 km (500 miles).
Fig. 10 Timing Chain Oii Tab installation (2) Install Camshaft Gear Installer Tool C-3509
(8) Install a long bolt into front of camshaft to fa
cilitate removal of the camshaft. Remove camshaft,
being careful not to damage cam bearings with the
cam lobes.
REMOVAL—BEARING
This procedure requires that the engine is removed
from the vehicle.
(1) With engine completely disassembled, drive out
rear cam bearing core hole plug.
washers (part of Camshaft Bearing Remover/Installer
Tool C-3132-A) at back of each bearing shell Drive Fig. 12 Camshaft Holding Tool C-3509 (Installed
out bearing shells (Fig. 11). Position)
pushed in too far and prevent knocking out the welch
installed until the camshaft and crankshaft
sprockets and timing chain have been installed.
Fig, 11 Camshaft Bearings Removal and Installation (5) Place both camshaft sprocket and crankshaft
with Tool C-3132-A sprocket on the bench with timing marks on exact
INSTALLATION—BEARING imaginary center line through both camshaft and
(1) Install new camshaft bearings with Camshaft crankshaft bores.
Bearing Remover/Installer Tool C-3132-A by sliding (6) Place timing chain around both sprockets.
the new camshaft bearing shell over proper adapter. (7) Turn crankshaft and camshaft to line up with
shaft sprocket.
(8) Lift sprockets and chain (keep sprockets tight (2) Drive bushing and tool into position, using a
against the chain In position as described). hammer (Fig. 15),
(9) Slide both sprockets evenly over their respec
of timing marks (Fig, 13).
Fig, 15 Distributor Dm&shafi Bushing installation

(3) As the burnisher is pulled through the bushing,
the bushing is expanded tight in the block and bur
Fig. 13 Alignment of Timing Marks nished to correct size (Fig. 16). BO NOT ream this
(10) Install the camshaft bolt/cup washer. Tighten bushing.
bolt to 68 N°m (50 ft. lbs.) torque.
(11) Measure camshaft end play Eefer to Specifica CAUTION" TSils procedure MUST be followed when
tions for proper clearance. If not within limits Install installing a new byshing or seizure io shaft ma\j oc=
a new thrust plate. cur.
(12) Each tappet reused must be Installed in the
same position from which it was removed. When,
camshaft is replaced, all ©f t h e tappets must be
replaced*
DISTRIBUTER BUSHING
mBmmmwm minmmmi
procedure.
(1) Remove the intake manifold (refer to Group 11, Fig. 13 Burnishing Distributor Driveshaft Bushing
Exhaust System and Intake Manifold). (4) Install the intake manifold (refer to Group 11,
(2) Insert Distributor Drive Shaft Bushing Puller Exhaust System and Intake Manifold).
Tool C-3052 into old bushing and thread down until a
tight fit is obtained (Fig. 14).
(3) Hold puller screw and tighten puller nut until Refer to the Component Removal/Installation sec
bushing is removed. tion of Group 8D, Ignition Systems for the proper
procedure. See Distributor. After the distributor has
been installed, Its rotational position must be set us
ing the SET SYNC mode of the DRB scan tool. Refer
to Checking Distributor Position following the Dis
tributor Installation section In Group 8D, Ignition
4 system. Do not attempt to adjust ignition timing
by rotating t h e distributor. It h a s no effect on
ignition timing. Adjusting distributor position
Before Installing the distributor, the oil pump drive
shaft must be aligned to number one cylinder.
Fig, 14 Distributor Driveshaft Bushing Removal (1) Rotate crankshaft until No.l cylinder is at top
IK._ _ (2) When In this position, the timing mark on vi
(1) Slide new bushing over burnishing end of Dis bration damper should be under 0 on the timing In
tributor Drive Shaft Bushing Driver/Burnisher Tool dicator,
C-3053. Insert the tool and bushing Into the bore.
BR. — — _ S J L ENGINE 9 - 67
(3) Install the shaft so that after the gear spirals

Into place, it will index with the oil pump shaft. The
slot on top of oil pump shaft should be aligned to
wards left, front intake manifold attaching bolt hole
(Fig. 17).
SLOT J9509-163
(3) Apply small amount of Mopar® Silicone Rubber
Fig. 17 Position or installed Distributor Drive Gear

OIL PAN
REMOVAL
(3) Raise vehicle.
cushion thru-bolt nut and raise the engine slightly.
Remove oil pan by sliding backward and out.
GLEAMING
Clean the block and pan gasket surfaces.
Trim or remove excess sealant film in the rear Fig. 2 Position of Dowels In Cylinder Block
main cap oil pan gasket groove. DO NOT remove
the sealant inside t h e r e a r m a i n cap slots. Adhesive Sealant, or equivalent in the corner of the
If present, trim excess sealant from inside the en cap and the cylinder block.
gine. (4) Slide the one-piece gasket over the dowels and
onto the block.
Clean oil pan in solvent and wipe dry with a clean (5) Position the oil pan over the dowels and onto
cloth. the gasket.
Clean oil screen and pipe thoroughly in clean sol (6) Install the oil pan bolts. Tighten the bolts to 24
vent. Inspect condition of screen. N*m (215 in. lbs.) torque.
(7) Remove the dowels. Install the remaining oil
INSPECTION pan bolts. Tighten these bolts to 24 N«m (215 in. lbs.)
Inspect oil drain plug and plug hole for stripped or torque.
damaged threads. Repair as necessary. (8) Lower the engine into the support cushion
Inspect oil pan mounting flange for bends or distor brackets and tighten the thru bolt nut to the proper
tion. Straighten flange, if necessary. torque.
(9) Install the drain plug. Tighten drain plug to 34
INSTALLATION N-m (25 ft. lbs.) torque.
(1) Fabricate 4 alignment dowels from 5/16 x 1 1/2 (10) Install the engine to transmission strut.
inch bolts. Cut the head off the bolts and cut a slot (11) Install exhaust pipe.
into the top of the dowel. This will allow easier in . (12) Lower vehicle.
stallation and removal with a screwdriver (Fig. 1). (13) Install dipstick.
(2) Install the dowels in the cylinder block (Fig. 2). (14) Connect the negative cable to the battery.
(15) Fill crankcase with oil to proper level.
I - S8 5.2L ENGINE
ijj- MymmriQM S Y S T E M
A gear—type positive displacement pump is (2) Remove the oil pump from rear main bearing
mounted at the underside of the rear main bearing cap,
cap. The pump draws oil through the screen and in
let tube from the sump at the rear of the oil pan. The INSTALLATION
oil is driven between the drive and Idler gears and (1) Install oil pump. During Installation slowly ro
pump body, then forced through the outlet to the tate pump body to ensure driveshaft-to-pump rotor
block. An oil gallery in the block channels the oil to shaft engagement.
the inlet side of the M l flow oil filter. After passing (2) Hold the oil pump base flush against mating
through the filter element, the oil passes from "the surface on No.5 main bearing cap. Finger tighten
center outlet of the filter through an oil gallery that pump attaching bolts. Tighten attaching bolts to 41
channels the oil up to the main gallery which ex N°m (30 ft. lbs.) torque.
tends the entire length on the right side of the block. (3) Install the oil pan.
The oil then goes down to the No. 1 main bearing,
back up to the left side of the block and into the oil PiSTGN AND CONNECTING ROD ASSEMBLY
gallery on the left side of the engine. The pistons are elliptically turned so that the di
Galleries extend downward from the main oil gal ameter at the pin boss is less than its diameter
lery to the upper shell of each main bearing. The across the thrust face. This allows for expansion un
crankshaft is drilled internally to pass oil from the der normal operating conditions. Under operating
main bearing journals to the connecting rod journals. temperatures, expansion forces the pin bosses away
Each connecting rod bearing has half a hole in it, oil from each other, causing the piston to assume a more
passes through the hole when the rods rotate and the nearly round shape.
hole lines up, oil is then thrown off as the rod ro All pistons are machined to the same weight, re
tates. This oil throwoff lubricates the camshaft lobes, gardless of size, to maintain piston balance.
distributor drive gear, cylinder walls, and piston The piston pin rotates in the piston only and is re
pins. tained by the press interference fit of the piston pin
The hydraulic valve tappets receive oil directly in the connecting rod.
from the main oil gallery. The camshaft bearings re
ceive oil from the main bearing galleries. The front
camshaft bearing journal passes oil through the cam (1) Remove the engine from the vehicle.
shaft sprocket to the timing chain. Oil drains back to (2) Remove the cylinder head.
the oil pan under the number one main bearing cap. (3) Remove the oil pan.
The oil supply for the rocker arms and bridged (4) Remove top ridge of cylinder bores with a reli
pivot assemblies is provided by the hydraulic valve able ridge reamer before removing pistons from cyl
tappets which pass oil through hollow push rods to a inder block. Be sure to keep tops of pistons covered
hole in the corresponding rocker arm. Oil from the during this operation.
rocker arm lubricates the valve train components. (5) Be sure the connecting rod and connecting rod
The oil then passes down through the push rod guide cap are identified with the cylinder number. Remove
holes, and the oil drain back passages in the cylinder connecting rod cap. Install connecting rod bolt guide
head past the valve tappet area, and returns to the set on connecting rod bolts.
oil pan. (6) Pistons and connecting rods must be removed
from top of cylinder block. When removing piston and
O I L PUMP connecting rod assemblies, rotate crankshaft to cen
ter the connecting rod in the cylinder bore and at
€JIL PUMP PRESSURE BDC. Be careful not to nick crankshaft journals.
The MINIMUM oil pump pressure is 41.4 kPa (8 (7) After removal, install bearing cap on the mat
psi) at curb idle. The MAXIMUM oil pump pressure ing rod.
is 207-552 kPa (80-80 psi) at 3,000 EPM or more.
CAUTION If oil pressure Is 2E30 at curb Idle, DO Check the crankshaft connecting rod journal for ex
HOT run engine at 3,000 R P M . cessive wear, taper and scoring.
Check the cylinder block bore for out-of-round,
taper, scoring and scuffing.
REMOVAL Check the pistons for taper and elliptical shape be
(1) Remove the oil pan. fore they are fitted into the cylinder bore (Fig. 4).
(a) Install oil rings being careful not to nick or
PISTON PIN BORE DIAMETER
\ 25.007-25.015 mm
scratch the piston. Install the oil control rings ac
cording to instructions in the package. It is not nec
essary to use a tool to install the upper and lower
rails. Insert oil rail spacer first, then side rails.
(b) Install the second compression rings using In
stallation Tool C-4184. The compression rings must
be installed with the identification mark face up
(toward top of piston) and chamfer facing down. An
identification mark on the ring is a drill point, a
RING GROOVE HEIGHT
TOP (Figs. 5 and 7).
OIL RAIL GROOVE 4.0309 - 4.0538 mm-***
(J 587-.1596 IN.) SECOND COMPRESSION RING CHAMFER
(BLACK CAST JftONJ
COMPRESSION RAIL GROOVE - « - J
2,0294 - 2.0548 mm
(.0799 - .0809 IN.)
TOTAL WEIGHT (FINISHED)
594.6 ± 2 GRAMS
PISTON A D1A = PiSTCM DIAMETER BORE DIAMETER

SIZE MIN. mm (IN.) MAX. mm (IN.) MSN. mm(IN.) MAX. mm (IN.)
A 99.280 (3.9087) 99.294 (3.9092) 99.306 (3.9097) 99.319(3.9102)
B 99.294 (3.9092) 99.306 (3.9097) 99.319(3.9102) 99.332 (3.9107)
C 99.306 (3.9097) 99.319(3.9102) 99.332 (3.9107) 99.344 (3.9112) TWO
D 99.319(3.9102) 99.332 (3.9107) 99.344(3.9112) 99.357(3.9117) J9009-46
E 99.332 (3.9107) 99.344(3.9112) 99.357(3.9117)
DOTS
99.370(3.9122)
J9509-80 Fig. 5 Second Compression Ring Identification
(Typical)
(c) Using a ring installer, install the top compres
FITTING PISTONS sion ring with the chamfer facing up (Fig. 6). An
Piston and cylinder wall must be clean and dry. identification mark on the ring is a drill point, a
Specified clearance between the piston and the cylin stamped letter O, an oval depression or the word
der wall is 0.013-0.038 mm (0.0005-0.0015 inch). TOP facing up.
Piston diameter should be measured at the top of
skirt, 90° to piston pin axis. Cylinder bores should be > COMPRESSION RING
(GRAY I N COLOR)
measured halfway down the cylinder bore and trans
verse to the engine crankshaft center line. I
Pistons and cylinder bores should be measured at
normal room temperature, 21°C (70°F).
FITTING RINGS ONE

(1) Measurement of end gaps: DOT
(a) Measure piston ring gap 2 inches from bot Kraal
tom of cylinder bore. An inverted piston can be HP
used to push the rings down to ensure positioning J9009-48
rings squarely in the cylinder bore before measur
ing. Fig. 6 Top Compression Ring Identification (Typical)
(b) Insert feeler gauge in the gap. The top com (d) Measure side clearance between piston ring
pression ring gap should be between 0.254-0.508 and ring land. Clearance should be 0.074-0.097 mm
mm (0.010-0.020 inch). The second compression (0.0029-0.0038 inch) for the compression rings. The
ring gap should be between 0.508-0.762 mm (0.020- steel rail oil ring should be free in groove, but
0.030 inch). The oil ring gap should be 0.254-1.270 should not exceed 0.246 mm (0.0097 inch) side
mm (0.010-0.050 inch). clearance.
(c) Rings with insufficient end gap may be prop (e) Pistons with insufficient or excessive side
erly filled to the correct dimension. Rings with ex clearance should be replaced.
cess gaps should not be used. (3) Arrange ring gaps 180° apart as shown in Fig.
(2) Install rings and confirm ring side clearance: 8.
BR- — — — — — §21 E l i l l E S - 71
CHAMFER T« %'RESSION
gered so that neither is in-line with oil ring rail gap.
(2) Before installing the ring compressor, make
sure the oil ring expander ends are butted and the
rail gaps located properly (Fig. 6).
SECOND (3) Immerse the piston head and rings in clean en
"^COMPRESSION gine oil. Slide Piston Ring Compressor Tool C-385
~A RING
over the piston and tighten with the special wrench
(part of Tool 0-385). Be sure position ©f rings
r ' . - PISTON J9409-37 does not change during this operation.
(4) Install connecting rod bolt protectors on rod
Fig }' f ^sskm Ring Chamfer location bolts, the long protector should be installed on the
(Typical) numbered side of the connecting rod.
OIL R I N G (5) Rotate crankshaft so that the connecting rod
SPACER GAP journal is on the center of the cylinder bore. Be sure
connecting rod and cylinder bore number are the
same. Insert rod and piston into cylinder bore and
guide rod over the crankshaft journal.
SECOND
COMPRESSION
(6) Tap the piston down in cylinder bore, using a
TOP hammer handle. At the same time, guide connecting
COMPRESSION RING GAP
RING GAP
OIL RING RAIL rod into position on crankshaft journal.
G A P (TOP)
(7) The notch or groove on top of piston must be
pointing toward front of engine. The larger chamfer
crankshaft journal fillet.
(8) Install rod caps. Be sure connecting rod, con
OIL R I N G RAIL necting rod cap and cylinder bore number are the
GAP (BOTTOM) J930S-80 same. Install nuts on cleaned and oiled rod bolts and
tighten nuts to 61 N-m (45 ft. lbs.) torque.
Fig. 3 Proper Ring Installation
CONNECTING ROB BEARINGS (10) Install the cylinder head.
Fit all rods on a bank until completed. DO NOT al (11) Install the engine into the vehicle.
ternate from one bank to another, because connecting
rods and pistons are not interchangeable from one CRANKSHAFT
bank to another. A crankshaft which has undersize journals will be
The bearing caps are not interchangeable and stamped with 1/4 inch letters on the milled flat on
should be marked at removal to ensure correct as the No.8 crankshaft counterweight (Fig. 9).
sembly. FOR EXAMPLE: R2 stamped on the No.8 crank
Each bearing cap has a small V-groove across the shaft counterweight indicates that the No.2 rod jour
parting face. When installing the lower bearing shell, nal is 0.025 mm (0.001 in) undersize. M4 indicates
make certain that the V-groove in the shell is in line that the No.4 main journal is 0.025 mm (0.001 in)
with the V-groove in the cap. This provides lubrica undersize. R3 M2 indicates that the No.3 rod journal
tion of the cylinder wall in the opposite bank. and the No.2 main journal are 0.025 mm (0.001 in)
The bearing shells must be installed so that the undersize.
tangs are in the machined grooves in the rods and When a crankshaft is replaced, all main and con
necting rod bearings should be replaced with new
caps.
bearings. Therefore, selective fitting of the bearings
Limits of taper or out-of-round on any crankshaft is not required when a crankshaft and bearings are
journals should be held to 0.025 mm (0.001 inch). replaced.
Bearings are available in 0.025 mm (0.001 inch),
0.051 mm (0.002 inch), 0.076 mm (0.008 inch), 0.254 REMOVAL
mm (0.010 inch) and 0.305 mm (0.012 inch) under (1) Remove the oil pan.
size. Install the bearings in pairs. DO NOT use a (2) Remove the oil pump from the rear main bear
new bearing half with a n ©Id bearing half. BO ing cap.
NOT file t h e rods or bearing caps. (3) Remove the vibration damper.
(4) Remove the timing chain cover.
9 - 72 5.21 ENGINE BR
Identification Stamp
Undersize Journal
the bearing cap with the yellow paint facing towards
0.025 mm (0.001 in.) (Rod) R1-R2-R3 or R4 the rear of the engine.
0.025 mm (0.001 in.) (Main) M1-M2-M3-M4 or M5 (6) Apply 5 mm (0.20 in) drop of Loctite 518, or
equivalent, on each side of the rear main bearing cap
#8 CRANKSHAFT /R-T-2V— {ROD) sealant to contact the rubber seal. Assemble bearing
COUNTERWEIGHT ^ ^ S ^ y M - ] / - (MAIN) cap to cylinder block immediately after sealant appli
cation.
n a—rs
MOPAR SILICONE RUBBER ADHESIVE SEALANT S10TS\
-f\ ~?T3
^LOCTITE 518 (OR EQUIVALENT).
*J9209-138
Fig. 1 Location of Crankshaft Identification

(5) Identify bearing caps before removal. Remove CAP
ALIGNMENT
bearing caps and bearings one at a time. SLOT
(6) Lift the crankshaft out of the block.
(7) Remove and discard the crankshaft rear oil
seals.
(8) Remove and discard the front crankshaft oil
. REAR MAIN
seal. BEARING CAP J9309-72
INSPECTION OF JOURNALS Fig. 2 Sealant Application to Bearing Cap

The crankshaft connecting rod and main journals
(7) To align the bearing cap, use cap slot, align
should be checked for excessive wear, taper and scor ment dowel and cap bolts. DO NOT remove excess
ing. The maximum taper or out-of-round on any material after assembly. DO NOT strike rear cap
crankshaft journal is 0.025 mm (0.001 inch). more than 2 times for proper engagement.
Journal grinding should not exceed 0.305 mm (8) Clean and oil all cap bolts. Install all main
(0.012 inch) under the standard journal diameter. DO bearing caps. Install all cap bolts and alternately
NOT grind thrust faces of No.3 main bearing. DO tighten to 115 N-m (85 ft. lbs.) torque.
NOT nick crank pin or bearing fillets. After grinding, (9) Install oil pump.
remove rough edges from crankshaft oil holes and (10) Install the timing chain cover.
clean out all oil passages. (11) Install the vibration damper.
CAUTION: After any journal grind, It Is important
that the final paper or cloth polish be in the same provide cap to block and oil pan sealing (Fig. 3). Ap
direction as the engine rotates. ply enough sealant until a small amount is squeezed
CLEANING
Clean Loctite 518 residue and sealant from the cyl (13) Install new front crankshaft oil seal.
inder block and rear cap mating surface. Do this be (14) Immediately install the oil pan.
fore applying the Loctite drop and the installation of CRANKSHAFT MAIN BEAR1NSS
rear cap.
INSTALLATION be marked at removal to ensure correct assembly.
(1) Lightly oil the new upper seal lips with engine Upper and lower bearing halves are NOT inter
oil. changeable. Lower main bearing halves of No.2 and 4
(2) Install the new upper rear bearing oil seal with are interchangeable.
the yellow paint facing towards the rear of the en Upper and lower No.3 bearing halves are flanged
to carry the crankshaft thrust loads. They are NOT
gine.
interchangeable with any other bearing halves in the
(3) Position the crankshaft into the cylinder block. engine (Fig. 4). Bearing shells are available in stan
(4) Lightly oil the new lower seal lips with engine dard and the following undersizes: 0.25 mm (0.001
oil. inch), 0.051 mm (0.002 inch), 0.076 mm (0.003 inch),
: 1
! : ' • : ; INSTALLING
Fig, 3 Apply Sealant to Bearing Cap to Block Joint
0.254 mm (0.010 inch) and 0.305 mm (0.012 inch). Fig, 5 Upper Main Bearing Removal and Installation
Never install an undersize bearing that will reduce with Tool C-3059
clearance below specifications. (1) Start bearing in place, and insert Crankshaft
Main Bearing Remover/Installer Tool C-3059 into oil
hole of crankshaft (Fig. 5).
(2) Slowly rotate crankshaft counterclockwise slid
ing the bearing into position. Remove Tool C-3059.
(3) Install the bearing caps. Clean and oil the
bolts. Tighten the capbolts to 115 N-m (85 ft. lbs.)
torque.
(4) Install the oil pump.
CRANKSHAFT REAR OIL SEALS

The service seal is a 2 piece, viton seal. The upper
seal half can be installed with crankshaft removed
from engine or with crankshaft installed. When a
new upper seal is installed, install a new lower seal.
The lower seal half can only be installed with the
Fig. 4 Main Bearing identification rear main bearing cap removed.
REMOVAL U P P E R SEAL REPLACEMENT—CRANKSHAFT
(1) Remove the oil pan. REMOVED
(2) Remove the oil pump from the rear main bear (1) Remove the crankshaft. Discard the old upper
ing cap. seal.
(3) Identify bearing caps before removal. Remove (2) Clean the cylinder block rear cap mating sur
bearing'caps one at a time. face. Make sure the seal groove is free of debris.
(4) Remove upper half of bearing by inserting (3) Lightly oil the new upper seal lips with engine
Crankshaft Main Bearing Remover/Installer Tool oil.
C-3059 into the oil hole of crankshaft (Fig. 5). (4) Install the new upper rear bearing oil seal with
(5) Slowly rotate crankshaft clockwise, forcing out the white paint facing towards the rear of the engine.
upper half of bearing shell. (5) Position the crankshaft into the cylinder block.
INSTALLATION oil.
Only one main bearing should be selectively fitted (7) Install the new lower rear bearing oil seal into
while all other main bearing caps are properly tight the bearing cap with the white paint facing towards
ened. All bearing capbolts removed' during service the rear of the engine.
procedures are to be cleaned and oiled before instal (8) Apply 5 mm (0.20 in) drop of Loctite 518, or
lation. equivalent, on each side of the rear main bearing cap
When installing a new upper bearing shell, slightly (Fig. 2). DO NOT over apply sealant or allow the
chamfer the sharp edges from the plain side. sealant to contact the rubber seal. Assemble bearing
5.2L ENGINE
cap to cylinder block immediately after sealant appli (18) Apply Mopar® Silicone Rubber Adhesive Seal
cation. ant, or equivalent, at bearing cap to block joint to
(9) lb align the bearing cap, use cap slot, align provide cap to block and oil pan sealing (Fig. 3). Ap
ment dowel and cap bolts. DO NOT remove excess ply enough sealant until a small amount is squeezed
material after assembly. DO NOT strike rear cap out. Withdraw nozzle and wipe excess sealant off the
more than 2 times for proper engagement. oil pan seal groove.
(10) Clean and oil all cap bolts. Install all main (14) Immediately install the oil pan.
tighten to 115 N-m (85 ft. lbs.) torque. Umm SEAL EMPLACEMENT
(11) Install oil pump. (1) Remove the oil pan.
(12) Apply Mopar® Silicone Rubber Adhesive Seal (2) Remove the oil pump from the rear main bear
ant, or equivalent, at bearing cap to block joint to ing cap.
provide cap to block and oil pan sealing (Fig. 3). Ap (3) Remove the rear main bearing cap and discard
ply enough sealant until a small amount is squeezed the old lower seal.
out. Withdraw nozzle and wipe excess sealant off the (4) Clean the rear main cap mating surfaces in
oil pan seal groove. cluding the oil pan seal grooves.
(13) Install new front crankshaft oil seal. (5) Carefully install a new upper seal (refer to Up
(14) Immediately install the oil pan. per Seal Replacement - Crankshaft Installed proce
UPPER SEAL REPLACEMENT—GIB&MB&§HAFT dure above).
msTAitm oil
(1) Remove the oil pan. (7) Install a new lower seal in bearing cap with
(2) Remove the oil pump from the rear main bear yellow paint facing the rear of engine.
ing cap. (8) Apply 5 mm (0.20 in) drop of Loctite 518, or
(3) Remove the rear main bearing cap. Remove equivalent, on each side of the rear main bearing cap
and discard the old lower oil seal. (Fig. 2). DO NOT over apply sealant or allow the
(4) Carefully remove and discard the old upper oil sealant to contact the rubber seal. Assemble bearing
seal cap to cylinder block immediately after sealant appli
(5) Clean the cylinder block mating surfaces before
cation.
oil seal installation.
(6) Lightly oil the new upper seal lips with engine (9) To align the bearing cap, use cap slot, align
oil. To allow ease of installation of the seal, loosen at ment dowel and cap bolts. DO NOT remove excess
least the 2 main bearing caps forward of the rear material after assembly. DO NOT strike rear cap
bearing cap. more than 2 times for proper engagement.
(7) Rotate the new upper seal into the cylinder (10) Install the rear main bearing cap with cleaned
block being careful not to shave or cut the outer sur and oiled cap bolts. Alternately tighten the cap bolts
face of the seal. To assure proper installation, use the to 115 N-m (85 ft. lbs.) torque.
installation tool provided with the kit. Install the (11) Install oil pump.
new seal with the white paint facing towards the (12) Apply Mopar® Silicone Rubber Adhesive Seal
rear of the engine. ant, or equivalent, at bearing cap to block joint to
(8) Install the new lower rear bearing oil seal into provide cap to block and oil pan sealing (Fig. 3). Ap
the bearing cap with the white paint facing towards ply enough sealant until a small amount is squeezed
the rear of the engine. out. Withdraw nozzle and wipe excess sealant off the
(9) Apply 5 mm (0.20 in) drop of Loctite 518, or oil pan seal groove.
equivalent, on each side of the rear main bearing cap (13) Immediately install the oil pan.
(Fig, 2). DO NOT over apply sealant or allow the
sealant to contact the rubber seal. Assemble bearing CYLINDER BL0CI
cap to cylinder block immediately after sealant appli
cation. Be sure the'white paint faces toward the rear Remove the engine assembly from the vehicle.
of the engine. m&ASSEMBLE
(10) To align the bearing cap, use cap slot, align (1) Remove the cylinder head.
ment dowel and cap bolts. DO NOT remove excess (2) Remove the oil pan.
material after assembly. DO NOT strike rear cap
more than 2 times for proper engagement. (3) Remove the piston/connecting rod assembly.
(11) Install the rear main bearing cap with cleaned
and oiled cap bolts. Alternately tighten ALL cap bolts _ ^JANINCI
to 115 N-m (85 ft,, lbs.) torque. Clean cylinder block thoroughly and check all core
(12) Install oil pump. hole plugs for evidence of leaking.
INSPECTION erly. Coat outside diameter of new plug with Mopar®
Examine block for cracks or - fractures. (Stud and Bearing Mount Adhesive), or equivalent.
The cylinder walls should be checked for out-of- Plug should be 54.0 to 57.7 mm (2-1/8 to 2-5/16
bound and taper with Cylinder Bore Indicator Tool inches) from bottom of the block,
6879. The cylinder block should be bored and honed (5) Assemble engine and check oil pressure.
with new pistons and rings fitted if:
• The cylinder bores show more than 0.127 mm ENGINE OIL JtfiP fSAMSÂPT PLUim
(0.005 inch) out-of-round. Engine core plugs have been pressed into the oil
r/
galleries behind the camshaft thrust plate (Fig, )>
• The cylinder bores show a taper of more than
This will reduce internal leakage and help maintain
0.254 mm (0.010 inch). higher oii pressure at idle.
• The cylinder walls are badly scuffed or scored.
ordinated with the fitting of pistons and rings so
specified clearances may be maintained.
Refer to Standard Service Procedures in the begin
ning of this Group for the proper honing of cylinder
bores.
OIL LIME PLUG

The oil line plug is located in the vertical passage
at the rear of the block between the Oil-To-Filter and
Oil-From-Filter passages (Fig. 6). Improper installa
tion or plug missing could cause erratic, low or no oil
pressure.
(1) Remove oil pressure sending unit from back of
block.
(2) Insert a 8.175 mm (1/8 inch) finish wire or
equivalent into passage.
(3) Plug should be 192.0 to 195.2 mm (7-1/2 to
7-11/16 inches) from machined surface of block (Fig.
6). If plug is too high, use a suitable flat dowel to po Fig. 7 Location of Cup Plugs in Oil Galleries
sition properly. RE10WAI
RIGHT OIL GALLERY
(1) Using a blunt tool such as a drift or a screw
driver and a hammer, strike the bottom edge of the
cup plug (Fig. 8).
(2) With the cup plug rotated, grasp firmly with
pliers or other suitable tool and remove plug (Fig. 8).
CYLINDER
DRIFT 9209-41
Fig, § Oil Line Plug
Fig. 8 Gore Hole- Plug Removal
(4) If plug is too low, remove oil pan and rear main
bearing cap. Use suitable flat dowel to position prop
S - 76 5.21 ENGINE —--^_----™= «-™=^-—^-^-^—;===™-™«««^ .~—• - -- - - — B H
CLEftliNG (2) Using proper plug driver, drive cup plug into
Thoroughly clean inside of cup plug hole in cylinder hole. The sharp edge of the plug should be at least
block or head. Be sure to remove old sealer. 0.50 mm (0.020 inch) inside the lead-in chamfer.
Make certain the new plug is cleaned of all oil or It is not necessary to wait for curing of the sealant.
grease. The cooling system can be filled and the vehicle
placed in service immediately.
INSTALLATION
(1) Coat edges of plug and core hole with Mopar® ASSEMBLE
Gasket Maker, or equivalent. (1) Install the piston/connecting rod assembly.
CAUTION: DO NOT drive cup plug into the easting (3) Install the cylinder head.
as restricted coolant flow can result and cause se (4) Install the engine into the vehicle.
SPECIFICATIONS—5.21 ENGINE
Camshaft
Bearing Diameter End Play 0.051-0.178 mm
No. 1 . . . . . . . . . . . . . . . . . . . . . . . . 50.800-50.825 mm (0.002-0.007 in)
(2.000-2.001 In) Max. Allowable . . . 0.254 mm
No. 2 . . . . . . . . . . . . . . . . . . . . . . . . 50.394-50.419 mm
(0.010 in)
(1.984-1.985 In)
No. 3 . . . . . . . . . . . . . . . . . . . . . . . . 50.013-50.038 mm Main Bearing Journals
(1.969-1.970 In) Diameter . . . . . . . . . . . . . . . . . 63.487-63.513 mm
No. 4 49.606-49.632 mm (2.4995-2.5005 in)
(1.953-1.954 In) Out-of-Round (Max.) 0.0254 mm
No. 5. . . . . . . . . . . . . . . . . . . . . . . . 39.688-39.713 mm (0.001 in)
(1.5625-1.5635 in) Taper (Max.) 0.0254 mm
Diametrical Clearance . . . . . . . . . . . . . 0.0254-0.0762 mm (0.001 in)
(0.001-0.003 in) C y l i n d e r Block
Max. Allowable . . . . . 0.127 mm Cylinder Bore
(0.005 in) Diameter 99.314-99.365 mm
End Play 0.051-0.254 mm (3.910-3.912 in)
(0.002-0.010 in) Out-of-Round (Max.) 0.127 mm
Bearing Journal Diameter (0.005 in)
No. 1 . . 50.749-50.775 mm Taper (Max.) 0.254 mm
(1.998-1.999 in) (0.010 in)
No. 2. 50.343,50.368 mm Oversize (Max.) . . . . . . . . . . . . . . . . 1.016 mm
(1.982-1.983 in) (0.040 in)
No. 3 49.962-49.987 mm Distributor Lower Drive Shaft
(1,967-1.968 in) Bushing (Press Fit in Block) . . . . . . . . 0.0127-0.3556 mm
No. 4 . 49.555-49.581 mm (0.0005-0.0140 in)
(1.951-1.952 in) Shaft-to-Bushing Clearance 0.0178-0.0686 mm
No. 5. 39.637-39.662 mm (0.0007-0.0027 in)
(1.5605-1.5615 in) Tappet Bore Diameter 22.99-23.01 mm
(0.9051-0.9059 in)
C o n n e c t i n g Rods
Bearing Clearance 0.013-0.056 mm Cylinder Head
(0.0005-0.0022 in) Compression Pressure 689 kPa
Max. Allowable... 0.08 mm (0.003 in) (100 psi)
Piston Pin Bore Diameter . 24.966-24.978 mm Gasket Thickness (Compressed) 1.2065 mm
(0.9829-0.9834 in) (0.0475 in)
Side Clearance (Two Rods) . . . . . . . . . 0.152-0.356 mm Valve Seat
(0.006-0.014 in) Angle. 44.25° - 44,75°
Total Weight (Less Bearing) . . . . . . . . . 726 grams Runout (Max.) . . . . . . . . . 0.0762 mm
(25.61 oz) (0.003 in)
Width (Finish) - Intake 1.016-1.524 mm
Crankshaft (0.040-0.060 in)
Connect Rod Journal
Width (Finish) - Exhaust 1.524-2.032 mm
Diameter 53.950-53.975 mm
(2.124-2.125 in) (0.060-0.080 in)
Out-of-Round (Max.) 0.0254 mm H y d r a u l i c Tappets
(0.001 in) Body Diameter . . . . . . . . . . . . . . . . . . 22.949-22.962 mm
Taper (Max.) . 0.0254 mm • (0.9035-0.9040 in)
(0.001 in) Clearance in Block. . .. 0.0279-0.0610 mm
(0.0011-0.0024 in)
Diametrical Clearance Dry Lash . . . . . . . . . . . . . . . . . . . . . . . 1.524-5.334 mm
No. 1 0.013-0.038 mm (0.060-0.210 in)
(0.0005-0.0015 in) Push Rod Length . . . . . . . . . . . . . . . . . 175.64-176.15 mm
Nos, 2, 3, 4 and 5 ................................ 0.013-0.051 mm (6.915-6.935 in)
(0.005-0.0020 In)
Max. Allowable (Nos, 2, 3, 4 & 5)......... 0.064 mm
(0.0025 in)
J9509-66
9 - 78 5.21 ENGINE BR
ENGINE SPECIFICATIONS—CONT.
Oil P u m p Piston Pins

Clearance Over Rotors (Max.). . . . . 0.1016 mm • Clearance
(0.004 In) In Piston 0.00635-0.01905 mm
Cover Out-of-Flat (Max.)......... 0.0381 mm (0.00025-0.00075 in)
(0.0015 In) In Rod (Interference) . . . . . . . . . . 0.0178-0.0356 mm
Inner Rotor Thickness (Min.) . . . . . . '20.955 mm (0.0007-0.0014 in)
(0.825 in) Diameter. . . . . . 24.996-25.001 mm
Outer Rotor
(0.9841-0.9843 in)
Clearance (Max.) 0.3556 mm
(0.014 in) End Play NONE
Length 75.946-76.454 mm
Diameter (Min.) 62.7126 mm
(2.990-3.010 in)
(2.469 in)
Thickness (Min.) 20.955 mm Piston Rings
(0.825 In) Ring G a p
Tip Clearance Between Rotors (Max). . 0.2032 mm Compression Rings 0.254-0.508 mm
(0.008 in) (0.010-0.020 in)
Oil Control (Steel Rails) . . . . . . . . 0.254-1.270 mm
O i l Pressure (0.010-0.050 in)
At Curb Idle Speed (Minimum)*. . . . . . 41.4 kPa Ring Side Clearance
(6 psi) Compression Rings 0.038-0.076 mm
At 3000 rpm . . . 207-552 kPa (0.0015-0.0030 in)
(30-80 psi) Oil Ring (Steel Rails) 0.06-0.21 mm
Oil Pressure Switch (0.002-0.008 in)
Actuating Pressure (Min.) 34.5-48.3 kPa
Ring Width
(5-7 psi)
Compression Rings . 1.971-1.989 mm
• C A U T I O N : If pressure is ZERO at curb idle, (0.0776-0.0783 in)
DO NOT run engine at 3,000 rpm. Oil Ring (Steel Rails) 3.848-3.975 mm
(0.1515-0.1565 in)
Oil filter Valves
Bypass Valve Setting . 62-103 kPa Face Angle 43.25^43.75°
(9-15 psi) Head Diameter
Intake 48.666 mm
Pistons
(1.916 in)
Clearance at Top of Skirt 0.0127-0.0381 mm
(0.0005-0.0015 in) Exhaust 41.250 mm
Land Clearance (Diametrical) 0.635-1.016 mm (1.624 in)
•(0.025-0.040 in)
Length (Overall)
Piston Length 86.360 mm Intake 124.28-125.92 mm
(3.40 in) (4.893-4.918 in)
Piston Ring Groove Depth Exhaust . . . . . . . . . . . . . . . . 124.64-125.27 mm
Nos. 1 and 2 4.572-4.826 mm
(4.9074.932 in)
(0.180-0.190 in)
Lift (Zero Lash) 10.973 mm
No. 3 3.810-4.064 mm
(0.150-0.160 in) (0.432 in)
Weight 592.6-596.6 grams Stem Diameter 7.899-7.925 mm
(20.90-21.04 oz) (0.311-0.312 in)
Stem-to-Guide Clearance 0.0254-0.0762 mm
(0.001-0.003 in)
Max. Allowable (Rocking Method). . 0.4318 mm
(0.017 in)
Guide Bore Diameter (Std) 7.950-7.976 mm
(0.313-0.314 in)
J9509-67
BR — 5.2L ENGINE 9 - 79
ENGINE SPECIFICATIONS—CONT*
Valve Springs Valve timing

Free Length (Approx.) 49.962 mm Exhaust Valve
(1.967 in) Closes (ATC) 21°
Spring Tension . @ 41.66 mm s 378 N Optus (BBC) ..... 60°
(Valve Closed) ( ® L 6 4 in - 85 lbs) Duration 264°
Spring Tension . . . . . . . . . . . . . . . . @ 30.89 mm = 890 N Intake Valve
(Valve Open) f@ 1.212 in = 200 lbs) Closes (ABC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61°
Number of Coils . . . . . . . . . . . . . . . 6.8 Opens (BTC) .............................10°
Installed H e i g h t . . . . . . . . . . . . . . . . 41.66 mm Duration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250°
(Spring Seat to Retainer) (1.64 in) Valve Overlap 31 °
(0.177 in)
J9409-99
OVERSIZE AND UNDERSIZE ENGINE COMPONENT MARKINGS
CONDITION IDENTIFICATION L O C A T I O N OF IDENTIFICATION
CRANKSHAFT JOURNALS R or M Milled flat on no. 8 crankshaft counterweight

(UNDERSIZE) M-2-3 etc. (indicating no. 2 and 3 main bearing
0.0254 mm (0.001 in.) journal)
and/or
R-l -4 etc. (indicating no. 1 and 4 connecting rod
journal)
HYDRAULIC TAPPETS Diamond-shaped stamp top pad - front of

(OVERSIZE) engine and flat ground on outside surface of
0.2032 mm (0.008 in.) each O / S tappet bore.

0.127 mm (0.005 in.) (3/8 in.) on each end of cylinder head. j
J9309-82
9 - 80 5.2L ENGINE
Adjusting Strap Bolt 23 N®m (200 in. lbs.) Rear Mount - Support Cushion-to-
Crossmember Nut 47 N®m (35 ft. lbs.)
Camshaft Bolt 68 N«m (50 ft. lbs.) Rear Mount - Support Cushion-to-
Camshaft Thrust Plate tells 24 N*m (210 in. lbs.) Trans. Support Bracket Nuts ............ 47 N«m (35ft.lbs.)
Chain Case Cover Bolts 41 N*m (30 ft. lbs.) Rear Mount - Transmission Support
Connecting Rod Cap Bolts .................. 61 N«m (45 ft. lbs.) Bracket Bolts 102 N*m (75ft.lbs.)
Crankshaft Main Bearing Cap Bolts .... 115 N«m (85 ft. lbs.) Rear Support Plate-to-Transfer
Cylinder Head Bolts Case Bolts 41 N«m (30ft.lbs.)
1 st Step 68 N*m (50 ft. lbs.) Rocker Arm Bolts 23 N*m (200 in. lbs.)
2nd Step 143 N«m (105 ft. lbs.)
Cylinder Head Cover Bolts 11 N«m (95 in. lbs.) Spark Plugs 41 N®m (30ft.lbs.)
Starter Mounting Bolts 68 N»m (50ft.lbs.)
Head Bolts/Nuts 34 N»m (25 ft. Ibs.j Throttle Body Bolts 23 N*m (200 in. lbs.]
68 N»m (50 ft. lbs.) Bolts 31 N»m (270 in. lbs.]
81 N»m (60 ft. lbs.) Mounting Plate Nuts ....................... 204 N*m (150 ft. lbs.)

Bolt ............................................... 183 N*m (135 ft. lbs.)
Cover Bolt 41 N®m (30ft.lbs.)
Oil Pan Bolts 23 N*m (200 in. lbs.]
Oil Pan Drain Plug . 34 N*m (25 ft. lbs.)
Oil Pump Attaching Bolts .................... 41 N®m (30 ft. lbs.)
Oil Pump Cover Bolts 11 N®m (95 in. lbs.) J9509-140
5 . 9 L ENGINE SERVICE PROCEDURES
INDEX
page page
Camshaft . . 93 Oil Pan 96

Cylinder Head Cover . . . .............. 85 Rocker Arms and Push Rods ................ 85
Cylinder Heads ........... 86 Timing Chain Cover . 91
Distributor Bushing . . . . . . . . . . . . . . . . ......... 95 Valve Components Replace—-Cylinder Head Not
Engine Assembly . . . . . .................... 82 Removed 85
Engine Front Mounts 81 Valve Stem Seal and Spring Replacement . . . . . . . 85
Engine Rear Mount 82 Valve Timing 90
Front Crankshaft Oil Seal Replacement 93 Valves and Valve Springs 87
General Information 81 Vibration Damper 91
Hydraulic Tappets 89
GENERAL INFORMATION
The 5.9 Liter (360 CID) eight-cylinder engine is a
V-Type lightweight, single cam, overhead valve en
gine with hydraulic roller tappets (Fig. 1). 0000
Engine Type 90° V-8 OHV /©®©\
Bore and Stroke..
Displacement
Compression Ratio
101.6 x 90.9 mm (4.00 x 3.58 in.)
5.91 (360 cu. in.)
9.1:1
OF N T
CLOCKWISE ROTATION
1-8-4-3.6-5-7.2
/ / T \ /5k
(© fD
/r\
©
OF \0©0/
Torque.. 448 N«m (3301, lb.) O 3,250 rpm
ENGINE r— 1
Firing Order 1-8-4-3-6-5-7-2
Lubrication
Engine Oil Capacity
Cooling System
Cooling Capacity
Pressure Feed - Full Flow Fihration
4.71 (5.0 Qts) w/fiStssr
Liquid Cooled - Forced Circulation
14.71 (15.5 Qfe) —
O000 ^ ^ — J908D-49
Cylinder Block ....Cast Iron
Fig. 2 Firing Order
Crankshaft ..Nodular Iron
Cylinder Head Cast Iron
Combustion Chambers Wedge-High Swirl Valve Shrouding X M 5.91 T XXXX XXXXXXXX
Camshaft Nodular Cast Iron
Pistons Cast Aluminum Alloy
Connecting Rods Forged Steel X = Last Digit of Model Year
M = Plant - M Mound Road
S Saltillo
T Trenton
J9409-11 K Toluca
5.9L = Engine Displacement
Fig. 1 Engine Description
T - Usage - T Truck
This engine is designed for unleaded fuel. XXXX = Month/Day
Engine lubrication system consists of a rotor type XXXXXXXX . Serial Code - Last 8 Digits of VIN No.
The cylinders are numbered from front to rear; 1, J9209-74
3, 5, 7 on the left bank and 2, 4, 6, 8 on the right
bank. The firing order is 1-8-4-3-6-5-7-2 (Fig. 2). Fig. 3 Engine Identification Number
The engine serial number is stamped into a ma ENGINE FRONT MOUNTS
chined pad located on the left, front corner of the cyl
inder block. When component part replacement is REMOVAL
necessary, use the engine type and serial number for (1) Disconnect the negative cable from the battery.
reference (Fig. 3). (2) Position fan to assure clearance for radiator top
tank and hose.
S - 82 5 J L ENGINE

manifold.

(Fig. 4). Remove the support bracket/cushion and
heat shields.
CUSHION
BRACKET
J9409-54

Fig, 4 Engine Front Mounts bolts and tighten to 102 N-m (75 ft. lbs.) torque.
(3) Lower engine with support/lifting fixture while 47 N-m (35 ft. lbs.) torque.
(4) Install thru-bolt nuts and tighten the nuts to
102 N-m (75 ft. lbs.) torque. ENGINE ASSEMBLY
(5) Lower the vehicle. REMOVAL
(6) Remove lifting fixture. (1) Remove the battery.
ENGINE REAR 10UNT System for the proper procedure).
REMOVAL
support.
(1) Raise the vehicle on a hoist. (4) Remove the transmission oil cooler.
(2) Position a transmission jack in place. (5) Discharge the air conditioning system, if
(3) Remove support cushion stud nuts (Fig. 6). equipped (refer to Group 24, Heating and Air Condi
(4) Raise rear of transmission and engine tioning for service procedures).
SLIGHTLY. (6) Remove the serpentine belt (refer to Group 7,
(5) Remove the bolts holding the support cushion Cooling System).
to the transmission support bracket. Remove the sup (7) Remove the A/C compressor with the lines at
port cushion. tached. Set aside.
(6) If necessary, remove the bolts holding the (8) If equipped, remove the condenser.
transmission support bracket to the transmission. (9) Remove the washer bottle.
5.9L ENGINE 9-
I - 84 5.9L ENGINE Bit
(11) Remove the fan. (5) Install rear transmission support.

(12) Remove the fan shroud. (j) Install the prop shaft (refer to Group 16, Pro
(13) Disconnect the lower radiator hose. peller Shaft).
(14) Remove radiator (refer to Group 7, Cooling (6) Install the dust shield and transmission cover.
System). (7) Install the starter and connect the starter wires
(15) Remove the generator with the wire connec (refer to Group 8B, Battery/Starter/Generator Ser
tions (refer to Group 8B, Battery/Starter/Generator vice).
Service). (8) Install exhaust pipe to manifold.
(16) Remove the air cleaner. (9) Install the transmission cooler line brackets
(17) Disconnect the throttle linkage. from oil pan.
(18) Remove throttle body. (10) Install engine front mount thru-bolt nuts.
(19) Remove the intake manifold (refer to Group Tighten the nuts.
11, Exhaust System and Intake Manifold). (11) Install the drain plug and tighten to 34 N-m
(20) Remove the distributor cap and wiring. (25 ft. lbs.) torque.
(21) Disconnect the heater hoses. (12) Lower the vehicle.
(22) Disconnect the power steering hoses, if (13) Remove engine lifting fixture.
equipped. (14) On Manual Transmission vehicles, install the
(23) Disconnect the transmission cooler lines. shift lever (refer to Group 21, Transmissions).
(24) Perform the Fuel System Pressure Release (15) Connect the fuel lines.
procedure (refer to Group 14, Fuel System). Discon (16) Connect the transmission cooler lines.
nect the fuel lines. (17) Connect the power steering hoses, if equipped.
(25) On Manual Transmission vehicles, remove the (18) Connect the heater hoses.
shift lever (refer to Group 21, Transmissions). (19) Install the distributor cap and wiring.
(26) Raise and support the vehicle on a hoist. (20) Install the intake manifold (refer to Group 11,
(27) Remove the drain plug and drain the engine Exhaust System and Intake Manifold).
oil. (21) Using a new gasket, install throttle body.
(28) Remove engine front mount thru-bolt nuts. Tighten the throttle body bolts to 23 N-m (200 in.
(29) Remove the transmission cooler line brackets lbs.) torque.
from oil pan.
(22) Connect the throttle linkage.
(30) Disconnect exhaust pipe at manifold.
(31) Disconnect the starter wires. Remove starter (23) Install the air cleaner box.
motor (refer to Group 8B, Battery/Starter/Generator (24) Install the generator and wire connections (re
Service). fer to Group 8B, Battery/Starter/Generator Service).
(32) Remove the dust shield and transmission (25) Install radiator (refer to Group 7, Cooling Sys
cover. tem).
(33) Refer to group 21, Transmissions for transmis (26) Connect the lower radiator hose.
sion removal. (27) Install the fan shroud.
(34) Remove the prop shaft (refer to Group 16, Pro (28) Install the fan.
peller Shaft). (29) Connect the top radiator hose.
(35) Lower the vehicle. (30) Install the washer bottle.
(36) Install a jack stand under the automatic (31) If equipped, install the condenser.
transmission. (32) Install the A/C compressor with the lines at
tached.
manifold.
Cooling System).
(37) Install an engine lifting fixture. (34) Evacuate and charge the air conditioning sys
(38) Remove engine from vehicle and install engine tem, if equipped (refer to Group 24, Heating and Air
assembly on a repair stand. Conditioning for service procedures).
INSTALLATION (36) Install the upper crossmember and top core
(1) Remove engine from the repair stand and posi support.
tion in the engine compartment. Position the thru- (37) Add coolant to the cooling system (refer to
bolt into the support cushion brackets. Group 7, Cooling System for the proper procedure).
(2) Install an engine support fixture. (38) Install the battery.
(3) Raise and support the vehicle on a hoist. (39) Warm engine and adjust.
(4) Refer to Group, 21 Transmissions for transmis (40) Road test vehicle.
sion installation
mm § J L ENGINE I - 85
CYLINDER H E A i COWER ROCKER CYUNDEI

again.
CYLINDER HEAD
COVER GASKET V
J9209-65
Fig. 2 Rocker Arms

INSTALLATION
J9209-105
Fig. 1 Cylinder Head Cower Gasket cover. This mark is located 147° ATDC from the No.l
firing position.
REMOVAL
(1) Disconnect the negative cable from the battery. CAUTION: DO NOT rotate or crank the engine dur
(2) Disconnect closed ventilation system and evap ing or immediately after rocker arm installation. Al
oration control system from cylinder head cover. low the hydraulic roller tappets adequate time to
(8) Remove cylinder head cover and gasket. The bleed down (about 5 minutes).
gasket may be used again.
CLEANING moved.
Clean cylinder head cover gasket surface. (3) Install rocker arm and pivot assemblies in the
Clean head rail, if necessary. same order as removed. Tighten the rocker arm bolts
INSPECTION
(4) Install cylinder head cover.
Inspect cover for distortion and straighten, if nec
(5) Connect spark plug wires.
essary.
Check the gasket for use in head cover installation. VALVE STEM SEAL AND SPRING REPLACEMENT
If damaged, use a new gasket. This procedure is done with the cylinder head in
INSTALLATION stalled.
(1) The cylinder head cover gasket can be used (1) Set engine basic timing to Top Dead Center
again. Install the gasket onto the head rail. (TDC) and remove air cleaner.
(2) Position the cylinder head cover onto the gas (2) Remove cylinder head covers and spark plugs.
ket. Tighten the bolts to 11 N-m (95 in. lbs.) torque. (3) Remove coil wire from distributor and secure to
(3) Install closed crankcase ventilation system and good ground to prevent engine from starting.
evaporation control system. (4) Using suitable socket and flex handle at crank
(4) Connect the negative cable to the battery. shaft retaining bolt, turn engine so the No.l piston is
at TDC on the compression stroke.
VALVE COMPONENTS REPLACE—CYLINDER HEAD (5) Remove rocker arms.
NOT REMOVED (6) With air hose attached to an adapter installed
in No.l spark plug hole, apply 620-689 kPa (90-100
ROCKER ARMS AND PUSH RODS psi) air pressure.
(7) Using Valve Spring Compressor Tool
REMOVAL MD-998772A, compress valve spring and remove re
(1) Disconnect spark plug wires by pulling on the tainer valve locks and valve spring.
boot straight out in line with plug. (8) Install seals on the exhaust valve stem and po
(2) Remove cylinder head cover and gasket. sition down against valve guides.
(3) Remove the rocker arm bolts and pivots (Fig. (9) The intake valve stem seals should be pushed
2). Place them on a bench in the same order as re firmly and squarely over the valve guide using the
moved. valve stem as a guide. DO NOT force seal against top
(4) Remove the push rods and place them on a of guide. When installing the valve retainer locks,
bench in the same order as removed. compress the spring only enough to install the locks.
I - Si 5.9L ENGINE BR
(10) Follow the same procedure on the remaining 7 (17) Remove rocker arm assemblies and push rods.
cylinders using the firing sequence 1-8-4-3-6-5-7-2. Identify to ensure installation in original locations.
Make sure piston in cylinder is at TDC on the valve (18) Remove the head bolts from each cylinder
spring that is being removed. head and remove cylinder heads. Discard the cylin
(11) Remove adapter from the No.l spark plug der head gasket.
hole. (19) Remove spark plugs.
(12) Install rocker arms.
(13) Install covers and coil wire to distributor. CLEANING
(14) Install air cleaner. Clean all surfaces of cylinder block and cylinder
(15) Road test vehicle. heads.
Clean cylinder block front and rear gasket surfaces
CYLINDER HEADS using a suitable solvent.
The alloy cast iron cylinder heads'(Fig. 3) are held
INSPECTION
in place by 10 bolts. The spark plugs are located in
the peak of the wedge between the valves. Inspect all surfaces with a straightedge if there is
The 5.9L cylinder head is identified by the foundry any reason to suspect leakage. If out-of-flatness ex
mark CF. ceeds 0.00075 mm/mm (0.00075 inch/inch) times the
span length in inches in any direction, either replace
EXHAUST SPARK EXHAUST SPARK EXHAUST head or lightly machine the head surface.
' VALVE RUGS VALVES PLUGS VALVE
FOR EXAMPLE: A 305 mm (12 inch) span is
able.
Inspect push rods. Replace worn or bent rods.
INSTALLATION
INTAKE INTAKE
cylinder block.
VALVES VALVES J9309-37
(2) Position the cylinder heads onto head gaskets
and cylinder block.
Fig. 3 Cylinder Head Assembly (3) Starting at top center, tighten all cylinder head
REMOVAL bolts, in sequence, to 68 N-m (50 ft. lbs.) torque (Fig.
(1) Disconnect the negative cable from the battery. 4). Repeat procedure, tighten all cylinder head bolts
(2) Drain cooling system (refer to Group 7, Cooling to 143 N-m (105 ft. lbs.) torque. Repeat procedure to
System for the proper procedures). confirm that all bolts are at 143 N-m (105 ft. lbs.)
(3) Remove the intake manifold-to-generator torque.
bracket support rod. Remove the generator.
(4) Remove closed crankcase ventilation system.
(5) Disconnect the evaporation control system.
(7) Disconnect the fuel lines.
(8) Disconnect accelerator linkage and if so
down cables.
(9) Remove the return spring.
(10) Remove distributor cap and wires.
(11) Disconnect the coil wires.
(12) Disconnect heat indicator sending unit wire.
(13) Disconnect heater hoses and bypass hose.
(14) Remove cylinder head covers and gaskets.
(15) Remove intake manifold and throttle body as
an assembly. Discard the flange side gaskets and the
front and rear cross-over gaskets.
(16) Remove exhaust manifolds. Fig. 4 Cylinder Head Bolt Tightening Sequence
5.9L ENGINE 9 - 87
CAUTION: When tightening the rocker arm bolts, (4) Before removing valves, remove any burrs from
make sure the piston in that cylinder is NOT at valve stem lock grooves to prevent • damage to the
TDC. Contact between the valves and piston could valve guides. Identify valves to ensure installation in
occur. original location.
(5) Install push rods and rocker arm assemblies in VALVE CLEANING
their original position. Tighten the bolts to 28 N-m Clean valves thoroughly. Discard burned, warped
(21 ft. lbs.) torque. and cracked valves.
(6) Install the intake manifold and throttle body Remove carbon and varnish deposits from inside of
assembly (refer to Group 11, Exhaust System and In valve guides with a reliable guide cleaner.
take Manifold). VALVE INSPECTION
(7) Install exhaust manifolds. Tighten the bolts
(8) Adjust spark plugs to specifications (refer to
Group 8D, Ignition System). Install the plugs and VALVE GUIBES .
tighten to 41 N-m (30 ft. lbs.) torque. Measure valve stem guide clearance as follows:
(9) Install coil wires. (a) Install Valve Guide Sleeve Tool C-3973 over
(10) Connect heat indicator sending unit wire. valve stem and install valve (Fig. 5). The special
(11) Connect the heater hoses and bypass hose. sleeve places the valve at the correct height for
(12) Install distributor cap and wires. checking with a dial indicator.
(13) Hook up the return spring.
down cables.
(18) Place the cylinder head cover gaskets in posi Fig. 5 Positioning Valve with Tool C-3973
tion and install cylinder head covers. Tighten the (b) Attach Dial Indicator Tool C-3339 to cylinder
bolts to 11 N-m (95 in. lbs.) torque. head and set it at right angle of valve stem being
(19) Install dosed crankcase ventilation system. measured (Fig. 6).
(20) Connect the evaporation control system.
(21) Install the air cleaner.
(22) Install the heat shields. Tighten the bolts to
41 N»m (30 ft, lbs.) torque.
System for proper procedure).
WilWES AND WALfE SPRINGS
The valves are arranged in-line and inclined 18°.
The rocker pivot support and the valve guides are
cast integral with the heads.
head.
REMOVAL
(2) Compress valve springs using Valve Spring Fig. 6 Measuring Waive Guide Wear
Compressor Tool MD-998772A. (c) Move valve to and from the indicator. The to
(3) Remove valve retaining locks, valve spring re tal dial indicator reading should not exceed 0.432
tainers, valve stem seals and valve springs. mm (0.017 inch). Ream the guides for valves with
9 - 88 5.9L ENGINE BR
oversize stems if dial indicator reading is excessive

or if the stems are scuffed or scored.
Service valves with oversize stems are available EXHAUST
INTAKE
(Fig. 7). VALVE
VALVE
Inner O/S Valve Guide Size
0.076 ram 8.026 - 8.052 mm

(0.003 in.) (0.316 -0.317 in.)
0.381 mm 8.331 -8.357 mm

(0.0151a) (0.328-0.329 in.)
VALVE SPRING
RETAINER LOCK
GROOVE
_\ J09-30
J9209-127
Fig. 7 Reamer Sizes
Slowly turn reamer by hand and clean guide thor Fig. 9 Intake and Exhaust Valves
oughly before installing new valve. Ream t h e valve
VALVE SEATS
guides from standard t© 0.381 m m (0.015 Inch).
Use a 2 step procedure so t h e valve guides a r e CAUTION: DO NOT un-shroud waives during valve
reamed true in relation to t h e valve seats seat refacing (Fig. 10).
• Step 1—Ream to 0.0768 mm (0.008 inch).
• Step 2—Ream to 0.381 mm (0,015 inch). A
,REFACING STONE
REFACING VALVES AND VALVE SEATS MUST NOT CUT
The intake and exhaust valves have a 43-1/4° to VALVE SHROUD
(Fig. 8).
CONTACT
POINT
/ / :0 ; 0 / tt
l Jit
:
s/j'L' WIS
RK635
Fig. 10 Refacing Valve Seats

(1) When refacing valve seats, it is important that
ing stones. A true and complete surface must be ob
tained.
(2) Measure the concentricity of valve seat using a
A - SEAT WIDTH - INTAKE 1.016-1.524 mm (0.040 - 0.060 in.| dial indicator. Total runout should not exceed 0.051
EXHAUST 1.524 - 2.032 mm (0.060 - 0.080 in.)
B - FACE ANGLE (INTAKE & EXHAUST) 437.° - 43 /4°
3 mm (0.002 inch) total indicator reading.
C - SEAT ANGLE (INTAKE I EXHAUST) 44V/ - 44 //3
(3) Inspect the valve seat with Prussian blue to de
D - CONTACT SURFACE
termine where the valve contacts the seat. To do this,
J9309-95 coat valve seat LIGHTLY with Prussian blue then set
valve in place. Rotate the valve with light pressure.
Fig. 8 Valve Face and Seat Angles If the blue is transferred to the center of valve face,
WftlWES contact is satisfactory. If the blue is transferred to
Inspect the remaining margin after the valves are the top edge of valve face, lower valve seat with a 15°
refaced (Fig. 9). Valves with less than 1.190 mm stone. If the blue is transferred to bottom edge of
(0.047 inch) margin should be discarded. valve face raise valve seat with a 60° stone.
BR S J L ENGINE 9 - SI
(4) When seat is properly positioned the width of terbore. This should bring spring height back to nor
intake seats should be 1.016-1.524 mm (0.040-0.060 mal 41.27 to 42.86 mm (1-5/8 to 1-11/16 inch).
inch). The width of the exhaust seats should be
1.524-2.082 mm (0.060-0.080 inch). HYDRAULIC TAPPETS
Before disassembling any part of the engine to cor
VALVE SPRING INSPECTION rect tappet noise, check the oil pressure. If vehicle
Whenever valves have been removed for inspection, has no oil pressure gauge, install a reliable gauge at
reconditioning or replacement, valve springs should the pressure sending unit. The pressure should be
be tested. As an example the compression length of between 207-552 kPa (30-80 psi) at 3,000 RPM.
the spring to be tested is 1-5/16 inch. Turn table of Check the oil level after the engine reaches normal
Universal Valve Spring Tester Tool until surface is in operating temperature. Allow 5 minutes to stabilize
line with the 1-5/16 inch mark on the threaded stud. oil level, check dipstick.
Be sure the zero mark is to the front (Fig. 11). Place The oil level in the pan should never be above the
spring over stud on the table and lift compressing le FULL mark or below the ADD OIL mark on dipstick.
ver to set tone device. Pull on torque wrench until Either of these 2 conditions could be responsible for
ping is heard. Take reading on torque wrench at this noisy tappets.
instant. Multiply this reading by 2. This will give the
spring load at test length. Fractional measurements OIL L E V E L
are indicated on the table for finer adjustments. Re HIGH
lowable tensions. Discard the springs that do not If oil level is above the FULL mark, it is possible
meet specifications.
engine running this condition could create foam in
LOW
When air is fed to the tappets, causes them to lose
length and allows valves to seat noisily. Any leaks on
intake side of oil pump through which air can be
drawn will create the same tappet action. When tap
pet noise is due to aeration, it may be intermittent or
engine should be operated at fast idle for sufficient
time. This allows all of the air inside of the tappets
to be bled out.
Fig. 11 Testing Valve Spring for Compressed Length
TAPPET NOISE DIAGNOSIS
INSTALLATION (1) To determine source of tappet noise, operate en
(1) Coat valve stems with lubrication oil and insert gine at idle with cylinder head covers removed.
them in cylinder head. (2) Feel each valve spring or rocker arm to detect
(2) If valves or seats are reground, check valve noisy tappet. The noisy tappet will cause the affected
stem height. If valve is too long, replace cylinder spring and/or rocker arm to vibrate or feel rough in
head. operation.
(3) Install new seals on all valve guides. Install Worn valve guides or cocked springs are
valve springs and valve retainers. sometimes mistaken for noisy tappets. If such is
(4) Compress valve springs with Valve Spring the case, noise may be dampened by applying
Compressor Tool MD-998772A, install locks and re side thrust on the valve spring. If noise is not
lease tool. If valves and/or seats are ground, measure appreciably reduced, it can be assumed the
the installed height of springs. Make sure the mea noise is in the tappet. Inspect the rocker arm
surement is taken from bottom of spring seat in cyl push rod sockets and push rod ends for wear.
inder head to the bottom surface of spring retainer. If (3) Valve tappet noise ranges from light noise to a
spacers are installed, measure from the top of spacer. heavy click. A light noise is usually caused by exces
If height is greater than 42.86 mm (1-11/16 inches), sive leak-down around the unit plunger or by the
install a 1.587 mm (1/16 inch) spacer in head coun- plunger partially sticking in the tappet body cylinder.
S - II SJ L EiiiiE in
The tappet should be replaced. A heavy click is valve seat on end of plunger is prevented from seat
caused by a tappet check valve not seating or by for ing, install a new tappet assembly,
eign particles becoming wedged between the plunger (4) Assemble tappets (Fig, 12).
and the tappet body. This will cause the plunger to
valve stem and rocker arm as valve closes, in either
case, tappet assembly should be removed for inspec
tion and cleaning.
The valve train generates a noise very much like a
light tappet noise during normal operation. Care
must be taken to ensure that tappets are making the SPRING CAP J9109-220
noise. In general, if more than one tappet seems to
be noisy, its probably not the tappets. Fig. 12 Hydraulic Tappet Assembly
INSTALLATION
REMOVAL
(1) Lubricate tappets,
(1) Remove the air cleaner. (2) Install tappets and push rods in their original
(2) Remove cylinder head cover. positions. Ensure that the oil feed hole in the side of
(3) Remove rocker assembly and push rods. Iden the tappet body faces up (away from the crankshaft).
tify push rods to ensure installation in original loca (3) Install rocker arm and shaft assembly.
tion. (4) install vent cover.
(4) Remove intake manifold. (5) Install distributor, start engine and reset tim
(5) Remove yoke retainer and aligning yokes. ing.
(6) Slide Hydraulic Tappet Remover/Installer Tool
C-4129-A through opening in cylinder head and seat CAUTION; To prevent damage to valve mechanism,
tool firmly in the head of tappet. engine must not be run above fast idle until all hy
(7) Pull tappet out of bore with a twisting motion. draulic tappets have filled with oil and have become
If all tappets are to be removed, identify tappets to quiet.
ensure installation in original location,
(8) If the tappet or bore in cylinder block is scored,
scuffed, or shows signs of sticking, ream the bore to VALVE TIMING
next oversize. Replace with oversize tappet. (1) Turn crankshaft until the No.6 exhaust valve is
closing and No.6 intake valve is opening.
CAUTION: The plunger and tappet bodies are not (2) Insert a 6.350 mm (1/4 inch) spacer between
interchangeable. The plunger and valve must al rocker arm pad and stem tip of No.l intake valve. Al
ways- be fitted to the original body. It is advisable to low spring load to bleed tappet down giving in effect
work on one tappet at a time to avoid mixing of a solid tappet.
parts.'Mixed parts are not compatible. DO NOT dis (3) Install a dial indicator so plunger contacts
assemble a tappet on a dirty work bench, valve spring retainer as nearly perpendicular as pos
sible. Zero the indicator.
DISASSEMBLE (4) Rotate the crankshaft clockwise (normal run
(1) Pry out plunger retainer spring clip (Fig. 12). ning direction) until the valve has lifted 0.863 mm
(2) Clean varnish deposits from inside of tappet (0.034 inch). The timing of the crankshaft should
body above plunger cap. now read from 10° before top dead center to 2° after
(8) Invert tappet body and remove plunger cap, top dead center. Remove spacer. .
plunger, check valve, check valve spring, check valve CAUTION; D O NOT turn crankshaft any further
retainer and plunger spring (Fig. 12). Check valve clockwise as valve spring might bottom and result
could be flat or ball.
in serious damage.
ASSEMBLE
(1) Clean all tappet parts in a solvent that will re (5) If reading is not within specified limits:
move all varnish and carbon. (a) Check sprocket index marks.
(2) Replace tappets that are unfit for further ser (b) Inspect timing chain for wear.
vice with new assemblies. (c) Check accuracy of DC mark on timing indica
(3) If plunger shows signs of scoring or wear, in tor.
stall a new tappet assembly. If valve is pitted, or
BR S J L ENGINE 9 - 91
VIBRATION DAMPER (7) Position the fan shroud and install the bolts.
Tighten the retainer bolts to 11 N-m (95 in. lbs.)
REMOVAL torque.
(1) Disconnect the negative cable from the battery. (8) Connect the negative cable to the battery.
shroud back over engine. TIMING CHAIN COVER
(3) Remove the cooling system fan. mEMOVAl
(4) Remove the serpentine belt (refer to Group 7, (1) Disconnect the negative cable from the battery.
Cooling System). (2) Drain cooling system (refer to Group 7, Cooling
(5) Remove the vibration damper pulley. System).
(6) Remove vibration damper bolt and washer from (3) Remove the serpentine belt (refer to Group 7,
end of crankshaft. Cooling System).
(7) Install bar and screw from Puller Tool Set (4) Remove water pump (refer to Group 7, Cooling
C-3688. Install 2 bolts with washers through the
System).
puller tool and into the vibration damper (Fig. 1).
(5) Remove power steering pump (refer to Group
19, Steering).
at each side.
damage the crankshaft seal bore of cover (Fig. 3).
(8) Pull vibration damper off of the crankshaft.
INSTALLATION
(1) Position the vibration damper onto the crank
shaft.
(2) Place installing tool, part of Puller Tool Set
C-3688 in position and press the vibration damper
onto the crankshaft (Fig. 2).
Fig. 3 Removal of Front Crankshaft Oil Seal

TIMING CHAIN STRETCH
any movement of the chain may be measured.
(2) Place a torque wrench and socket over cam
shaft sprocket attaching bolt. Apply torque in the di
rection of crankshaft rotation to take up slack; 4 1
N-m (30 ft. lbs.) torque with cylinder head installed
moved. With a torque applied to the camshaft
Fig. 2 Installing Vibration Damper sprocket bolt, crankshaft should not be permitted to
(3) Install the crankshaft bolt and washer. Tighten move. It may be necessary to block the crankshaft to
the bolt to 183 N-m (135 ft. lbs.) torque. prevent rotation.
(4) Install the crankshaft pulley. Tighten the pul (3) Hold a scale with dimensional reading even
ley bolts to 23 N-m (200 in. lbs.) torque. with the edge of a chain link. With cylinder heads in
(5) Install the serpentine belt (refer to Group 7, stalled, apply 14 N-m (30 ft. lbs.) torque in the re
Cooling System). verse direction. With the cylinder heads removed,
(6) Install the cooling system fan. Tighten the bolts apply 20 N-m (15 ft. lbs.) torque in the reverse direc
to 23 N-m (17 ft. lbs.) torque. tion. Note the amount of chain movement (Fig. 4).
9 - 92 5JL ENGINE BR
INSTALLATION
time.
J9409-96 Front Oil Seal Installation Tool 6635 (Fig. 6). Seat
Fig. 4 Measuring Timing Chain Wear and Stretch CRANKSHAFT fc INSTALL THIS
(4) Install a new timing chain, if its movement ex FRONT OIL END INTO
SEAL SPECIAL TOOL
ceeds 8.175 mm (1/8 inch). 6635
(5) If chain is not satisfactory, remove camshaft
sprocket attaching bolt and remove timing chain with
crankshaft bores.
shaft sprocket. J9309-44
(9) Lift sprockets and chain (keep sprockets tight
against the chain in position as described). Fig. 6 Placing Oil Seal on Installation Tool 6635
(10) Slide both sprockets evenly over their respec (3) Position the seal and tool onto the crankshaft
tive shafts and use a straightedge to check alignment (Fig. 7).
of timing marks (Fig. 5). (4) Tighten the 4 lower chain case cover bolts to
13N-m (10 ft.lbs.) to prevent the cover from tipping
during seal installation.
OIL
SEAL
TIMING J9409-97
MARKS
Fig. 5 Alignment of Timing Marks
(11) install the camshaft bolt. Tighten the bolt to
(12) Check camshaft end play. The end play should
thrust plate and up to 0.254 mm (0.010 inch) with a
used thrust plate. If not within these limits install a
new thrust plate.
CLEANING TIMING'
Be sure mating surfaces of chain case cover and CHAIN
COVER J9309-45*
cylinder block are clean and free from burrs.
The water pump mounting surface must be Fig. 7 Position Tool and Seal onto Crankshaft
cleaned.
mm — — — S J L ENGINE S - 93
(5) Using the vibration damper bolt, tighten the (3) If front seal is suspected of leaking, check front
bolt to draw the seal into position on the crankshaft oil seal alignment to crankshaft. The seal installa
(Fig, 8). tion/alignment tool 6635, should fit with minimum
(6) Loosen the 4 bolts tightened in step 4 to allow interference. If tool does not fit, the cover must be re
realignment of front cover assembly. moved and installed properly.
(7) Tighten chain case cover bolts to 41 N-m (30 (4) Place a suitable tool behind the lips of the oil
ft.lbs.) torque. Tighten oil pan bolts to 24 N-m (215 seal to pry the oil seal outward. Be careful not to
in. lbs.) torque. damage the crankshaft seal surface of cover.
(6) Position the seal and tool onto the crankshaft
(Fig. 7).
(Fig. 8).
stallation tool.
CAMSHAFT
THRUST
PLATE
J9309-46
OIL PUMP AND
Fig. 8 Installing OII Seal DISTRIBUTOR DRIVE
GEAR INTEGRAL
(8) Remove the vibration damper bolt and seal in WITH CAMSHAFT
stallation tool.
* CAMSHAFT SPROCKET
(10) Install vibration damper. J9309-71

Fig. 9 Camshaft and Sprocket Assembly
ing new gaskets (refer to Group 7, Cooling System).
Tighten bolts to 41 N-m (30 ft. lbs.) torque. MEMOVAL
(12) Install power steering pump (refer to Group (1) Remove intake manifold.
19, Steering). (2) Remove cylinder head covers.
(13) Install the serpentine belt (refer to Group 7, (3) Remove timing case cover and timing chain.
Cooling System). (4) Remove rocker arms.
(14) Install the cooling system fan. Tighten the (5) Remove push rods and tappets. Identify each
bolts to 23 N-m (17 ft. lbs.) torque. part so it can be installed in its original location.
(15) Position the fan shroud and install the bolts. (6) Remove distributor and lift out the oil pump
Tighten the bolts to 11 N-m (95 in. lbs.) torque. and distributor drive shaft.
(16) Fill cooling system (refer to Group 7, Cooling (7) Remove camshaft thrust plate, note location of
System for the proper procedure). oil tab (Fig, 10).
(17) Connect the negative cable to the battery. (8) Install a long bolt into front of camshaft to facil
itate removal of the camshaft. Remove camshaft, being
FRONT CRANKSHAFT OIL SEAL REPLACEMENT careful not to damage cam bearings with the cam lobes.
The oil seal can be replaced without removing the REMOVAL—BEARING
timing chain cover provided the cover is not mis This procedure requires that the engine is removed
aligned. from the vehicle.
(1) Disconnect the negative cable from the battery. (1) With engine completely disassembled, drive out
(2) Remove vibration damper. rear cam bearing core hole plug.
I - 94 5JL ENGINE
INSTALLATION
gine for a minimum of 805 km (500 . miles).
(2) Install Camshaft Gear Installer Tool C-3509
Fig. 10 Timing Chain Oii Tab Installation

washers (part of Camshaft Bearing Remover/Installer Fig. 12 Camshaft Holding Tool C-3509—Installed
Tool C-3132-A) at back of each bearing shell. Drive Position
out bearing shells (Fig. 11).
pushed in too far and prevent knocking out the welch
installed until the camshaft and crankshaft
sprockets and timing chain have been installed.
Fig. 11 Camshaft Beatings Removal and Installation sprocket on the bench with timing marks on exact
with Tool O'3132-A imaginary center line through both camshaft and
INSTALLATION—BEARING
crankshaft bores.
(1) Install new camshaft bearings with Camshaft (6) Place timing chain around both sprockets.
Bearing Remover/Installer Tool C-3132-A by sliding (7) Turn crankshaft and camshaft to line up with
the new camshaft bearing shell over proper adapter. keyway location in crankshaft sprocket and in cam
(2) Position rear bearing in the tool. Install horse shaft sprocket.
shoe lock and by reversing removal procedure, care (8) Lift sprockets and chain (keep sprockets tight
fully drive bearing shell into place. against the chain in position as described).
(3) Install remaining bearings in the same manner. (9) Slide both sprockets evenly over their respec
Bearings must be carefully aligned to bring oil holes tive shafts and use a straightedge to check alignment
into full register with oil passages from the main of timing marks (Fig. 13).
bearing. If the camshaft bearing shell oil holes are (10) Install the camshaft bolt/cup washer. Tighten
not in exact alignment, remove and install them cor bolt to 68 N-m (50 ft. lbs.) torque.
rectly. Install a new core hole plug at the rear of (11) Measure camshaft end play. Refer to Specifica
camshaft. Be sure this plug does not leak. tions for proper clearance. If not within limits, install
a new thrust plate.
Fig. 13 Alignment of Timing Marks Fig. 15 Distributor Driveshaft Bushing Installation
(12) Each tappet reused must be installed in the CAUTION: This procedure MUST be followed when
same position from which it was removed. When installing a new bushing or seizure to shaft may oc
camshaft is replaced, all of the tappets must be cur.
replaced.
DISTRIBUTOR BUSHING
DISTRIBUTER REMOVAL
REMOVAL
procedure.
REMOVAL—DRIVE SHAFT BUSHING
(1) Remove the intake manifold (refer to Group 11,
Exhaust System and Intake Manifold). Fig. 16 Burnishing Distributor Driveshaft Bushing
(2) Insert Distributor Drive Shaft Bushing Puller (4) Install the intake manifold (refer to Group 11,
Tool C-3052 into old bushing and thread down until a Exhaust System and Intake Manifold).
tight fit is obtained (Fig. 14).
(3) Hold puller screw and tighten puller nut until DISTRIBUTOR INSTALLATION
bushing is removed. Refer to the Component Removal/Installation sec
tion of Group 8D, Ignition Systems for the proper
procedure. See Distributor. After the distributor has
been installed, its rotational position must be set us
ing the SET SYNC mode of the DRB scan tool. Refer
to Checking Distributor Position following the Dis
tributor Installation section in Group 8D, Ignition
system. Do not attempt to adjust ignition timing
by rotating the distributor. It has no effect on
ignition timing. Adjusting distributor position
Before installing the distributor, the oil pump drive
Fig. 14 Distributor Driveshaft Bushing Removal shaft must be aligned to number one cylinder.
(1) Rotate crankshaft until No.l cylinder is at top
INSTALLATION—DRIVE SHAFT BUSHING
(1) Slide new bushing over burnishing end of Dis (2) When in this position, the timing mark on vi
tributor Drive Shaft Bushing Driver/Burnisher Tool bration damper should be under 0 on the timing in
C-3053. Insert the tool and bushing into the bore. dicator.
(2) Drive bushing and tool into position, using a (3) Install the shaft so that after the gear spirals
hammer (Fig. 15). into place, it will index with the oil pump shaft. The
(3) As the burnisher is pulled through the bushing, slot on top of oil pump shaft should be aligned to
the bushing is expanded tight in the block and bur wards left front intake manifold attaching bolt hole
nished to correct size (Fig. 16). DO NOT ream this (Fig. 17).
bushing.
I - IS 5 J L ENGINE in
DISTRIBUTOR DRIVE 5/16" x 17/BOLT
DOWEL
SLOT J9509-163

Fig. 17 Position of Oii Pump Shaft Slot
DOWEL DOWEL
OIL PAN
REMOVAL
(8) Raise vehicle.
cushion thru-bolt and raise the engine slightly. Re
move oil pan by sliding backward and out.
CLEANING
Clean the block and pan gasket surfaces.
Trim or remove excess sealant film in the rear
main cap oil pan gasket groove. DO NOT remove
the sealant inside the r e a r main cap slots.
If present, trim excess sealant from inside the en
gine. DOWEL// J9309-79
Clean oil pan in solvent and wipe dry with a clean
cloth. Fig. 2 Position of Dowels in Cylinder Block
Clean oil screen and pipe thoroughly in clean sol (5) Position the oil pan over the dowels and onto
vent. Inspect condition of screen. the gasket.
(6) Install the oil pan bolts. Tighten the bolts to 24
INSPECTION
Inspect oil drain plug and plug hole for stripped or (7) Remove the dowels. Install the remaining oil
damaged threads. Repair as necessary.
pan bolts. Tighten these bolts to 24 N-m (215 in. lbs.)
inspect oil pan mounting flange for bends or distor
tion. Straighten flange, if necessary. torque.
(8) Lower the engine into the support cushion
INSTALLATION brackets and tighten the thru-bolt to the proper
(1) Fabricate 4 alignment dowels from 5/16 x 1 1/2 torque.
inch bolts. Cut the head off the bolts and cut a slot (9) Install the drain plug. Tighten drain plug to 34
into the top of the dowel. This will allow easier in N-m (25 ft. lbs.) torque.
stallation and removal with a screwdriver (Fig. 1). (10) Install the engine to transmission strut.
(2) Install the dowels in the cylinder block (Fig. 2). (11) Install exhaust pipe.
(3) Apply small amount of Mopar® Silicone Rubber (12) Lower vehicle.
Adhesive Sealant, or equivalent in the corner of the (13) Install dipstick.
cap and the cylinder block. (14) Connect the negative cable to the battery.
(4) Slide the one-piece gasket over the dowels and (15) Fill crankcase with oil to proper level.
onto the block.
A gear—type positive displacement pump is passes through the hole when the rods rotate and the
mounted at the underside of the rear main bearing hole lines up, oil is then thrown off as the rod ro
cap. The pump draws oil through the screen and in tates. This oil throwoff lubricates the camshaft lobes,
let tube from the sump at the rear of the oil pan. The distributor drive gear, cylinder walls, and piston
oil is driven between the drive and idler gears and pins.
pump body, then forced through the outlet to the The hydraulic valve tappets receive oil directly
block. An oil gallery in the block channels the oil to from the main oil gallery. The camshaft bearings re
the inlet side of the full flow oil filter.-After passing ceive oil from the main bearing galleries. The front
through the filter element, the oil passes from the camshaft bearing journal passes oil through the cam
center outlet of the filter through an oil gallery that shaft sprocket to the timing chain. Oil drains back to
channels the oil up to' the main gallery which ex the oil pan under the number one main bearing cap.
tends the entire length on the right side of the block. The oil supply for the rocker arms and bridged
The oil then goes down to the No. 1 main bearing, pivot assemblies is provided by the hydraulic valve
back up to the left side of the block and into the oil tappets which pass oil through hollow push rods to a
gallery on the left side of the engine. hole in the corresponding rocker arm. Oil from the
Galleries extend downward from the main oil gal rocker arm lubricates the valve train components.
lery to the upper shell of each main; bearing. The The oil then passes down through the push rod guide
crankshaft is drilled internally to pass oil from the holes, and the oil drain back passages in the cylinder
main bearing journals to the connecting rod journals. head past the valve tappet area, and returns to the
Each connecting rod bearing has half a hole in it, oil oil pan.
CO

OIL P O I P INNER.:ROTOR DI5JMBUIOR" DRIVESH"AFT
OIL PUMP PRESSURE

The MINIMUM oil pump pressure is 41.4 kPa (6
psi) at curb idle. The MAXIMUM oil pump pressure
is 207-552 kPa (30-80 psi) at 8,000' RPM or more.
CAUTION: if oii pressure is Z E R O at curb idle, DO

NOT run engine at 3,000 R P M .
REMOVAL ::CHAMFERED '

(1) Remove the oil pan. EDGE RY10B
(2) Remove the oil pump from rear main bearing Fig. 5 Oil Pump
cap.
DISASSEMBLE
(1) Remove the relief valve as follows:
(a) Remove cotter pin. Drill a 3.175 mm (1/8
inch) hole Into the relief valve retainer cap and in
sert a self-threading sheet metal screw.
(b) Clamp screw into a vise and while supporting
oil pump, remove cap by tapping pump body using
a soft hammer. Discard retainer cap and remove
spring and relief valve (Fig. 4).
Fig. 6 Checking Oil Pump Cover Flatness

Measure thickness and diameter of OUTER rotor.
If outer rotor thickness measures 20.9 mm (0.825
inch) or less or if the diameter is 62.7 mm (2.469
inches) or less, replace outer rotor (Fig. 7).
Fig. 4 Oii Pressure Relief Valve

(2) Remove oil pump cover (Fig. 5).
(3) Remove pump outer rotor and inner rotor with
shaft (Fig. 5).
(4) Wash all parts in a suitable solvent and inspect
Fig. 7 Measuring Outer Rotor Thickness
INSPECTION If inner rotor measures 20.9 mm (0.825 inch) or
Mating surface of the oil pump cover should be less, replace inner rotor and shaft assembly (Fig. 8).
smooth. Replace pump assembly if cover is scratched Slide outer rotor into pump body. Press rotor to the
or grooved. side with your fingers and measure clearance be
Lay a straightedge across the pump cover surface tween rotor and pump body (Fig. 9). If clearance is
(Fig. 6). If a 0.088 mm (0.0015 inch) feeler gauge can 0.356 mm (0.014 inch) or more, replace oil pump as
be inserted between cover-and sembly.
straightedge, pump assembly should be replaced.
9 - 100 5 J L ENGINE BR
Fig. 11 Measuring Clearance Over Rotors
Fig. 8 Measuring inner Rotor Thickness Inspect oil pressure relief valve plunger for scoring
and free operation in its bore. Small marks may be
imately 49.5 mm (1.95 inches). The spring should
test between 19.5 and 20.5 pounds when compressed
to 34 mm (1-11/32 inches). Replace spring that fails
to meet these specifications (Fig. 12).
Fig. 9 Measuring Outer Rotor Clearance In Housing

Install inner rotor and shaft into pump body, if
clearance between inner and outer rotors is 0.208
mm (0.008 inch) or more, replace shaft and both ro
tors (Fig. 10).
RN98
Fig. 12 Proper Installation of Retainer Cap

MSSEmBLE
(1) Install pump rotors and shaft, using new parts
as required.
(2) Position the oil pump cover onto the pump
body. Tighten cover bolts to 11 N-m (95 in. lbs.)
torque.
(3) Install the relief valve and spring. Insert the
cotter pin.
Fig. 10 Measuring Clearance Between Rotors
(4) Tap on a new retainer cap.
Place a straightedge across the face of the pump, (5) Prime oil pump before installation by filling ro
between bolt holes, if a feeler gauge of 0.102 mm tor cavity with engine oil.
(0.004 inch) or more can be inserted between rotors
and the straightedge, replace pump assembly (Fig. INSTALLATION
11). (1) Install oil pump. During installation slowly ro
tate pump body to ensure driveshaft-to-pump rotor
shaft engagement.
BR 5.9L ENGINE 9 -101
(2) Hold the oil pump base flush against mating PISTON PIN BORE DIAMETER
surface on No.5 main bearing cap. Finger tighten
pump attaching bolts. Tighten attaching bolts to 41
PISTON ANi CONNECTING ROi ASSEMBLY

The pistons are elliptically turned so that the di
ameter at the pin boss is less than its diameter
across the thrust face. This allows for expansion un
der normal operating conditions. Under operating
temperatures, expansion forces the pin bosses away
from each other, causing the piston to assume a more
nearly round shape.
All pistons are machined to the same weight, re
gardless of size, to maintain piston balance.
The piston pin rotates in the piston only and is re
tained by the press interference fit of the piston pin
in the connecting rod.
A
REMOVAL PISTON A DIA = PISTON DIAMETER BORE DIAMETER
SIZE MIN. mm (IN.) M A I .ram(IN.) MIN. mm (IN.) MAX. KM (IN.)
(1) Remove the engine from the vehicle. A
(2) Remove the cylinder head. B 101.580 (3.9992) 101.592(3.9997) 101.605(4.0002} 101.618(4.0007)
(3) Remove the oil pan. C 101.592 (3.9997) 101.605(4.0002) 101.618(4.0007} 101.630(4.0012)
(4) Remove top ridge of cylinder bores with are li D 101.605 (4.0002) 101.618(4.0007) 101.630 (4.0012) 101.643 (4.0017)
E
able ridge reamer before removing pistons from cyl
inder block. Be sure to keep tops of pistons covered 39509-79
during this operation.
(5) Be sure the connecting rod and connecting rod FITTING RINGS
cap are identified with the cylinder number. Remove (1) Measurement of end gaps:
connecting rod cap. Install connecting rod bolt guide (a) Measure piston ring gap 2 inches from bot
set on connecting rod bolts. tom of cylinder bore. An inverted piston can be
(6) Pistons and connecting rods must be removed used to push the rings down to ensure positioning
from top of cylinder block. When removing piston and rings squarely in the cylinder bore before measur
connecting rod assemblies, rotate crankshaft center ing.
the connecting rod in the cylinder bore and at BDC.
Be careful not to nick crankshaft journals. (b) Insert feeler stock in the gap. The compres
(7) After removal, install bearing cap on the mat sion ring gap should be between 0.254-0.508 mm
ing rod. (0.010-0.020 inch). The second compression ring
• gap should be between 0.508-0.762 mm (0.020-
INSPECTION 0.030 inch). The oil ring gap should be 0.254-1.270
Check the crankshaft connecting rod journal for ex mm (0.010-0.050 inch).
cessive wear, taper and scoring. (c) Rings with insufficient end gap may be prop
Check the cylinder block bore for out-of-round, erly filled to the correct dimension. Rings with ex
taper, scoring and scuffing. cess gaps should not be used.
Check the pistons for taper and elliptical shape be (2) Install rings and confirm ring side clearance:
fore they are fitted into the cylinder bore (Fig. 1). (a) Install oil rings being careful not to nick or
FITTING PISTONS cording to instructions in the package. It is not nec
Piston and cylinder wall must be clean and dry. essary to use a tool to install the upper and lower
Specified clearance between the piston and the cylin rails. Insert oil rail spacer first, then side rails.
der wall is 0.013-0.038 mm (0.0005-0.0015 inch). (b) Install the second compression rings using In
Piston diameter should be measured at the top of stallation Tool C-4184. The compression rings must
skirt, 90° to piston pin axis. Cylinder bores should be be installed with the identification mark face up
measured halfway down the cylinder bore and trans (toward top of piston) and chamfer facing down. An
verse to the engine crankshaft center line. identification mark on the ring is a drill point, a
Pistons and cylinder bores should be measured at stamped letter O, an oval depression or the word
normal room temperature, 2PC (70°F). TOP (Figs. 2 and 4).
9 - 102 5.9L ENGINE
SECOND COMPRESSION RING (3) Arrange r i n g gaps 180° apart as shown i n F i g .

CHAMFER
(BLACK CAST IRON) 5.
OIL RING
SPACER GAP
SECOND
. TOP COMPRESSION
COMPRESSION RING GAP
RING GAP OIL RING RAIL
TWO GAP (TOP)
DOTS J9009-46
Fig. 2 Second Compression Ring Identification

(Typical)
(c) Using a r i n g installer, install the top compres OIL R I N G RAIL
sion r i n g w i t h the chamfer facing u p (Fig. 3). A n GAP (BOTTOM) J9309-80
identification m a r k on the r i n g is a d r i l l point, a

stamped letter O , an oval depression or the word Fig. S Proper Ring Installation
T O P facing up. CONNECTING ROD BEAMINGS
Fit all rods on a bank until completed. DO NOT al
TOP C O M P R E S S I O N R I N G
(GRAY I N COLOR) ternate from one bank to another, because connecting
rods and pistons are not interchangeable from one
CHAMFER bank to another.
The bearing caps are not interchangeable and
should be marked at removal to ensure correct as
sembly.
Each bearing cap has a small V-groove across the
parting face. When installing the lower bearing shell,
make certain that the V-groove in the shell is in line
J9009-48 tion of the cylinder wall in the opposite bank.
Fig. 3 Top Compression Ring Identification (Typical)
The bearing shells must be installed so that the
tangs are in the machined grooves in the rods and
CHAMFER V.PRESSION caps.
. HG Limits of taper or out-of-round on any crankshaft
journals should be held to 0.025 m m (0.001 inch).
. .1 Bearings are available in 0.025 m m (0.001 inch),
0.051 m m (0.002 inch), 0.076 m m (0.003 inch), 0.254
m m (0.010 inch) and 0.305 m m (0.012 inch) under
SECOND size. Install the bearings in pairs. DO NOT use a
* COMPRESSION new bearing half with an old bearing half* DO
RING
NOT file t h e rods or bearing caps.
* PISTON J9409-37 INSTALLATION

Fitx 4 Ion Ring Chamfer Location gered so that neither is in line with oil ring rail gap.
(Typical)
(2) Before installing the ring compressor, make
(d) Measure side clearance between piston ring sure the oil ring expander ends are butted and the
and ring land. Clearance should be 0.074-0.097 mm rail gaps located properly (Fig. 5).
(0.0029-0.0038 inch) for the compression rings. The (3) Immerse the piston head and rings in clean en
steel rail oil ring should be free in groove, but gine oil. Slide Piston Ring Compressor Tool C-385
should not exceed 0.246 mm (0.0097 inch) side over the piston and tighten with the special wrench
clearance. (part of Tool C-385). Be sure position of rings
(e) Pistons with insufficient or' excessive side does not change during this operation.
clearance should be replaced.
(4) Install connecting rod bolt protectors on rod REMOVAL

bolts, the long protector should be installed on the (1) Remove the oil pan.
numbered side of the connecting rod. (2) Remove the oil pump from the rear main bear
(5) Rotate crankshaft so that the connecting rod ing cap.
journal is on the center of the cylinder bore. Be sure (3) Remove the vibration damper.
connecting rod and cylinder bore number are the (4) Remove the timing chain cover.
same. Insert rod and piston into cylinder bore and (5) Identify bearing caps before removal. Remove
guide rod over the crankshaft journal. bearing caps and bearings one at a time.
(6) Tap the piston down in cylinder bore, using a (6) Lift the crankshaft out of the block.
hammer handle. At the same time, guide connecting (7) Remove and discard the crankshaft rear oil
rod into position on crankshaft journal. seals.
(7) The notch or groove on top of piston must be (8) Remove and discard the front crankshaft oil
pointing toward front of engine. The larger chamfer seal.
crankshaft journal fillet. INSPECTION OF JOURNALS
(8) Install rod caps. Install nuts on cleaned and The crankshaft connecting rod and main journals
oiled rod bolts and tighten nuts to 61 N-m (45 ft. lbs.) should be checked for excessive wear, taper and scor
torque. ing. The maximum taper or out-of-round on any
(9) Install the oil pan. crankshaft journal is 0.025 mm (0.001 inch).
(10) Install the cylinder head. Journal grinding should not exceed 0.305 mm
(11) Install the engine into the vehicle. (0.012 inch) under the standard journal diameter. DO
NOT grind thrust faces of No.3 main bearing. DO
CRANKSHAFT NOT nick crank pin or bearing fillets. After grinding,
remove rough edges from crankshaft oil holes and
A crankshaft which has undersize journals will be clean out all oil passages.
stamped with 1/4 inch letters on the milled flat on
the No.3 crankshaft counterweight (Fig. 6). CAUTION: After any journal grind, it is important
FOR EXAMPLE: R2 stamped on the No.3 crank that the final paper or cloth polish be in the same
shaft counterweight indicates that the No.2 rod jour direction a s the engine rotates.
nal is 0.025 mm (0.001 in) undersize. M4 indicates
that the No.4 main journal is 0.025 mm (0.001 in)
undersize. R3 M2 indicates that the No.3 rod journal CLEANING
and the No.2 main journal are 0.025 mm (0.001 in) Clean Loctite 518 residue and sealant from the cyl
undersize. inder block and rear cap mating surface. Do this be
fore applying the Loctite drop and the installation of
rear cap.
Undersize Journal Identification Stamp
INSTALLATION
0.025 mm (0.001 inch) (Rod) R1-R2-R3 or R4
(1) Lightly oil the new upper seal lips with engine
0.025 mm (0.001 inch) (Main) M1-M2-AA3-M4 or M5
oil.
(2) Install the new upper rear bearing oil seal with
VS LETTERS 2W (ROD) the white paint facing towards the rear of the engine.
-J—(MAIN) (3) Position the crankshaft into the cylinder block.
oil.
the bearing cap with the yellow paint facing towards
the rear of the engine.
(6) Apply 5 mm (0.20 in) drop of Loctite 518, or
J9309-52 equivalent, on each side of the rear main bearing cap
Fig. 6 Location of Crankshaft Identification sealant to contact the rubber seal. Assemble bearing
When a crankshaft is replaced, all main and con cap to cylinder block immediately after sealant appli
necting rod bearings should be replaced with new cation.
bearings. Therefore, selective fitting of the bearings (7) To align the bearing cap, use cap slot, align
is not required when a crankshaft and bearings are ment dowel and cap bolts. DO NOT remove excess
replaced. material after assembly. DO NOT strike rear cap
inch), 0.051 mm (0.002 inch), 0.076 mm (0.003 inch),

0.254 mm (0.010 inch) and 0.305 mm (0.012 inch).
o O Never install an undersize bearing that will reduce

clearance below specifications.
o UPPER
3 r
.25 DROP OF LOCTITE 515
ON BOTH SIDES OF
REAR MAIN CAP J9509-75
LOWER
Fig. 7 Sealant Application to Bearing Cap
tighten to 115 N-m (85 ft. lbs.) torque. J9309-101
(9) Install oil pump. Fig. 9 Main Bearing Identification
ant, or equivalent, at bearing cap to block joint to REMOVAL
provide cap to block and oil pan sealing (Fig. 8). Ap (1) Remove the oil pan.
ply enough sealant until a small amount is squeezed (2) Remove the oil pump from the rear main bear
out. Withdraw nozzle and wipe excess sealant off the ing cap.
oil pan seal groove. (3) Identify bearing caps before removal. Remove
(11) Install new front crankshaft oil seal. bearing caps one at a time.
(4) Remove upper half of bearing by inserting
Crankshaft Main Bearing Remover/Installer Tool
MOPAR SILICONE SEALANT C-3059 into the oil hole of crankshaft (Fig. 10).
RUBBER ADHESIVE APPLIED (5) Slowly rotate crankshaft clockwise, forcing out
SEALANT
NOZZLE TIP
upper half of bearing shell.
SPECIAL
TOOL C-3059
REAR MAIN
BEARING CAP
J9309-87
Fig. 8 Apply Sealant to Bearing Cap to Block Joint
CRANKSHAFT MAIN BEARINGS
be marked at removal to ensure correct assembly.
m 9209-59
Upper and lower bearing halves are NOT inter Fig. 10 Upper Main Bearing Removal and
REMOVING
changeable. Lower main bearing halves of No.2 and 4 Installation with Tool C-3059
are interchangeable. INSTALLATION
Upper and lower No.3 bearing halves are flanged Only one main bearing should be selectively fitted
to carry the crankshaft thrust loads. They are NOT while all other main bearing caps are properly tight
interchangeable with any other bearing halves in the ened. All bearing capbolts removed during service
engine (Fig. 9). Bearing shells are available in stan procedures are to be cleaned and oiled before instal
dard and the following undersizes: 0.25 mm (0.001 lation.
mm 5 J L ENGINE 9 -105
When installing a new upper bearing shell, slightly UPPER SEAL REPLACEMENT—CRANKSHAFT
chamfer the sharp edges from the plain side. INSTALLED
(1) Start bearing in place, and insert Crankshaft (1) Remove the oil pan.
Main Bearing Remover/Installer Tool C-3059 into oil (2) Remove the oil pump from the rear main bear
hole of crankshaft (Fig. 10). ing cap.
(2) Slowly rotate crankshaft counterclockwise slid (3) Remove the rear main bearing cap. Remove
ing the bearing into position. Remove Tool C-3059. and discard the old lower oil seal.
(8) Install the bearing cap. Clean and oil the bolts. (4) Carefully remove and discard the old upper oil
Tighten the capbolts to 115 N-m (85 ft. lbs.) torque. seal.
(4) Install the oil pump. (5) Clean the cylinder block mating surfaces before
(5) Install the oil pan. oil seal installation.
(6) Lightly oil the new upper seal lips with engine
CRANKSHAFT REAR OIL SEALS oil. To allow ease of installation of the seal, loosen at
The service seal is a 2 piece, viton seal. The upper least the 2 main bearing caps forward of the rear
seal half can be installed with crankshaft removed bearing cap.
from engine or with crankshaft installed. When a (7) Rotate the new upper seal into the cylinder
new upper seal is installed, install a new lower seal. block being careful not to shave or cut the outer sur
The lower seal half can only be installed with the face of the seal. To assure proper installation, use the
rear main bearing cap removed. installation tool provided with the kit. Install the
new seal with the white paint facing towards the
UPPER SEAL REPLACEMENT—CRANKSHAFT rear of the engine.
REMOVED (8) Install the new lower rear bearing oil seal into
(1) Remove the crankshaft. Discard the old upper the bearing cap with the white paint facing towards
seal. the rear of the engine.
(2) Clean the cylinder block rear cap mating sur (9) Apply 5 mm (0.20 in) drop of Loctite 518, or
face. Make sure the seal groove is free of debris. equivalent, on each side of the rear main bearing cap
(3) Lightly oil the new upper seal lips with engine (Fig. 7). DO NOT over apply sealant or allow the
oil. sealant to contact the rubber seal. Assemble bearing
(4) Install the new upper rear bearing oil seal with cap to cylinder block immediately after sealant appli
the white paint facing towards the rear of the engine. cation. Be sure the white paint faces toward the rear
(5) Position the crankshaft into the cylinder block. of the engine.
(6) Lightly oil the new lower seal lips with engine (10) To align the bearing cap, use cap slot, align
oil. ment dowel and cap bolts. DO NOT remove excess
(7) Install the new lower rear bearing oil seal into material after assembly. DO NOT strike rear cap
the bearing cap with the white paint facing towards more than 2 times for proper engagement.
the rear of the engine. (11) Install the rear main bearing cap with cleaned
(8) Apply 5 mm (0.20 in) drop of Loctite 518, or and oiled cap bolts. Alternately tighten ALL cap bolts
equivalent, on each side of the rear main bearing cap to 115 N-m (85 ft. lbs.) torque.
(Fig. 7). DO NOT over apply sealant or allow the (12) Install oil pump.
sealant to contact the rubber seal. Assemble bearing (13) Apply Mopar® Silicone Rubber Adhesive Seal
cap to cylinder block immediately after sealant appli ant, or equivalent, at bearing cap to block joint to
cation. provide cap to block and oil pan sealing (Fig. 8). Ap
(9) To align the bearing cap, use cap slot, align ply enough sealant until a small amount is squeezed
ment dowel and cap bolts. DO NOT remove excess out. Withdraw nozzle and wipe excess sealant off the
material after assembly. DO NOT strike rear cap oil pan seal groove.
more than 2 times for proper engagement. (14) Immediately install the oil pan.
bearing caps. Install all cap bolts and alternately LOWER SEAL REPLACEMENT
tighten to 115 N-m (85 ft. lbs.) torque. (1) Remove the oil pan.
(11) Install oil pump. (2) Remove the oil pump from the rear main bear
(12) Apply Mopar® Silicone Rubber Adhesive Seal ing cap.
ant, or equivalent, at bearing cap to block joint to (3) Remove the rear main bearing cap and discard
provide cap to block and oil pan sealing (Fig. 8). Ap the old lower seal.
ply enough sealant until a small amount is squeezed (4) Clean the rear main cap mating surfaces in
out. Withdraw nozzle and wipe excess sealant off the cluding the oil pan seal grooves.
oil pan seal groove. (5) Carefully install a new upper seal (refer to Up
(13) Install new front crankshaft oil seal. per Seal Replacement - Crankshaft Installed proce
(14) Immediately install the oil pan. dure above).
9 - 106 5 J L ENGINE mm
(6) Lightly oil the new lower seal lips with engine GIL LINE PLm
oil. The oil line plug is located in the vertical passage
(7) Install a new lower seal in bearing cap with at the rear of the block between the Oil-To-Filter and
yellow paint facing the rear of engine. Oil-From-Filter passages (Fig. 11). Improper installa
(8) Apply 5 mm (0.20 in) drop of Loctite 518, or tion or plug missing could cause erratic, low or no oil
equivalent, on each side of the rear main bearing cap pressure.
(Fig. 7). DO NOT over apply sealant or allow the (1) Remove oil pressure sending unit from back of
sealant to contact the rubber seal. Assemble bearing block.
cap to cylinder block immediately after sealant appli (2) Insert a 3.175 mm (1/8 inch) finish wire or
cation. equivalent into passage.
(9) To align the bearing cap, use cap slot, align (3) Plug should be 190.0 to 195.2 mm (7-172 to
ment dowel and cap bolts. DO NOT remove excess 7-11/16 inches) from machined surface of block (Fig.
material after assembly. DO NOT strike rear cap 11). If plug is too high, use a suitable flat dowel drift
to position properly.
(10) Install the rear main bearing cap with cleaned RIGHT OIL GALLERY
and oiled cap bolts. Alternately tighten the cap bolts
(11) Install oil pump.
provide cap to block and oil pan sealing (Fig. 8). Ap
ply enough sealant until a small amount is squeezed
CYLINDER BLOCK
Remove the engine assembly from the vehicle. J9109-229
DISASSEMBLE Fig. 11 Oil Line Plug
(1) Remove the cylinder head. (4) If plug is too low, remove oil pan and rear main
(2) Remove the oil pan. bearing cap. Use suitable flat dowel to position prop
erly. Coat outside diameter of plug with Mopar®
(3) Remove the piston/connecting rod assembly. (stud and bearing mount adhesive), or equivalent.
Plug should be 54.0 to 57.7 mm (2-178 to 2-5/16
CLEANING
inches) from bottom of the block.
Clean cylinder block thoroughly and check all core (5) Assemble engine and check oil pressure.
hole plugs for evidence of leaking.
INSPECTION JZNGIBSiE ©©ME, OIL AMD CAMSHAFT PLUGS
Examine block for cracks or fractures. Engine core plugs have been pressed into the oil
The cylinder walls should be checked for out-of- galleries behind the camshaft thrust plate (Fig. 12).
round and taper with Cylinder Bore Indicator Tool This will reduce internal leakage and help maintain
6879. The cylinder block should be bored and honed higher oil pressure at idle.
with new pistons and rings fitted if:
• The cylinder bores show more than 0.127 mm REMOVAL
(0.005 inch) out-of-round. (1) Using a blunt tool such as a drift or a screw
• The cylinder bores show a taper of more than driver and a hammer, strike the bottom edge of the
0.254 mm (0.010 inch). cup plug (Fig. 13).
• The cylinder walls are badly scuffed or scored. (2) With the cup plug rotated, grasp firmly with
Boring and honing operation should be closely co pliers or other suitable tool and remove plug (Fig.
18).
specified clearances may be maintained. CLEAI11G
Refer to Standard Service Procedures in the begin Thoroughly clean inside of cup plug hole in cylinder
ning of this Group for the proper honing of cylinder block or head. Be sure to remove old sealer.
bores. Make certain the new plug is cleaned of all oil or
grease.
BR — - 5 J L ENGINE 9 -107
INSTALLATION
(1) Coat edges of plug and core hole with Mopar®
Gasket Maker, or equivalent.
n-lays engine problems.

It is not necessary to wait for curing of the sealant.
The cooling system can be filled and the vehicle
ASSEMBLE
(1) Install the piston/connecting rod assembly.
(3) Install the cylinder head.
(4) Install the engine into the vehicle.
DRIFT 9209-41
Fig. 13 Core Hole Plug Removal

9 -110 5.9L ENGINE BR
Valve Springs Valve Timing

Free Length (Approx.) 49.962 mm Exhaust Valve
.(1.967 in) Closes (ATC) ........23°
Spring Tension @ 41.66 mm » 378 N Opens (BBC) .........61°
(Valve Closed) (@ 1.64 in = 85 lbs) Duration .......264°
Spring Tension @ 30.89 mm - 890 N Intake Valve
(Valve Open) (@ 1.212 in - 200 lbs) Closes (ABC) .80°
Number of Coils 6.8 Opens (BTC) ........13°
Installed Height 41.66 mm Duration.......................................................... .........274°
(Spring Seat to Retainer) {1.64 in) Valve Overlap................. ....36.5°
(0.177 in)
J9509-97
OVERSIZE AND UNDERSIZE ENGINE COMPONENT MARKINGS
CONDITION IDENTIFICATION m^mmm OF mmiwmmmm
0.025 mm (0.001 inch) R or M Milled flat on number three crankshaft

U/S Crankshaft M - 2 - 3 etc. (Indicating No. 2 & 3 main counterweight
bearing journal)
and/or
R-1-4 etc. (Indicating No. 1 & 4 connecting
rod journal)
0.508 mm (0.020 inch) A Following engine serial number.

O/S Cylinder Bores
0.203 mm (0.008 inch) 3 / 8 " diamond-shaped stamp Top pad — Front

O/S Tappets # of engine and flat ground on outside surface of
each O/S tappet bore.
0.127 mm (0.005 inch) X Milled pad adjacent to two 3 / 8 " tapped holes
O/S Valve Stems on each end of cylinder head.
J9209-120
DESCRIPTION DESCRIPTION TOftOJi
Adjusting Strap Bolt 23 N®m (200 in. lbs.) Rear Mount - Support Cushion-to-
Crossmember Nut........................... 47 Nnn (35 ft. lbs.)
Camshaft Bolt 68 N*m (50 ft. lbs.) Rear Mount - Support Cushion-to-
Camshaft Thrust Plate Bolts . 24 N«m (210 in. lbs.) Trans. Support Bracket Nuts 47 N*m (35 ft. lbs.)
Chain Case Cover Bolts ......... 41 N®m (30 ft. lbs.) Rear Mount - Transmission Support
Connecting Rod Cap lolls .................. 61 N«m (45 ft. lbs.) Bracket Bolts 102 N*m (75 ft. lbs.)
Crankshaft Main Bearing Cap Bolts «... 115 N®m (85 ft. lbs.) Rear Support Plate-to-Transfer
Cylinder Head Bolts Case Bolts ...................................... 41 N*m (30 ft. lbs.)
1st Step 68N«m (50 ft. lbs.) Rocker Arm Bolts 23 N»m (200 in. lbs.)
2nd Step 143 N«m (105 ft. lbs.)
Cylinder Head Cover Bolts ................. 11 N«m (95 in. lbs.) Sparkplugs 41 N#m (30 ft. lbs.)
Starter Mounting Bolts 68 N*m (50 ft. lbs.)
Head Bolts/Nuts 34 N«m (25 ft. lbs.) Throttle Body Bolts ............................. 23 N*m (200 in. lbs.)
68 N«m (50 ft. lbs.) Bolts 31 N*m (270 in. lbs.)
81 N»m (60 ft. lbs.) Mounting Plate Nuts 204 N*m(150 ft. lbs.)

Bolt 183 N*m{135 ft. lbs.)
Cover Bolt ...................................... 41 N»m (30 ft. lbs.)
Oil Pan Bolts 23 N*m (200 in. lbs.)
Oil Pan Drain Plug 34 N*m (25 ft. lbs.)
Oil Pump Attaching Bolts .................... 41 N*m (30 ft. lbs.)
Oil Pump Cover Belts 11 N«m (95 in. lbs.) J9509-140
8 J L ENGINE 9 -113
8.0L ENGINE SERVICE PROCEDURES
page page
Camshaft 129 Rocker Arms and Push Rods . . . . . . . . . . . . . . . . 118

Cylinder Head Cover 117 Timing Chain Cover ...................... 126
Cylinder Heads ... 119 Timing Chain Cover Oil Seal . . . . . . . . . . . . . . . . 128
Engine Assembly 115 Valve Components Replace—Cylinder Head Not
Engine Mount—Rear . . . . . . . r . . . . . . . . . . . . . . 114 Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Engine Mounts—Front 114 Valve Stem Seal and Spring Replacement . . . . . . 118
General Information 113 Valve Timing 125
Hydraulic Tappets 124 Valves and Valve Springs 121
Oil Pan . . . . . . 131 Vibration Damper 125
GENERAL INFORMATION The cylinders are numbered from front to rear; 1,

The 8.0 Liter (488 CID) ten-cylinder engine is a V- 3, 5, 7, 9 on the left bank and 2, 4, 6, 8, 10 on the
Type lightweight, single cam, overhead valve engine right bank. The firing order is 1-10-9-4-3-6-5-8-7-2
with hydraulic roller tappets (Fig. 1). (Fig. 2).
This engine is designed for unleaded fuel. The engine serial number is located on the lower
Engine lubrication system consists of a gerotor type left front of the cylinder block in front of the engine
oil pump mounted in the timing chain cover and mount (Fig. 3). When component part replacement is
driven by the crankshaft. The V-10 uses a full flow necessary, use the engine type and serial number for
oil filter. reference.
Engine Type 90° V-10OHV

Bore and Stroke 101.6x98.6 mm (4.00x3.88 in.)
Displacement 8.0L (488 cu. in.)
Torque.. ...617 N T n (450 ft. lbs.) @ 2,400 rpm
Firing Order 1 -10-9-4-3-6-5-8-7-2
Lubrication ..Pressure Feed - Full Flow Filtration
(Direct Crankshaft Driven Pump)
Engine Oil Capacity.... 6.6L (7.0 Qts) w/filter
Cooling System Liquid Cooled - Forced Circulation
Cooling Capacity ...20.5L (21.75 Qts)
Cylinder Block.. .Cast Iron
Crankshaft Nodular Cast Iron
Cylinder Head Cast Iron
Combustion Chambers Wedge-High Swirl
Camshaft Nodular Cast Iron
Pistons Cast Aluminum Alloy
Connecting Rods Forged Steel
J9509-179
Fig. 1 Engine Description

§ -114 8.0L ENGINE BR
REAR COIL PACK FRONT COIL PACK (3) Install engine support/lifting fixture.
thru-bolt and nut and rubber engine restrictors. (Fig.
4).
(Fig. 4). Remove the support bracket/cushion and
heat shields.
ENGINE MOUNT
HEAT SHIELD
ENGINE SUPPORT
BRACKET/CUSHION
THRU-BOLT
RESTRICTION PADS
J9409-144
RIGHT LEFT
Fig. 4 Engine Mounts—Front
HANK IANK
FIRING ORDER INSTALLATION
1-10-9-4-3-6-5-8-7-2 j 948D-12 (1) With engine raised SLIGHTLY, position the en
gine support bracket/cushion and heat shields to the
Fig. 2 Firing Order
block. Install new bolts and tighten to 81 N-m (60 ft.
ENGINE 10UITS—PFtONT lbs.) torque.
(2) Install the thru-bolt and 2 piece rubber engine
REMOVAL rubber restrictors onto the engine support bracket/
(1) Disconnect the negative cable from the battery. cushion.
(2) Position fan to assure clearance for radiator top (3) Lower engine with support/lifting fixture while
tank and hose. guiding the engine bracket/cushion and thru-bolt into
support cushion brackets (Fig. 5).
CAUTION: D© NOT lift the engine b y t h e intake (4) Install thru-bolt nuts and tighten the nuts to
manifold. 68 N«m (50 ft. lbs.) torque.
ENGINE
ENGINE SERIAL NO. MOUNT
LOCATION j ENGINE M0UNT™BEM
REMOVAL
(1) Raise the vehicle on a hoist.
(2) Position a transmission jack in place.
(3) Remove support cushion stud nuts (Fig. 6).
(4) Raise rear of transmission and engine
SLIGHTLY.
(5) Remove the bolts holding the support cushion
to the transmission support bracket. Remove the sup
port cushion.
(6) If necessary, remove the bolts holding the
J9409-93 transmission support bracket to the transmission.
Fig. 3 Engine Identification

BR 8 J L ENGINE 9 -115
(12) Remove the fan shroud.

(13) Disconnect the lower radiator hose.
(14) Disconnect the transmission cooler lines.
(15) Remove radiator (refer to Group 7, Cooling
System).
(16) Remove the generator with the wire connec
tions (refer to Group 8B, Battery/Starter/Generator
Service).
(18) Disconnect the throttle linkage.
(19) Remove throttle body.
(20) Remove the upper intake manifold (refer to
Group 11, Exhaust System and Intake Manifold).
(21) Remove the coil assemblies with the ignition
cables.
(22) Disconnect the heater hoses.
(23) Disconnect the power steering hoses, if
equipped.
CUSHION
(24) Perform the Fuel System Pressure release
procedure (refer to Group 14, Fuel System). Discon
nect the fuel line.
(25) On Manual Transmission vehicles, remove the
Fig. 5 Positioning Engine Mounts—Front shift lever (refer to Group 21, Transmissions).
INSTALLATION (26) Raise and support the vehicle on a hoist.
(1) If removed, position the transmission support (27) Remove the drain plug and drain the engine
bracket to the transmission. Install new attaching oil.
bolts and tighten to 102 N»m (75 ft. lbs.) torque. (28) Loosen front engine mount thru-bolt nuts.
(2) Position support cushion to transmission sup (29) Remove the transmission cooler line brackets
port bracket. Install stud nuts and tighten to 47 N*m from oil pan.
(85 ft. lbs.) torque. (30) Disconnect exhaust pipe at manifold (refer to
(3) Using the transmission jack, lower the trans Group 11, Exhaust System and Intake Manifold).
mission and support cushion onto the crossmember (31) Disconnect the starter wires. Remove starter
(Fig. 6). motor (refer to Group 8B, Battery/Starter/Generator
(4) Install the support cushion bolts and tighten to Service).
47 N-m (35 ft. lbs.) torque. (32) Refer to Group 21, Transmissions for trans
mission removal.
(5) Remove the transmission jack.
(33) Lower vehicle.
CAUTION; DO NOT lift the engine by the intake
ENGINE ASSEMBLY manifold.
REMOVAL (34) Install an engine lifting fixture.

(1) Remove the battery. (35) Remove engine from vehicle and install engine
(2) Drain cooling system (refer to Group 7, Cooling assembly on a repair stand.
(3) Discharge the air conditioning system,- if INSTALLATION
equipped (refer to Group 24, Heating and Air Condi (1) Remove engine from the repair stand and posi
tioning for service procedures). tion in the engine compartment. Position the thru-
(4) Remove the upper crossmember. bolt into the support cushion brackets.
(5) Remove the transmission oil cooler. (2) Install an engine support fixture.
(6) Remove the serpentine belt (refer to Group 7, (3) Raise and support the vehicle on a hoist.
Cooling System). (4) Refer to Group 21, Transmissions for transmis
(7) Remove the A/C compressor with the lines at sion installation.
tached. Set aside. (5) Install the prop shaft (refer to Group 16, Pro
(8) If equipped, remove the condenser. peller Shaft).
(9) Remove the washer bottle. (6) Install the starter and connect the starter wires
(10) Disconnect the top radiator hose. (refer to Group 8B, B attery/Starter/Generator Ser
(11) Remove the fan. vice).
4X4
4X2 . 3500 MANUAL 4X2 4X4
3500 MANUAL 4500 ALL AUTOMATICS AUTOMATICS
J9509-126
Fig. 6 Engine Rear Support Cushion Assembly

(7) Install exhaust pipe to manifold (refer to Group CYLINDEI HEAD CiWEi
11, Exhaust System and Intake Manifold), Die-cast magnesium cylinder head covers (Fig. 1)
(8) Install the transmission cooler line brackets reduce noise and provide a good sealing surface. A
from oil pan. steel backed silicon gasket is used with the cylinder
(9) Tighten the Front mount thru-bolts and nuts to head cover (Fig. 2). This gasket can be used again.
102N
31m (75 ft. lbs.). CAUTION: The cylinder head cover fasteners have a
(10) Install the drain plug and tighten to 34 N-m special plating. DO NOT use alternative fasteners.
(11) Prime oil pump by squirting oil in the oil filter
mounting hole and filling the J-trap of the front tim
ing cover. When oil is running out, install oil filter
that has been filled with oil.
(13) Remove engine lifting fixture.
(14) On Manual Transmission vehicles, install the
shift lever (refer to Group 21, Transmissions).
(15) Connect the fuel lines.
(16) Connect the heater hoses.
(17) Install the upper intake manifold (refer to
Group 11, Exhaust System and Intake Manifold).
(18) Install the coil assemblies with the ignition
cables.
(19) Using a new gasket, install throttle body.
Tighten the throttle body nuts to 23 N-m (200 in.
lbs.) torque.
(20) Connect the throttle linkage.
(21) Install the air cleaner box.
(22) Install the generator and wire connections (re
fer to Group 8B, Battery/Starter/Generator Service).
(23) Install the upper crossmember.
(24) Install radiator (refer to Group 7, Cooling Sys
tem).
(25) Connect the lower radiator hose.
(27) Connect the transmission cooler lines.
Fig. 1 Cylinder Head Covers
(28) Connect the power steering hoses, if equipped.
(29) Install the fan shroud. CYLINDER HEAD COVER GASKETS LEFT
(30) Install the fan.
(31) Connect the top radiator hose. FRONT
(33) Install the washer bottle. OF
ENGINE
(34) If equipped, install the condenser.
(35) Install the A/C compressor with the lines at
tached. RIGHT
(36) Install the serpentine belt (refer to Group 7, COVER
Cooling System).
(37) Evacuate and charge the air conditioning sys 109=135
tem, if equipped (refer to Group 24, Heating and Air
Conditioning for service procedures). Fig. 2 Cylinder Head Cover Gaskets
(38) Add coolant to the cooling system (refer to REMOVAL
Group 7, Cooling System for the proper procedure). (1) Disconnect the negative cable from the battery.
(39) Install the battery. (2) Disconnect closed ventilation system and evap
(40) Warm engine and adjust. oration control system from cylinder head cover.
(41) Road test vehicle. Identify each system for installation. *
I -118 8 J L ENGINE BR
(8) Remove the upper intake manifold to remove

the right side head cover (refer to Group 11, Exhaust
System and Intake Manifold).
ROCKER
(4) Remove cylinder head cover bolts and stud . ARM
bolts. Remove the covers and gaskets. The gasket PEDESTALS
may be used again.
CLEANING
Clean cylinder head cover gasket surface.
Clean head rail, if necessary.
INSPECTION
This gasket may be used again.
Check the gasket for use in head cover installation.
If damaged, use a new gasket. J9409-60
INSTALLATION Fig. 3 Rocker Arm Assembly

(1) The cylinder head cover gasket can be used ow the hydraulic roller tappets adequate time to
again. Install the gasket onto the head rail. For the
left side t h e number t a b is at the front of en oleed down (about 5 minutes).
gine with t h e number up. For the right side t h e (1) Install the push rods in the same order as re
number tab is at the rear of engine with the moved.
number up. (2) Install rocker arm assemblies in the same order
CAUTION: The cylinder head cover fasteners have a
as removed. Tighten the rocker arm bolts to 28 N-m
special plating. DO NOT use alternative fasteners.
(3) Install cylinder head cover and gasket. DO
(2) Position the cylinder head cover onto the gas NOT use alternative fasteners.
ket. Install the stud bolts and hex head bolts in the (4) Connect spark plug wires.
proper positions (Fig. 1). Tighten the stud bolts and
the bolts to 16 N-m (144 in. lbs.) torque. VALVE STEM SEAL AND SPRING REPLACEMENT
(3) If removed, install the upper intake manifold This procedure is done with the cylinder head in
(refer to Group 11, Exhaust System and Intake Man stalled.
ifold). (1) Disconnect the negative cable from the battery.
(4) Install closed crankcase ventilation system and (2) Set engine basic timing to Top Dead Center
evaporation control system onto the proper head (TDC) and remove air cleaner.
cover. DO NOT switch the systems. (3) Remove cylinder head covers and spark plugs.
(5) Connect the negative cable to the battery. (4) Using suitable socket and flex handle at crank
shaft retaining bolt, turn engine so the No.l piston is
VALVE COMPONENTS REPLACE—CYLINDER HEAD at TDC on the compression stroke.
NOT REMOVED (5) Remove rocker arms.
(6) With air hose attached to an adapter installed
ROCIER ARMS AND POSH RODS in No.l spark plug hole, apply 620-689 kPa (90-100
psi) air pressure.
REMOVAL (7) Using Valve Spring Compressor Tool
(1) Disconnect spark plug wires by pulling the boot MD-998772A with adapter 6716A, compress valve
straight out in line with plug. spring and remove retainer valve locks and valve
(2) Remove cylinder head cover and gasket. spring.
(3) Remove the rocker arm bolts and the rocker
(8) Install seals on the exhaust valve stem and po
arm assembly (Fig. 3). Place rocker arm assemblies
sition down against valve guides. The exhaust valve
on a bench in the same order as removed.
(4) Remove the push rods and place them on a stem seal is brown.
bench in the same order as removed. (9) The black intake valve stem seals should be
pushed firmly and squarely over the valve guide us
INSTALLATION ing the valve stem as a guide. DO NOT force seal
against top of guide. When installing the valve re
CAUTION: DO NOT rotate o r crank the engine dur tainer locks, compress the spring only enough to in
ing or immediately after rocker arm installation. Al- stall the locks.
mm 8.0L ENGINE 9 - 119
(10) Follow the same procedure on the remaining 9

cylinders using the firing sequence 1-10-9-4-8-6-5-8-
7-2. Make sure piston in cylinder is at TDC on the
valve spring that is being removed.
(11) Remove adapter from the No.l spark plug
hole.
(12) Install rocker arms.
left side the number tab is at the front of en
gine with the number up. For the right side the
number tab is at t h e r e a r of engine w i t h the
number up.
CAUTION: The cylinder head cower fasteners hawe a
Fig. 5 Spark Plug Wire Heat Shields (Left Side
(14) Position the cylinder head cover onto the gas Shown)
ket. Install the stud bolts and hex head bolts in the
proper positions (Fig. 1). Tighten the stud bolts and (7) Remove the air cleaner.
the bolts to 16 N-m (144 in. lbs.) torque. (8) Perform the Fuel System Pressure release pro
(15) Install closed crankcase ventilation system. cedure (refer to Group 14, Fuel System). Disconnect
(16) Connect the evaporation control system. the fuel line.
(17) Install air cleaner. (9) Disconnect accelerator linkage and if so
(18) Connect the negative cable to the battery. equipped, the speed control and transmission kick-
(19) Road test vehicle and check for leaks. down cables.
(10) Remove coil pack and bracket (Fig. 6).
CYLINDER H E 1 D S COIL PACKS
The alloy cast iron cylinder heads (Fig. 4) are held AND BRACKET
in place by 12 bolts. The spark plugs are located in
the peak of the wedge between the valves.
INTAKE VALVES INTAKE VALVES INTAKE VALVE
MOUNTING
BOLTS (4) '
EXHAUST EXHAUST
VALVES VALVE
J9409-1
Fig. 4 Cylinder Head Assembly FRONT O F ENGINE J9414-55

HEMOWAL
(1) Disconnect the negative cable from the battery. Fig. 6 Coil Pack and Bracket
(2) Drain cooling system (refer to Group 7, Cooling (11) Disconnect the coil wires.
System for the proper procedures). (12) Disconnect heat indicator sending unit wire.
(3) Remove the heat shields (Fig. 5). (13) Disconnect heater hoses and bypass hose.
(4) Remove the intake manifold-to-generator (14) Remove upper intake manifold and throttle
bracket support rod. Remove the generator. body as an assembly.
(5) Remove closed crankcase ventilation system. (15) Remove cylinder head covers and gaskets.
(6) Disconnect the evaporation control system.
(16) Remove the EGR tube. Discard the gasket, for

right side only.
(17) Remove lower intake manifold. Discard the
flange side gaskets and the front and,rear cross-over
gaskets.
(18) Disconnect exhaust pipe from exhaust mani
fold (refer to Group 11, Exhaust System and Intake
Manifold). •
(19) Remove exhaust manifolds and gaskets (refer
to Group 11, Exhaust System and Intake Manifold). Jf409-14
(20) Remove rocker arm assemblies and push rods.
Identify to ensure installation in original locations. Fig. 7 Cylinder Head Bolt Tightening Sequence
(21) Remove the head bolts from each cylinder (4) Install push rods and rocker arm assemblies in
head and remove cylinder heads. Discard the cylin their original position. Tighten the bolts to 28 N-m
der head gasket. (21 ft. lbs.) torque.
(21) Remove spark plugs. (5) Install the side intake manifold gaskets. Re
CLEANING
sure that the locator dowels are positioned in the
Clean all surfaces of cylinder block and cylinder head (Fig. 8).
heads. Be sure material does not fall into the lifters
and surrounding valley.
Clean cylinder block front and rear gasket surfaces
using a suitable solvent.
Clean the exhaust manifold to cylinder head mat
ing areas.
INSPECTION
Inspect ail surfaces with a straightedge if there is
any reason to suspect leakage. The out-of-flatness
specifications are 0.0007 mm/mm (0.0004 inch/inch),
0.127 mm/152 mm (0.005 inch/6 inches) any direction Fig. 8 Intake Manifold Flange Gasket Alignment
or 0.254 mm (0.010 inch) overall across head. If ex
ceeded, either replace head or lightly machine the (6) Peel off the protective paper (blue - rear and
head surface. brown - front) and press firmly onto the block (Fig.
The cylinder head surface finish should be 9). BE SURE THE B L O C K IS O I L FREE*. Align
1.78-4.57 microns (15-80 microinches). ing slots in end seals with notches in intake manifold
Inspect push rods. Replace worn or bent rods. gaskets.
Inspect rocker arms. Replace if worn or scored.
INSTALLATION
cylinder block.
(2) Position the cylinder heads onto head gaskets
and cylinder block.
(8) Tighten the cylinder head bolts in two steps
(Fig. 7):
• Step 1—Tighten all cylinder head bolts, in se
e
quence, to 58 N m (43 ft. lbs.) torque.
• Step 2—Tighten all cylinder head bolts, in se
quence, to 148 N-m (105 ft. lbs.) torque.
CAUTION; When tightening the rocker arm bolts, {BLUE PEEL-OFF) J9409-63
make sure the piston in that cylinder is NOT at
TDC. Contact between the waives and piston could Fig. 9 Intake Manifold-to-Block Seals
occur.
BR S.OL ENGINE 9 -121
(7) Insert Mopar® Silicone Rubber Adhesive Seal (17) Adjust spark plugs to specifications (refer to
ant, or equivalent, into the four comer pockets (Fig. Group 8D, Ignition System). Install the plugs and
10). Fill the pocket, but DO NOT overfill. tighten to 41 N-m (30 ft. lbs.) torque.
(18) Install coil packs and bracket. Tighten the
bracket bolts to 21 N-m (190 in. lbs.) torque. Connect
the coil wires.
(19) Connect heat indicator sending unit wire.
(20) Connect the heater hoses and bypass hose.
down cables.
(22) Install the fuel line.
bracket support rod. Tighten the bolts to 41 N-m (30
ft. lbs.) torque.
left side the number tab is at the front of en
gine with the number up. For the right side the
number tab is at the rear of engine with the
Fig. 10 Mopar® Silicone Rubber Adhesive Sealant
number up.
Application Locations
(8) The lower intake manifold MUST be installed CAUTION: The cylinder head cover fasteners have a
within 3 minutes of sealant application. Carefully special plating. DO NOT use alternative fasteners.
lower intake manifold into position on the cylinder
block and cylinder heads. After intake manifold is in (26) Position the cylinder head cover onto the gas
place, inspect to make sure seals and gaskets are in ket. Install the stud bolts and hex head bolts in the
place. proper positions (Fig. 1). Tighten the stud bolts and
(9) Finger start all bolts, alternate one side to the the bolts to 16 N-m (144 in. lbs.) torque.
other. (27) Install closed crankcase ventilation system.
(10) Tighten the lower intake manifold bolts to 54 (28) Connect the evaporation control system.
N-m (40 ft. lbs.) torque. (29) Install the air cleaner.
(11) Using a new gasket, position the upper intake (30) Fill cooling system (refer to Group 7, Cooling
manifold onto the lower intake manifold. System for proper procedure).
(12) Tighten upper intake manifold bolts to 22 N-m (31) Connect the negative cable to the battery.
(16 ft. lbs.) torque. (32) Check for leaks (fuel, oil, antifreeze, etc.).
(13) Install the exhaust manifolds and new gas
VALVES AND VALVE SPRINGS
kets. Tighten the bolts and stud bolts to 22 N-m (16
ft. lbs.) torque. The valves are arranged in-line and inclined 18°.
(14) Install exhaust pipe to the exhaust manifold. The rocker pivot support and the valve guides are
Tighten the bolts to 34 n-m (25 ft. lbs.) torque. cast integral with the heads.
(15) Using a new gasket, position the EGR tube to
head.
the intake manifold and the exhaust manifold.
Tighten the EGR tube nut to 34 N-m (25 ft. lbs.) REMOVAL
torque. Tighten the bolts to 20 N-m (174 in. lbs.) (1) Remove the cylinder head.
torque. (2) Special studs must be used to adapt the Valve
(16) Install the heat shields and the washers. Spring Compressor Tool to the V-10 cylinder head
Make sure that heat shields tabs hook over the (Fig. 11). Install the metric end into the Special Tool
exhaust gasket. Tighten the nuts to 15 N-m (132 in. MD998772A and the 5/16 end into the cylinder head.
lbs.) torque. (3) Compress valve springs using Valve Spring
Compressor Tool MD-998772A with Adapter 6716A
Remove carbon and varnish deposits from inside of

FITS INTO TOOL MD 998772A valve guides with a reliable guide cleaner.
VALVE INSPECTION
VALVE GUIDES
Measure valve stem guide clearance as follows:
(A) Install Black Valve Guide Sleeve Tool C-6819
over valve stem for the INTAKE valve and install
valve (Fig. 13). The special sleeve places the valve at
the correct height for checking with a dial indicator.
(B) Install Silver Valve Guide Sleeve Tool C-6818
over valve stem for the EXHAUST valve and install
valve. The special sleeve places the valve at the cor
rect height for checking with a dial indicator.
FITS INTO CYLINDER HEAD

J9409-95
Fig. 11 Special Studs 6715 for V-10 Engine
and Screw 8765 (Fig. 12). Tap the retainer using a
brass drift and ball peen hammer to loosen locks
away from retainer.
Fig. 13 Positioning Valve Spacer Tool (Typical)

(C) Attach Dial Indicator Tool C-3339 to cylinder
head and set it at right angle of valve stem being
measured (Fig. 14).
Fig. 12 Valve Spring Compressor MB-998772A with

Adaptor 6716-A and Screw 8765
tainers and valve springs. Check for abnormal wear,
replace as required.
(5) Remove the valve stem seals.
(6) Before removing valves, remove any burrs from Fig. 14 Measuring Valve Guide Wear
valve guides. Identify valves to ensure installation in (D) Move valve to and from the indicator. The total
original location. dial indicator reading should not exceed 0.432 mm
(0.017 inch). Ream the guides for valves with over
VALVE GLEAMING size stems if dial indicator reading is excessive or if
Clean valves thoroughly. Discard burned, warped the stems are scuffed or scored.
and cracked valves.
Service valves w i t h oversize stems are available

(Fig. 15).
INTAKE EXHAUST
Reamer O / S Valve Guide Size VALVE
VMVE
0.076 mm 8.026 - 8.052 mm

(0.003 in.) (0.316-0.317 in.)
0.381 mm 8.331-8,357 mm STEM-

•(0.015 in.) (0.328 - 0.329 in.)
VALVE SPRING
J9309-30 RETAINER LOCK
GROOVE
Fig. 15 Reamer Sizes
Slowly t u r n reamer by hand and clean guide thor J9209-127
oughly before installing new valve. R e a m the v a l v e
guides f r o m standard to 0.381 m m (0.015 inch). Fig. 17 Intake and Exhaust Valves
Use a 2 step procedure so the valve guides are
VALVE SEATS
reamed true in relation to the valve seat:
(1) When refacing valve seats, i t is important that
i n g stones. A true and complete surface must be ob
REFACING VALVES AND VALVE SEATS tained.
The intake and exhaust valves have a 45° face an (2) Measure the concentricity of valve seat using a
gle and a 45° to 44 1/2° seat angle (Fig. 16). dial indicator. Total runout should not exceed 0.038
m m (0.0015 inch) total indicator reading.
CONTACT
POINT (3) Inspect the valve seat w i t h Prussian blue to de
termine where the valve contacts the seat. To do this,
coat valve seat L I G H T L Y w i t h Prussian blue then set
valve i n place. Rotate the valve w i t h l i g h t pressure.
I f the blue is transferred to the center of valve face,
contact is satisfactory. I f the blue is transferred to
the top edge of valve face, lower valve seat w i t h a 15°
stone. I f the blue is transferred to bottom edge of
valve face raise valve seat w i t h a 60° stone.
(4) When seat is properly positioned the w i d t h of
valve seats should be 1.016-1.524 m m (0.040-0.060
inch).
VALVE SPRING INSPECTION

Whenever valves have been removed for inspection,
A - SEAT WIDTH - INTAKE 1.016-1.524 mm ( 0 . 0 4 0 - 0 . 0 6 0 in.) reconditioning or replacement, valve springs should
EXHAUST 1 . 0 1 6 - 1 . 5 2 4 mm ( 0 . 0 4 0 - 0 . 0 6 0 in.) be tested. As an example the compression length of
B - FACE ANGLE (INTAKE & EXHAUST) the spring to be tested is 1-5/16 inch. T u r n table of
C - SEAT ANGLE'(INTAKE & EXHAUST)
D - C O N T A C T SURFACE Universal Valve Spring Tester Tool u n t i l surface is in
line w i t h the 1-5/16 inch m a r k on the threaded stud.
J9409-133
Be sure the zero m a r k is to the front (Fig. 18). Place
Fig. 16 Valve Face and Seat Angles spring over stud on the table and l i f t compressing le
ver to set tone device. P u l l on torque wrench u n t i l
VALWES ping is heard. Take reading on torque wrench at this
Inspect the remaining m a r g i n after the valves are instant. M u l t i p l y this reading by 2. This w i l l give the
refaced (Fig. 17). Valves w i t h less t h a n 1.190 m m spring load at test length. Fractional measurements
(0.047 inch) margin should be discarded. are indicated on the table for finer adjustments. Re
lowable tensions. Discard the springs t h a t do not
meet specifications.
I - 124 8 J L ENGINE
OIL LEVEL
HIGH
If oil level is above the FULL mark, it is possible
engine running this condition could create foam in
LOW
When air is fed to the tappets, causes them to lose
length and allows valves to seat noisily. Any leaks on
intake side of oil pump through which air can be
drawn will create the same tappet action. When tap
Fig. 18 Testing Valve Spring for Compressed pet noise is due to aeration, it may be intermittent or
Length constant, and usually more than 1 tappet will be
INSTALLATION noisy. When oil level and leaks have been corrected,
(1) Make sure there are no burrs on valve stems. engine should be operated at fast idle for sufficient
(2) Coat valve stems with lubrication oil. Insert time. This allows all of the air inside of the tappets
valves into valve guides in cylinder head. to be bled out.
(3) Install new seals on all valve guides (BLACK
on intake a n d BROWN on exhaust). Install valve TAPPET NOISE DIAGNOSIS
springs and valve retainers. (1) To determine source of tappet noise, operate en
(4) Compress valve springs with Valve Spring gine at idle with cylinder head covers removed.
Compressor Tool MD-998772A and adapter 6716A, (2) Feel each valve spring or rocker arm to detect
install locks and release tool. Tap the retainer with a noisy tappet. The noisy tappet will cause the affected
brass or heavy plastic hammer to ensure locks have spring and/or rocker arm to vibrate or feel rough in
been seated. operation.
(5) If valves and/or seats were ground, measure Worn valve guides or cocked springs are
the installed height of springs. Make sure the mea sometimes mistaken for noisy tappets. If such is
surement is taken from bottom of spring seat in cyl the case, noise may be dampened by applying
inder head to the bottom surface of spring retainer. If side thrust on the valve spring. If noise is not
spacers are installed, measure from the top of spacer. appreciably reduced, it can be assumed the
If height is greater than 42.86 mm (1-11/16 inches), noise is in the tappet. Inspect the rocker arm
install a 1.587 mm (1/16 inch) spacer in head coun- push rod sockets and push rod ends for wear.
terbore. Ensure this brings spring height back to nor (3) Valve tappet noise ranges from light noise to a
mal, 41.27 to 42.86 mm (1-5/8 to 1-11/16 inch). heavy click. A light noise is usually caused by exces
sive leak-down around the unit plunger or by the
HYDRAULIC TAPPETS plunger partially sticking in the tappet body cylinder.
Before disassembling any part of the engine to cor The tappet should be replaced. A heavy click is
rect tappet noise, check the oil pressure. If vehicle caused by a tappet check valve not seating or by for
has no oil pressure gauge, install a reliable gauge at eign particles becoming wedged between the plunger
the pressure sending unit. The pressure should be and the tappet body. This will cause the plunger to
between 207-552 kPa (50-60 psi) at 3,000 RPM with stick in the down position. This heavy click will be
a fully warmed engine. accompanied by excessive clearance between the
Check the oil level after the engine reaches normal valve stem and rocker arm as valve closes. In either
operating temperature. Allow 5 minutes to stabilize case, tappet assembly should be removed for inspec
oil level, check dipstick. The oil level in the pan tion and cleaning.
should never be above the FULL mark or below the The valve train generates a noise very much like a
ADD OIL mark on dipstick. Either of these 2 condi light tappet noise during normal operation. Care
tions could be responsible for noisy tappets. must be taken to ensure that tappets are making the
noise. In general, if more than one tappet seems to
be noisy, its probably not the tappets.
mm 8 J L ENGINE i -125
REMOVAL tighten to 28 N-m (21 ft. lbs.) torque.

(1) Disconnect the negative cable from the battery. (7) Install lower and upper intake manifold.
(2) Remove the air cleaner. (8) The cylinder head cover gasket can be used
(8) Remove cylinder head cover. again. Install the gasket onto the head rail. For the
(4) Remove rocker arm assembly and push rods. left side the member tab is at the front of en
Identify push rods to ensure installation in original gine with the number up. For the right side the
location. mnsber tab is at the rear of engine with the
(5) Remove upper and lower intake manifold. number up.
(6) Remove the cylinder head, if the end tappets
are to be removed. CAUTION: The cylinder head cower fasteners have a
(7) Remove yoke retainer spider and tappet align special plating. DO NOT use alternative fasteners.
ing yokes (Fig. 1).
(9) Position the cylinder head cover onto the gas
ket. Install the stud bolts and hex head bolts in the
proper positions (Fig. 1). Tighten the stud bolts and
the bolts to 16 N*m (144 in. lbs.) torque.
(10) Install the air cleaner.
C A U T I O N To prevent damage to valve mechanism,
engine must not be run above fast idle until all hy
draulic tappets have filled with oil and have become
quiet

(12) Road test vehicle and check for leaks.
VALVE TlillG
(1) Turn crankshaft until the No.6 exhaust valve is
closing and No.8 intake valve is opening.
(2) Insert a 6.350 mm (1/4 inch) spacer between
rocker arm pad and stem tip of No.l intake valve. Al
low spring load to bleed tappet down giving in effect
a solid tappet.
(3) Install a dial indicator so plunger contacts
valve spring retainer as nearly perpendicular as pos
Fig. 1 Tappets, Aligning Yoke and Woke Retaining sible. Zero the indicator.
Spider (4) Rotate the crankshaft clockwise (normal run
ning direction) until the valve has lifted 0.863 mm
(8) Pull tappet out of bore with a twisting motion. (0.034 inch). The timing of the crankshaft should
If all tappets are to be removed, identify tappets to now read from 10° before top dead center to 2° after
ensure installation in original location. top dead center. Use a protractor as there are no tim
(9) If the tappet or bore in cylinder block is scored, ing marks on the engine.
scuffed, or shows signs of sticking, ream the bore to
next oversize. Replace with oversize tappet. CAUTaOrl: DO HOT turn crankshaft any further
(10) Check camshaft lobes for abnormal wear. clockwise as valve spring might bottom and result
in serious damage.
INSTALLATION
(1) Lubricate tappets. (5) If reading is not within specified limits:
(2) Install tappets in their original positions. En (a) Check sprocket index marks.
sure that' the oil bleed hole (if so equipped) (b) Inspect timing chain for wear.
faces forward. (c) Check accuracy of TDC mark on timing indi
(8) Install tappet aligning yokes. Position the yoke cator.
retainer spider over the tappet aligning yokes (Fig.
1). Install the yoke retaining spider bolts and tighten ORATION DAMPER
(4) Install cylinder head if removed. REMOVAL
(5) Install the push rods in their original location. (1) Disconnect the negative cable from the battery.
(6) Position the rocker arm assembly on the pedes (2) Remove fan shroud retainer bolts and set
tal and align to the push rods. Install the bolts and shroud back over engine.
I -111 § J L ENGINE BR
(8) Remove the cooling system fan.

(4) Remove the serpentine belt (refer to Group 7,
Cooling System).
(5) Remove crankshaft pulley/damper bolt and
washer from end of crankshaft (Fig. 2).
J9409-142
Fig. 3 Installing Crankshaft Pulley—Damper

(4) Unbolt A/C compressor and set on top of en
gine.
(6) Remove generator, air pump, and bracket as
J9409-138
sembly.
Fig. 2 Crankshaft Pulley—Damper (5) Remove water pump (refer to Group 7, Cooling
(8) Using a 3-prong puller tool, pull pulley— System).
damper off of the crankshaft. (7) Using a 3-prong puller to remove pulley/
(7) Inspect crankshaft oil seal (Fig. 8). damper from the crankshaft.(Fig.4)
INSTALLATION
(1) Position the crankshaft pulley/damper onto the
crankshaft.
(2) Use tool C-3688 to press the pulley/damper
onto the crankshaft. Install crankshaft bolt and
washer and tighten to 188 N-m (185 ft. lbs.) torque
(Pig.3).
Cooling System).
T H U G CHAIN COWER
REMOVAL
(2) Drain cooling system (refer to Group 7, Cooling J9409-138
System).
(3) Remove the serpentine belt (refer to Group 7, Fig. 4 Pulley—Damper Removal
Cooling System).
(8) Remove fan shroud.
(4) Remove fan.
en 8 J L ENGINE S -127
(8) Loosen oil pan bolts and remove the front oil
pan bolts that mount the pan to the timing chain
coven
(9) Eemove the cover bolts.
(10) Remove timing chain cover and gasket using
extreme caution to avoid damaging oil pan gasket.
(11) Inspect surface of cover. Remove any burrs or
high spots.
TIMING CHAIN STRETCH
any movement of the chain may be measured.
(2) Place a torque wrench and socket over cam
shaft sprocket attaching bolt. Apply torque in the di
rection of crankshaft rotation to take up slack; 41
N-m (30 ft. lbs.) torque with cylinder head installed
moved. ' With a torque applied to the camshaft
sprocket bolt, crankshaft should not be permitted to
move. It' may be necessary to block the crankshaft to
prevent rotation.
(3) Hold a scale with dimensional - reading even
with the edge of a chain link. With cylinder heads in
stalled, apply 14 N-m (80 ft. lbs.) torque in the re
verse direction. With the cylinder heads removed,
apply 20 N-m (15 ft. lbs.) torque in the reverse direc
tion. Note the amount of chain movement (Fig. 5).
J9409-96
Fig. 5 Measuring Timing Chain Wear and Stretch

(4) Install a new timing chain, if its movement ex
ceeds 3.175 mm (1/8 inch). /
SPECIAL SPECIAL
(5) If chain is not satisfactory, aline camshaft and TOOL TOOL
MD990799 J9409-140
crankshaft centerline. Remove camshaft sprocket at G3718
taching bolt and remove timing chain and camshaft
Fig. 7 Crankshaft Sprocket Installation
sprockets.
(6) Use puller 6444 and jaws 6820 to remove crankshaft sprocket. Check to see that timing marks
crankshaft sprocket (Fig. 6). are on the centerline of the crankshaft and camshaft
(6) Line up key in crankshaft with keyway in centerline (Fig. 8).
sprocket, press on crankshaft timing sprocket, use (11) Install the camshaft bolt. Tighten the bolt to
tools C-3688, C-3718 and MB-990799, seat sprocket 61 N-m (45 ft. lbs.) torque.
against crankshaft shoulder (Fig.7). (12) Check camshaft end play. The end play should
(7) Turn crankshaft to line up the timing mark be 0.051-0.152 mm (0.002-0.006 inch) with a new
with the crankshaft and camshaft centerline. thrust plate and up to 0.254 mm (0.010 inch) with a
(8) Put chain on camshaft sprocket. used thrust plate. If not within these limits install a
(9) Take chain and camshaft sprocket, align timing new thrust plate.
marks and install chain and cam sprocket onto
I - 128 8 J L ENGINE HR
(3) Tighten timing chain cover bolts to 47 N-m (35

CAMSHAFT ft. lbs.) torque. Tighten oil pan bolts to 24 N-m (215
SPROCKET
in. lbs.) torque.
(4) Install pulley/vibration damper use tool C-3688
(Fig.10)
TIMING
MARKS
CRANKSHAFT
SPROCKET
J9409-69 SPECIAL
TOOL
Fig. 8 Alignment of Timing Marks C-3688
CLEANING
Be sure mating surfaces of timing chain cover and
cylinder block are clean and free from burrs.
INSTALLATION
(1) Lubricate the pump rotors using petroleum
jelly or lubriplate and install in the timing chain
cover (Fig. 9)
J9409-142
Fig. 10 Installing Crankshaft Pulley/Damper

(5) Prime oil pump by squirt oil in the oil filter
FILL WITH mounting hole and filling the J-trap of the front tim
PETROLEUM JELLY ing cover. When oil is running out, install oil filter
OR LUBER PLATE that has been filled with oil.
ing o-ring (refer to Group 7, Cooling System). Tighten
(7) Install generator, air pump, and bracket assem
bly.
(8) Install A/C compressor.
Cooling System).
J9409-141
Fig. 9 Priming Oil Pump. (13) Connect the negative cable to the battery.
(14) Road test vehicle and check for leaks.
(2) Using a new cover gasket, carefully install tim
ing chain cover to avoid damaging oil pan gasket. TIMING CHAIN COVER OIL S E A L
hesive Sealant, or equivalent, at the joint between REMOVAL IN VEHICLE
timing chain cover gasket and the oil pan gasket. (1) Disconnect the negative cable from the battery.
Finger tighten the timing chain cover bolts at this (2) Remove the cooling fan and shroud.
time. (3) Remove the serpentine belt (refer to Group 7,
Cooling Systems).
R - — — 8 J L ENGINE 9 -129
(4) Using a 3-jaw puller tool, pull pulley/damper REMOVAL O U TO F VEHICLE

off of the crankshaft. (1) With timing cover removed from engine place a
(5) Place a suitable tool behind the lips of the oil suitable tool behind the lips of the oil seal to pry the
seal to pry the oil seal outward. Be careful not to oil seal outward. Be careful not to damage the crank
damage the crankshaft seal surface of the cover (Fig. shaft seal surface of the cover.
11).
INSTALLATION OUT OF VEHICLE
(1) Position the crankshaft front oil seal onto seal
installer special tool 6806.
(2) Use tool 6 7 6 1 to support timing chain cover
when installing oil seal with tool 6 8 0 6 (Fig. 13), in
stall seal.
J9409-68
Fig. 11 Timing Chain Cover and Oii Seal

INSTALLATION IN VEHICLE
(3) Position the crankshaft front oil seal onto seal
installer special tool 6806 and C-3688 (Fig. 12). In
stall seal.
J9409-137
Fig. 13 Oil Seal, Tools—6806 and 6761

CAMSHAFT
REMOVAL
(1) Remove cylinder head covers.
(2) Remove rocker arm assemblies, identify each
part so it can be installed in its original location..
(3) Remove push rods and tappets. Identify each
part so it can be installed in its original location.
The 4 corner tappets can not be removed without
removing the cylinder heads and gaskets. They can
TOOL
be lifted and retained for camshaft removal.
6806 J9409-136 (4) Remove upper and lower intake manifold (refer
Fig. 12 Timing Chain Cower and Oil Seal to Group 11 Intake and Exhaust Systems).
(2) Install crankshaft pulley/damper using tool (5) Remove timing chain cover and timing chain.
C-3688. (6) Remove camshaft thrust plate (Fig. 16).
(3) Install serpentine belt (refer to Group 7, Cool (7) Install a long bolt into front of camshaft to fa
ing System). cilitate removal of the camshaft. Remove camshaft,
(4) Install cooling fan and shroud. being careful not to damage cam bearings with the
(5) Connect negative cable to the battery. cam lobes.
9 - 131 8 J L ENGINE
SPECIAL
TOOL
6806
9209-93
dilation
with Tool C-3182-A
INSTALLATION—BEARING
(1) Install new camshaft bearings with Camshaft
Bearing Remover/Installer Tool C-3132-A by sliding
the new camshaft bearing shell over proper adapter.
SPECIAL (2) Position rear bearing in the tool. Install horse
TOOL shoe lock and by reversing removal procedure, care
6761 J9409-143
Fig. 14 Oii Seal Installed
THRUST
PLATE
PUMP AND rectly. Install a new core hole plug at the rear of
DISTRIBUTOR DRIVE camshaft. Be sure this plug does not leak.
GEAR INTEGRAL
WITH CAMSHAFT
NSTALLATION .
'CAMSHAFT SPROCKET
J9309-71 journals. Using a long bolt, insert the camshaft into
the cylinder block.
lg. 15 Camshaft and Sprocket Assembly Whenever an engine has been rebuilt, a new
CAMSHAFT pint of Mopar® Crankcase Conditioner, or
gine for a minimum of 805 k m (500 miles).
(2) Install camshaft thrust plate. Tighten the torx
(3) Check camshaft end play. The end play should
-THRUST PLATE
thrust plate and up to 0.254 mm (0.010 inch) with a
J9409-70
used thrust plate. If not within these limits install a
Fig. 16 Camshaft
new thrust plate.
(4) Line up key with keyway in sprocket, press on
REMOVAL—BEARINO crankshaft timing sprocket, use tools C-3688, C-3718
This procedure requires that the engine is removed and MB990799, to seat sprocket against crankshaft
from the vehicle. shoulder (Fig. 18).
(1) With engine completely disassembled, drive out (5) Align timing mark on crankshaft sprocket with
rear cam bearing core hole plug. center line of crankshaft and camshaft.
(2) Install proper size adapters and horseshoe (6) Put chain on camshaft sprocket.
washers (part of Camshaft Bearing Remover/Installer (7) Take chain and camshaft sprocket and align
Tool C-3132-A) at back of each bearing shell. Drive mark with centerline of crankshaft and camshaft in
out bearing shells (Fig. 17). stall camshaft sprocket and chain to camshaft.
BR S.OL ENGINE I -131
OIL PAN
REMOVAL
(2) Raise vehicle.
(5) Remove oil pan and one-piece gasket. The en
gine may have to be raised slightly on 2WD vehicles.
(6) Remove the oil pick-up tube assembly (Fig. 1).
Discard the gasket.
PICK-UP
TUBE
SEALANT AT
SPECIAL SPECIAL SPLIT-LINE SEALANT
TOOL TOOL AT SPLIT-
MD990799 C-3718 J9409-140 LINES
Fig. 18 Crankshaft Sprocket installation

(8) Install the camshaft bolt. Tighten bolt to 75
(9) Install the timing chain cover.
(10) Install the crankshaft pulley/damper use tool J9409-76
C-8688.
Fig. 1 Oil Pick-Up Tube
mounting hole and filling the J-trap of the front tim CLEANING
ing cover. When oil is running out, install oil filter Clean the block and pan gasket surfaces.
that has been filled with oil. If present, trim excess sealant from inside the en
(12) Each tappet reused must be installed in the gine.
same position from which it was removed. When Clean oil pan in solvent and wipe dry with a clean
camshaft is replaced, all of the tappets must be cloth.
replaced. Clean oil screen and pipe thoroughly in clean sol
(13) Install tappets and push rods in their original vent. Inspect condition of screen.
location.
(14) Install the rocker arms. INSPECTION
(15) The cylinder head cover gasket can be used Inspect oil drain plug and plug hole for stripped or
again. Install the gasket onto the head rail. For the damaged threads. Repair as necessary.
left side the number tab is at the front of en Inspect oil pan mounting flange for bends or distor
gine with the number up. For the right side the tion. Straighten flange, if necessary.
number tab is at the rear of engine with the
' INSTALLATION
number up.
(1) Fabricate 4 alignment dowels from 5/16 x 1 1/2
CAUTION: The cylinder head cover fasteners have a inch bolts. Cut the head off the bolts and cut a slot
into the top of the dowel. This will allow easier in
stallation and removal with a screwdriver (Fig. 2).
(16) Position the cylinder head cover onto the gas (2) Install the dowels in the cylinder block at the
ket. Install the stud bolts and hex head bolts in the four corners.
proper positions (Fig. 1). Tighten the stud bolts and (3) Apply small amount of Mopar® Silicone Rubber
the bolts to 16 N-m (144 in. lbs.) torque. Adhesive Sealant, or equivalent at the split lines.
(17) Install the intake manifolds, (refer to Group The split lines are between the cylinder block, the
11 Intake and Exhaust Systems). timing chain cover and the rear crankshaft seal as
sembly (Fig. 1). After the sealant is applied you
have 3 minutes to install the gasket and oil pan.
w
5/16" x 1 Vz BOLT
V
11 1
DOWEL
SLOT J9509-163 • 1/4-20 BOLTS

© 5/16-18 BOLTS J9409-74
Fig. 3 Oil Pan Bolt Location
(4) Slide the one-piece gasket oyer the dowels and
onto the block. (8) Install the drain plug. Tighten drain plug to 84
(5) Position the oil pan over the dowels and onto N-m (25 ft. lbs.) torque.
the gasket. The engine may have to be slightly raised (9) Install the engine to transmission strut.
on 2WD vehicles. (10) Lower vehicle.
(6) Install the oil pan bolts (Fig. 3). Tighten the 1/4 (11) Connect the negative cable to the battery.
inch bolts to 11 N-m (96 in. lbs.) torque. Tighten the (12) Fill crankcase with oil to proper level.
stud bolts to 16 N-m (144 in. lbs.) torque. Tighten the
5/16 inch bolts to 16 N-m (144 in. lbs.) torque.
(7) Remove the dowels. Install the remaining 5/16
inch oil pan bolts. Tighten these bolts to 16 N-m (144
in. lbs.) torque.
The lubrication system is a full flow filtration pres main oil gallery. This oil gallery feeds oil under pres
sure feed type. Oil stored in the oil pan is taken in sure to the main and rod bearings and camshaft
and discharged by an internal gear pump directly bearings. Passages in the cylinder block feed oil to
coupled to the crankshaft. Its pressure is regulated the hydraulic lifters through hollow push rods which
by the relief valve located in the chain case cover. feeds the rocker arm sockets.
The oil is pump through an oil filter and feeds three
OIL GALLERY
FOR TAPPETS
TAPPET
OIL PRESSURE RELIEF VALVE
CAMSHAFT
HYDRAULIC
TAPPET
FRTOF
BLOCK
OIL PICKUP J9509-144
FIG. 4 ENGINE LUBRICATION SYSTEM

9 • 134 8 J L ENGINE — — — — — — BR
OIL PUMP Lay a straightedge across the pump cover surface

(Fig. 7). If a 0.076 mm (0.003 inch) feeler gauge can
REMOVAL be inserted between cover and straightedge, cover
(1) Remove the timing chain cover, should be replaced.
(2) Remove the relief valve plug, gasket, spring
and valve (Fig. 5). Discard the gasket.
PLUG TIMING
>-68
Fig. 7 Checking Oil Pump Cover Flatness

Measure thickness (Figs. 7 and 8) and diameter of
Fig, 5 OII Pressure Relief Valve rotors. If either rotor thickness measures 18.92 mm
(3) Remove oil pump cover (Fig. 6). (0.744 inch) or less, or if the diameter is 82.45 mm
(3.246 inches) or less, replace rotor set.
(4) Remove pump rotors (Fig. 6).
OUTER INNER
ROTOR ROTOR
Fig. 8 Measuring Outer Rotor Thickness

Slide outer rotor into timing chain cover pump
body. Press rotor to the side with your fingers and
TIMING CHAIN measure clearance between rotor and pump body
COVER J9409-7! (Fig. 10). If clearance is 0.19 mm (0.007 inch) or
more, and outer rotor is within specifications, replace
Fig. 6 Oil Pump timing chain cover.
GLEANING Install inner rotor into timing chain cover pump
Wash all parts in a suitable solvent and inspect body (Fig. 12). Inner rotor should be positioned with
carefully for damage or wear. chamfer up or toward engine when cover is installed.
This allows easy installation over crankshaft. If
INSPECTION clearance between inner and outer rotors is 0.150
Mating surface of the oil pump cover should be mm (0.006 inch) or more, replace both rotors.
smooth. Replace pump cover if scratched or grooved. Place a straightedge across the face of the timing
chain cover pump body, between bolt holes (Fig. 12).
8.IL ENGINE S -131
9309-70
Fig. § Measuring Inner Rotor Thickness Fig. 12 Measuring Clearance Over Rotors
inspect oil pressure relief valve plunger for scoring
and free operation in its bore. Small marks may be
imately 49.5 mm (1.95 inches). The spring should
test between 100 and 109 N (22.5 and 24.5 pounds)
when compressed to 84 mm (1-11/82 inches). Replace
spring that fails to meet these specifications.
INSTALLATION
(1) Lubricate the pump rotors using petroleum
jelly or lubriplate and install in the timing chain
cover. Use new parts as required (Fig. 18).
Fig. 11 Measuring Inner Rotor Clearance in Cower

If a feeler gauge of 0,077 mm (0.008 inch) or more
can be inserted between rotors and the straightedge,
and the rotors are within specifications, replace tim
ing chain cover.
Fig. 18 Priming Oil Pump.
(2) Position the oil pump cover onto the timing INSPECTION
chain cover. Tighten cover bolts to 14 N°m (125 in, Check the crankshaft connecting rod journal for ex
lbs.) torque. cessive wear, taper and scoring.
(8) Make sure that inner ring moves freely after Check the cylinder block bore for out-of-round,
cover is installed. taper, scoring and scuffing.
(4) Install the timing chain cover.
(5) Squirt oil into relief valve hole until oil runs FITTING PISTONS
out. Piston and cylinder wall must be clean and dry.
(6) Install the relief valve and spring. Specified clearance between the piston and the cylin
(7) Using a new pressure relief valve gasket, in der wall is 0.013-0.038 mm (0.0005-0.0015 inch).
stall the relief valve plug. Tighten the plug to 20 N*m Piston diameter should be measured at the top of
(15 ft. lbs.) torque. skirt, 90° to piston pin axis. Cylinder bores should be
(8) Install oil filter that has been filled with oil. measured halfway down the cylinder bore and trans
verse to the engine crankshaft center line.
PISTON AND CONNECTING ROD ASSEMBLY Pistons and cylinder bores should be measured at
The pistons are elliptically turned so that the di normal room temperature, 2PC (70°F).
ameter at the pin boss is less than its diameter (1) To correctly select the proper size piston, a cyl
across the thrust face. This allows for expansion un inder bore gauge, Special Tool 6879 or equivalent, ca
der normal operating conditions. Under operating pable of reading in .0001" INCREMENTS is required.
temperatures, expansion forces the pin bosses away If a bore gauge is not available, do not use an inside
from each other, causing the piston to assume a more micrometer.
nearly round shape. The coating material is applied to the piston after
All pistons are machined to the same weight, re the final piston machining process. Measuring the
gardless of size, to maintain piston balance. outside diameter of a coated piston will not provide
The piston pin rotates in the piston only and is re accurate results. Therefore measuring the inside di
tained by the press interference fit of the piston pin ameter of the cylinder bore with a dial Bore Gauge is
in the connecting rod. MANDATORY.. To correctly select the proper size
The pistons have a unique dry-film lubricant coat piston, a cylinder bore gauge capable of reading in
ing baked onto the skirts to reduce friction. The lu .0001" increments is required.
bricant is particularly effective during engine break- Piston installation into the cylinder bore require
in, but with time, the material becomes embedded slightly more pressure than that required for non-
into cylinder bore walls and continues to reduce fric coated pistons. The bonded coating on the piston will
tion. give the appearance of a line-to-line fit with the cyl
inder bore.
REMOVAL B
" (1) Eemove the engine from the vehicle (refer to
Engine Eemoval of this manual).
(2) Remove the valve cover, rocker arms, push rods
and cylinder head. Mark parts as removed.
(3) Remove the oil pan and oil pump pick-up tube.
(4) Remove top ridge of cylinder bores with a reli
able ridge reamer before removing pistons from cyl
inder block. Be sure to keep tops of pistons covered
during this operation.
(5) Be sure the connecting rod and connecting rod
cap are identified with the cylinder number. Remove
connecting rod cap. Install connecting rod bolt guide
set on connecting rod bolts.
(6) Pistons and connecting rods must be removed
from top of cylinder block. When removing piston and
connecting rod assemblies, rotate crankshaft center
the connecting rod in the cylinder bore and at BDC.
Be careful not to nick crankshaft journals. DO
NOT try to remove Mack coating on skirt. This
is the dry film lubricant. J9509-125
(7) After removal, install bearing cap on the mat
ing rod. Fig. 14 Bore Gauge
mm — _ S J L ENGINE I -137
FITTING RINGS TOP COMPRESSION RING

(1) Measurement of end gaps; (GRAY IN COLOR)
(a) Measure piston ring gap 2 inches from bot
tom of cylinder bore. An inverted piston can be
used to push the rings down to ensure positioning
rings squarely in the cylinder bore before measur
ing.
(b) Insert feeler stock in the gap. Gap for com
pression rings should be between 0.254-0.508 mm
(0.010-0.020 inch).. The oil ring gap should be
0.381-1.397 mm (0.015-0.055 inch).
J9009-48
(c) Rings with insufficient end gap may be prop
erly filed to the correct dimension. Ends should be Fig. 16 Top Compression Ring Identification-
stoned smooth after filing with Arkansas White Typical
Stone. Rings with excess gaps should not be used.
(2) Install rings and confirm ring side clearance: CHAMFER TOP COMPRESSION
(a) Install oil rings being careful not to nick or ^ ^^ RING
cording to instructions in the package. It is not nec
essary to use a tool to install the upper and lower
rails. Insert oil rail spacer first, then side rails.
(b) Install the second compression rings using In SECOND
^-COMPRESSION
stallation Tbol 0-4184. The compression rings must
mm
be installed with the identification mark face up
(toward top of piston) and chamfer facing down. An 1 ?
^JS^^B^M^P: N
identification mark on the ring is a drill point, a PISTON J9409-37

TOP Figs. 15 and 17. Fig, T7 Compression Ring Chamfer Location-
Typical
SECOND COMPRESSION RING CHAMFER
(BLACK CAST IRON) (8) Arrange ring gaps 180° apart as shown in Fig.
18.
TOP COMPRESSION RING GAP
. UPPER OIL RING GAP
SPACER FRONT
TWO . GAP . Of
DOTS J9009-46 ENGINE
m
Fig. 15 Second Compression Ring Identification—
Typical
(c) Using a ring installer, install the top compres
sion ring with the chamfer facing up (Fig. 16). An 2ND COMPRESSION RING GAP
LOWER OIL RAIL GAP
identification mark on the ring is a drill point, a smm*77
TOP facing up.. Fig. 18 Proper Ring Installation
(d) Measure side clearance between piston ring CONNECTING- ROD BEARINGS
and ring land. Clearance should be 0.074-0.097 mm Fit all rods on a bank until completed. DO NOT al
(0.0029-0.0038 inch) for the compression rings. The ternate from one bank to another, because connecting
steel rail oil ring should be free in groove, but rods and pistons. are not interchangeable from one
should not exceed 0.246 mm (0.0097 inch) side bank to another.
clearance. The bearing caps are not interchangeable and
(e) Pistons with insufficient or excessive side should be marked at removal to ensure correct as
clearance should be replaced. sembly.
Each bearing cap has a small V-groove across the FRONT I.P.
parting face. When installing the lower bearing shell, TOWARDS THIS SIDE
make certain that the V-groove in the shell is in line
tion of the cylinder wall in the opposite bank.
The bearing shells must be installed so that the
tangs are in the machined grooves in the rods and
caps.
Limits of taper or out-of-round on any crankshaft
journals should be held to 0.025 mm (0.001 inch).
Bearings are available in 0.025 mm (0.001 inch),
0.051 mm (0.002 inch), 0.076 mm (0.003 inch), 0.254
mm (0.010 inch) and 0.305 mm (0.012 inch) under
size. Install the bearings in pairs. DO NOT use a
new bearing half with an old bearing half. DO
NOT file the rods or bearing caps.
INSTALLATION
gered so that neither is in line with oil ring rail gap.
(2) Before installing the ring compressor, make ORIENTATION BUTTON ORIENTATION BUTTON
sure the oil ring expander ends are butted and the TOWARDS FRONT TOWARDS REAR
rail gaps located properly (Fig. 15). (LH. ONLY) (R.H. ONLY)
(3) Immerse the piston head and rings in clean en 1,3,5,7,9 2,4,6,8,10
gine oil. Slide Piston Ring Compressor Tool C-385
over the piston and tighten with the special wrench
(part of Tool C-385). Be sure position of rings
J9409-78
does not change during this operation.
(4) Install connecting rod bolt protectors on rod
Fig. 19 Piston and Rod Orientation
bolts, a long protector should be installed on the
numbered side of the connecting rod. bearings. Therefore, selective fitting of the bearings
(5) Rotate crankshaft so that the connecting rod is not required when a crankshaft and bearings are
journal is on the center of the cylinder bore in the replaced.
bottom dead center position. Be sure connecting rod
and cylinder bore number are the same. Insert rod REMOVAL
and piston into cylinder bore. Be sure the piston and (1) Remove the oil pan.
rod assemblies are installed in the proper orientation (2) Remove the oil pickup tube.
(Fig. 19). (3) Remove the timing chain cover and gasket. Re
(6) The notch, groove or arrow on top of piston move and discard the front crankshaft oil seal and
must be pointing toward front of engine. The larger cover gasket.
chamfer of the connecting rod bore must be installed (4) Remove Transmission (refer to Group 21,
toward crankshaft journal fillet. Transmission).
(7) While tapping the piston down in cylinder bore (5) Remove the rear seal retainer. Remove and dis
with the handle of a hammer, guide the connecting card the crankshaft rear oil seal and retainer gasket.
rod over the crankshaft journal. (6) Identify main bearing caps before removal (Fig.
(8) Install rod caps. Install nuts on cleaned and 20). Remove bearing caps and bearings one at a time.
oiled rod bolts and tighten nuts to 61 N-m (45 ft. lbs.) (7) Remove the connecting rod bearing caps.
torque. (8) Lift the crankshaft straight out of the block.
(9) Install the oil pump pick-up tube and oil pan.
(10) Install the cylinder head, push rods, rocker JOURNALS
arms and valve cover. The crankshaft connecting rod and main journals
(11) Install lower intake manifold. should be checked for excessive wear, taper and scor
(11) Install the engine into the vehicle.(refer to En ing. The maximum taper or out-of-round on any
gine Installation of this manual). crankshaft journal is 0.025 mm (0.001 inch).
CRANKSHAFT Journal grinding should not exceed 0.305 mm
When a crankshaft is replaced, all main and con (0.012 inch) under the standard journal diameter. DO
necting rod bearings should be replaced with new NOT grind thrust faces of No.3 main bearing. DO
BR - < - - - S.OL ENGINE 9 -139
thrust bearing against No.3 bulkhead. Repeat proce

dure, driving crankshaft forward to align rear flange
of thrust bearings in a common plane. Front face of
No.l main cap must not extend forward in front of
face of No.l bulkhead.
(9) Install the oil pickup tube. Tighten the bolts to
16 N-m (144 in. lbs.) torque.
CRANKSHAFT MAIN BEARINGS

be marked at removal to ensure correct assembly.
Upper and lower bearing halves are NOT inter
changeable. All lower main bearing halves are inter
changeable. Upper main bearing halves of No. 2, 4,
and 5 are interchangeable. Upper main bearing
halves of No. 1 and 6 are interchangeable, this also
applies to the lower bearing halves.
The No.3 main bearing is flanged to carry the
crankshaft thrust loads. This bearing is NOT inter
changeable with any other bearing halves in the en
Fig. 20 Main Bearing identification
gine. Bearing shells are available in standard and
the following undersizes: 0.25 mm (0.001 inch), 0.051
NOT nick crank pin or bearing fillets. After grinding, mm (0.002 inch), 0.076 mm (0.003 inch), 0.254 mm
remove rough edges from crankshaft oil holes and (0.010 inch) and 0.305 mm (0.012 inch). Never install
clean out all oil passages. an undersize bearing that will reduce clearance be
low specifications.
CAUTION: After any journal grind, it is important
that the final paper or cloth polish be in the same REMOVAL
direction as the engine rotates. (1) Remove the oil pan and oil pump pick-up tube.
(2) Identify bearing caps before removal. Remove
INSTALLATION
bearing caps one at a time.
(1) Lubricate crankshaft main bearings with clean (3) Remove upper half of bearing by inserting
engine oil. Crankshaft Main Bearing Remover/Installer Tool
(2) Install the crankshaft into the cylinder block. C-3059 into the oil hole of crankshaft (Fig. 21).
(3) Lubricate the main journals with clean engine (4) Slowly rotate crankshaft clockwise, forcing out
oil. Install main bearing caps and bolts. Follow the 2 upper half of bearing shell.
step tightening sequence.
• Step 1—Starting with bearing cap No.l, tighten
the bolts to 27 N-m (20 ft. lbs.) torque.
• Step 2—Starting with bearing cap No.l, tighten
the bolts to 115 N-m (85 ft. lbs.) torque.
(4) Lubricate the connecting rod bearings and jour
nals with clean engine oil. Carefully install connect
ing rods to the crankshaft.
(5) Install the rear seal retainer with a new gasket
and oil seal. Use seal installer 6687 when installing
the oil seal.
(6) Install the timing chain cover with a new gas
ket and oil seal.
mounting hole and filling the J-trap of the front tim
ing cover. When oil is running out, install oil filter
that has been filled with oil. Fig. 21 Upper Main Bearing Removal and
(8) Apply a rearward axial load of 667 N (150 lbs-f) Installation with Tool C-3059
on crankshaft centerline, driving No.3 main cap and
B R
S - m O L ENGINE «
INSTALLATION
Cnly one main bearing should be selectively fitted (1) Position the rear seal in the retainer.
while all .other main bearing caps are properly tight (2) Using Special Tool 6687, position the retainer
ened. All bearing capbolts removed during service and oil seal over the crankshaft. Install the bolts and
procedures are to be cleaned and oiled before instal tighten to 22 N-m (16 ft. lbs.) torque.
lation. (3) The seal face surface must be within 0.508 mm
When installing a new upper bearing shell, slightly (0.020 in) full indicator movement relative to rear
chamfer the sharp edges from the plain side. face of crankshaft. If out of limits, gently tap the
(1) Start bearing in place, and insert Crankshaft high side into the retainer.
Main Bearing Remover/Installer Tool C-3059 into oil (-4) Add a small amount of Mopar® Silicone Rubber
hole of crankshaft (Fig. 21). Adhesive Sealant at split-line.
(2) Slowly rotate crankshaft counterclockwise slid (5) Install the oil pan.
ing the bearing into position. Remove Tool C-3059. (7) Install the transmission (refer to group 21,
(8) Lubricate the main journals with clean engine Transmissions).
oil. Install main bearing caps and bolts. Follow the 2
step tightening sequence. GYUMDER BLOCK
«? Step 1—Starting with bearing cap No.l, tighten
the bolts to 27 N-m (20 ft. lbs.) torque. Remove the engine assembly from the vehicle.
© Step 2—Starting with bearing cap No.l, tighten
the bolts to 115 N-m (85 ft. lbs.) torque. (1) Remove the cylinder head and valve train.
(4) Apply a rearward axial load of 667 N (150 lbs-f) (2) Remove the intake system.
on crankshaft 'centerline, driving No.8 main cap and
( 8 ) Remove the timing cover and timing chain with
thrust bearing against No.8 bulkhead. Repeat proce
dure, driving crankshaft forward to align rear flange sprockets.
of thrust bearings in a common plane. Front face of (4) Remove the oil pan.
No.l main cap must not extend forward in front of (5) Remove the piston-connecting rod assemblies.
face of No.l bulkhead. (6) Remove the crankshaft and bearings.
(5) Instsli the oil pump pick-up tube and oil pan.
'HiQ
CRANKCH^f ; mm %mi mmnm Clean. ;ylinder block thoroughly and check all core
;,cl3 -yczgs for evidence of leaking.
REMOVAL
(1) Remove the transmission (refer to Group 21,
Transmissions). Examine block for cracks or fractures.
(2)' Remove the oil pan. The cylinder walls should be checked for out-of-
(3) Remove the rear seal retainer. Discard the oil round and taper with Cylinder Bore Indicator Tool,
seal and the gasket (Fig. 22). Special tool 6879 or equivalent. The cylinder block
should be bored and honed with new pistons and
rings fitted if:
o The cylinder bores show more than 0.127 mm
(0.005 inch) out-of-round.
o The cylinder bores show a taper of more than
0.254 mm (0.010 inch).
© The cylinder walls are badly scuffed or scored.
specified clearances may be maintained.
Refer to Standard Service Procedures in the begin
ning of this Group for the proper honing of cylinder
bores.
ENGINE QQms ui^jiimimpT PLUGS

Engine core plugs have been pressed into the oil
Fig. 22 Crankshaft Resr 3eai R?4;dner galleries behind the camshaft thrust plate. This will
reduce internal leakage and help maintain higher oil
OLSAUINQ
pressure at idle.
Wash all parts in a suitable solvent and inspect
BR S.OL ENGINE 9 -141
RE10WAI CLEAIlie
(1) Using a blunt tool such as a drift or a screw Thoroughly clean inside of cup plug hole in cylinder
driver and a hammer, strike the bottom edge of the block or head. Be sure to remove old sealer.
cup plug (Fig. 28). Make certain the new plug is cleaned of all oil or
(2) With the cup plug rotated, grasp firmly with grease.
pliers or other suitable tool and remove plug (Fig. INSTALLATION
23).
(1) Coat edges of plug and core hole with Mopar®
CYLINDER Gasket Maker, or equivalent.

It is not necessary to wait for curing of the sealant.
The cooling system can be filled and the vehicle
ASSEMBLE
(1) Install crankshaft and bearings.
(1) Install the piston/connecting rod assembly.'
Fig, 23 Core Hole Plug Removal (4) Install timing cover, timing chain and sprock
ets.
(3) Install the cylinder head and valve train.
(4) Install the engine into the vehicle.
(6) install intake system.
SPECIFICATIONS—8.0L ENGINE
Camshaft Crankshaft (Cont.)
Bore Diameter Main Bearing Diametrical Clearance

No.l 53.16 - 53.19 mm No 1 - No 6 0.0051 - 0.058 mm
(2.093 - 2.094 in)
No.2 52.76 - 52.78 mm (0.0002 - 0.0023 in)
(2.077-2.078 in) Max. Allowable ........0.071 mm
No.3 52.35 - 52.37 mm
(2.061 -2.062 in) (0.0028 in)
No.4 51,94 - 51.97 mm End Plav 0.076 - 0.305 mm
(2.045 - 2.046 in) X
* ( 0 . 0 0 3 - 0 . 0 1 2 in)
No.5 ....51.54 - 51.56 mm
(2.029 - 2.030 in) 3 1
No.6 ......48.74 - 48.77 mm Max. Allowable •••••9AI, j ? " ! 1
(1.919 -1.920 in) (0.015 in)

Diametrical Clearance M a i n Bearing Journals
Diameter 76.187 - 7A.2T3 mm
No.l & No.3 - No.6 ...0.0254 - 0.0762 mm
(0.001 - 0.003 in) • (2.9995 - 3.0005 in)
No.2 ..0.0381 -0.0889 mm Out-of-Round (Max.) °£ £ l 2 5 m r T
(0.0015-0.0035 in)
End Play 0.127-0.381 mm (0.001 in)
(0.005-0.015 in)
Bearing Journal Diameter 0
S ™ i
Cylinder Block
No.l 53.11 -53.14 mm
Cylinder Bore _ ,„
(2.091 - 2.092 in)
No.2 ................52.69 - 52.72 mm Diameter ...101.60 -101.61 mm
(2.0745 - 2.0755 in) (4.0000 - 4.0005 in)
No.3 ....52.30 - 52.32 mm
(2.059 - 2.060 in) Out-of-Round (Max.) 0.127 mm
No.4 ........51.89 - 51.92 mm (0.005 in)
(2.043 - 2.044 in) '•"»•-"*"'• ? ^ o l " i
No.5 .......51.49-51.51 mm Tappet Bore Diameter Z U « - « X n O -
(2.027 - 2.028 in) Cylinder Head
No.6 48.69 - 48.72 mm
(1.917- 1.918 in) Compression Pressure ...1172 -1310 kPa
K
(170- 190 psi)
Connecting tods Gasket Thickness (Compressed) 0.991 - 1.118 mm
(0.039 - 0.044 in)
Bearing Clearance 0.005 - 0.074 mm Valve Seat
(0.0002 - 0.0029 in) Angle 44.5

Piston Pin Bore Diameter 24.940 - 24.978 mm Runout (Max.) ?'°J£j I nn
(0.9819-0.9834 in)
Side Clearance (Two Rods) 0.25 - 0.46 mm (0.003 in)
(0.010-0.018 in) W i d t h (Finish)
Total Weight (Less Bearing) 744 grams Intake & Exhaust 1 02 - 1.52 mm
(26.24 oz) (0.040 - 0.060 in)
Crankshaft Guide Bore Diameter (Std.) 7.95 - 7.98 mm
Connecting Rod Journal (0.313-0.314 in)

Diameter ....53.950 - 53.975 mm
(2.124-2.125 in) Hydraulic Tappets
Out-of-Round (Max.) ..0.0254 mm
(0.001 in) Body Diameter .......................22.949 - 22.962 mm
7
Taper (Max.) 0.0254 mm (0.9035 - 0.9040 in)

Clearance in Block (Diametrial) 0.2030 - 0.0610 mm
(0.001 in) (0.0008 - 0.0024 in)
mrT
Plunger Travel Minimum (Dry) • 4.24 )
* (0.167 in)
1 9 5
Push Rod Length p 6 ^
J9509-141
JR S.OL ENGINE 8 143
Oii Pump Piston Rings
Clearance over Rotors (Max.) 0.1906 mm Ring Gap

(0.0075 in) Compression Rings 0,254 - 0.508 mm
Cover Out-of-Flat (Max.) ., 0.051 mm (0.010-0.020 in)
Oil Control (Steel Rails) 0.381 - 1.397 mm
(0.002 in) (0.015-0.055 in)
Inner Rotor Thickness (Min.) .....14.925 -14.950 mm Ring Side Clearance
(0.5876-0.5386 in) Compression Rings 0.074 - 0.097 mm
(0.0029 - 0.0038 in)
Outer Rotor Oil Ring (Steel Rails) 0.185 - 0.246 mm
Clearance (Max.) ......0.1626 mm (0.0)73 - 0.0097 in)
(0.006 in) Ring Width
Diameter (Min.) 82.461 mm Compression Rings 4.115 - 4.369 mm
(3.246 in) (0.162-0.172 in)
Oil Ring (Steel Rails) 2.591 - 2.743 mm
Thickness (Min.) 14.925 mm
(0.102-0.108 in)
(0.5876 in)
Tip Clearance between Rotors (Max.) 0.584 mm Yokes
(0.0230 in)
Oil Pressure (Engine Face Angle 45°
At Curb Idle Speed * . 83 - 172 kPa Head Diameter
Intake ...48.640 - 48.900 mm
( 1 2 - 2 5 psi)
(1.915-1.925 in)
At 3000 rpm 345 - 414 kPa Exhaust 41.123-41.377 mm
(50 - 60 psi) (1.619-1.629 in)
•CAUTION: If pressure is ZERO at curb idle, DO NOT Length (Overall)
run engine at 3,000 rpm. Intake 145.19- 145.82 mm
Pistons (5.716-5.741 in)
Exhaust .145.54- 146.18 mm
Land Clearance (Diametrical) 0.013 - 0.038 mm (5.730 - 5J5S in)
(0.0005-0.0015 in) Lift (Zero Lash)
Piston Length 82.5 mm Intake 9.91 mm
(0.390 in)
(3.25 in)
Exhaust 10.34 mm
Piston Ring Groove Diameter
(0.407 in)
No.l & N o . 2 91.30-91.55 mm
Valve Stem Tip Height 47.50 - 48.13 mm
(3.594 -3.604 in)
(1.870- 1.895 in)
No.3 92.90 - 93.15 mm
Stem Diameter 7.900 - 7.920 mm
(3.657-3.667 in)
(0,311 -0.312 in)
Weight 463 - 473 grams
Stem-to-Guide Clearance
(16.33- 16.68 oz)
Intake & Exhaust 0.025 - 0.076 mm
Piston Pins
(0.001 - 0.003 in)
Clearance Max. Allowable (Rocking Method) .0.4318 mm
In Piston ....0.2489 - 0.5537 mm (0.017 in)
(0.0098-0.0218 in) J9409-83
In Rod (Interference) 0.018 - 0.061 mm
(0.0007 - 0.0024 in)
Diameter 24.996 - 25.001 mm
(0.9841 - 0.9843 in)
End Play ....NONE
Length 67.818- 68.326 mm
(2,670 - 2.690 in)
9 - 144 8.0L ENGINE SR
ENGINE SPECIFICATIONS—GONT B
Valve Springs Valve liming
Free Length (Approx.) .......49.962 mm Exhaust Valve

(1.967 in) Closes (ATC) ....25°
Spring Tension Opens (BBC) ...60°
Valve Closed .............369 - 405 N @41.66 mm Duration 265°
(81 • 89 lbs @1.640 in) Intake Valve
Valve Open .......865 - 956 N ©30.89 mm Closes (ABC) .....61 °
(190 - 210 lbs ©1.216 in) Opens (BTC) .6°
Number of Coils ....6.79 Duration 246°
Wire Diameter .........................4.496 mm Valve Overlap ...31°
(0.177 in)
J9509-142
CONDITION IDENTIFICATION L O C A T I O N O F IDENTIFICATION
CRANKSHAFT JOURNALS RorM Milled flat on no. 8 crankshaft counterweight.

(UNDERSIZE) M-2-3 etc. (indicating no. 2 and 3 main bearing
0.0254 mm (0.001 in.) journal)
and/or
R-l -4 etc. (indicating no. 1 and 4 connecting rod
journal)
CYLINDER BORES A Following engine serial number.

(OVERSIZE)
0.508 mm (0.020 in.)
HYDRAULIC TAPPETS Diamond-shaped stamp top pad - front of

(OVERSIZE) engine and flat ground on outside surface of
0.2032 mm (0.008 in.) each O / S tappet bore.

0.127 mm (0.005 in.) (3/8 in.) on each end of cylinder head.
J 9 2 0 9 - 1 4 2
BR 8 J L ENGINE I -145
Camshaft Bolt .... 75 N*m (55ft.lbs.) Intake Manifold Bolts (Upper).... 22 N®m (16ft.lbs.)
Camshaft Thrust Plate Torx Bolts 22 N*m (16ft.lbs.) Oil Filter 9 N®m (80 in. lbs.)
Coil-Pack Bracket Bolts 21 N*m (190 in. lbs.) +45°
Connecting Rod Cap Bolts 61 N»m (45ft.lbs.) Oil Filter Connector 46 N®m (34ft.lbs.)
Crankshaft Main Bearing Cap Bolts Oil Pan Bolts (1/4-20)........................... 11 N*m (96 in. lbs.)
1st Step...... 27 N*m (20ft.lbs.)
Oil Pan Stud Bolts.......... 16 N*m (144 in. lbs.;
2nd Step 115 Ntm (85ft.lbs.) Oil Pan Bolts (5/16-18) 16N*m (144 in. lbs.;
Crankshaft Pulley/Damper Bolt.......... 183 N*m (135ft.lbs.) Oil Pan Drain Plug ................................ 34 N®m (25ft.lbs.)
Crankshaft Rear Seal Retainer Bolts... 22 N»m (16ft.lbs.) Oil Pan Pick-Up Tube Bolts 16 N«m (144 in. lbs.;
Cylinder Head Bolts 58 N»m (43ft.lbs.) Oil Pump Attaching Bolts 41 N«m (30ft.lbs.)
1st Step............................. 143 N*m (105ft.lbs.) Oil Pump Cover Bolts 14 N«m (125 in. lbs.;
2nd Step 16N*m (144 in. lbs.) Oil Pump Pressure Relief Plug................. 20 H*m (15ft.lbs.)
Cylinder Head Cover Bolts/Studs 75 N*m (55ft.lbs.) Rear Oil Seal Retainer Bolts ................... 22 N«m (16ft.lbs.)
Drive Plate-to-Crankshaft Bolts 75 N*m (55ft.lbs.) Rocker Arm felts................. 28 N*m (21ft.lbs.)
Drive Plate-to-Torque Converter Bolts , 34N*m (25ft.lbs.) Spark Plugs 41 N*m (30ft.lbs.)
EGR Tube Nut........... 20N*m (174 in. lbs.) Starter Mounting Bolts 68 N*m (50ft.lbs.)
Engine
EGR Support Bracket/Cushion
felts Timing Chain Cover felts.............. 47 N«m (35ft.lbs.)
Thru-Bolt................. 68 N*m (50ft.lbs.) Thermostat Housing Bolts 25 N»m (220 in. lbs.;
Engine Support Bracket/Cushion Throttle Body Nuts.... 11 N»m (96 in. lbs.)
Mounting Bolts 47 N*m (35ft.lbs.)
Torque Converter Drive Plate felts .......... 31 N»m (270 in, lbs.]
Exhaust Manifold-to-Cylinder Transfer Case-to-lnsulator Mounting
22 N*m (16ft.lbs.)
Head Bolts.... , Plate Nuts....... 204 N*m (150ft.lbs.)
75N*m (55ft.lbs.)
Flywheel-to-Crankshaft Bolts........ Transmission Support Bracket Bolts ......... 102 N*m (75ft.lbs.)
41 N*m (30ft.lbs.)
Generator Mounting Bolt............ Transmission Support Cushion Bolts........ 47 N»m (35ft.lbs.)
Generator-to-intake Manifold
41 Hm (30ft.lbs.) Transmission Support Cushion
Bracket Bolts..........................
Heat Shield Nuts 20 N»m (175 in. lbs.] Stud Nuts 47 N*m (35ft.lbs.)
Hydraulic Tappet Yoke Retaining Water Pump-to-Chain Case Cover Bolt.... 41 N»m (30ft.lbs.)
Spider Bolts 22 N*m (16ft.lbs.) Water Pump Pulley felts 22 N»m (16ft.lbs.)
Intake Manifold Bolts (Lower)....... 54 N*m (40ft.lbs.)
J9509-143
9 - 146 5.9L (DIESEL) ENGINE BR
5 . 9 L (DIESELf EUGINE S E R V I C E P R O C E D U R E S
INDEX
page page
Camshaft ............................... 165 General Information . . . . . . . . . . 146

Crankshaft .................. . . . . . . . 177 Oil Pan and Suction Tube . . . . . . . . . . . . . . . . . . 184
Cylinder Block . . . . . . . . . . . . . . . . . ...... 167 Piston and Connecting Rod Assembly . . . . . . . . . 171
Cylinder Head 151 Rocker Levers and Push Rods 150
Engine Assembly 147 Tappet 163
Engine Front Mounts 146 Timing Pin 161
Engine Rear Mount 147 Valve Clearance Adjustment 158
Gear Housing and Cover 159 Valves and Valve Springs 153
GENERAL INFORMATION
1 — S__3~-_4~2--4
The 5.9 Liter (359 CID) six-cylinder diesel engine is
an In-line valve-in head type (Fig. 1).
Engine Type In-line 6 (Diesel-Turbo)

Bore and Stroke 102.0 x 120.0 mm (4.02 x 4.72 in.)
Displacement 5.9L (359 cu. in.)
Torque (Automatic) 542 H^m (400 ft. lbs.) @ 1600 rpm
(Manual). 569 N«m (420 ft. lbs.) © 1600 rpm 5 •
Firing Order .1-5-3-6-2-4
Lubrication.... ..Pressure Feed - Full Flow
Filtration w/Bypass Valve
Engine Oil Capacity 9.51 (10.0 Qts) w/Filter
Cooling System Liquid Cooled - Forced Circulation J9409-107
Cooling Capacity 23L (24 Qts) Fig. 2 Firing Order
Cylinder Block Cast Iron
Crankshaft Induction Hardened Forged Steel ENGINE FRONT MOUNTS
Cylinder Head Cast Iron REMOVAL
Combustion Chambers High Swirl Bowl (1) Disconnect the negative cable from the battery.
Camshaft Chilled Ductile Iron (2) Position fan to assure clearance for radiator top
Pistons Cast Aluminum tank and hose.
Connecting Rods ....Forged Steel (3) Install engine support/lifting fixture.
J9409-12
Fig. 1 Diesel Engine Description thru-bolt and nut (Fig. 3).
This engine is designed for No.2 Diesel Fuel. Only (Fig. 3). Remove the support bracket/cushion.
use No.l Diesel Fuel where extended arctic condi
tions exist (below -23°C or -10°F). INSTALLATION
Engine lubrication system consists of a gerotor type (1) With engine raised SLIGHTLY, position the en
oil pump and a full flow oil filter with a bypass valve. gine support bracket/cushion to the block. Install new
The cylinders are numbered from front to rear; 1 to bolts and tighten to 189 N-m (140 ft. lbs.) torque.
6. The firing order is 1-5-3-6-2-4 (Fig. 2). (2) Install the thru-bolt into the engine support
The engine data plate is located on the driver side bracket/cushion.
(3) Lower engine with support/lifting fixture while
of the engine forward of the fuel injection pump.
guiding the engine bracket/cushion and thru-bolt into
support cushion brackets (Fig. 4).
- (4) Install thru-bolt nuts and tighten the nuts to
BR 5 J L (DIESEL) ENGINE S -147
(3) Using the transmission jack, lower the trans

mission and support cushion onto the crossmember
(Fig. 5).
(4) Install the support cushion bolts and tighten to
(5) Remove the transmission jack.
ENGINE ASSEMBLY
REMOVAL
(1) Remove the battery.
support.
Fig. 3 Front Engine Mounts
(4) Remove the transmission oil cooler.
ENGINE (5) Discharge the air conditioning system, if
SUPPORT equipped (refer to Group 24, Heating and Air Condi
BRACKET/
CUSHION tioning for service procedures).
(6) Remove the serpentine belt (refer to Group 7,
Cooling System).
(7) Remove the A/C compressor with the lines at
tached. Set aside.
(8) If equipped, remove the condenser.
(9) Remove the washer bottle.
(10) Remove the radiator overflow bottle.
(12) Remove the fan.
(13) Remove the fan shroud.
(14) Disconnect the lower radiator hose.
BRACKET J9409-122 (15) Remove radiator (refer to Group 7, Cooling
System).
(16) Remove the generator (Fig. 7) with the wire
ENGINE REAR MOUNT connections (refer to Group 8B, Battery/Starter/Gen
erator Service).
REMOVAL (17) Disconnect the heater hoses at the dash panel
(1) Raise the vehicle on a hoist. and at the water valve (Fig. 8).
(2) Position a transmission jack in place. (18) Disconnect the air inlet tube from the turbo
(3) Remove support cushion stud nuts (Fig. 5). charger (Fig. 9) and the air intake housing. Remove
(4) Raise rear of transmission and engine the tube.
SLIGHTLY. (19) Remove the exhaust pipe from the turbo
(5) Remove the bolts holding the support cushion charger outlet flange (Fig. 9).
to the transmission support bracket. Remove the sup (20) Disconnect the intercooler inlet duct from the
port cushion. turbocharger and the intercooler. Remove the inlet
(6) If necessary, remove the bolts holding the duct.
transmission support bracket to the transmission. (21) Disconnect the intercooler outlet duct from the
air inlet housing and the intercooler. Remove the out
INSTALLATION let duct.
(1) If removed, position the transmission support (22) Disconnect the accelerator linkage, the speed
bracket to the transmission. Install new attaching control linkage and the throttle valve linkage.
bolts and tighten to 102 N-m (75 ft. lbs.) torque. (23) Disconnect the power steering hoses, if
(2) Position support cushion to transmission sup equipped.
port bracket. Install stud nuts and tighten to 47 N-m (24) Disconnect the transmission cooler lines.
(35 ft. lbd.) torque. (25) Disconnect all electrical connections from the
engine. Put tags on the connections to identify their
locations.
^0>
4X4
4X2 3500 MANUAL 4X2 4X4
3500 MANUAL 4500 ALL AUTOMATICS AUTOMATICS
)
BR I J L (DIESEL) ENGINE 9 -149
Fig. 7 Generator Removal Fig. 9 Air Inlet Tube and Exhaust Pipe Connection
(39) Lift the engine out of the vehicle.
(40) Install the engine on a suitable stand.
(41) Remove all accessories and brackets not previ
ously removed for use with the replacement engine.
INSTALLATION
(1) Check the data plate to verify that the replace
ment engine is the same model and rating as the en
gine that was removed.
(2) Install all accessories and brackets that had
been removed from the previous engine.
Fig. 8 Heater Hoses (3) Use the lifting brackets to lift the engine off of
the stand.
(26) Disconnect the fuel lines to the lift pump and (4) Position the engine in the chassis with the
fuel return. Use tags to identify the lines. thru-bolt installed.
(27) On Manual Transmission vehicles, remove the (5) Remove the covers or tape covering the engine
shift lever (refer to Group 21, Transmissions). openings.
(28) Raise and support the vehicle on a hoist. (6) Raise and support the vehicle.
(29) Drain the engine lubricating oil. Dispose of (7) Refer to Group 21, Transmissions for transmis
the oil according to all applicable regulations. sion installation.
(80) Remove the oil pan. (8) Install the dust shield and transmission cover.
(81) Remove engine front mount thru-bolt nuts. (9) Install the prop shaft (refer to Group 16, Pro
(32) Remove the transmission cooler line brackets peller Shaft).
from oil pan. (10) Install the starter motor (refer to Group 8B,
(33) Disconnect exhaust pipe at manifold. Battery/Starter/Generator Service). Connect the
(34) Disconnect the starter wires. Remove starter starter wires.
motor (refer to Group 8B, Battery/Starter/Generator (11) Install the transmission cooler line brackets to
Service). oil pan.
(35) Remove the dust shield and transmission (12) Install and tighten engine front mount thru-
cover. bolt nuts.
(86) Refer to Group 21, Transmissions for trans (13) Install the oil pan. Install the drain plug.
mission removal. (14) Lower the vehicle.
(37) Lower the vehicle. (15) On Manual Transmission vehicles, install the
(38) Put a cover or tape over all engine openings. shift lever (refer to Group 21, Transmissions).
I - 1SI S J L (DIESEL) ENGINE
(16) Connect the fuel lines to the lift pump and ROCKER LEVERS AND PUSH RODS
fuel return. Use tags to identify the lines.
(17) Connect all electrical connections to the en REMOVAL
gine. Use tags to identify their locations. (1) Remove the valve covers.
(18) Connect the transmission cooler lines. (2) Loosen the adjusting screw locknuts. Loosen
(19) Connect the power steering hoses, if equipped. the adjusting screws until they stop (Fig. 1).
(20) Connect the accelerator linkage, the speed (3) Remove the bolts from the rocker lever pedes
control linkage and the throttle valve linkage. tals. Remove the pedestals and rocker lever assem
(21) Install the outlet duct. Connect the intercooler blies (Fig. 1).
outlet duct to the air inlet housing and the inter (4) Remove the push rods. The rear two push rods
cooler. must be raised through holes in cab overhang.
(22) Install the inlet duct. Connect the intercooler
inlet duct to the turbocharger and the intercooler. LOCKNUT ADJUSTING
(23) Install the exhaust pipe to the turbocharger
outlet flange.
(24) Install the air inlet tube. Connect the air inlet
tube to the turbocharger and the air intake housing.
(25) Connect the heater hoses at the dash panel
and at the water valve.
(26) Install the generator and wire connections (re
fer to Group 8B, Battery/Starter/Generator Service).
(27) Install the radiator (refer to Group 7, Cooling
System).
(28) Connect the lower radiator hose.
(29) Install the fan shroud.
J9109-31
(30) Install the fan.
(81) Connect the top radiator hose. Fig. 1 Location of Rocker Lever Components
(82) Install the radiator overflow bottle.
(88) Install the washer bottle. DISASSEMBLE—ROCKER LEVERS
(34) If equipped, install the condenser. (1) Remove the retaining rings and thrust washers
(85) Install the A/C compressor with the lines at (Fig. 1).
tached. (2) Remove the rocker levers (Fig. 1). DO NOT dis
(36) Evacuate and charge the air conditioning sys assemble the rocker lever shaft and pedestal. The
tem, if equipped (refer to Group 24, Heating and Air pedestal and shaft must be replaced as an assembly.
Conditioning for service procedures). (3) Remove the locknut and adjusting screw (Fig.
(87) Install the transmission oil cooler. 1).
(4) Clean all parts in a strong solution of laundry-
(88) Install the upper crossmember and top core
detergent in hot water.
support.
(5) Use compressed air to dry the parts after rins
(39) Install the serpentine belt (refer to Group 7, ing in clean hot water. The pedestals are made from
Cooling System). powdered metal and may continue to show wetness
(40) Fill the cooling system with a mixture of 50% after they have been cleaned and dried.
water and 50% ethylene-glycol base antifreeze (refer (6) Inspect for excessive wear in the bore and the
Group 7, Cooling System for the proper procedure). contact surface for the valve stem.
(41) Fill the engine with the required amount of (7) Measure the rocker lever bore diameter. The
clean engine lubricating oil (refer to Group 0, Lubri maximum diameter is 19.05 mm (0.75 inch). Replace
cation and Maintenance). if out of limits.
(42) Install the battery and connect the battery ca (8) Inspect the pedestal and shaft.
bles. (9) Measure the shaft diameter. The minimum di
(43) Check the oil level after the engine has run ameter is 18.94 mm (0.746 inch). Replace if out of
for 2 or 3 minutes. Oil held in the oil filter and oil limits.
passages will cause the oil level in the pan to be
lower than normal for a short period of time. ASSEMBLE—ROCKER LEVERS
(44) Operate the engine at idle for 5 to 10 minutes (1) Install the adjusting screw and locknut.
and check for leaks and loose parts. (2) Lubricate the shaft with clean engine oil. Be
sure to assemble the intake and exhaust rocker le
vers in the correct location.
BR 5 J L (DIESEL) ENGINE I -151
(3) Position the levers on the rocker shaft. Install REMOVAL

the thrust washers. (1) Drain the coolant. DO NOT waste reusable
(4) Clean the push rods in the hot soapy water. coolant. If the solution is clean, drain the coolant into
(5) Inspect the push rod ball and socket for signs a clean container for reuse.
of scoring or cracks where the ball and the socket are (2) Drain the engine oil. Dispose of the used oil
pressed into the tube, properly.
(6) Check the push rods for roundness and (3) Disconnect the radiator and heater hoses (refer
straightness. to Group 7, Cooling System).
(7) Install the push rods into the sockets of the (4) Remove the turbocharger.
valve tappets. Lubricate the push rod sockets with (5) Remove the exhaust manifold (Fig. 3).
clean engine oil.
(8) Make sure the rocker lever adjusting screws
are completely backed out.
INSTALLATION
(1) Make sure the dowel rings in the pedestals are
installed into the dowel bores in the cylinder head.
(2) If the push rod is holding pedestal off head, bar
the engine until the pedestal will set on the head
surface without interference.
(3) Use clean engine oil to lubricate the cylinder
head bolt threads and under the bolt heads.
(4) Install the long bolts (12 mm) into the rocker
lever pedestals. Tighten the bolts as follows:
• Step 1—Tighten the bolts, in sequence (Fig. 2), to
90 N-m (66 ft. lbs.) torque. Check the torque. If lower
than 90 N-m (66 ft. lbs.), tighten to this torque. Fig. 3 Exhaust Manifold
• Step 2—Tighten the bolts, in sequence (Fig. 2), to (6) Remove the fuel lines and injector nozzles (re
120 N-m (89 ft. lbs.) torque. Check the torque. If fer to Group 14, Fuel System).
lower than 120 N-m (89 ft. lbs.), tighten to this (7) Remove the valve covers.
torque. (8) Remove the rocker levers and push rods.
• Step 3—Tighten the bolts, in sequence (Fig. 2), an (9) Remove the fuel filter/water separator (Fig. 4).
additional 90°. Refer to Group 14, Fuel System, for the proper pro
cedures. Remove the remote fuel filter/water separa
C=i FRONT tor head.
(10) If the engine is hot, remove the cylinder head
bolts in the sequence shown in Fig. 5. The removal
sequence is not important if the engine is cold. There
are 3 sizes of head bolts. Note the position of each
bolt for future installation.
(11) Remove the cylinder head and gasket from the
cylinder block.
J9109-32 INSPECTION
Remove the cup plugs and inspect the coolant pas
Fig. 2 Rocker Lever (Head Bolts) Tightening sages. A large build up of rust and lime will require
Sequence removal of the cylinder block for cleaning in a hot
(5) Tighten the 8 mm bolts to 24 N-m (18 ft. lbs.) tank.
torque. Inspect the cylinder bores for damage or excessive
(6) Install the valve cover. Tighten the valve cover wear. Rotate the crankshaft so the piston is at Bot
bolt to 24 N-m (18 ft. lbs.) torque. tom Dead Center (BDC) to inspect the bores.
Measure the cylinder bores (Fig. 6). DO NOT pro
CYLINDER HEAD ceed with in-chassis repair if the bores are damaged
These cylinder heads can only be used on engines or worn beyond the limits (refer to Cylinder Bore Re
with an intercooler. DO NOT interchange with ear pair - Cylinder Block).
lier models. Check the top surface for damage caused by the
cylinder head gasket leaking between cylinders.
FUEL TEMPERATURE SENSOR
MIN. 102.0 mm (4.0157 inch)

MAX. 102.116 m m (4.0203 inch)
Out-of-Round 0.038 mm (0.0015 inch)
EL Taper 0.76 mm (0.003 inch)
TRANSFER Oversize pistons and rings are
PUMP
ELECTRICAL available for bored cylinder blocks.
CONNECTOR
FUEL J9109-75
HEATER J9414-94
Fig. 6 Cylinder Bore Diameter
Fig. 4 Fuel/Water Separator Filter
FEELER
STRAIGHT GAUGE
EDGE
J9109-157
Fig. 7 Cylinder Head Combustion Deck Face

Measurement
J9109-36
stock removed each t i m e m u s t be steel stamped
Fig. 5 Cylinder Head Bolt Removal Sequence- above combustion deck edge, on the lower r i g h t hand
Cylinder Head Hot corner of the rear face (Fig. 8). Check valve p r o t r u
sion after head surface refacing.
Inspect the block and head surface for nicks, ero
Surface finish requirements are 1.5-3.2 microme
sion, etc.
ters (60-126 microinch).
Check the head distortion (Fig. 7). The distortion of
the combustion deck face is not to exceed 0.010 m m
CLEANING
(0.0004 inch) i n any 50.8 m m (2.00 inch) diameter.
Clean the carbon from the injector nozzle seat w i t h
Overall v a r i a t i o n end to end or side to side 0.30 m m
a nylon or brass brush.
(0.012 inch).
Scrape the gasket residue from all gasket surfaces.
DO N O T proceed w i t h the in-chassis overhaul i f
Wash the cylinder head i n hot soapy water solution
the cylinder head or block surface is damaged or not
(88°C or 140°F).
flat ( w i t h i n specifications).
A f t e r rinsing, use compressed a i r to d r y the cylin
der head.
REFACING HEAD S U R F A C E
Polish the gasket surface w i t h 400 g r i d paper. Use
The cylinder head combustion deck m a y be refaced
an orbital sander or sanding block to m a i n t a i n a flat
i n whatever increments necessary to clean up the
surface.
surface and m a i n t a i n the surface finish and flatness
tolerances. The combined t o t a l of stock removed m u s t
not exceed 1.00 m m (0.03937 inch). The amount of
BR 5.9L (DIESEL) ENGINE 9 -153
REFERENCE • Step 1—Tighten all bolts, in sequence (Fig. 10), to

HEIGHT (MIN 90 N-m (66 ft. lbs.) torque. Check the torque. If lower
than 90 N-m (66 ft,. lbs.), tighten to this torque,
• Step 2—Tighten all long 12 mm bolts (Nos. 4, 5,
12, 13, 20 and 21), in sequence (Fig. 10), to 120 N-m
(89 ft. lbs.) torque. Check the torque. If lower than
120 N-m (89 ft, lbs,,), tighten to this torque,
• Step 3—Tighten all bolts, in sequence (Fig. 10), an
additional 90°.
STOCK
REMOVED-
STOCK j IDENTIFICATION
x
TOTAL (MM.) SURFACE FINISH AREA
STOCK TOTAL (MAX.)

1.00 mm (0.03937 Inch)
REFERENCE HEIGHT (MIN.)
94.00 ±0.25 mm • t «l • • • •
(3.7008 ±0.0010 inch)
SURFACE FINISH
1.5 to 3.2 micrometers
(60 to 128 microinches)
J9109-134
(^<3T(b ®- ®- (a)
Fig. 8 Cylinder Head Stock Removal
J9109-36
INSTALLATION
(1) The cylinder block and head must be clean and Fig. 10 Cylinder Head Tightening Sequence
dry, (7) Be sure to lubricate the push rod sockets with
(2) Position the gasket onto the dowels (Fig. 9). clean engine oil. Be sure push rod is seated properly
Make sure the gasket is correctly aligned with the in the tappet.
holes in the cylinder block, (8) Install the rocker lever pedestal bolts and
(3) Carefully put the cylinder head onto the gasket tighten to 24 N-m (18 ft. lbs.) torque.
and cylinder block. Make sure the cylinder head is (9) Adjust the valve clearance.
installed onto the dowels in the cylinder block (Fig. (10) Install the valve covers. Tighten the bolts to
9). 24 N-m (18 ft. lbs.) torque.
(11) Install the injector nozzles and fuel lines (refer
CYLINDER HEAD
to Group 14, Fuel System).
(12) Install the remote fuel filter/water separator
head. Install the fuel filter/water separator (refer to
Group 14, Fuel System for the proper procedures).
(13) Install the exhaust manifold (refer to Group
11, Exhaust System and Intake Manifold).
(14) Install the turbocharger.
(15) Connect the radiator and heater hoses.
(16) Fill the engine with new coolant or the clean
drained coolant (refer to Group 7, Cooling System for
the proper procedure).
(17) Fill the engine with clean lubricating oil (refer
to Group 0, Lubrication and Maintenance).
J9109-133
1ALVES 1ND VALVE SPRINGS
Fig. 9 Cylinder Head/Gasket Alignment
REMOVAL
(4) Install the push rods and rocker levers. (1) Remove the cylinder head.
(5) Use clean engine oil to lubricate the cylinder (2) Mark the valves to identify their position.
head bolt threads and under the bolt heads. (3) Compress the valve spring and remove the
(6) The cylinder head bolts are 3 different sizes. valve stem collets (Fig. 1).
Install the bolts in the proper hole. Tighten the bolts (4) Release valve spring and remove the retainer
as follows: and spring (Fig. 1). *
S • 114 5.9L (DIESEL) ENGINE BR
(5) Remove the remaining collets, retainers, INTAKE EXHAUST

springs and valves. Keep the valves in a labeled rack.
(6) Remove the valve stem seals (Fig. 1).
COLLETS
RETAINER
SPRING
VALVE
STEM
SEAL _ ^ ©0 ^
J9109-41
Fig. 3 Waive Seat Angle
J9109-38 VALVE RIM

THICKNESS
Fig. 1 Valve Removal
VALVES

Before cleaning, note the valve number. Clean the
valve heads with a soft wire wheel. Mark the valve
with the number noted above.
Polish the valve stems with crocus cloth. J9109-146
Inspect for abnormal wear on the valve heads and
Fig. 4 Valve Rim Thickness
stems. Replace badly worn valves.
Check for bent valves. Replace bent valves. Check the valve stem tip for flatness. If required,
Measure the valve stem diameter (Fig. 2). The re-surface the tip.
valve stem diameter should be 7.935-7.960 mm
(0.3126-0.3134 inch). If out of limits, replace the VALWE GUIDES
valve. Mark the new valves with the replacement lo
INSPECTION
cation.
Inspect the valve guides for scuffing or scoring.
Measure the valve guide bore (Fig. 5). The bore di
ameter should be 8.019-8.089 mm (0.3157-0.3185
inch).
If the valve guide bores are larger than the worn
limit, the cylinder head must be machined for service
valve guides. New valve guides must be reamed to
size after they are installed.
7
MEASURE AT THESE POINTS J9109-144 If the cylinder head needs service valve guides and
valve seat inserts, the valve guides should be in
Fig. 2 Measure Valve Stem Diameter stalled first.
Inspect the end of the valve stem for flatness. INSTALLATION
If required, resurface the valve end. THIN WALL—SERVICE GUIDES
Machine the cylinder head valve guide bores to
VALWE GR1N01NG
11.125 ±0.013 mm (0.4380 ±0.0005 inch) in diameter
The valve -seat angle should be 30° (Intake Valve) (Fig. 6).
and 45° (Exhaust Valve) - (Fig. 3). Service valve guides must be centered with valve
Measure the rim thickness (Fig. 4). The minimum seats within 0.35 mm (0.01378 inch) diameter. They
valve rim thickness is 0.79 mm (0.031 inch).
Grind the face of valves to be reused.
BR 5 J L (DIESEL) ENGINE I -155
VALVE GUIDE BORES CYLINDER

HEAD
EXHAUST
INTAKE
CYLINDER HEAD VALVE GUIDE BORES

NEW DIAMETER LIMITS CYLINDER HEAD VALVE GUIDE BORES
8.019-8.029 mm (0.3157-0.3165 Inch) 11.125 ±0.013 mm (0.438 ±0.0005 in)
WORN LIMIT VALVE GUIDE BORES
8.090 mm (0.3185 inch) 8.029 ±0.010 mm (0.3161 ±0.0004 in)
J9109-135 J9109-136
Fig. 5 Valve Guide Bore Fig. 6 Service we Guides -Thin Wall

must also be square w i t h the combustion face w i t h i n VALVE GUIDE BORES
0.10 m m (0.004 inch) at 50.0 m m (1.9685 inch) r a CYLINDER
dius. HEAD
Lubricate the valve guides w i t h oil and press the
guides flush to the bottom of the bosses.
Trim off the top of t h e valve guides flush to top of
guide bosses, i f necessary.
Machine the valve guide bores to 8.029 ±0.010 m m
(0.3161 ±0.0004 inch) - (Fig. 6).
The valve guide bore must be centered w i t h the
EXHAUST INTAKE
valve seat w i t h i n 0.35 m m (0.0138 inch) diameter. I t
also must be square w i t h the combustion face w i t h i n
0.010 m m (0.0004 inch) at 50.0 m m (2.0 inch) radius.
THICK WALL-SERVICE GUIDES CYLINDER HEAD VALVE GUIDE BORES
Machine the * cylinder head valve guide bores to
14.000 ±0.013 m m (0.5512 ±0.0005 inch) diameter CYLINDER HEAD VALVE GUIDE BORES
(Fig. 7). 14.000 ±0.013 mm (0.5512 ± 0.0005 in)
Valve' guides must be centered w i t h valve seats VALVE GUIDE BORES
w i t h i n 0.35 m m (0.01378 inch) diameter. Valve 8.029 ±0.010 mm (0.3161 ±0.0004 in)
guides m u s t also be square w i t h the combustion face J9109-137
w i t h i n 0.10 m m (0.004 inch) at 50.0 m m (2.0 inch)
radius. Fig. 7 Service Valve Guides—Thick Wall
Lubricate the valve guides w i t h oil and press i n the
Measure the valve spring force. 359 N (81 lbs.) is
guides to 12.25 ±0.50 m m (0.4823 ±0.020 inch) pro
the m i n i m u m acceptable load required to compress
trusion above the cylinder head.
the spring to a height of 49.25 m m (1.94 inch).
Ream the bores to 8.029 ±0.010 m m (0.3161
I f the valve spring does not meet the l i m i t s above,
±0.0004 inch) - (Fig. 7).
replace the spring.
VALVE SPRINGS
Measure the valve spring length. The approximate
free length is 60 m m (2.36 inch) w i t h the m a x i m u m
inclination of 1.0 m m (0.039 inch).
I - 156 5 J L (DIESEL) ENGINE BR
VALVE SEATS INTEGRAL WALWE SEAT GRINDING

After resurfacing the valves and determining that
INSPECTION all valves meet specifications, install the valves in
Cylinder head with integral valve seats can be their designated locations and measure valve depth
ground only once. Previously ground integral seats (Fig. 10). The valve depth is the distance from the
must be replaced with service seats. valve face to the head deck. Record the depth of each
One X stamped into the head casting identify seats valve.
that have been ground previously (Fig. 8).
CYLINDER VALVE
Two X's stamped on the head indicate service seats
HEAD DECK ^ FACE
have been installed (Fig. 8). Service seats can be
ground.
SERVICE SEATS
INSTALLED
VALVE
DEPTH J9109-140
Fig. 10 Valve Depth

Grind the valve seats to remove scores, scratches
and burns. The seat angle should be—Intake 30° and
Exhaust 45°,
Install the valves in their respective bores and
measure the depth again (Fig. 10). Record the depth
J9109-138 of each valve.
The grinding depth is the difference between the
Fig. 8 Reworked Cylinder Head Seats—Stamped measurement before grinding and the measurement
Identification after grinding. The grinding depth maximum limit
On the integral seat head, if 0.254 mm (0.010 inch) (integral seats only) is 0.254 mm (0.010 inch). Service
or more has been removed from the head combustion valve seats are available for over limit integral valve
surface, service seats must be installed. seats.
To determine if the head has been previously resur Identify ground valve seats by stamping the cylin
faced, before calculating valve depth, process as fol der head.
lows: Install the valves in their designated locations and
(1) Check the rear lower right corner of the head measure the depth of each. The valve depth limit (In
for a stamping that would indicate previous resurfac tegral and Inserted Seats) is 0.99 mm to 1.52 mm
ing (.003). (0.039 inch to 0.060 inch). Replace the valve if the
(2) To verify the information, or if no amount is in depth is over this limit.
dicated, measure the head height (Fig. 9). Apply a light coat of valve lapping compound to
(3) If the head height is 94.75 mm (3.730 inch) or each valve and lap each valve to its mating seat.
greater, the valve seats may be ground, if they have Remove the valves and clean lapping compound
not been ground previously. from the valves and seats.
CYLINDER
Measure the valve seat width indicated by the lap
HEAD ping surface. The valve seat width limit is 1.50-2.00
HEIGHT mm (0.060-0.080 inch).
If required, grind the areas with a 60° stone and a
15° stone to center the seat on the valve face. Main
tain the valve seat width limits (Fig. 11).
SERVICE WALWE SEAT INSTALLATION
Inspect the valve guide bores as described in the
valve guide section of this manual. If it is necessary
J9109-139 to install valve guides, install the guides before in
stalling the service seats.
Fig. 9 Cylinder Head Height
BR 5 J L (DIESEL) ENGINE S -157
VALVE GRIND TO 15° COMBUSTION

SEAT FACE
WIDTH
VALVE
SEAT
DEPTH
J9109-141
Fig. 11 Grind Valve Seat

Replacement valve seat inserts must be installed if VALVE SEAT DEPTH
the valve seats have been ground previously. The il 10.20 ±0.10 mm (0.4015 ± 0.004 inch)
lustrated marks indicate valve seats have been
VALVE SEAT WIDTH
ground previously.
Machine the cylinder head to install the service 43.65 ±0.013 mm (1.7185 ±0.0005 in)
valve seats (Figs. 12 and 13). MAXIMUM RADIUS
COMBUSTION 0.40 mm (0.0157 inch) MAX.
FACE
SURFACE FINISH
3.2 micrometers (128.0 microinch)
J9409-116
Fig. 13 Machining for Service Valve Seats—Exhaust

Valve
SERWiCI WilWE SEAT GRINDING
Install the valves in their designated location and
VALVE measure the valve depth. The valve depth is the dis
SEAT tance from the valve face to the head deck.
DEPTH
Record the depth of each valve (Fig. 14). The depth
is 0.99-1.52 mm (0.039-0.060 inch).
Grind the valve seats to remove scores, scratches
VALVE SEAT DEPTH and burns. The valve seat angle is 30° (Intake) and
10.40 ±0.10 nun (0.4094 ±0.004 inch) 45° (Exhaust).
Install the valves in their respective bores and
VALVE SEAT WIDTH
measure the depth again (Fig. 14). The valve depth
47.0 ±0.013 mm (1.8504 ±0.0005 in) limit is 0.99-1.52 mm (0.039-0.060 inch). Replace the
MAXIMUM RADIUS valve if the depth is over the limit.
0.40 mm (0.0157 inch) MAX. Apply a light coat of valve lapping compound to
each valve and lap each valve to its companion seat.
SURFACE FINISH Remove the valves and clean the lapping compound
3.2 mkrometeri (128.0 mkrotnch) from the valve and seats.
J9409-U5 Measure the valve seat width indicated by the
lapped surface (Fig. 15). The width limits are 1.5-2.0
Fig. 12 Machining for Service Valve Seats—Intake mm (0.060-0.080 inch). If required, grind lower area
Valve with 60° stone and upper area with 15° stone (Fig.
Press service seats into the machined pockets. 15). Be sure to center the seat on the valve face.
Stake the valve seats into the pockets. Maintain the valve seat within limits.
MIN. - 0.990 mm (0.039 inch)

MAX. - 1.520 mm (0.060 inch)
Fig. 16 Valve Stem Seal Installation
COLLETS VALVE
J9109-44
Fig. 14 Valve Depth with Seat Insert
MAXIMUM
Fig. 17 Waive, Valve Spring and Collet Installation

(6) Tap the ends of the valve stems w i t h a mallet
to verify the collets are seated.
Fig. 15 Valve Seat Width (7) Install the cylinder head.
SERVICE VALVE SEAT REPLACEMENT (8) Check the valve clearance adjustment.
Tb replace service seat inserts, machine the insert
i n the same manner as i f machining out the internal VALVE CLEARANCE ADJUSTMENT
seat. H o l d the same tolerances and follow the same Use the t i m i n g pin to locate Top Dead Center
installation procedures. (TDC) for cylinder N o . l (Fig. 18). The t i m i n g pin is
located at the back of the gear housing and below the
INSTALLATION injection pump. Be sure to disengage the timing
(1) Clean all cylinder head components before as pin after locating top dead center. Refer to
sembling. TIMING PIN for more information.
(2) I n s t a l l the valve stem seals (Fig. 16). The i n Adjust the valves when the engine is cold, below
take and exhaust valve seals are the same. 60°C (140°F).
(3) Lubricate the stems w i t h SAE 90W oil before
installing the valves. I n s t a l l the valves i n the same STEP 1
positions as removed. Adjust the clearance for the valves shown i n Fig.
(4) Compress the valve spring after installing the 19. The valve lash adjustment is 0.254 m m (0.010
spring and retainer (Fig. 17). inch) for the intake valve. The valve lash adjustment
(5) I n s t a l l new valve collets and release the spring is 0.508 m m (0.020 inch) for the exhaust valve.
tension (Fig. 17). Tighten the valve adjusting nuts to 24 N*m (18 ft.
lbs.) torque.
WARNING: W E A R PROTECTIVE EQUIPMENT AND Be sure timing pin is disengaged before rotat
DO NOT STAND IN LINE WITH THE VALVE STEM ing the crankshaft. M a r k the pulley and rotate the
W H E N TAPPING THE VALVES. crankshaft 360°.
BR 5.9L (DIESEL) ENGINE 9-159
GEIR HOUSING AND COVER
GEAR HOUSING
REM0WAL
(1) Remove the engine assembly from the vehicle.
(2) Remove the front end components and the gear
housing cover (refer to Gear Housing Cover Removal
for the proper procedures).
(8) Remove the following:
• Camshaft
© Gear driven accessories
• Fuel injection pump (refer to Group 14, Fuel Sys
tem)
• Fan hub assembly (refer to Group 7, Cooling Sys
Fig. 18 Locating TDC using Timing Pin tem)
(4) Remove the gear housing and gasket (Fig. 1).
I = INTAKE E - EXHAUST (5) Clean the gasket material from the cylinder
block.
E I E I E !
© © © © © ©
J9109-34 FRONT s=^>
Fig. 19 Adjust Valve Clearance—Step 1

STEP 2
Adjust the clearance for the valves shown in Fig.
20. The valve lash adjustment is 0.254 mm (0.010 Fig. 1 Gear Housing/Gasket
inch) for the intake valve. The valve lash adjustment
INSTALLATION
is 0.508 mm (0.020 inch) for the exhaust valve.
Tighten the bolts to 24 N-m (18 ft. lbs.) torque. (1) Install a new gasket and the gear housing.
Tighten the bolts to 24 N-m (18 ft. lbs.) torque.
I = INTAKE E = EXHAUST (2) Install the camshaft. Make sure the alignment
marks on the camshaft and crankshaft gears are
E l I E 1 E aligned (Fig. 2). ,
(3) If a new housing is installed, the timing pin as
sembly must be accurately located.
(4) Install the following:
© Fan hub assembly (refer to Group 7, Cooling Sys
tem)
• Fuel injection pump (refer to Group 14, Fuel Sys
tem)
• Gear driven accessories
© © © © © © (5) Install the gear housing cover (refer to Gear
Housing Cover Installation for the proper proce
J9109-35 FRONT O dures). ^
Fig. 20 Adjust Valve Clearance—Step 2 (6) Install the front end components.
(7) Install the engine assembly into the vehicle.
S - 160 O L (DIESEL) ENGINE mm
(6) Remove the bolts that hold the gear cover to
the gear housing.
(7) Gently pry the cover away from the housing,
taking care not to mar the gasket surfaces (Fig. 5).
(8) Clean the old gasket residue from the back of
the gear cover and front of the gear housing.
J9109-104
Fig. 2 Camshaft/Crankshaft Gear Alignment

GEAR HOUSING COVER
iEliWAL
(1) Remove fan drive assembly.
(2) Remove the fan belt (Fig. 3).
(8) Remove belt tensioner (Fig. 3). Fig. 5 Gear Housing and Cower
INSTALLATION
(1) Lubricate the front gear train with clean en
gine oil.
(2) Thoroughly clean the front seal area of the
crankshaft. The seal lip and the sealing surface on
the crankshaft must be free from all oil residue to
prevent seal leaks.
(8) Install the gear housing cover and a new gas
ket.
(4) Install the bolts but DO NOT tighten them at
this time.
(5) Use the alignment/installation tool from the
seal kit to align the cover to the crankshaft (Fig. 6).
Fig. 6 Alignment/Installation Tool

(6) Tighten the gear housing cover bolts to 24 N-m
(7) Remove the alignment/installation tool. Always
Pig. 4 Oii Fill Tube use a seal pilot when you install a seal.
(5) Remove vibration damper. (8) Apply a bead of Loctite 277 to the outside di
ameter of the seal. Install the pilot from the seal kit
Bl? 5 J L (DIESEL) ENGINE 9 -161
onto the crankshaft. Install the seal onto the pilot

and start into the gear housing cover. Remove the pi
lot.
(9) Use the alignment/installation tool and a plas
tic hammer to install the seal to the correct depth. To
prevent damage to the seal carrier, hit the align
ment/installation tool alternately at the 12, 8, 6 and
9 o'clock positions.
(10) Install the oil fill tube and mounting bolts.
Tighten the bolts to 43 N-m (32 ft. lbs.) torque.
(11) Install the vibration damper. DO NOT tighten
the bolts to the correct torque valve at this time.
(12) Install the belt tensioner. Tighten the mount
ing bolts to 43 N-m (32 ft. lbs.) torque.
(13) Raise the belt tensioner to install the belt.
(14) Tighten the vibration damper bolts to 125 N-m Fig, 7 Engine Timing Pin Location
(92 ft. lbs.) torque. Use an engine barring tool to (1) Look through the hole in the gear housing and
keep the engine from rotating during tightening op
rotate the engine until the hole in the cam gear can
eration.
be seen.
TIMING PIN (2) Remove the injector nozzles from all of the cyl
The timing pin is used for three different proce inders. This step is important to vent the cylinders so
dures: the crankshaft can be rotated smoothly to locate TDC
© Valve adjustment for cylinder No.l.
• Top Dead Center (TDC) location (3) Temporarily install the vibration damper.
• Fuel injector pump timing procedure (4) Fabricate and install a wire pointer (Fig. 8).
Refer to Fuel Injector Pump in the Diesel Engine— This can be done by forming a piece of wire that can
Component Removal/Installation section of Group 14, be tighten under one of the gear housing capscrews.
Fuel System. The wire should extend from the gear cover to a
place on the crankshaft vibration damper that is eas
TIMING PIN REPLACEMENT ily seen.
The timing pin can be replaced without removing
the assembly from the gear housing.
(1) Remove the timing pin by prying the retaining
ring out with a small screwdriver. Replace the retain
ing ring if it is damaged during removal.
(2) If timing pin assembly is removed from gear
housing, it must be precisely reset to obtain exact
TDC.
(3) Install a new O-Ring, lubricate the pin and po
sition in the housing (Fig. 7). Install the new retain
ing ring to 1.5 mm (0.059 inch).
TIMING PIN HOUSING ASSEMBLY AND
GASKET
REMOVAL
(1) Locate TDC for cylinder No.l.
(2) Remove the timing pin housing assembly and Fig. 8 Fabricated Wire Pointer
gasket. (5) Rotate the crankshaft one-quarter rotation in
(3) Clean any gasket material from the gear hous
the direction of engine rotation.
ing and from the timing pin housing assembly.
(6) Tighten the adjusting screw for the No.l intake
INSTALLATION—CYLINDER HEAD ON valve to zero lash plus 5 turns.
The location of the timing pin assembly on the gear
CAUTION: Use extreme care when rotating the
housing is critical for correct engine adjustment. Fol
crankshaft. Use of too much force could damage
low this procedure to install the assembly so that it
the valve or push rod (Fig. 9).
corresponds to TDC for cylinder No.l.
I - 162 5.9L (DIESEL) ENGINE BR
(7) Rotate the crankshaft slowly in the opposite di

rection of normal engine rotation until the piston
touches the intake valve (Fig. 9).
(8) Mark the vibration damper at the wire pointer
(Fig. 9).
Fig. 11 Location of Top Dead Center (TDC)

(13) Rotate the crankshaft in the direction of nor
mal engine rotation until the pointer is aligned with
the TDC mark. Rotate crankshaft one additional
turn.
(14) The timing pin hole in the cam gear should be
visible or felt through the back side of the gear hous
ing. If not, the crankshaft must be rotated one revo
lution in the direction of engine rotation.
-Fig. 9 Locate and Mark Vibration Damper—First (15) Apply a coat of Loctite™ 59241 (Liquid Te
Mark flon), or equivalent to the threads of the Torx head
bolts. Install the timing pin assembly and new
(9) Rotate the crankshaft in the direction of nor O-ring.
mal engine rotation until the piston touches the in (16) Hold the timing pin in the hole to align the
take valve (Fig. 10). Make sure that the piston housing and install the Torx head bolts. Tighten the
touches the intake valve with approximately Torx bolts to 5 N-m (44 in. lbs.) torque.
the same amount of force as in the previous (17) Install the remaining rocker lever pedestal as
step (Fig. 1 0 ) . semblies. Tighten the rocker lever pedestal mounting
(10) Mark the vibration damper at the wire pointer capscrews.
(Fig. 10). (18) Adjust the valves.
(19) Install the injectors and bleed the fuel system
(refer to Group 14, Fuel System).
(20) Install the fuel pump (refer to Group 14, Fuel
System).
(21) Install the gear cover.
(22) Remove the pointer. Install the crankshaft vi
bration damper.
INSTALLATION—CYLINDER HEAD iFF
The timing pin assembly is precisely located on the
gear housing to correspond to TDC for Cylinder No.l.
The timing pin assembly must be relocated if the
gear housing is interchanged.
(1) Temporarily install the vibration damper and a
fabricated wire pointer (Fig. 12). Put a fiat washer
between the pointer and gear housing to prevent
Fig. 10 Mark Vibration Damper—Second Mark damage to the gear housing.
(11) Measure the distance and mark the vibration (2) Fabricate a steel plate (Fig. 13).
damper at one-half that distance between the two (3) Use two flywheel housing bolts to assemble the
marks. This mark is the TDC mark (Fig. 11). plate over No.l cylinder (Fig. 14).
(4) Rotate the crankshaft in the direction of rota
(12) Completely loosen the intake valve adjusting
tion until the piston contacts the plate.
screw. If not done, damage to the intake valve or
(5) Mark the vibration damper (Fig. 11).
push rod could occur when the crankshaft is rotated. (6) Rotate the engine in the opposite direction un
til the piston contacts the plate.
mm — — 5.9L (DIESEL) ENGINE 9 -163
(10) Look for the timing pin hole in the camshaft

gear. If it is not visible, rotate the crankshaft one
complete rotation. Align the pointer with the TDC
mark.
(11) Install the timing pin housing assembly with a
new gasket.
(12) Apply a coat of Loctite 59241 liquid teflon, or
equivalent to the threads of the torx head bolts.
(13) Push the pin into the hole in the cam gear to
align the timing pin housing.
(14) Hold the pin in while tightening the torx head
bolts to 5 N-m (44 in. lbs.) torque. Be sure timing pin
is disengaged before rotating the engine.
(15) Remove the vibration damper and wire
pointer.
Fig. 12 Fabricated Wire Pointer
TAPPET
REMOVAL
(1) Remove the camshaft.
(2) Insert a trough the full length of the cam bore
(Fig. 1). Cummins Tappet Changing Tool 3822513 is
available for this job.
(3) Make sure the trough is positioned so it will
catch the tappet when the wooden dowel is removed.
(4) Identify the location of each tappet as it is re
moved. The tappets must be installed in their origi
nal locations.
(5) Only remove one tappet at a time. Remove the
rubber band from the two companion tappets, secur
ing the tappet not to be removed with the rubber
band.
Fig. 13 Fabricated Steel Plate (6) Pull the wooden dowel from the tappet bore al
lowing the tappet to fall into the trough (Fig. 1).
(7) Normally the tappet will fall over when it drops
into the trough. Use a flashlight to determine this. If
the tappet does not fall over, shake the trough gently
to get it to do so.
(8) Special care should be taken, when removing
the No.6 cylinder tappets. DO NOT knock or shake
the tappet over the end barrier of the trough.
(9) Carefully pull the trough and tappet from the
cam bore and remove the tappet. Repeat the process
until all tappets are removed.
INSPECTION
Fig. 14 Fabricated Plate Location on No. 1 Cylinder
Inspect the tappet socket, stem and face for exces
(7) Mark the vibration damper (Fig. 11). sive wear, cracks and other damage (Fig. 2).
(8) Mark the vibration damper for TDC. TDC will The minimum tappet stem diameter is 15.925 mm
be one-half the distance between the first two marks (0.627 inch) - (Fig. 2). If the tappet is out of limits,
(Fig. 11). replace the tappet.
(9) Remove the plate and rotate the engine in the
direction of rotation until the pointer aligns with the INSTALLATION
TDC mark. (1) Insert the trough the full length of the cam
bore.
(2) Feed the installation tool down the tappet bore
and into the trough (Fig. 3).
tappets is installed, work the tool in and out of the

tappet several times before installing the tappets.
(6) Place the tappet and tool in the trough and
slide the trough back into the cam bore (Fig. 4).
Fig. 1 Tappet Removal using a Trough
Fig. 4 Insert Installation Tool into Tappet

(7) Pull the tool/tappet through the cam bore and
up into the tappet bore (Fig. 5).
J91G9-152
Fig. 2 Tappet Inspection
Fig. 5 Pull Tappet/Tool into Position

(8) Difficulty could be experienced in getting the
tappet to make the bend from the trough up to the
tappet bore (due to the webbing of the block). If this
occurs, pull the trough out enough to allow the tap
pet to drop down and align itself. Now pull the tap
pet up into the bore carefully.
(9) After the tappet has been pulled up into posi
Fig. 3 Tappet Installation Tool tion, slide the trough back into the cam bore and ro
(3) Feed the installation tool cord through the cam tate it 1/2 turn. This will position the round side of
bores. Carefully pull the trough and installation tool the trough up, which will hold the tappet in place.
out the front. The barrier at the rear of the trough (10) Remove the installation tool from the tappet.
will assure the tool will be pulled out with it. (11) Install a wooden dowel into the top of the tap
(4) Lubricate the tappets with Lubriplate 105, or pet and secure it with a rubber band.
equivalent. (12) Repeat this process until all tappets have
(5) Insert the installation tool into the tappet (Fig. been installed.
4). To aid in removing the installation tool after the (13) Install the camshaft.
EH — — — — ™ — - — 5 j l (DIESEL) ENGINE 9-165
CAMSHAFT .
REMOVAL
(1) Remove the following parts:
• Valve covers
• Rocker lever assemblies
• Push rods
• Drive belt
• Fan hub assembly
• Vibration damper
• Gear housing cover
• Lift pump
(2) Insert the dowels through the push tube holes
and into the top of each tappet. When properly in
stalled, the dowels can be used to pull the tappets up
(Fig. 6). Fig. 8 Thrust Plate Bolt Location
(8) Pull the tappets up and wrap a rubber band
around the top of the dowel rods (Fig. 6). This will INSPECTION
prevent the tappets from dropping down. Inspect the lift pump lobe, valve lobes and bearing
journals for wear, cracking, pitting and other dam
DOWEL TOOL age.
Clean the camshaft and gear with solvent and a
lint free cloth.
Inspect the gear teeth for wear and damage. Look
for cracks at the root of the teeth.
Measure the bearing journals, lift pump lobe and
valve lobes (Fig. 9).
Fig. 6 Holding Tappets in Place

(4) Rotate the crankshaft to align the crankshaft to
camshaft timing marks (Fig. 7).
CAMSHAFT JOURNAL DIAMETER (MIN.)

53.962 mm (2.1245 inch)
VALVE LOBE HEIGHT (MIN.)
INTAKE - 47.040 min (1.852 inch)
EXHAUST - 46.770 mm (1.841 inch)
LIFT PUMP LOBE DIAMETER (MIN.)

35.500 mm (K398 inch)
J9109-51
J9109-53
Fig. 7 Align Crankshaft to Camshaft
Fig. 9 Bearing Journal/Valve Lobe Measurements
(5) Remove the bolts from the thrust plate (Fig. 8)
(6) Remove the camshaft, gear and thrust plate.
9 - 166 5.9L (DIESEL) ENGINE
CAMSHAFT BUSHING—REPLACEMENT WARNING: W E A R PROTECTIVE G L O V E S TO HAN

(1) Measure the diameter of each bore. (The limit DLE THE HOT G E A R .
for the bushing in the No.l bore is the same as for
the other bores without bushings). The limit of the (6) Install the gear with the timing marks visible.
inside diameter is 54.133 mm (2.1312 inch). If the Be sure the gear is seated against the camshaft
camshaft bore for the first cam bushing is worn be shoulder.
yond the limit, install a new service bushing. Inspect (7) If the camshaft is not to be used immediately,
the rest of the camshaft bores for damage or exces lubricate the lobes and journals to prevent rust.
sive wear.
INSTALLATION
(2) If the bores without a bushing are worn beyond
the limit, the engine must be removed for machining (1) Apply a coat of Lubriplate 105 to the camshaft
and installation of service bushings. If badly worn, bores.
replace the cylinder block. (2) Lubricate the camshaft lobes, journals and
(3) Remove the bushing from the No.l bore, using thrust washer with Lubriplate 105, or equivalent.
a universal cam bushing tool. CAUTION: When installing the camshaft, DO NOT
(4) Mark the cylinder block so you can align the oil push it in farther than it will go with the thrust
hole in the cylinder block with the oil hole in the washer in place. Pushing it too far can dislodge the
bushing. plug in the rear of the camshaft bore and cause an
Apply a coating of loctite® 609 to the backside of oil leak.
the new bushing. Avoid getting loctite® in the oil
hole. (3) Install the camshaft/thrust washer. Align the
(5) Use a universal cam bushing installation tool timing marks as illustrated (Fig. 7).
and install the bushing so that it is even with the (4) Install the thrust washer bolts and tighten to
front face of the cylinder block. The oil hole must be 24 N-m (18 ft. lbs.) torque.
aligned. A 3.2 mm (0.128 inch) diameter rod must be (5) Verify the camshaft has the correct amount of
able to pass through the hole (Fig. 10). backlash and end clearance (Fig. 11).
(6) Measure the installed bushing. The limit of the
inside diameter is 54.133 mm (2.1312 inch). CAMSHAFT
GEAR
1/
J9109-54 GEAR
CLEARANCE •l^"J9109-57
Fig. 10 Oil Hole Alignment
BACKLASH - 0.080-0.330 mm
CAMSHAFT GEAR—REPLACEMENT (0.003-0.013 inch)
(1) Press the camshaft out of the gear. CLEARANCE - 0.152-0.254 mm
(2) Remove all burrs and smooth any rough sur (0.006-0.010 inch)
faces caused by removing the gear.
(3) Install the camshaft key. Fig. 11 Camshaft Backlash and End Clearance
(4) Lubricate the camshaft surface with Lubriplate (6) Install the following parts:
105, or equivalent. Lift pump
Gear housing cover
CAUTION: The camshaft gear will be permanently Vibration damper
distorted If overheated. The oven temperature Fan hub assembly
should never exceed 177°C (350°F). Drive belt
Push rods
(5) Heat the gear in an oven at 177°C (350°F) for Rocker lever assemblies
45 minutes. • Valve covers
(7) Install the engine in the vehicle.
BR i J L (DIESEL) ENGINE I -167
(8) Operate the engine at idle for five to ten min

utes and check for leaks and loose parts.
CYLINDER BLOCK
REMOVAL
(2) Remove the cylinder head from the block.
(3) Remove the camshaft.
(4) Remove the piston/connecting rod assemblies.
INSPECTION
Measure the combustion deck face using a straight
edge and a feeler gauge (Fig. 1). The distortion of the MIN. 102.0 mm (4.0157 inch)
combustion deck face is not to exceed 0.010 mm MAX. 102.116 mm (4.0203 inch)
(0.0004 inch) in any 50.00 mm (2.0 inch) diameter. Out-of-Round 0.038 mm (0.0015 inch)
Overall variation end to end or side to side is 0.075 Taper 0.0 76 mm (0.003 inch)
mm (0,003 inch).
Oversize pistons and rings are
If the surface exceeds the limit, refer to Cylinder
Block Refacing. available for bored cylinder blocks.
J9209-167
Fig. 2 Cylinder Bore Diameter
Fig. 1 Combustion Deck Face Measurement

Inspect the cylinder bores for damage or excessive
wear.
Measure the cylinder bores (Fig. 2). If the cylinder
bores exceeds the limit, refer to Cylinder Bore Re
pair.
Inspect the camshaft bores for scoring or excessive
CAMSHAFT BORE DIAMETER
wear.
Measure the camshaft bores (Fig. 8). Limit for the
No.l bore applies to the ID of the bushing. MAX. 54.133 mm (2.1312 inch)
If a bore exceeds the limit, refer to Camshaft Bore
Repair. J9109-78
Inspect the tappet bores for scoring or excessive
wear (Fig. 4). Fig. 3 Camshaft Bores
If out of limits, replace the cylinder block. (Fig. 5). For the rough hone, use 80 grit honing
stones. To finish hone, use 280 grit honing stones.
CYLINDER BORES—DE-GLAZE
(5) Use a drill, a fine grit Flex-hone and a mixture
(1) New piston rings may not seat in glazed cylin
der bores. of equal parts of mineral spirits and SAE SOW engine
(2) De-glazing gives the bore the correct surface oil to de-glaze the bores.
finish required to seat the rings. The size of the bore (6) The Crosshatch angle is a function of drill speed
is not changed by proper de-glazing, and how fast the hone is moved vertically (Fig. 6).
(3) Cover the lube holes in the top of the block (7) Vertical strokes MUST be smooth continuous
with waterproof tape. passes along the full length of the bore (Fig. 6).
(4) A correctly honed surface will have a cross- (8) Inspect the bore after 10 strokes.
hatch appearance with the lines at 15° to 25° angles
9 - 168 5.9L (DIESEL) ENGINE B R
(11) Check the bore cleanliness by w i p i n g w i t h a

w h i t e , l i n t free, l i g h t l y oiled cloth. I f g r i t residue is
s t i l l present, repeat the cleaning process u n t i l all res
idue is removed. Wash the bores and the complete
block assembly w i t h solvent and d r y w i t h compressed
air.
(12) Be sure to remove the tape covering the lube
holes after the cleaning process is complete.
CYLINDER BLOCK REFACING

(1) The combustion deck can be refaced twice. The
first reface should be 0.25 m m (0.0098 inch). I f addi
t i o n a l refacing is required, an additional 0.25 m m
(0.0098 inch) can be removed. Total allowed refacing
is 0.50 m m (0.0197 inch) - (Fig. 7).
BORE DIAMETER
MAX. 16.055 mm (0.632 inch)
J9109-79
Fig. 4 Tappet Bore Diameter
TOP OF BLOCK
1st REFACE 0.15 mm (0.0058 inch)

2nd REFACE 0.35 mm (0.0138 inch)
© Total 0.50 mm (0.0197 inch)

Fig. 5 Cylinder Bore Crosshatch Pattern
® Standard 323.00 mm ±0.10 mm
(12.7165 inch ±0.0039 inch)
1st REFACE 322.85 mm ±0.10 mm
(12.7106 inch ±0.0039 inch)
2nd REFACE 322.50 mm ±0.10 mm
(12.6968 inch ±0.0039 inch)
J9109-118
Fig. 7 Refacing Dimensions of the Cylinder Block

(2) The upper r i g h t corner of the rear face of the
block m u s t be stamped w i t h a X when the block is
refaced to 0.25 m m (0.0098 inch). A second X must be
stamped beside the first when the block is refaced to
1 STROKE ( f + | ) / P E R SECOND 0.50 m m (0.0197 inch) - (Fig. 8).
(3) Consult the parts catalog for the proper head
Fig. 6 De-Glazing Drill Speed and Vertical Speed gaskets which must be used w i t h refaced blocks to
(9) Use a strong solution of hot w a t e r and l a u n d r y ensure proper piston-to-valve clearance.
detergent to clean the bores. Clean the cylinder bores
immediately after de-glazing. CYLINDER BORE REPAIR
(10) Rinse the bores u n t i l the detergent is removed Cylinder bore(s) can be repaired by one of two
and blow the block d r y w i t h compressed air. methods:
5.9L (DIESEL) ENGINE .9-169
BORING AND
HONING DIAMETERS
Fig. 8 Stamp Block after Reface

BORING DIAMETER DIMENSION
• Method 1:—Over boring and using oversize pistons
and rings. 1st REBORE - 102,469 mm
• Method 2:—Boring and installing a repair sleeve (4.0342 inch)
to return the bore to standard dimensions. 2nd REBORE - 102.969 mm
(4.0539 inch)
METHOD 1—OVERSIZE BORE
HONING DIAMETER DIMENSIONS
Oversize pistons and rings are available in two
sizes - 0.50 mm (0.0197 inch) and 1.00 mm (0.0393
STANDARD 102.020 ±0.020 mm
inch). (4.0165 ±0.0008 inch)
Any combination of standard, 0.50 mm (0.0197 1st REBORE 102.520 ± 0.020 mm
inch) or 1.00 mm (0.0393 inch) overbore may be used (4.0362 ± 0.0008 inch)
in the same engine. 2nd REBORE 103.020 ± 0.020 mm
If more than 1.00 mm- (0.0393 inch) overbore is (4.0559 ± 0.0008 inch)
needed, a repair sleeve can be installed (refer to
CHAMFER DIMENSIONS
Method 2—Repair Sleeve).
Cylinder block bores may be bored twice before use
Approx. 1.25 mm (0.049 inch)
of a repair sleeve is required (Fig. 9). The first bore by 15°
is 0.50 mm (0.0197 inch) oversize. The second bore is
1.00 mm (0.0393 inch) oversize. J9109-119
After boring to size, use a honing stone to chamfer
the edge of the bore (Fig. 9). 6 x 3.5 Fig. 9 Cylinder Bore Dimensions
A correctly honed surface will have a Crosshatch TOP OF BLOCK
appearance with the lines at 15° to 25° angles with
the top of the cylinder block (Fig. 10). For the rough
hone, use 80 grit honing stones. To finish hone, use
280 grit honing stones.
A maximum of 1.2 micrometer (48 microinch) sur
face finish must be obtained.
After finish honing is complete, immediately clean
the cylinder bores with a strong solution of laundry
detergent and hot water.
After rinsing, blow the block dry.
Fig. 10 Crosshatch Pattern of Repaired Sleeve(s)
Check the bore cleanliness by wiping with a white,
lint-free, lightly-oiled cloth. There should be no grit METHOD 2—REPAIR SLEEVE
residue present. If more than a 1.00 mm (0.03937 inch) diameter
If the block is not to be used right away, coat it oversize bore is required, the block must be bored
with a rust-preventing compound. and a repair sleeve installed.
Bore the block cylinder bore to 104.500-104.515
mm (4.1142-4.1148 inch) - (Fig. 11).
Repair sleeves can be replaced by using a boring A sleeve driver can be constructed as follows (Fig.
bar to bore out the old sleeve. DO NOT cut the cyl
inder bore beyond the oversize limit.
DRIVE - ALUMINUM
HANDLE - STEEL
A = 127 mm (5 inch)
B = 38 mm (1.5 inch)
B L O C K REBORE F O R R E P A I R SLEEVE
C = 6.35 mm (0.25 inch)
D = 25.4 mm (1 inch)
BORE DIA. - 104.500 + 0.015 mm E - 101 mm (3.976 inch)
(4.1142 +0.0006 Inch) F = 107.343 mm (4.226 inch)
STEP DIM. - 6.35 mm (0.25 inch)
J9109-122
J9109-120
Fig. 13 Sleeve Driver Construction
Fig. 11 Block Bore for Repair Sleeve Dimensions
Set up a boring bar and machine the sleeve to
After machining - the block for the new repair 101.956 mm (4.014 inch) - (Pig. 14).
sleeve, thoroughly clean the bore of all metal chips, After removing the boring bar, use a honing stone
debris and oil residue before installing the sleeve. to chamfer the corner of the repair sleeve(s) - (Fig.
Cool the repair sleeve(s) to a temperature of -12°C 14).
(10°F) or below for a minimum of one hour. Be ready
to install the sleeve immediately after removing it
from the freezer.
Apply a coat of Loctite 620, or equivalent to the
bore that is to be sleeved.
Wear protective gloves to push the cold sleeve into
the bore as far as possible.
Using a sleeve driver, drive the sleeve downward
until it contacts the step at the bottom of the bore
(Fig. 12).
SLEEVE DIAMETER - 101.956 mm

(4.014 inch)
SLEEVE PROTRUSION
MIN. - FLUSH WITH BLOCK
MAX. - 0.050 mm (0.0019 inch)
SLEEVE CHAMFER
APPROX. 1.25 mm (Q.Q49 inch)
BY 15° •
' J9109-123
Fig. 14 Sleeve Machining Dimensions

A correctly honed surface w i l l h a v e a Crosshatch
appearance with the lines at 15° to 25° angles with
Fig. 12 Sleeve Installation
the top of the cylinder block,, For the rough hone, use (3) Drive the cup plugs in until they bottom in the
80. grit honing stones. To finish hone, use 280 grit bore (Fig. 16).
honing stones. (4) Fill the engine with oil. Run the engine and
Finished bore inside dimension is 102.020 ±0.020 check for leaks.
mm (4.0165 ±0.0008 inch). (5) Stop the engine and check the oil level with the
A maximum of 1.2 micrometer (48 microinch) sur dipstick.
face finish must be obtained.
After finish honing is complete, immediately clean
the cylinder bores with a strong solution of laundry
detergent and hot water.
After rinsing, blow the block dry with compressed
air.
Wipe the bore with a white, lint-free, lightly oiled
cloth. Make sure there is no grit residue present.
Apply a rust-preventing compound if the block will
not be used immediately.
A standard diameter piston and a piston ring set
must be used with a sleeved cylinder bore.
CAM BORE REPAIR
The front cam bushing bore can be bored to 57.740
Mm ±0.018 mm (2.278 inch ±0.0007 inch) oversize. Fig. 16 Cup Plug Locations in Cylinder Block
DO NOT bore the intermediate or rear cam bore to INSTALLATION
the front cam bore oversize dimensions. Intermediate (1) Install the cylinder head onto the block.
and rear cam bores may be bored to 57.240 mm (2) Install the engine assembly into the vehicle.
±0.018 mm (2.253 inch ±0.0007 inch) oversize.
A surface finish of 2.8 micrometers (92 microinch) PISTON AND CONNECTING ROD ASSEilLY
must be maintained. Not more than 20% of an area
The turbocharged intercooler piston has a Ni-Resist
of any one bore may be 3.2 micrometers (126 micro-
inch). insert with a keystone profile for the top compression
Camshaft bores can be repaired individually. It is ring. The new piston has a new design bowl and a 7
not necessary to repair undamaged cam bores in or mm longer piston pin. These pistons can not be inter
der to repair individually damaged cam bores. The changed with earlier models.
standard front bushing cannot be used to repair in
REMOVAL
termediate or rear bores.
Install all cam bushings flush or below the front
(2) Remove the cylinder head from the block.
cam bore surface. The oil hole must align to allow a
(3) Remove the oil pan and suction pump.
3.2 mm (0.125 inch) rod to pass through freely (Fig.
(4) If the cylinder bores have ridges, use a ridge
15).
reamer to cut the ridge from the top of the cylinder
bore before removing the piston. Make sure the ridge
reamer does not make a deep cut into the bore. DO
NOT remove more metal than is necessary to remove
the ridge.
(5) If cylinders have ridges, the cylinders are over
size and will need boring.
(6) Use a hammer and a steel stamp to mark the
cylinder number onto each connecting rod cap. Mark
the cylinder number onto the top of each piston.
(7) Remove the connecting rod bolts and rod caps.
Use care so the cylinder bores and connecting rods
are not damaged.
Fig. 15 Oii Hole Alignment (8) Use a hammer handle or similar object to push
CUP PLUG—REPLACEMENT the piston and connecting rod through the cylinder
(1) Remove the cup plugs from the oil passages bore.
(Fig. 16). (9) Store the piston/rod assemblies in a rack.
(2) Apply a bead of Loctite 277 around the outside (10) If a piston must be replaced, replace with the
diameter of the oil passage cup plugs. same part number (grading) that was removed.'
I -172 S J L (DIESEL) ENGINE
DISASSEMBLE
(1) Remove the retainer rings from the piston (Fig.
IX
(2) Remove the piston pin. Heating the piston is
not required.
(3) Remove the piston rings (Fig. 1).
J9109-63
Fig. 2 Piston Skirt Diameter

Use a new oil ring to measure the clearance in the
oil groove (Fig. 3). I f the clearance exceeds 0.127 mm
(0.005 inch), replace the piston.
—^ J9i 09-62
Fig. 1 Retainer Rings

CLEANING
CAUTION; DO NOT use bead blast to clean the pis

tons. DO NOT clean the pistons and rods In an acid PISTON
tank.
J9109-64
Soak the pistons in cold parts cleaner. Soaking the
pistons overnight will usually loosen the carbon de Fig. 3 Intermediate and Oil Ring Clearances
posits. Measure the pin bore (Fig. 4). The maximum diam
Wash the pistons and rods in a strong solution of eter is 40.025 mm (1.5758 inch). If the bore is over
laundry detergent and hot water. limits, replace the piston.
Clean the remaining deposits from the ring grooves PISTON
with the square end of a broken ring. DO NOT use a
ring groove cleaner and be sure not to scratch the
ring sealing surface in the piston groove.
Wash the pistons again in a detergent solution or
solvent.
Rinse the pistons. Use compressed air to dry.
INSPECTION
Inspect the rod journals for deep scratches, indica
tion of overheating and other damage.
Inspect the pistons for damage and excessive wear.
Check top of the piston, ring grooves, skirt and pin
bore. J9109-65
Measure the piston skirt diameter (Fig. 2). If the
piston is out of limits, replace the piston. Fig. 4 Piston Pin Bore
The upper groove only needs to be inspected for Inspect the piston pin for nicks, gouges and exces
damage. sive wear.
Use a new piston ring to measure the clearance in Measure the pin diameter (Fig. 5). The minimum
the intermediate ring groove (Fig. 3). If the clearance diameter is 39.990 mm (1.5744 inch). If the diameter
of the intermediate ring exceeds 0.152 mm (0.006 is out of limits, replace the pin.
inch), replace the piston. Inspect the rod for damage and wear. The I-Beam
section of the connecting rod cannot have dents or
S J L (DIESEL) ENGINE 9 -173
PISTON
30Z3>
4
J9109-66
Fig. 5 Piston Pin Diameter
MIN, 68.962 mm {2.7)5 inch)
other damage. Damage to this part can cause stress MAX, 69.013 mm (2.717 inch)
risers which will progress to breakage.
Measure the connecting rod pin bore (Fig. 6). The Out-of-Round - Max,
maximum diameter is 40.042 mm (1.5784 inch). If 0.050 mm (0.002 Inch)
out of limits, replace the connecting rod. Taper - Max,
CONNECTING
0.013 mm (0.0005 Inch)
Bearing Clearance - Max.
0.089 mm (0.0035 Inch)
J9109-91
Fig. 7 Connecting Rod Journal Diameter Limits

PISTON GRADING
When rebuilding an engine with the original cylin
der block, crankshaft and pistons, make sure the pis
tons are installed in the original cylinder.
If replacing the piston(s), make sure the replace
ment piston(s) are the same grade as the original pis
ton.
If a new cylinder block or crankshaft is used, the
Fig, 6 Connecting Rod Pin Bore piston grading procedure MUST be performed to de
mMMB&WMm m©m BEARING AND termine the proper piston grade for each cylinder.
CRANKSHAFT JOURNAL CLEARANCE
PISTON GRADING PROCEDURE
Measure the connecting rod bore with the bearings
installed and the bolts tightened to 100 N-m (78 ft. (1) Install any of the original connecting rod and
lbs.) torque. piston assemblies into the No.l cylinder. DO NOT in
Record the smaller diameter. stall the piston rings.
Measure the diameter of the .rod journal at the lo (2) Install the upper bearing shell in the connect
cation shown (Fig. 7). Calculate the average diameter ing rod with the tang of the bearing in the slot of the
for each side of the journal. connecting rod. The connecting rod bearing shell
The clearance is the difference between the con must be installed in the original connecting rod and
necting rod bore {smallest diameter) and the average cap. Use clean lubricating oil to coat the inside diam
diameter for each side of the crankshaft journal. eter of. the connecting rod bearing shell.
If the crankshaft is within limits, .replace the bear (3) Install the bearing shell in the connecting rod
ing. If the crankshaft is out of limits, grind the cap with the tang of the bearing in the slot to the
crankshaft to the next smaller size and use oversize cap. Use clean lubricating oil to coat the inside diam
rod bearings. eter of, the bearing shell.
(4) The four digit number stamped on the connect
ing rod and cap at the parting line must match and
be installed on the oii cooler side of the engine; In-
i - 176 5.9L (DIESEL) ENGINE BR
TOP
RING
INTERMEDIATE
RING
N O I L CONTROL
RING
/ J m 09-73
J9109-84
Fig. 17 Piston Ring Positioning
Fig. 20 Piston/Rod Assembly at BDC
top of the block. Carefully pull the connecting rod
onto the crankshaft journal.
(8) Use clean engine oil to lubricate the threads
and under the heads of the connecting rod bolts.
0.250 mm (.0098 in. (9) The 4 digit number stamped on the rod cap at
0.500 mm (.0197 in. the parting line must match and be installed towards
0.750 mm (.0295 in. the oil cooler side of the engine (Fig. 21).
1.000 mm .0394 in.
J9109-82
Fig. 18 Connecting Rod Bearing Size Location

(3) Compress the rings using a piston ring com
pressor tool (Fig. 19). If using a strap-type ring com
f
pressor, make sure the inside end o the strap does
not hook on a ring gap and break the ring.
J9109-85
Fig. 21 Correct Rod Cap Installation

(10) Install the rod cap and bolts to the connecting
rod. Tighten the connecting rod and bolt evenly in 3
PISTON
RING
steps.
C O M P R E S S O R TOOL • Tighten the bolts to 35 N-m (26 ft. lbs.) torque.
J9109-83 © Tighten the bolts to 70 N-m (51 ft. lbs.) torque.
Fig. 19 Piston Ring Compressor Tool • Tighten the bolts to 100 N-m (73 ft. lbs.) torque.
(11) The crankshaft must rotate freely. Check for
(4) Bar the crankshaft so the rod journal for the freedom of rotation as the caps are installed. If the
piston to be installed is at BDC (Bottom Dead Cen crankshaft does not rotate freely, check the installa
ter) - (Fig. 20). tion of the rod bearing and the bearing size.
(5) Be sure the FRONT marking on the piston and (12) Measure the side clearance between the con
the numbers on the rod and cap are oriented as illus
necting rod and the crankshaft (Fig. 22). DO NOT
trated.
(6) Position the piston and rod assembly into the measure the clearance between the cap and crank
cylinder bore with the word FRONT on the piston to shaft.
wards the front of the cylinder block. Use care when (13) Install the suction tube and oil pan.
you install the piston and connecting rod so the cyl (14) Install the cylinder head onto the block.
inder bore is not damaged. (15) Install the engine assembly into the vehicle.
(7) Push the piston into the bore until the top of
the piston is approximately 50 mm (2 inch) below the
J9109-86
SIDE CLEARANCE LIMITS

MIN. 0.100 mm (0.004 inch)
MAX 0.300 mm (0.012 inch) j J9109-88
Fig. 22 Side Clearance between Connecting Fig. 2 Main Bearing Cap Removal
Rod/Crankshaft CAUTION: Crankshaft must be lifted straight off the
CRANKSHAFT bearings to prevent damage to the thrust bearings.
REMOVAL CRANKSHAFT
(1) Remove the rear crankshaft seal housing.
(2) Remove the gear housing.
(3) Rotate the engine to a horizontal position and
remove the main bearing bolts.
(4) The main bearing caps should be numbered. If
they are not, be sure to mark them, beginning with
number one at the front and ending with number
seven at the rear (Fig. 1).
MAIN
BEARING
CAP J9109-89
Fig. 3 Lifting Crankshaft out of Cylinder Block

(7) Remove the main bearings from the block and
the main caps.
(8) Remove the piston cooling nozzles by using a
3/16 inch pin punch to push them out (Fig. 4).
PISTON
COOLING
NOZZLE
J9109-87
> \
Fig. 1 Numbering Main Bearing Caps
CAUTION: DO NOT pry on the main caps to free
them from the cylinder block.
0)
(5) Use two of the main bearing cap bolts to wiggle
the main cap loose, being careful not to damage the
bolt threads (Fig. 2). Remove the caps. i/
9109-90
WARNING: U S E A HOIST TO AVOID INJURY.
Fig. 4 Piston Cooling Nozzles
(6) Lift the crankshaft and gear from the cylinder CLEMMING AND INSPECTION
block (Fig. 3). Clean the crankshaft oil galley holes with a nylon
brush.
Rinse in clean solvent and dry with compressed air.
I -118 5 J L (DIESEL) ENGINE BR
Inspect the front and rear seal contact areas of the Thrust journals can be ground in the same incre
crankshaft for scratches or grooving. ments and using the same specifications as all other
The service seal kit will position the seal slightly main journals. The main journal radius may be
deeper into the seal bore so it will contact the crank ground using either the preferred or the alternative
shaft at a different location. If this has already been procedure providing the thrust surface width is not
done and the crankshaft has two worn areas, install being ground. The preferred procedure must be used
a wear sleeve to provide a new contact surface for when the main bearing thrust width surface is
the seal. ground. When the thrust surface width requires
Inspect the rod and main journal for deep scores, grinding, the main journal must be ground to the
signs of overheating and other abnormal marks. same undersize dimension (Fig. 6).
CllAMEwLifl^h :
h a knit ww WW~H'H«
THRUST J O U R N A L WIDTH
Crankshaft main and rod journals may be ground 37.500 ±0.025 mm
in increments of 0.25 mm (0.0098 inch) up to a total (1.4764 ±0,001 inch)
of 1.00 mm (0.0394 inch).
UNDERSIZES REGRIND WIDTH TO
The only exception is the main journal thrust
0.50 mm 38.000 ±0.025 mm
width surface. This journal must be ground in incre
(0.0197 inch) (1.4961 ±0.001 inch
ments of 0.50 mm (0.0197 inch) up to a total of 1.00
mm (0.0394 inch). The thrust surface is located on 1.00 mm 38.500 ±0.025 mm
(0.0394 inch) (1.5158 ±0.001 inch)
the No.6 main bearing. When the thrust surface re
J9109-127
quires grinding, the main journal must be ground to
the same undersize dimension. Fig. 6 Crankshaft Thrust Journal Width Dimensions
CAUTION: Welding of the crankshaft is not allowed. • The thrust surface is to be ground on center within
Failure of the crankshaft will result 0.10 mm (0.004 inch). It also must be perpendicular
to the front and rear mains within 0.0015 mm
(0.00006 inch) per radial inch on the thrust area
MAIN J0URIAL (Fig. 7). The surface finish requirement is 0.04 mi
All main journals are to be ground in the opposite crometer (16.0 microinch).
direction of engine rotation (clockwise as viewed from
JOURNAL
the front of crankshaft). Polish the journals in the
same direction as engine rotation.
The main bearing grinding specifications are shown
in Fig. 5.
STANDARD MAIN JOURNAL DIAMETER

83.000 ±0.013 mm
(3.2677 ±0.0005 Inch)
W O R N M A I N J O U R N A L DIAMETER LIMIT
82.962 (3.2662 inch)
UNDERSIZES R E G R I N D TO
0.25 mm 82.750 +0.013 mm
(0.0098 inch) (3.2579 ±0.0005 inch)
0.50 mm 82.500 ±0.013 mm
J9109-128
(0.0197 inch) (3.2480 ±0.0005 inch)
0.75 mm 82.250 ±0.013 mm
(3.2381 ±0.0005 inch) Fig. 7 Crankshaft Thrust Surface
(0.0295 inch)
1.00 mm 82.000 ±0.013 mm PREFERRED PROCEDURE:
(0.0394 inch) (3.2283 ±0.0005 inch)
Smoothly blend a 4.20 ±0.020 mm (0.1654 ±0.0008
OUT-OF R O U N D & TAPER (MAX.) inch) radius to the ground diameters (Fig. 8).
0.005 mm (0.0002 inch)
CAUTION: DO NOT use the Alternative Procedure
ALL M A I N J O U R N A L S A R E TO BE PARALLEL
TO THE FRONT A N D REAR M A I N S W I T H I N : when the thrust surface width is ground.
0.030 mm 0.001 inch)
J9109-125 ALTERNATIVE PROCEDURE:
Smoothly blend a 1.25 ±0.020 mm (0.0492 ±0.0008
Fig. 5 Crankshaft Main Journal Dimensions inch) radius to the ground diameters (Fig. 9).
BR S J L (DIESEL) ENGINE 9 - 179
ORIGINAL RADIUS ORIGINAL RADIUS

NEW UNDERCUT RADIUS ^
NEW UNDERCUT RADIUSv
JOURNAL SURFACEs
JOURNAL SURFACE SURFACE FINISH

SURFACE FINISH © 0.8 micrometer (32.0 microinch)
© 0.8 micrometer (32.0 microinch) for a minimum of 45° into the
for a minimum of 45° Into the fillet beyond journal surface
fillet beyond journal surface 1.6 micrometer (64.0 miaoirtcb)
for remainder of fillet
•® 1.6 micrometer (64.0 microinch)
for remainder of fillet © 0.4 micrometer (16.0 microinch)
0.4 micrometer (16.0 microinch) WIDTH OF REGRIND/UNDERCUT RADIUS

© 34.5 ±0.025 mm (1.358 ±0.001 in)
J9109-129
J9109-130
Fig. 8 Grind Crankshaft Main Journal—Preferred Fig. 9 Grind Crankshaft Main Journal—AIternative
Method Method
FtOO JOURNAL
All rod journals are to be ground in the opposite di STANDARD ROD J O U R N A L DIAMETER
rection of engine rotation (clockwise as viewed from 69.000 ±0.013 mm
the front of crankshaft). Polish the journals in the (2.7165 ±0.0005 inch)
same direction as engine rotation. W O R N ROD J O U R N A L DIAMETER LIMIT
The rod bearing grinding specifications are shown 68.962 (2.7150 inch)
in Fig. 10. UNDERSIZES REGRIND TO
PREFERRED PROCEDURE: 0.25 mm 68.750 +0.013 mm
Smoothly blend a 4.00 ±0.020 (0.1575 ±0.0008 (0.0098 inch) (2.7067 ±0.0005 inch)
inch) radius to the ground diameters and side faces 0.50 mm 68.500 +0.013 mm
(0.0197 inch) (2.6969 ±0.0005 inch)
(Fig. 11). 0.75 mm 68.250 ±0.013 mm
ALTERNATIVE PROCEDURE: (0.0295 inch) (2.6870 ±0.0005 inch)
Smoothly blend a 1.25 ±0.020 mm (0.0492 ±0.0008 1.00 mm 68.000 ±0.013 mm
inch) radius to the ground journals (Fig. 12). (0.0394 inch) (2.6772 ±0.0005 inch)
OUT-OF R O U N D & TAPER (MAX.)

CRANKSHAFT FRONT SEAL 0.005 mm (0.0002 inch)
REM0WAL ALL M A I N J O U R N A L S ARE TO BE PARALLEL

TO THE FRONT A N D REAR M A I N S W I T H I N :
(1) Remove the drive belt. 0.030 mm 0.001 inch)
(2) Remove the vibration damper. J9109-126
(3) Drill two l/8th inch holes into the seal face,
180° apart. Fig. 10 Crankshaft Rod Journal Dimensions
(4) Use a slide hammer tool with a #10 metal INSTALLATION
screw. Pull alternating from side-to-side until the
(1) The sealing surface on the crankshaft must be
seal is free.
free from all oil residue to prevent seal leaks.
ORIGINAL RADIUS ORIGINAL RADIUS

NEW UNDERCUT RADIUS
NEW UNDERCUT RADIUS\
JOURNAL SURFACE.
Mi
JOURNAL SURFACE SURFACE FINISH
SURFACE FINISH © 0.8 micrometer (32.0 microinch)

for a minimum of 45® into the
© 0.6 micrometer (32.0 microinch) ^ filet beyond journal surfooi
for Q minimum of 45° Into trie W 1.6 micrometer (64.0 microiriefi)
^ fill©! beyond journal surface ^ for remainder of fillet
( P 1.6 micrometer (64.0 microinch) v£/ 0.4 micrometer (16.0 microinch)
^ for remainder of fillet
(£) 0,4 miff©meter (16.0 microinch) WIDTH OF REGRIND/UNDERCUT RADIUS
© 34.79 ± 0.025 mm (1.369 ±0.001 In)
J9109-131 J9109-132
Fig. 11 Crankshaft Rod Journal Grind—Preferred Fig. 12 Grind Crankshaft Rod Journal—Alternative
Method Method
(2) If the gear cover was replaced, use the align (2) Support the seal area of the rear seal housing
ment tool from the seal kit to make sure the cover is and press/drive out the seal using a hammer and a
aligned with the crankshaft. pin pinch.
(3) Apply a bead of Loctite 277 to the outside di (3) Clean the rear seal housing.
ameter of the seal.
(4) Install the pilot from the seal kit onto the
crankshaft.
(5) Install the seal onto the pilot and start it into
the gear housing cover seal bore.
(6) Remove the pilot.
(7) Use the alignment/installation tool and a plas
tic hammer to install the seal to the correct depth.
(8) Install the vibration damper, but DO NOT
tighten the damper bolt until the belt is installed.
(9) Install the drive belt.
(10) Tighten the vibration damper bolts to 125 N*m
(92 ft. lbs.) torque. Use the engine barring tool to
keep the engine from rotating during torquing oper
ation.
Fig. 13 Crankshaft Rear Seal Housing/Gasket
CRANKSHAFT REAR Sill MOUSING AND
SEAL INSTALLATION
(1) Clean and dry the rear crankshaft sealing sur
REM0WAL face. The seal lip and the sealing surface on the
(1) Remove the rear seal housing and gasket (Fig. crankshaft must be free from all oil residue to pre
13). vent seal leaks.
i J L (DIESEL) ENGINE
(2) Assemble the rear seal housing and gasket to

ALIGNMENT AND \
the cylinder block with the bolts. INSTALLATION TOOL
(3) Align the seal housing to the crankshaft with
the alignment tool provided in the seal kit (Fig. 14).
Make sure the seal housing is level with both sides of
the block oil pan rail Tighten the bolts to 9 N-m (7
ft. lbs.) torque.
(4) Remove the alignment tool and trim the gasket
even with the oil pan mounting surface (Fig. 14).
ALIGNMENT
TOOL
J9109-102
Fig. 16 Crankshaft Rear Seal Alignment/Installation

Tool
CRANKSHAFT REAR SEAL
iEiiWAL
(1) Remove the transmission (refer to Group 21,
Transmission for the proper procedure).
J9109-100 (2) Remove the clutch cover.
(3) Remove the clutch plate.
Fig. 14 Crankshaft Rear Seal Housing Alignment (4) Remove the flywheel.
Tool (5) Drill holes 180° apart into the seal. Be careful
not to get the drill against the crankshaft.
(5) The rubber O.D. rear crankshaft seals are lu
(6) Install #10 sheet metal screws in the drilled
bricated with soapy water. Seals without rubber O.D.
holes and remove the rear seal with a slide hammer
use Loctite 277, or equivalent.
(Fig. 17).
(6) Install the seal pilot (provided with the replace
ment kit) onto the crankshaft. Push the seal onto the REAR
crankshaft (Fig. 15). NO. 10" SEAL CRANKSHAFT
(7) Remove the seal pilot. SCR£W3iJ\\~~-
J9109-60
SEAL PILOT
Fig. 17 Crankshaft Rear Seal Removal
INSTALLATION
J9109-101
Fig. 15 Crankshaft Rear Seal Pilot CAUTION; The seal lip and the sealing surface on
the crankshaft must be free from all oil residue to
(8) Use alignment and installation tool packaged prevent seal leaks.
in the seal kit (Fig. 16). Alternately, drive the seal at
the 12, 3, 6 and 9 o'clock positions to prevent bending The crankshaft and seal must be dry when the seal
the seal carrier during installation. is installed.
S - 182 5.9L (DIESI IQINE BR
(1) Install the seal pilot, provided in the replace RING GEAR
ment kit, on the crankshaft. Push the seal on the pi 7£
lot and crankshaft.
(2) Remove the seal pilot.
(3) Seal O.D. lubricant/sealant:
® Rubber O.D. rear crankshaft seals are lubricated
with soapy water.
• Seals without rubber O.D. use Loctite 277 or
equivalent sealant. BEVEL
(4) Use the alignment tool to install the seal to the
correct depth in the housing. Use a hammer to drive
the seal into the housing until the alignment tool
stops against the housing (Fig. 18).
(5) Hit the tool at the 12, 3, 6 and 9 o'clock posi J9109-58 FLYWHEEL
tions to drive the seal evenly and prevent bending

the seal housing. Fig. 19 Flywheel/Ring Gear Position
INSTALLATION
ALIGNMENT
TOOL'
CAUTION: Never use the timing pin to hold the
crankshaft in position.
(1) Use the engine b a r r i n g tool to hold the crank

shaft when the flywheel bolts are being tightened.
(2) Tighten the bolts i n a criss-cross pattern to 137
N-m (101 f t . lbs.) torque.
MAIN BEARING CLEARANCE

Inspect the m a i n bearing bores for damage or ab
normal wear.
I n s t a l l the crankshaft m a i n bearings and measure
J9109-61 - m a i n bearing bore diameter w i t h the m a i n bolts
tightened to 176 N-m (130 ft. lbs.) torque (Fig. 20).
Fig. 18 Seal installation using Alignment Tool MAIN BEARING
FLYWHEEL RING GEAR CAPS
REliWAL
(1) Remove the transmission.
(2) Remove t h e clutch cover.
(3) Remove the clutch plate.
(4) Remove the flywheel.
WARNING: WEAR EYE PRCh E C T I O N WHEN Y O U

DRIVE T H E GEAR FROM TKIi FLYWHEEL. DO NOT
U S E A STEEL DRIFT PIN.
(5) Use a d r i f t p i n to drive the r i n g gear from t h e

flywheel (Fig. 19). Strike the gear at several points
around t h e wheel u n t i l i t is off.
(6) Heat the new r i n g for 20 minutes i n an oven Fig. 20 Crankshaft Main Bearing Bore Diameter
preheated to 127°C (250°F). Measure the diameter of the m a i n j o u r n a l at t h e
locations shown (Fig. 21). Calculate t h e average d i
WARNING; W E A R PROTECTIVE G L O V E S WHEN
ameter for each side of the j o u r n a l .
YOU INST/ LL THE HEATED G E A F
Calculate the m a i n bearing j o u r n a l to bearing
(7) I n s t a l l the gear. The gear must be installed so clearance, the clearance specifications are 0.119 m m
the bevel on the teeth is towards the crankshaft side (0.00475 inch). I f the crankshaft j o u r n a l is w i t h i n
of the flywheel (Fig. 19).
Bit 5.9L (DIESEL) ENGINE 9 - 183
Position the gear with the timing mark out and in
stall it on the crankshaft using the alignment pin.
Make sure the gear contacts the shoulder.
INSTALLATION
CAUTION: Use only hand force to push the nozzle

in place. If driven with a hammer, the nozzle will be
damaged.
(1) Use a center punch to push the piston cooling

nozzle into place. Install nozzles so they are even
with or slightly below the saddle surface.
(2) Make sure the saddle surface is clean and dry.
Install the upper main bearings.
(3) Install the combination thrust/main bearing in
the number six main bearing location.
MIN. 82.962 mm (3.2662 inch) (4) Lubricate the bearings with Lubriplate 105, or
MAX. 83.103 mm 13.2682 inch) equivalent.
J9109-93
WARNING: TO AVOID INJURY, U S E A HOIST TO IN
STALL THE CRANKSHAFT.
Fig. 21 Crankshaft Main Journal Diameter
limits, replace the main bearings. If not within spec (5) Install the crankshaft.
ifications, grind the crankshaft to next size and use
oversize bearings. CAUTION: Crankshaft must be lowered onto the
bearings straight to prevent damage to thrust bear
CRANKSHAFT GEAR - REPLACEMENT ings.
Remove the crankshaft gear using a heavy duty
puller. (6) Install the ring dowels in the main bearing
Remove all burrs and make sure the gear surface caps (Fig. 23).
on the end of the crankshaft is smooth.
If removed, install a new alignment pin. Drive the
pin in using a ball-peen hammer, leaving it protrud
ing 1.60 mm (0.063 inch) to 2.39 mm (0.094 inch)
above the crankshaft (Fig. 22).
J9109-95
Fig. 23 Install Ring Dowels

Fig. 22 Installing Alignment Pin (7) Install the lower main bearings in the caps.
Heat the crankshaft gear for 45 minutes at a tem (8) Lubricate the bearings with Lubriplate, or
perature of 121°C (250°F). equivalent.
(9) Numbers on the main bearings caps face the oil
CAUTION: DO NOT heat the gear longer than 45 cooler side of the engine with number one at the
minutes. front of the engine.
(10) Place the caps in their respective positions.
WARNING: W E A R PROTECTIVE G L O V E S TO P R E (11) Lubricate the main bearing bolt threads and
VENT INJURY. underside of the bolt head with clean engine oil.
9 -134 S J L (DIESEL) ENGINE BR
(12) Tighten the bolts evenly in the sequence CRANKSHAFT

shown using the following torque steps (Fig. 24). END
• STEP 1—Tighten all bolts in sequence to 60 N-m CLEARANCE
• STEP 2—Tighten all bolts in sequence to 119 N-m
• STEP 3—Tighten all bolts in sequence to 176 N-m
CRANKSHAFT
GEAR
MIN. 0.100 mm (0.004 inch)
MAX. 0.430 mm (0.017 inch)
J9409-120
Fig. 26 Crankshaft End Clearance

OIL PAN AND SUCTION TUBE
REMOVAL
(1) Remove the engine from the vehicle and mount
on an engine stand.
J9109-96
WARNING: HOT OIL CAN C A U S E P E R S O N A L IN
Fig. 24 Main Bearing Bolt Tightening Sequence JURY.
(13) Turn the crankshaft to determine that it will (2) Drain the used engine oil. Dispose of the used
rotate freely all 360°. Check the main bearing cap in oil properly.
stallations and/or the bearing sizes if the shaft does (3) Remove the oil pan and gasket (Fig. 1). Be sure
not turn easily. to connect the support bracket.
(14) Push the crankshaft towards one end of its (4) If required, remove the suction tube and gasket
thrust and place a dial indicator as shown (Fig. 25). (Fig. 1).
GASKET
DIAL
INDICATOR
CYLINDER
BLOCK
SUCTION
J9109-97 TUBE
Fig. 25 Position of Dial Indicator

(15) Zero the indicator needle and push the crank
shaft towards the other end of its thrust and record
the crankshaft end clearance (Fig. 26). J9109-19
Fig. 1 Oil Pan, Suction Tube and Gasket

S.IL (DIESEL) ENGINE 1-181
INSTALLATION (5) Install the drain plug with a new sealing

(1) Clean the sealing surface. washer and tighten to 80 N-m (60 ft. lbs.) torque.
(2) Install the suction tube and gasket. Tighten the (6) Install the engine assembly into the vehicle.
bolts to 24 N-m (18 ft. lbs.) torque. (7) Fill the engine with clean lubrication oil (refer
(8) Fill the joint between the pan rail/gear housing to Group 0, Lubrication and Maintenance). Eun the
and pan rail/rear cover with sealant. Use Three Bond engine and check for leaks.
1207-C, or equivalent. (8) Stop the engine and let it set for five minutes.
(4) Install the pan and gasket (Fig. 1). Tighten the Check the oil level, and add oil if needed.
[LUBRICATION SYSTEM
The engine uses a gerotor type lubricating pump. The turbocharger receives filtered, cooled and pres
The machined cavity in the block is the same for all surized lubricating oil through a supply line from the
engines. The pressure regulating valve is designed to filter head. A drain line connected to the bottom of
keep the lubricating oil pressure from exceeding the turbocharger housing returns the lubricating oil
449kPa (65 PSI). When the lubricating oil pressure to the lubricating oil pan through a fitting in the cyl
from the pump is greater the 499kPa (65 PSI), The inder block.
valve opens uncovering the dump port so part of the The main bearings and the valve train are lubri
lubricating oil is routed to the oil pan. Because of cated by pressurized oil directly from the main oil
manufacturing tolerances of the components and the gallery, the other power components, connecting rods,
oil passages, the lubricating oil pressure can differ as pistons, and camshaft receive pressurized oil directly
much as 69 kPa (10 PSI) between engines. from the main oil gallery. Passages in the crankshaft
The engines use full flow, plate type oil coolers. The supply oil to the connecting rods bearings. The oil is
oil flows through a cast passage in the cooler cover supplied to the camshaft journals through passages
and through the element where it is cooled by the en
in the main bearings saddles. Smaller passages in
gine coolant flowing past the plates of the elements.
After the oil is cooled, it flows through the full flow the main bearings saddles supply oil to the pistons
oil filter. cooling nozzles. The spray from the nozzles also pro
The lubricating oil cooler cover contains a bypass vides lubrication for the piston pins.
valve the will let the lubricating oil flow bypass a Lubrication for the valve train is supplied through
plugged filter. The valve is designed to open when separate passages in the cylinder block. Oil flows
the pressure drop across the filter is more than 138 through the passages and across the oil transfer slot
kPa (20 PSI), as with a plugged filter and lets the lu in the cylinder head gasket. From the transfer slot,
bricating oil continue on through the engine. When a the oil flows around the outside diameter at the cyl
filter becomes plugged, an oil pressure decrease of 60 inder capscrew, across a slot in the bottom of the
kPa (10 PSI) or less from normal operating pressure rocker lever support, and up the vertical passage in
can be observed on the vehicle lubricating oil pres the support. From these passages, oil flows through
sure gauge. This allows unfiltered oil into the engine. passages in the rocker lever shaft to lubricate the
This condition should be avoided by changing the fil rocker levers. The oil from the channel lubricates the
ter at each oil change. valves stems, push rods, and tappets.
5.9L (DIESEL) ENI11E S ^ 187
Fig. 3 Lubricating System Passages

OIL PUMP
The non-intercooled turbocharged engine oil pumps
can not be used on intercooled engines.
REMOVAL
(1) Remove the radiator (refer to Group 7, Cooling
(2) Loosen the crankshaft vibration damper and re
move the drive belt.
(8) Remove the fan clutch assembly.
(4) Remove the fan hub.
(5) Remove the oil fill tube.
(6) Remove the crankshaft vibration damper.
(7) Remove the gear housing cover.
(8) Remove the four mounting bolts and pull the J9109-20
pump from the bore in the cylinder block (Fig. 4).
C L E A N AND INSPECT Fig. 4 Oil Pump Removal
Visually inspect the lube pump gears for chips, Remove the back plate (Fig. 5).
cracks or excessive wear.
I - 188 5 J L (DIESEL) ENGINE —
Mark TOP on the gerotor planetary using a felt tip GEROTOR

PORT
pen (Fig. 5). PLATE
Remove the gerotor planetary (Fig. 5).
OIL PUMP
BACK PLATE,
, GEROTOR
V
GET*"'C *
Fig. 7 Gerotor to Port Plate
GEROTOR
BODY PLANETARY
BORE
J9109-156
F/g. 5 Gerotor Planetary and Gerotor

Inspect for excessive wear or damage.
Clean all parts in solvent and dry with compressed
air.
Inspect the pump housing and gerotor drive for J9i09-23
damaged and excessive wear.
Install the gerotor planetary in the original posi Fig. 8 Gerotor Planetary to Body Bore Clearance
tion. The chamfer must be on the O.D. and down.
OIL PUMP
Measure the tip clearance (Fig. 8). Maximum clear DRIVE IDLER GEAR
ance is 0.1778 mm (0.007 inch). If the oil pump is out GEAR
of limits, replace the pump.
FEELER *
GAUGE BACKLASH
BACKLASH
J9109-24
Fig. 9 Measure Gear Backlash

INSTALLATION
J9109-21 (1) Lubricate the pump with clean engine oil. Fill
ing the pump with clean engine oil during installa
Fig. 8 Tip Clearance
tion will help to prime the pump at engine start up.
Make sure the idler gear pin is installed in the lo
Measure the clearance of the gerotor drive/gerotor cating bore in the cylinder block.
planetary to port plate (Fig. 7). Maximum clearance (2) Install the pump. Tighten the oil pump mount
is 0.127 mm (0.005 inch). If the oil pump is out of ing bolts in two steps and in the sequence shown
limits, replace the pump. (Fig. 4).
Measure the clearance of the gerotor planetary to © Step 1—Tighten to 5 N-m (44 in. lbs.) torque.
the body bore (Fig. 8). Maximum clearance is 0.381 • Step 2—Tighten to 24 N-m (18 ft. lbs.) torque.
mm (0.015 inch). If the oil pump is out of limits, re (3) The back plate on the pump seats against the
place the pump. bottom of the bore in the cylinder block. When the
Measure the gears backlash (Fig. 9). The limits of a pump is correctly installed, the flange on the pump
used pump is 0.080-0.380 mm (0.003-0.015 inch). If will not touch the cylinder block.
the backlash is out of limits, replace the oil pump. (4) Measure the idler gear to pump drive gear
Install the back plate. backlash and the idler gear to crankshaft gear back
lash (Fig. 10). The backlash should be 0.080-0.330
5.9L (DIESEL) ENGINE 9 -189
mm (0.008-0,018 Inch). If the backlash is out of lim (2) Apply a light film of lubricating oil to the seal
its, replace the oil pump drive gear and the idler ing surface before installing the filter.
gear.
(5) If the adjoining gear moves when you measure C A U T I O N Mechanical over-tightening may distort
the backlash, the reading will be incorrect. the threads or damage the filter element seal.
(3) Install the filter as specified by the filter man

ufacturer.
(4) Clean the drain plug and the sealing surface of
the pan. Check the condition of the threads and seal
ing surface on the oil pan and drain plug.
(5) Install the drain plug using a new sealing
washer. Tighten the plug to 80 N-m (60 ft. lbs.)
torque.
(6) Use only High-Quality Multi-Viscosity lubricat
ing oil in the Cummins Turbo Diesel engine. Choose
the correct oil for the operating conditions outlined in
Fig. 10 Idler Gear to Pump Drive Gear and Group 0, Lubrication and Maintenance.
Crankshaft Gear Backlash (7) Fill the engine with the correct grade of new
oil. The engine capacity is 9.46 liters (10 quarts) in
OIL FILTER the crankcase and 0.95 liters (1 quart) in the lubri
When replacing the oil filter, use replacement filter cating oil filter.
specified In your Operator's Manual. (8) Start the engine and operate it at idle for sev
eral minutes. Check for leaks at the filter and drain
CAUTION; The internal filtering medium of some fil
plug.
ters has been known to disintegrate. Debris from
(9) Stop the engine. Wait approximately 15 min
failed filters may plug the piston oil cooling noz
utes to let the oil in the upper parts of the engine to
zles, resulting in scuffed pistons and eventual en
drain back to the oil pan. Check the oil level again.
gine failure.
Add oil as necessary to bring the level to the H
(High) mark on the dipstick.
REMOVAL
OIL FILTER BYPASS VALWE
WARNING^ HOT OIL CAM CAUSE PERSONAL IN
JURY. MEMOVAL
(1) Remove the oil cooler cover (Fig. 11).
(1) Operate the engine until the water temperature (2) Remove the valve from the cooler cover (Fig.
reaches 60°C (140°F). Shut the engine off. 11).
(2) Use a container that can hold at least 14 liters
(15 quarts) to hold the used oil. Remove the oil drain
plug and drain the used engine oil into the container.
(3) Always check the condition of the used oil. This
can give you an indication of some engine problems
that might exist.
^ Thin, black oil indicates fuel dilution.
* Milky discoloration indicates coolant dilution.
(4) Clean the area around the lubricating oil filter
head. Remove the filter using a 90-95 mm filter
wrench.
(5) Clean the gasket surface of the filter head. The
filter canister O-Ring seal can stick on the filter Fig, 11 Removing Filter Bypass Valve
head. Make sure it is removed.
(1) Drive the new valve in until it bottoms against
INSTALLATION
the step in the bypass valve bore (Fig. 12).
(1) Fill the oil filter element with clean oil before
(2) Install the oil cooler cover.
installation. Use the same type oil that will be used
in the engine.
FILTER VALVE OPEN

BYPASS • HEIGHT: 41.25mm (1.62 inch)
VALVE • LOAD: 126 N (28.4 lb)
FREE LENGTH: 66mm (2.6 inch)
OIL COOLER
COVER
J9109-15
J9509-161
Fig. 12 Installing New Filter Bypass Waive
Fig. 14 Oil Pressure Regulator Spring Check
OIL PRESSURE REGULATOR VALVE AND SPRING Tighten the plug to 80 N-m (60 ft. lbs.) torque.
When oil pressure from the oil pump exceeds 448
kPa (65 psi), the regulator valve opens to allow oil to OIL COOLER ELEMENT AND GASKET
drain back into the pan. The non-intercooled turbocharged engine filter
head/coolers can not be used on intercooled engines.
REMOVAL
(1) Remove the threaded plug, gasket, spring and [REMOVAL
valve (Fig. 13). (1) Drain the cooling system (refer to Group 7,
Cooling System for the proper procedures).
PLUG GASKET (2) Remove the oil filter.
(3) Clean around the oil cooler cover.
(4) Disconnect the turbocharger supply line (Fig.
15).
[71
SPRING
J9109-14
J9109-17
Fig. 13 Oil Pressure Regulator

Fig. 15 Turbocharger Supply Line
(2) Check the spring for height and load limita
(5) Remove the oil cooler cover, gaskets and cooler
tions (Fig. 14). Replace the spring if out of limits.
element.
INSTALLATION
CLEANING AND'INSPECTION
(1) Clean and inspect the plunger, bore and seat Clean the sealing surfaces.
before assembly. The plunger must move freely in the Apply 483 kPa (70 psi) air pressure to the element
valve bore. to check for leaks. If the element leaks, replace the
(2) Install the valve, spring, gasket and plug. element.
5.9L (DIESEL) ENGINE 9-191
INSTALLATION
(1) If a new oil cooler Is being installed, remove the
shipping plugs (Fig. 16).
(2) Assemble the oil cooler, gaskets and the cover
(Fig. 16). Tighten the bolts to 24 N-m (18 ft. lbs.)
torque.
(3) Connect the turbocharger oil supply line.
Tighten the nut to 15 N-m (11 ft. lbs.) torque,
(4) Fill the filter with clean lubricating oil and ap
ply a light coat of oil to the sealing gasket. Install
the oil filter.
(5) Fill the coolant system and operate the engine
to check for leaks. Stop the engine and check the
coolant and oil level.
PLUG J9109-18
Fig. 16 Oil Cooler

S - 192 5 J L (DIESEL) ENGINE BR
SPECIFICATIONS—S.9L DIESEL ENGINES

Camshaft C r a n k s h a f t (Cant.)
Journal Diameter (Min.) 53.962 mm Gear Backlash .0.080-0.330 mm

{0.003-0.03 in)
(2.1245 in)
C y l i n d e r Block
Valve Lobes (Min. Diameter @ Peak of Lobe)
Intake .47.040 mm Cylinder Bore
(1.852 In)
Exhaust ' .•.. 46770 mm Diameter . 102.116 mm
(1.841 in) (4.0203 in)
Lift Pump Lobe (Min. Diameter @ Peak of Lobe) . . 35.500 mm Out-of-Round (Max.) 0.038 mm
(0.0015 in)
(1.398 in) Taper (Max.) 0.076 mm
End Clearance 0.152-0.254 mm (0.003 in)
(0.006-0.010 in) Tappet Bore Diameter . 16.055 mm
Gear Backlash . . . . . . ........... .0.080-0.330 mm (0.632 in)
(0.003-0.013 in) Top Surface Flatness (Max. Overall V a r i a t i o n ) . . . . .0.075 mm
Connecting Rods
(0.003 in)
Pin Bore Diameter (Max.) . 40.042 mm
Max. Variation any 50 mm (2 in) Diameter Area . . . 0.010 mm
(1,5764 in)
(0.0004 in)
Side Clearance 0.100-0.300 mm
Refacing Combustion Deck
(0.004-0.012 in)
First Reface 0.250 mm
Crankshaft
(0.0098 in)
Main Bearing Journal Diameter
Second Reface .0.250 mm
Standard 82.962 mm
(0.0098 in)
(3.2662 in)
Machined 0.25 mm 82.712 mm Total Reface 0.500 mm
(0.0098 in) (3.2564 in) (0.0197 in)
Machined 0.50 mm 82.462 mm Surface Finish 1.50-3.20 micrometers
(0.0197 in) (3.2465 in)
Machined 0.75 mm .82.212 mm (60-126 microinches)
(0.0295 in) (3.2367 in) Main Bearing Bore Diameter (Max.) .83.106 mm
Machined 1.00 mm 81.962 mm with Bearing Installed (3.2719 in)
0.0394 in) (3.2269 in)
Camshaft Bore Diameter (Max.)
Out-of-Round (Max.) .0.050 mm
(0.002 in) No. 1 without Bushing 57.258 mm
Taper (Max.) 0.013 mm (2.2543 in)
(0.0005 in) Nos. 1-7 with Bushing .54.133 mm
Oil Clearance (Max.) 0.119 mm
(2.1312 in)
(0.0047 in)
Cylinder Head
Connecting Rod Journal Diameter
Flatness Max. Overall .0.030 mm
(0.012 in)
Standard . .68.962 mm
Max. Variation within 0.01 mm (0.0004 in) in any
(2.7150 in) 50.8 mm (2.00 in) diameter area.
Machined 0.25 mm . 68.712 mm Valve Seat Angle
(0.0098 in) (2.7052 in)
Machined 0.50 mm .68.462 mm Intake.....................................30°
(0.0197 in) (2.6954 in)
Machined 0.75 mm . .68.212 mm Exhaust .45°
(0.0295 in) (2.6855 in)
Machined 1.00 m m . . . . . . . . .67.962 mm Valve Seat Width
(0.0394 in) (2.6757 in)
Out-of-Round (Max.) . . . . . . . . . . . . . . . . . . . . .0.050 mm Minimum ..................... . . . . . . . 1.52 mm
(0.002 in) (0.060 in)
Taper (Max) . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.013 mm Maximum . . . . . . .2.03 mm
(0.0005 in) (0.080 in)
Oil Clearance . . . . . . . . . . 0.089 mm Tappets
(0.0035 in)
End Clearance 0.100-0.430 mm Stem Diameter 15.925 mm
(0.004-0.017 in) (0.627 in)
J9409-4
BR S J L (DIESEL) ENGINE 9 -193
ENGINE SPECIFICATIONS—CONT,
Oil P u m p Piston Pins
Tip Clearance (Max.) . .0.1778 mm Diameter (Min.) . 39.990 mm

(0.007 in) (1.5744 in)
Gerotor Drive/Planetary to Port 0.127 mm Bore Diameter (Max.] 40.025 mm
(1.5758 in)
Plate Clearance (Max) (0.005 in)
Gerotor Planetary to Body . . . . . . .0.381 mm Piston Rings
Clearance (Max.) (0.015 in)
Ring End G a p
Gear Backlash (Used Pump) . . . . . . . . . . . .0.080-0.380 mm
Top Ring . . 0.400-0.700 mm
(0.003-0.015 in) (0.016-0.0275 in)
Intermediate Ring . . 0.250-0.550 mm
Oil Pressure (minimum) (0.010-0.0215 in)
Oil Control Ring . , . 0.250-0.550 mm
At Idle Speed* ..... . . . . . . . .69 kPa (0.010-0.0215 in)
(10 psi)
At 2,500 r p m . . . . . . . . . . . . . . . . . . . . . . .
207 kPa Valves
(30 psi) Clearance — Intake • 0-25 mm
Regulating Valve Opening Pressure .448 kPa (0.010 in)
• CAUTIONS If pressure is Z E R O a t curb i d l e , (65 psi) Exhaust • • 0.51 mm
OO NOT run e n g i n e a t 2 , 5 0 0 r p m . (0.020 in)
Guide Diameter • • 8.019-8.089 mm
(0.3157-0.3185 in)
Oil Filter Stem Diameter. .7.935-7.960 mm
(0.3126-0.3134 in)
Differential Pressure to Open Filter Bypass . . . . . . . . . 172.3 kPa
Depth (Installed) 0.99-1.52 mm
(25 psi) K X
Valve S p r i n g s (0.039-0.060 in)
Pistons
Free Standing Length. ....... 60 mm
Skirt Diameter . . 101.880-101.823 mm (2.36 in)
(4.0110-4.0088 in) Inclination (Max.) 1.00 mm
Ring Groove Depth (0.039 in)
Minimum Load @49.25 mm-359 N
I n t e r m e d i a t e . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.150 mm (@1.94»n-81 lbs)
(0.006 in)
Oil Control 0.130 mm
(0.005 in) J9509-159
9 - 1 9 4 5 . 9 L (DIESEL) ENGINE BR
Air Fuel Control Fitting fin Head)............ 8 N®m (6 ft. lbs.) Intercooler Attaching Bolts.... 2 N*m 17 in. lbs.)
Intercooler Duct Clamp Nuts. 8 N*m 72 in. lbs.)
Battery Cable (Negative)
Mounting to Block 7 7 N * m ( 5 7 ft. lbs.) Lifting Bracket (Rear) 77 N*m 57 ft. lbs.)
Belt Tensioner Mounting 43 N«m ( 3 2 ft. lbs.)
Oil Cooler Assembly 24 N*m 18ft. lbs.)
Block Heater Mounting 1 2 N«m ( 9 ft. lbs.)
Oil Fill Tube Bracket Bolt 43N»m 32ft.lbs.)
Cab Heater Hose Clamp 4 N » m ( 3 5 in. lbs.)
Oil Filter 3/4 Turn Afteir Contact
Cab Heater Tubing Clamp Mounting 9 N«m ( 7 ft. lbs.)
Oil Pan Drain Plug 80N*m 60 ft. lbs.)
Camshaft Thrust Plate Bolts 2 4 N*m ( 1 8 ft. lbs.)
Oil Pan Bolts.... 24N»m 18ft. lbs.)
Clutch Cover Mounting to
Oil Pressure Regulator Plug 80N»m 60ft.lbs.)
Flywheel Bolts.......*... 23 N*m (17 ft. lbs.)
Oil Pressure Sender/Switch 16N*m 12ft. lbs.)
Connecting Rod Bolts
Step 1 (Alternately Tighten) 3 5 N*m ( 2 6 ft. lbs.) Oil Pump Mounting Bolts 24N*m 18ft. lbs.)
Step 2 (Alternately Tighten) 7 0 N«m ( 5 1 ft. lbs.) Oil Suction Tube (Flange) 24N*m 18ft. lbs.)
Step 3 (Alternately Tighten) 1 0 0 N»m ( 7 3 ft. lbs.)
Oil Suction Tube Brace Bolt 24N»m 18ft. lbs.)
Cooling Fan Mounting to Fan Clutch 2 0 N»m ( 1 5 ft lbs.)
Oil Supply Fitting for Vacuum Pump. 10N*m 7V2 ft. lbs.)
Crankshaft Main Bearing Bolts
Step 1 6 0 N»m ( 4 5 ft. lbs.) Rear Mount — Support
Step 2 1 1 9 N t h (88 ft. lbs.) 4 7 N * m 35ft.lbs.)
Cushion-to-Crossmember Nut
Step 3 . . . . . . . . . . . . . . . . . . . ; . . . . . . . . . . . 176N*m|129ft.lbs.)
Rear Mount •— Support Cushion-to-Trans.
Cylinder Head Bolts Support Bracket Nuts 47 N*m 35ft.lbs.)
All Bolts 9 0 N*m ( 6 6 ft. lbs.)
All Long Bolts 1 2 0 N*m ( 8 9 ft. lbs.) Rear Mount — Transmission Support
Tighten All Bolts an Additional 9 0 ° Bracket Bolts 102 N*m 75ft.lbs.)
Rear Support Plate-to-Transfer
Exhaust Manifold Bolts 4 3 N*m ( 3 2 ft. lbs.) Case Bolts 41 N*m 30ft.lbs.)
Fan Clutch Mounting/Fan Hub Rocker Arm Bolts 2 4 N * m 18ft. lbs.)
(Left Hand Threads) 57 N*m (42 ft. lbs.) Starter Mounting Bolts. 68 N*m 50ft.lbs.)
Fan Hub Bracket Mounting 2 4 N « m ( 1 8 ft. lbs.)
Torque Converter Drive Plate Bolts.... 31 N*m 270 in. lbs.)
Fan Hub Bearing Retaining Capscrew .... 7 7 N®m ( 5 7 ft. lbs.)
Transfer Case-to-Insulator Mounting
Fan Pulley to Fan Hub 9 N « m ( 7 ft. lbs.) Plate Nuts 204 N-m 150 ft. lbs.)
Fan Shroud Mounting Nuts... 1 1 N«m ( 9 5 in. lbs.) Transmission Support Bracket Bolts
Flywheel Bolts.... 1 3 7 N * m ( 1 0 1 ft. lbs.) (2WD) 6 8 N * m 50 ft. lbs.)
Flywheel Housing Adaptor 7 7 N»m ( 5 7 ft. lbs.) Transmission Support Spacer Bolts
(4WD) 68 N»m 50 ft. lbs.)
Front Mount — Thru-Bolt Nut 6 8 N*m ( 5 0 ft. lbs.)
Transmission Support Spacer-to-Insulator
Front Mount — Engine Support
Mounting Plate Nuts (4WD) 204 N*m 150 ft. lbs.)
Bracket/Cushion Bolts 1 7 6 N * m ( 1 4 0 ft. lbs.)
Generator Mounting Bolts 4 1 N®m ( 3 0 ft. lbs.) Vacuum Pump Oil Supply Line 10N*m 7V2 ft. lbs.)
Generator Pulley 8 0 N ° m ( 5 9 ft. lbs.) Vibration Damper Retainer Bolts 125 N*m 92ft.lbs.)
Generator Support (Upper) 2 4 N » m ( 1 8 ft. lbs.)

Water Pump 24 N*m 18ft. lbs.)
Gear Cover. 24 N«m (18 ft. lbs.)
Gear Housing Bolts 2 4 N « m ( 1 8 ft. lbs.)
Intake Manifold Cover Bolts 24N«m(18ft. lbs.) J9509-160

BR EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 1
EXHAUST SYSTEM AND INTAKE MANIFOLD
CONTENTS
page page
EXHAUST SYSTEM DIAGNOSIS 4 SERVICE PROCEDURES—GASOLINE

GENERAL INFORMATION 1 ENGINES 5
SERVICE PROCEDURES—DIESEL ENGINES .. 14 SPECIFICATIONS 22
GENERAL INFORMATION
EXHAUST SYSTEM heating may occur. If a converter is heat-damaged,

The gasoline engine exhaust system consists of en correct the cause of the damage at the same time the
gine exhaust manifolds, exhaust pipes, catalytic con converter is replaced. Also, inspect all other compo
verters), extension pipe (if needed), exhaust heat nents of the exhaust system for heat damage.
shields, muffler and exhaust tailpipe (Fig. 1). Unleaded gasoline must be used in gas engines to
The diesel engine exhaust system consists of an en avoid contaminating the catalyst core.
gine exhaust manifold, turbocharger, exhaust pipe,
catalytic converter, extension pipe (if needed), muffler EXHAUST HEAT SHIELDS
and exhaust tailpipe (Fig. 2). Exhaust heat shields are needed to protect both the
The engine exhaust manifolds on gasoline engines vehicle and the environment from the high tempera
are equipped with ball flange outlets to assure a tures developed by the catalytic converter. The com
tight seal and strain free connections. bustion reaction facilitated by the catalyst releases
The exhaust system must be properly aligned to additional heat in the exhaust system. Under severe
prevent stress, leakage and body contact. If the sys operating conditions, the temperature increases in
tem contacts any body panel, it may amplify objec the area of the reactor. Such conditions can exist
tionable noises from the engine or body. when the engine misfires or otherwise does not oper
When inspecting an exhaust system, critically in ate at peak efficiency. DO NOT remove spark plug
spect for cracked or loose joints, stripped screw or wires from plugs or by any other means short out
bolt threads, corrosion damage and worn, cracked or cylinders. Failure of the catalytic converter can occur
broken hangers. Replace all components that are due to a temperature increase caused by unburned
badly corroded or damaged. DO NOT attempt to re fuel passing through the converter.
pair. DO NOT allow the engine to operate at fast idle for
When replacement is required, use original equip extended periods (over 5 minutes). This condition
ment parts (or their equivalent). This will assure may result in excessive temperatures in the exhaust
proper alignment and provide acceptable exhaust system and on the floor pan.
noise levels.
CAUTION: Avoid application of rust prevention com EXHAUST GAS RECIRCULATION (EGR)—GASOLINE
pounds or undercoating materials to exhaust sys ENGINES
tem floor pan exhaust heat shields. Light overspray To assist in the control of oxides of nitrogen (NOx)
near the edges is permitted. Application of coating in engine exhaust, all engines are equipped with an
will result in excessive floor pan temperatures and exhaust gas recirculation system. The use of exhaust
objectionable fumes. gas to dilute incoming air/fuel mixtures lowers peak
flame temperatures during combustion, thus limiting
the formation of NOx.
CATALYTIC CONVERTER Exhaust gases are taken from openings in the ex
There is no regularly scheduled maintenance on haust gas crossover passage in the intake manifold.
any Mopar® stainless steel catalytic converter body. Refer to Group 25, Emission Control Systems for
Excessive heat can result in bulging or other distor complete description, diagnosis and service proce
tion, but excessive heat will not be the fault of the dures of the exhaust gas recirculation system and
converter. If unburned fuel enters the converter, over components.
11 -4 EXHAUST SYSTEM AND INTAKE MANIFOLD BR
EXHAUST SYSTEM DIAGNOSIS
CONDITION P O S S I B L E CAUSE CORRECTION
EXCESSIVE EXHAUST N O I S E 1. Leaks at pipe joints. 1. Tighten clamps at leaking joints.

2. Burned or blown-out muffler. 2. Replace muffler assembly. Check
exhaust system.
3. Burned or rusted-out exhaust pipe. 3. Replace exhaust pipe.
4. Exhaust pipe leaking at manifold flange. 4. Tighten connection attaching nuts.
5. Exhaust manifold cracked or broken. 5. Replace exhaust manifold.
6. Leak between exhaust manifold and 6. Tighten exhaust manifold to cylinder
cylinder head. head stud nuts or bolts.
7. Restriction in muffler or tail pipe. 7. Remove restriction, if possible. Replace
muffler or tail pipe, as necessary.
L E A K I N G EXHAUST G A S E S 1. Leaks at pipe joints. 1. Tighten clamps at leaking joints.

2. Damaged or improperly installed gaskets. 2. Replace gaskets, as necessary.
E N G I N E HARD TO W A R M UP 1. Blocked crossover passage in intake 1. Remove restriction or replace intake

OR WILL NOT RETURN TO manifold. manifold.
N O R M A L IDLE
J9211-3
SERVICE P R O C E D U R E S — G A S O L I N E E N G I N E S
INDEX
page page
Catalytic Converters 6 Exhaust Tailpipe 7

Engine Exhaust Manifold—V-10 Engine . 13 Intake Manifold—V-10 Engine 10
Engine Exhaust Manifold—V-6 and V-8 Engines . . 12 Intake Manifold—V-6 and V-8 Engines 7
Exhaust Heat" Shields 7 Mufflers 6
Exhaust Pipe 5
EXHAUST PIPE RETAINERS RIGHT SIDE
REMOVAL
(2) Saturate the bolts and nuts with heat valve lu
bricant. Allow 5 minutes for penetration.
(3) Remove exhaust manifold bolts, retainers and
nuts (Fig. 1 or 2).
(4) Remove the clamp nuts (Fig. 1 or 3).
(5) Disconnect the exhaust pipe from the support
hangers on the 5.9L (Heavy Duty) and the 8.0L en
gines (Fig. 2).
(6) Remove the exhaust pipe.
CLEANING
Clean ends of pipes to assure mating of all parts.
INSPECTION Fig. 2 Exhaust Pipe for 5.9L—Heavy Duty and S.OL
Discard rusted clamps, broken or worn supports proper alignment with other parts in the system and
and attaching parts. Replace a component with orig provide acceptable exhaust noise levels.
inal equipment parts, or equivalent. This will assure
Fig. 1 Exhaust Pipe for 3.9L, 5.2L and 5.9L—Light Fig. 3 Exhaust Pipe damp Location for 5.9L—Heavy
Duty Duty and 8.0L
11-6 EXHAUST SYSTEM AND INTAKE MANIFOLD BR
INSTALLATION INSTALLATION
(1) Connect the exhaust pipe support hangers on (1) Connect the support hanger on the 3.9L, 5.2L
the 5.9L (Heavy Duty) and the 8.0L engine (Fig. 2). and 5.9L—Light Duty engines (Fig. 1).
(2) Position the exhaust pipe for proper clearance (2) Assemble converter and clamps loosely to per
with underbody parts. mit proper clearance with exhaust heat shields and
(3) Position the exhaust pipe to manifold. Install underbody parts.
the bolts, retainers and nuts. Tighten the nuts to 34 (3) Tighten all clamp nuts to 43 N-m (32 ft. lbs.)
N-m (25 ft. lbs.) torque. torque.
(4) Tighten the clamp nuts to 43 N-m (32 ft. lbs.) (4) Lower the vehicle.
torque. (5) Start the engine and inspect for exhaust leaks
(5) Lower the vehicle. and exhaust system contact with the body panels.
(6) Start the engine and inspect for exhaust leaks Adjust the alignment, if needed.
and exhaust system contact with the body panels.
Adjust the alignment, if needed. MUFFLEiS
CATALYTIC CONWEiTEiS REMOVAL

REMOVAL (2) Saturate the clamp nuts with heat valve lubri
(1) Raise and support vehicle. cant. Allow 5 minutes for penetration.
(2) Saturate the bolts and nuts with heat valve lu (3) Disconnect the muffler hanger (Fig. 4 or 5).
bricant. Allow 5 minutes for penetration. (4) Remove clamps and nuts (Fig. 4 or 5).
(3) Remove clamps and nuts (Fig. 1, 3 and 4). (5) Remove the muffler.
Fig. 4 Catalytic Converter Clamp Location for Fig. 5 Muffler for 3.9L 5.2L and 5.9L—
9
5.9L—Heavy Duty and 8.0L Light Duty Engines

(4) Disconnect the catalytic converter from the sup CLEANING
port hanger on the 3.9L, 5.2L and 5.9L—Light Duty Clean ends of pipes and muffler to assure mating
engines (Fig. 1). of all parts.
(5) Remove the catalytic converter.
INSPECTION
CLEANING Discard rusted clamps, broken or worn hangers,
Clean ends of pipes and muffler to assure mating supports and attaching parts. Replace a component
of all parts. with original equipment parts, or equivalent. This
will assure proper alignment with other parts in the
INSPECTION system and provide acceptable exhaust noise levels.
Discard rusted clamps, broken or worn supports
and attaching parts. Replace a component with orig INSTALLATION
inal equipment parts, or equivalent. This will assure (1) Assemble muffler and clamps loosely to permit
proper alignment with other parts in the system and proper alignment of all parts.
provide acceptable exhaust noise levels. (2) Connect the muffler hanger.
(3) Tighten the clamp nuts to 43 N-m (32 ft. lbs.)

torque.
(5) Start the engine and inspect for exhaust leaks
Adjust the alignment, if needed.
EXHAUST TAILPIPE
REMOVAL
(2) Saturate the clamp nuts with heat valve lubri
cant. Allow 5 minutes for penetration.
(3) Disconnect the exhaust tailpipe support hanger
(Fig. • 6). If used, disconnect the extension pipe sup
port hanger (Fig. 7).
(4) Remove clamps and nuts (Fig. 6).
(5) Remove the exhaust tailpipe and extension
pipe, if used.
HANGER
Fig. 7 Extension Pipe

EXHAUST HEAT SHIELDS
REMOVAL . '
(2) Remove the nuts or bolts holding the exhaust
heat shield to the floor pan, crossmember or bracket.
(3) Slide the shield out around the exhaust system.
Fig. 6 Exhaust Tailpipe
INSTALLATION
GLEANING (1) Position the exhaust heat shield to the floor
Clean ends of pipes and muffler to assure mating pan, crossmember or bracket and install the nuts or
of all parts. bolts.
INSPECTION (2) Tighten the nuts and bolts.
Discard rusted clamps, broken or worn hangers, (3) Lower the vehicle.
supports and attaching parts. Replace a component
with original equipment parts, or equivalent. This INTAKE MANIFOLD—V-6 and V-8 ENGINES
will assure proper alignment with other parts in the The aluminum intake manifold is a single plane
system and provide acceptable exhaust noise levels. design with equal length runners. The manifold is
sealed by flange side gaskets with front and rear
INSTALLATION cross-over gaskets. The intake manifold has internal
(1) Loosely assemble exhaust tailpipe and exten EGR.
sion pipe, if used, to permit proper alignment of all
parts. REMOVAL •
(2) Connect the support hangers (Fig. 6 and 7). (1) Disconnect the negative cable from the battery.
(3) Position the exhaust tailpipe and extension (2) Drain the cooling system (refer to Group 7,
pipe, if used, for proper clearance with the underbody Cooling System for the proper procedures).
parts. (3) Remove the generator.
(4) Tighten all clamp nuts to 43 N-m (32 ft. lbs.) (4) Remove the air cleaner.
torque.
11 - 8 EXHAUST SYSTEM AND INTAKE MANIFOLD BR
(5) Perform the Fuel System Pressure release pro INSTALLATION

cedure (refer to Group 14, Fuel System). Disconnect (1) Install the plenum pan, if removed, as follows:
the fuel lines. (a) Turn the intake manifold upside down. Sup
(6) Disconnect the accelerator linkage and if so port the manifold.
equipped, the speed control and transmission kick- (b) Place a new plenum pan gasket onto the seal
down cables. rail of the intake manifold. Position the pan over
(7) Remove the return spring. the gasket. Align all the gasket and pan holes with
(8) Remove the distributor cap and wires. the intake manifold.
(9) Disconnect the coil wires. (c) Hand start all bolts.
(10) Disconnect the heat indicator sending unit (d) Tighten the bolts, in sequence (Fig. 2), as fol
wire. lows:
(11) Disconnect the heater hoses and bypass hose.
(12) Remove the closed crankcase ventilation and V-6 _\A8
evaporation control systems.
(13) Remove intake manifold bolts.
(14) Lift the intake manifold and throttle body out
of the engine compartment as an assembly.
(15) Remove and discard the flange side gaskets
and the front and rear cross-over gaskets.
(16) Remove the throttle body bolts and lift the
throttle body off the intake manifold (Fig. 1). Discard
the gasket.
Fig. 2 Plenum Pan Bolt Tightening Sequence

• Step 1-Tighten bolts to 2.7 N-m (24 in. lbs.)
torque.
torque.
Fig. 1 Throttle Body Assembly
(17) Remove the plenum pan as follows: torque.
(a) Turn the intake manifold upside down. Sup • Step 4—Check that all bolts are tighten to 9.5 N-m
port the manifold. (84 in. lbs.) torque.
(b) Remove the bolts and lift the pan off the (2) Using a new gasket, install the throttle body
manifold. Discard the gasket. onto the intake manifold. Tighten the bolts to 23 N-m
CLEANING
Clean manifold in solvent and blow dry with com (3) Place the 4 plastic locator dowels into the holes
pressed air. in the block Fig. 3).
Clean cylinder block front and rear gasket surfaces (4) Apply Mopar® Silicone Rubber Adhesive Seal
using a suitable solvent. ant, or equivalent, to the four corner joints. An exces
The plenum pan rail must be clean and dry (free of sive amount of sealant is not required to ensure a
all foreign material). leak proof seal. However, an excessive amount of
sealant may reduce the effectiveness of the flange
INSPECTION gasket. The sealant should be slightly higher than
Inspect manifold for cracks. the cross-over gaskets, approx. 5 mm (0.2 in).
Inspect mating surfaces of manifold for flatness (5) Install the front and rear cross-over gaskets
with a straightedge. onto the dowels (Fig. 3).
EXHAUST SYSTEM AND INTAKE MANIFOLD 11-1
FRONT CROSS-OVER GASKET I LANGE GASKET
REAR CROSS-OVER GASKET J9209-99
Fig. 3 Cross-Over Gaskets and Locator Dowels

(6) Install the flange gaskets. Ensure that the ver
tical port alignment tab is resting on the deck face of
the block. Also the horizontal alignment tabs must be
in position with the mating cylinder head gasket tabs CYLINDER
(Fig. 4). The words MANIFOLD SIDE should be vis
HEAD GASKET J9209-101
ible on the center of each flange gasket.
(7) Carefully lower intake manifold into position on Fig. 4 Intake Manifold Flange Gasket Alignment
the cylinder block and cylinder heads. Use the align INTAKE
ment dowels in the cross-over gaskets to position the
intake manifold. After intake manifold is in place, in
spect to make sure seals are in place.
(8) Install the intake manifold bolts and tighten as
follows:
¥-6 ENGINE—(Fig. 5)
• Step 1-Tighten bolts 1 and 2 to 8 N-m (72 in. lbs.)
torque. Tighten in alternating steps 1.4 N-m (12 in.
lbs.) torque at a time.
• Step 2—Tighten bolts 3 through 12, in sequence,
• Step 3—Check that all bolts are tighten to 8 N-m
• Step 4—Tighten all bolts, in sequence, to 16 N-m
• Step 5—Check that all bolts are tighten to 16 N-m
V-8 ENGINE - ( F i g . 6)
• Step 1—Tighten bolts 1 through 4, in sequence, to OF ENGINE
8 N-m (72 in. lbs.) torque. Tighten in alternating J9209-59
steps 1.4 N-m (12 in. lbs.) torque at a time. Fig. 5 Intake Manifold Bolt Tightening
• Step 2—Tighten bolts 5 through 12, in sequence, Sequence—V-6
• Step 3—Check that all bolts are tighten to 8 N-m • Step 5—Check that all bolts are tighten to 16 N-m
(72 in. lbs.) torque. (12 ft. lbs.) torque.
• Step 4—Tighten all bolts, in sequence, to 16 N-m (9) Install closed crankcase ventilation and evapo
(12 ft. lbs.) torque. ration control systems.
11 - 10 EXKAU27 SYSTEM AND IHTAKE MANIFOLD
J9209-60
Fig. 6 intake Manifold Bolt Tightening Fig. 7 Generator and A/C Compressor Braces
Sequence—¥-8
(10) Connect the coil wires.
(11) Connect the heat indicator sending unit wire.
(12) Connect the heater hoses and bypass hose.
(13) Install distributor cap and wires.
(14) Hook up the return spring.
down cables.
tem for the proper adjusting of belt tension.
(18) Install the air cleaner. Fig, 8 Air intake Housing
(19) Fill cooling system (refer to Group 7, Cooling (7) Perform the Fuel System Pressure release pro
System for the proper procedure). cedure (refer to Group 14, Fuel System). Disconnect
(20) Connect the negative cable to the battery. the fuel lines.
. (8) Disconnect the accelerator linkage and if so
INTAKE MANIFOLD—V-10 ENGINE equipped, the speed control and transmission kick-
The aluminum intake manifold has two plenum down cables.
chambers which supply air to five runners each. Pas (9) Remove the coil assemblies with the ignition
sages across the longitudinal center of the manifold cables.
feed air from the throttle body to the plenum cham (10) Disconnect the vacuum lines.
bers. (11) Disconnect the heater hoses and, bypass hose.
(12) Remove the closed crankcase ventilation and
REMOVAL evaporation control systems.
(1) Disconnect the negative cable from the battery. (13) Remove the throttle body bolts and lift the
(2) Drain the cooling system (refer to Group 7, throttle body off the upper intake manifold (Fig. 9).
Cooling System for the proper procedures). Discard the gasket.
(3) Remove the accessory drive belt (refer to Group (14) Remove the front upper intake manifold bolts.
7, Cooling System for the proper procedures). (15) Retain the 3 rear bolts in the up position with
(4) Remove the generator brace and generator (Fig. tape or rubber bands.
7). (16) Lift the upper intake manifold out of the en
(5) Remove the A/C compressor brace (Fig. 7). Re gine compartment (Fig. 9). Discard the gasket.
move the compressor and set aside. (17) Remove the lower intake manifold bolts and
(6) Remove the air cleaner cover and filter. Remove remove the manifold (Fig. 10).
the air cleaner housing (Fig. 8). Discard the gasket. • (18) Discard the lower intake manifold gaskets
(Fig. 11).
BR — — — — EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 1 1
UPPER INTAKE THROTTLE LOWER SEALANT

MANIFOLD INTAKE INTAKE MANIFOLD
BODY (MPI) GASKET
MANIFOLD
Fig. 9 Upper intake Manifold and Throttle Body
J9409-65
f
er intah
LOCATOR DOWELS-
J9511-1
LOCATOR DOWELS' J9409-64
Fig. 10 Lower Intake Manifold
CLEANING Fig. 12 intake Manifold Flange Gasket Alignment
Clean manifolds in solvent and blow dry with com (4) The lower intake manifold MUST be installed
pressed air. within 3 minutes of sealant application. Carefully
Clean cylinder block front and rear gasket surfaces lower intake manifold into position on the cylinder
using a suitable solvent. block and heads. After intake manifold is in place, in
spect to make sure seals and gaskets are in place.
INSPECTION
Finger start all the lower intake bolts.
Inspect manifolds for cracks.
Inspect mating surfaces of the manifolds for flat (5) Tighten the lower intake manifold bolts in se
ness with a straightedge. quence to 54 N-m (40 ft. lbs.) torque (Fig. 10).
(6) Using a new gasket, position the upper intake
INSTALLATION manifold onto the lower intake manifold.
(1) Install the intake manifold side gaskets. Be (7) Finger start all bolts, alternate one side to the
sure that the locator dowels are positioned in the other.
head (Fig. 12). (8) Tighten upper intake manifold bolts in se
(2) Peel off the protective paper (blue - rear and quence to 22 N-m (16 ft. lbs.) torque (Fig. 9).
brown - front) and press firmly onto the block (Fig. (9) Using a new gasket, install the throttle body
11). BE SURE THE BLOCK IS OIL FREE.. Align onto the upper intake manifold. Tighten the bolts to
ing slots in end seals with notches in intake manifold 23 N-m (200 in. lbs.) torque.
gaskets. (10) Install closed crankcase ventilation and evap
(3) Insert Mopar® Silicone Rubber Adhesive Seal oration control systems.
ant, or equivalent, into the four corner pockets (Fig. (11) Connect the heater hoses and bypass hose.
11). Fill the pocket, but DO NOT overfill. (12) Connect the vacuum lines.
11-12 EXHAUST SYSTEM AND INTAKE MANIFOLD ^
(13) Install the coil assemblies and the ignition ca (1) Position the engine exhaust manifolds on the
bles. two studs located on the cylinder head. Install coni
(14) Connect the accelerator linkage and if so cal washers and nuts on these studs (Fig. 14 or 15).
equipped, the speed control and transmission kick- (2) Install two bolts and conical washers at the in
down cables. ner ends of the engine exhaust manifold outboard
(15) Install the fuel lines. arms. Install two bolts WITHOUT washers on the
(16) 'Using a new gasket, install the air cleaner center arm of engine exhaust manifold (Fig. 14 or
housing. Tighten the nuts to 11 N-m (96 in. lbs.) 15). Starting at the center arm and working outward,
torque. Install the air cleaner filter and cover. tighten the bolts and nuts to 34 N-m (25 ft. lbs.)
(17) Install the A/C compressor. Position the com torque.
pressor brace and install the bolts. Tighten the brace (3) Install the exhaust heat shields.
(18) Install the generator. Position the generator
(5) Assemble exhaust pipe to manifold and secure
brace and install the bolts. Tighten the brace bolts to
41 N-m (30 ft. lbs.) torque. with bolts, nuts and retainers. Tighten the bolts and
(19) Install the accessory drive belt (refer to Group nuts to 34 N-m (25 ft. lbs.) torque.
7, Cooling System). (6) Lower the vehicle.
(20) Fill cooling system (refer to Group 7, Cooling (7) Connect the negative cable to the battery.
ENGINE EXHAUST MANIFOLD—V-6 and V-8

Engine exhaust manifolds are LOG type with port
ing for air injection into the LOG.
REMOVAL
(3) Remove the bolts and nuts attaching the ex
haust pipe to the engine exhaust manifold.
(5) Remove the exhaust heat shields.
(6) Remove bolts, nuts and washers attaching
manifold to cylinder head.
(7) Remove manifold from the cylinder head. Fig. 14 Engine Exhaust Manifold Installation—3.9L
Engine
CLEANING
Clean mating surfaces on cylinder head and mani
fold. Wash with solvent and blow dry with com
pressed air.
INSPECTION
Inspect manifold for cracks.
Inspect mating surfaces of manifold for flatness
with a straight edge. Gasket surfaces must be flat
within 0.2 mm per 300 mm (0.008 inch per foot).
INSTALLATION
CAUTION: If the studs came out with the nuts when

removing the engine exhaust manifold, install new
studs. Apply sealer on the coarse thread ends. Wa
J931M1
ter leaks may develop at the studs if this precaution
is not taken. Fig. 15 Engine Exhaust Manifold Installation—5.2U
5.9L Engines
BR EXHAUST SYSTEM AND INTAKE MANIFOLD 11 -13
ENGINE EXHAUST MANIFOLD—V-10 ENGINE

Engine exhaust manifolds are made of high molyb
denum ductile cast iron. A special ribbed design helps
control permanent dimensional changes during heat
cycles.
REMOVAL
(1) Disconnect the negative cable from the battery
(3) Remove the bolts and nuts attaching the ex
haust pipe to the engine exhaust manifold.
(5) Remove the exhaust heat shields (Figs. 16 and
17).
(6) Right exhaust manifold—Remove the EGR tube
and gasket (Fig. 16). Discard the gasket.
EXHAUST
SHIELD J94H-14
Fig. 17 Left Engine Exhaust Manifold

INSPECTION
Inspect manifold for cracks.
Inspect mating surfaces of manifold for flatness
with a straight edge. Gasket surfaces must be flat
within 0.2 mm per 300 mm (0.008 inch per foot).
INSTALLATION
(1) Using a new gasket position the engine exhaust
manifold onto the cylinder head. Refer to Figs. 16
and 17 to install bolts and stud bolts in the proper
position. Tighten the bolts to 22 N-m (16 ft. lbs.)
torque.
(2) Right side exhaust manifold—Install the EGR
HEAT tube using a new gasket (Fig. 16). Tighten the tube
SHIELD J9411-13 assembly nut to 34 N-m (25 ft. lbs.) torque. Tighten
the two EGR nuts to 20 N-m (175 in. lbs.) torque.
Fig. 16 Right Engine Exhaust Manifold and EGR (3) Right exhaust manifold—Install the dipstick
Tube bracket to the manifold.
(7) Right exhaust manifold—Remove the dipstick (4) Position washers and exhaust heat shields onto
bracket from the manifold. the manifold stud bolts (Figs. 16 and 17). Be sure the
(8) Remove bolts attaching manifold to cylinder tabs on the heat shields are hooked over the top of
head. the exhaust gasket. Install the nuts and tighten to 20
(9) Remove manifold from the cylinder head. Dis N-m (175 in. lbs.) torque.
card the gasket. (5) Raise and support the vehicle.
(6) Assemble exhaust pipe to manifold and secure
CLEANING with bolts. Tighten the bolts to 34 N-m (25 ft. lbs.)
Clean mating surfaces on cylinder head and mani torque.
fold. Wash with solvent and blow dry with com (7) Lower the vehicle.
pressed air. (8) Connect the negative cable to the battery.
11 -14 EXHAUST S Y S T E M AND INTAKE MANIFOLD BR
SERVICE PROCEDURES—DIESEL ENGINES
INDEX
page page
Catalytic Converters 14 Exhaust Tailpipe 15

Charge Air Cooler—Intercooler 20 Intake Manifold Cover—Air Intake Heater . 17
Engine Exhaust Manifold 16 Muffler 15
Exhaust Heat Shields 16 Turbocharger 18
Exhaust Pipe 14 Wastegate Adjustment 19
EXHAUST P I P E (3) Tighten the clamp nuts to 43 N-m (32 ft. lbs.)
torque.
REMOVAL (4) Install the exhaust pipe support clamps and
(1) Raise and support the vehicle on a hoist. nuts. Tighten the nuts to 54 N-m (40 ft. lbs.) torque.
(2). Saturate the bolts and nuts with heat valve lu (5) Lower the vehicle.
bricant. Allow 5 minutes for penetration. (6) Start the engine and inspect for exhaust leaks
(3) Remove the bolts and nuts from the exhaust and exhaust system contact with the body panels.
pipe to turbocharger exhaust pipe (Fig. 1). Adjust the alignment, if needed.
(4) Remove the clamp nuts.
(5) Disconnect the exhaust pipe support hanger. CATALYTIC CONVERTERS
REMOVAL
(2) Saturate the bolts and nuts with heat valve lu
bricant. Allow 5 minutes for penetration.
(3) Remove clamps and nuts (Fig. 2).
J9411-18
Fig. 1 Exhaust Pipe Mounting

CLEANING
Clean ends of pipes to assure mating of all parts.
INSPECTION
Discard rusted clamps, broken or worn supports Fig. 2 Catalytic Converter
and attaching parts. Replace a component with orig (4) Remove the catalytic converter.
inal equipment parts, or equivalent. This will assure
proper alignment with other parts in the system and CLEANING
provide acceptable exhaust noise levels. Clean ends of pipes and muffler to assure mating
of all parts.
INSTALLATION
(1) Connect the exhaust pipe support hangers (Fig. INSPECTION
1). Discard rusted clamps and attaching parts. Replace
(2) Align the exhaust pipe with the turbocharger a component with original equipment parts, or equiv
exhaust pipe and the catalytic converter. Install the alent. This will assure proper alignment with other
bolts and nuts. Tighten the nuts to 34 N-m (25 ft. parts in the system and provide acceptable exhaust
lbs.) torque. noise levels.
BR bXHAUST SYSTEM AND INTAKE MANIFOLD 11 -15
INSTALLATION EXHAUST TAILPIPE

(1) Assemble converter and clamps loosely to per
mit proper clearance with exhaust heat shields and REMOVAL
underbody parts. (1) Raise and support the vehicle.
(2) Tighten all clamp nuts to 43 N-m (32 ft. lbs.) (2) Saturate the clamp nuts with heat valve lubri
torque. cant. Allow 5 minutes for penetration.
(3) Lower the vehicle. (3) Disconnect the exhaust tailpipe support hanger
(4) Start the engine and inspect for exhaust leaks (Fig. 4). If used, disconnect the extension pipe sup
and exhaust system contact with the body panels. port hanger (Fig. 5).
Adjust the alignment, if needed. (4) Remove clamps and nuts (Fig. 4).
(5) Remove the exhaust tailpipe and extension
MUFFLER pipe, if used.
REMOVAL HANGER
(2) Remove the clamps and nuts (Fig. 3).
(3) Disconnect the support hanger (Fig. 3).
(4) Remove the muffler.
Fig. 3 Muffler
CLEANING
Clean ends of pipes and muffler to assure mating
of all parts.
INSPECTION
Discard rusted clamps, broken or worn hangers,
supports and attaching parts. Replace a component
with original equipment parts, or equivalent. This
system and provide acceptable exhaust noise levels.
Fig. 5 Extension Pipe
INSTALLATION CLEANING
(1) Connect the support hanger (Fig. 3). Clean ends of pipes and muffler to assure mating
(2) Install the clamps and nuts. Tighten the nuts of all parts.
(3) Lower the vehicle. INSPECTION
(4) Start the engine and inspect for exhaust leaks Discard rusted clamps, broken or worn hangers,
and exhaust system contact with the body panels. supports and attaching parts. Replace a component
Adjust the alignment, if needed. with original equipment parts, or equivalent. This
system and provide acceptable exhaust noise levels.
11 -11 EXHAUST SYSTEM AND INTAKE MANIFOLD BR
INSTALLATION
(1) Loosely assemble exhaust tailpipe and exten
sion pipe, if used, to permit proper alignment of all
parts.
(2) Connect the support hangers (Fig. 4 and 5).
(8) Position the exhaust tailpipe and extension
pipe, if used, for proper clearance with the underbody
parts.
(4) Tighten all clamp nuts to 43 N-m (32 ft. lbs.)
torque.
EXHAUST HEAT SHIELDS
REMOVAL
(2) Remove the nuts or bolts holding the exhaust
heat shield to the floor pan, crossmember or bracket.
(3) Slide the shield out around the exhaust system.
Fig. 6 Mir intake Pipe, Exhaust Pipe and
INSTALLATION Turbocharger
(1) Position the exhaust heat shield to the floor
pan, crossmember or bracket and install the nuts or
bolts.
(2) Tighten the nuts and bolts.
ENGINE EXHAUST MANIFOLD
REMOVAL
(1) Disconnect the air intake and exhaust pipes
(Fig. 6).
(2) Disconnect the turbocharger oil supply line and
the oil drain tube from the turbocharger (Fig. 7).
(3) Disconnect the charge air cooler (Intercooler)
inlet duct from the turbocharger (Fig. 7).
(4) Remove the turbocharger and gasket.
(5) Remove the cab heater supply and return lines.
(6) Remove the engine exhaust manifold and gas
kets (Fig. 8).
(7) Clean the sealing surfaces.
INSTALLATION
(1) Install the engine exhaust manifold and gas Fig. 7 Oii Supply Line and Charge Air Cooler
kets use anti-seize on capscrews. Tighten the exhaust (Intercooler) Inlet Duct
manifold bolts in sequence to 43 N-m (32 ft. lbs.) (4) Position the air intake pipe and the exhaust
torque (Fig. 9). pipe onto the turbocharger. Tighten the clamps to 8
(2) Install the turbocharger. Apply anti-seize to the N-m (74 in. lbs.) torque.
studs and then tighten the turbocharger mounting (5) Install the oil drain tube and oil supply line to
nuts to 32 N-m (24 ft. lbs.) torque. the turbocharger. Tighten the drain tube bolts to 24
(3) Position the charge air cooler (intercooler) inlet N-m (18 ft. lbs.) torque. Tighten the oil supply line
duct to the turbocharger. With the clamp in position, fitting nut to 15 N-m (11 ft. lbs.) torque.
tighten the clamp nut to 8 N-m (72 in. lbs.) torque.
BR EXHAUST SYSTEM AND INTAKE MANIFOLD 11 -17
AIR INTAKE
Fig. 10 Air Inlet Tube and Heater Ground Wire
Fig. 9 Engine Exhaust Manifold Bolt Tightening

Sequence
(6) Connect the cab heater supply and return lines.
Tighten the line nuts to 24 N-m (18 ft. lbs.) torque.
(7) Operate the engine to check for leaks.
Fig. 11 Air Intake Heater
INTAKE MANIFOLD COVER—AIR INTAKE HEATER
(8) Remove the manifold intake cover and gasket
REMOVAL (Fig. 13). Keep the gasket material and any other
(1) Remove the charge air cooler (intercooler) out material out of the air intake.
let duct from the air inlet tube (Fig. 10). (9) Clean the sealing surface.
(2) Remove the high pressure fuel lines.
INSTALLATION
(3) Disconnect and remove the air intake heater
ground wire (Fig. 10). (1) Using a new gasket, install the intake manifold
(4) Disconnect the air intake heater power supply cover.
lines (Fig. 11). Remove the air intake heater and gas (2) Install the fuel heater ground wire. Tighten the
kets (Fig. 11). Clean the mounting surface of the in bolt to 12 N-m (110 in. lbs.) torque.
take manifold cover. (3) Connect the air temperature switch to the in
(5) Disconnect the charge air temperature sensor take manifold cover.
from the intake manifold cover (Fig. 12). (4) Connect the charge air temperature sensor to
(6) Disconnect the air temperature switch from the the intake manifold cover.
intake manifold cover (Fig. 12). (5) Some of the intake manifold bolt holes are
(7) Disconnect the fuel heater ground wire from in drilled through and must be sealed. Apply liquid te-
take manifold cover (Fig. 13).
11-18 EXHAUST SYSTEM AND INTAKE MANIFOLD B i t
(11) Install and bleed the high pressure fuel lines.

Tighten the high pressure fuel line nuts to 24 N-m
TURBOCHARGER
REMOVAL
(2) Disconnect the air intake pipe and exhaust pipe
(Fig. 14).
Fig. 14 Air Intake Pipe, Exhaust Pipe and

Turbocharger
(3) Remove the oil drain tube bolts.
(4) Remove the oil supply line (Fig. 15).
(5) Disconnect the charge air cooler (intercooler)
inlet duct from the turbocharger (Fig. 15).
Fig. 13 Manifold intake Cower and Fuel Heater (6) Remove the turbocharger mounting nuts and
Ground Wire the turbocharger.
flon sealant to the bolts, install the intake manifold (7) If the turbocharger is not to be installed imme
cover bolts. Tighten the bolts to 24 N-m (18 ft. lbs.) diately, cover the opening to prevent material from
torque. entering into the manifold.
(6) Install a new gasket between the air intake (8) Clean and inspect the sealing surface.
heater and the intake manifold cover. Install a new
gasket on top of the air intake heater. DISASSEMBLY
(7) Install the air inlet tube. Tighten the air inlet CAUTION: The turbocharger is a precision piece
tube bolts to 24 N-m (18 ft. lbs.) torque.
of equipment and should only be repaired by an au
(8) Connect the intake manifold heater ground
thorized facility. Disassembly is not recommended,
wire.
as engine/turbo failure could result
(9) Install and tighten the air intake heater power
supply nuts to 14 N-m (10 ft. lbs.) torque.
(10) Position the charge air cooler (intercooler) out INSTALLATION
let duct onto the air inlet tube. Tighten the charge (1) Install a new gasket and apply anti-seize com
air cooler (intercooler) outlet duct clamps to 8 N-m pound to the mounting studs.
BR EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 1 9
and no adjustment should be necessary, unless

wastegate assembly is damaged.
Fig. 15 Oii Supply Line and Charge Air Cooler

(Intercooler) inlet Duct
(2) Install the turbocharger. Tighten the turbo Fig. 1 Wastegate Turbocharger
charger mounting nuts to 32 N-m (24 ft. lbs.) torque. CAUTION: DO NOT adjust the wastegate so that
(3) Use a new gasket and connect the drain line. higher pressures are required to open the waste-
Tighten the drain line connection bolts to 24 N-m (18 gate valve. The turbocharger speed will be in
ft. lbs.) torque. creased and can cause damage to the turbocharger
(4) New turbocharger must be pre-lubricated with and cause a loss of engine performance.
clean engine lubricating oil before start up. Pour
50-60 cc (2-3 ounces) of oil into supply fitting. (1) Connect regulated air pressure to the waste-
gate actuator (Fig. 2). Install a dial indicator to mea
WARNING: DO NOT U S E YOUR FINGER TO TURN sure the control rod movement. Apply 103 - 138 kPa
THE TURBINE W H E E L (15 - 20 psi) to seat the components and take any
slack out of the control rod. Release the air pressure
(5) Rotate the turbine wheel to allow oil to enter
and zero the dial indicator gauge.
the turbocharger.
(6) Install the oil supply line. Tighten the oil sup
ply line fitting nut to 15 N-m (11 ft. lbs.) torque.
(7) Position the Charge air cooler (intercooler) inlet
duct to the turbocharger. With the clamp in position,
tighten the clamp nut to 8 N-m (72 in. lbs.) torque.
(8) Position the air intake pipe and the exhaust
pipe onto the turbocharger. Tighten the clamps to 8
(10) Operate the engine and check for leaks.
WASTEGATE ADJUSTMENT
The wastegate turbocharger provides additional
low speed boost without over-boost at high speeds. INDICATOR AIR PRESSURE m ] h U
This increases low speed torque and better driveabil-

ity. Fig. 2 Wastegate and Dial Indicator
Proper adjustment of the wastegate assembly is
critical to the operation of the wastegate turbo (2) Apply 133 kPa (19.3 psi) air pressure to the ac
charger (Fig. 1). The control rod is set at the factory tuator. The control rod should move 0.33 - 1.27 mm
11 - 2 0 EXHAUST SYSTEM AND INTAKE MANIFOLD
(0.013 - 0.050 in) total travel. If the rod travel is out (2) Remove the front support bracket (Fig. 4).
of limits, the wastegate linkage must be adjusted. (3) If the vehicle is equipped with air conditioning,
(3) To adjust the wastegate linkage, apply air pres remove the condenser as follows:
sure to the actuator to release the spring tension on (a) Discharge the air conditioning system (refer
the lever. Remove the control rod from the wastegate to Group 24, Heating and Air Conditioning for the
lever (Fig. 3). Pull the wastegate lever toward the ac proper procedures).
tuator (closed position). (b) Remove the bolt from the sealing plate (Fig.
(4) Adjust the length of the clevis end of the con 4).
trol rod to align the clevis pin hole to the wastegate (c) Remove the nuts holding the condenser to the
lever. Install the adjusting link and retaining clip charge air cooler (intercooler) (Fig. 4). Lift the con
(Fig. 3). denser and sealing plate assembly away from the
charge air cooler (intercooler).
CAUTION; DO NOT pull, push or force the align
ment of the clevis pin.
(5) After the adjustment is complete, tighten the

actuator rod jam nut (Fig. 3).
Fig. 4 Condenser and Charge Air Cooler—

WASTEGATE ACTUATOR J9411 -17 Intercooler
(4) Remove the inlet and outlet ducts from the
Fig. 3 Adjustment of Wastegate Actuator charge air cooler (intercooler)—(Fig. 5).
(6) Recheck the travel on the wastegate control (5) Remove the charge air cooler (intercooler) bolts.
rod. Adjust, if necessary. Pivot the charge air cooler (intercooler) forward and
up to remove.
CHARGE AIR COOLER—INTERCOOLER
Intake air is drawn through the air cleaner and CLEANING
into the turbocharger compressor housing. Pressur If the engine experiences a turbocharger failure or
ized air from the turbocharger then flows forward any other occasion where oil or debris is put into the
through the charge air cooler (intercooler) located in charge air cooler, the charge air cooler must be
front of the radiator. From the charge air cooler (In cleaned.
tercooler) the air flows back into the intake manifold. (1) Remove the charge air cooler from the vehicle,
The charge air cooler (Intercooler) is a heat ex refer Charge Air Cooler in this section.
changer that uses air flow to dissipate heat from the (2) Flush the charge air cooler internally with a
intake air. As the turbocharger increases air pres non caustic solvent in the opposite direction of nor
sure, the air temperature increases. Lowering the in mal air flow. Shake the charge air cooler and
take air temperature increases engine efficiency and LIGHTLY tap on the end tanks with a rubber mallet
power. to dislodge trapped debris. Continue flushing until
REMOVAL all debris or oil is removed.
(3) Use a flashlight and mirror to visually inspect
WARNING: IF THE ENGINE W A S J U S T TURNED the charge air cooler for internal debris.
OFF, THE INTAKE AND OUTLET DUCTS MAY B E
HOT CAUTION: If internal debris cannot be removed,
scrap the charge air cooler.
(1) Remove the grille (refer to Group 23, Body for
the proper procedure).
BR EXHAUST SYSTEM AND INTAKE MANIFOLD 11-21
INSPECTION
(1) Visually inspect the charge air cooler
(2) Inspect the tubes, fins and welds for tears,
breaks or other damage. If any damage causes the
charge air cooler to fail, the charge air cooler must
replaced.
INSTALLATION
(1) Position the charge air cooler (intercooler) -
(Fig. 4). Install the bolts and tighten to 2 N-m (17 in.
lbs.) torque.
(2) Install the inlet and outlet ducts to the charge
air cooler (intercooler)—(Fig. 5). With the clamps in
position, tighten the clamp nut to 8 N-m (72 in. lbs.)
torque.
(3) If the vehicle is equipped with air conditioning,
install the condenser as follows:
(a) Position the condenser and sealing plate as
sembly onto the charge air cooler (intercooler)
studs. Install the nuts and tighten.
J9509-53
(b) Connect the halves of the sealing plate (Fig.
Fig. 5 Charge Air Cooler Intercooler Ducts
4). Install the bolt and tighten.
(c) Charge the air conditioning system (refer to
CAUTION: DO NOT U S E CAUSTIC C L E A N E R S TO Group 24, Heating and Air Conditioning for the
C L E A N THE C H A R G E AIR COOLER. DAMAGE TO proper procedures).
THE C H A R G E AIR COOLER WILL RESULT.
(4) Install the front support bracket (Fig. 4). In
(4) After the charge air cooler has been thoroughly stall and tighten the bolts.
cleaned of all oil and debris with the non caustic sol (5) Install the grille (refer to Group 23, Body for
vent, wash the charge air cooler internally with hot the proper procedure).
soapy water to remove the remaining solvent.
(5) Rinse thoroughly with clean water.
(6) Blow compressed air into the charge air cooler
in the opposite direction of normal air flow until the
charge air cooler is dry internally.
11-22 EXHAUST SYSTEM AND INTAKE MANIFOLD BR
SPECIFICATIONS
TURBOCHARGER SPECIFICATIONS
COMPONENT DIMENSIONS
Air Intake Restrictions 635 mm Water (25 in. Water) Max.
Turbo Radial Clearance 0.300-0.460 mm (0.012-0.018 inch)
Turbo Rotor Assembly End Play
Before S / N 840638 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.102-0.152 mm (0.004-0.006 inch)

S/N 840638 A N D AFTER 0.026-0.076 mm (0.001-0.003 inch)
J9511-23
Adjusting Strap Bolt 23 N*m (200 in. lbs.] Intake Manifold Capbolts Refer to Procedure in
Air Heater Power Supply Nuts 14 N«m (10 ft. lbs.) Service Manual.
Intake Manifold Cover Bolts 24 N®m (18 ft. lbs.)
Cab Heater Supply/Return Line Nuts 24 N»m (18 ft. lbs.) Intercooler Attaching Bolts 2 N®m (17 in. lbs.)
Catalytic Converter-to-Muffler Intercooler Duct Clamp Nuts 8 N*m (72 in. lbs.)
Clamp Nuts 43 N«m (32 ft. lbs.)
Muffler-to-Tail Pipe Clamp Nuts 43 N«m (32 ft. lbs.)
Head Bolts (5.9L Diesel) 43 N*m (32 ft. lbs.) Throttle Control Bracket
Exhaust Pipe-to-Catalytic Mounting Bolts 24 N»m (18 ft. lbs.)
Converter Clamp Nuts 43 N»m (32 ft. lbs.) Turbocharger Mounting Nuts 32 N»m (24 ft. lbs.)
Exhaust Pipe-to-Exnaust Turbocharger Oil Drain Tube Bolts 24 N»m (18 ft. lbs.)
Manifold Bolts/Nuts 26 N»m (19 ft. lbs.) Turbocharger Oil Supply Line Fitting Nut... 1 5 N«m (11 ft. lbs.)
Turbocharger V-Bana Clamp 8.5 N*m (75 in. lbs.)
Fuel Heater Ground Bolt. 12 N»m (110 in. lbs.]
Fuel Line Nuts 24 N*m (18 ft. lbs.)
Generator Mounting Bolt 41 N»m (30 ft. lbs.)
J9511-24
BUMPERS A N D F R A M E 13 - 1
BUMPERS AND FRAME
CONTENTS
page page
BUMPERS AND FRAME COMPONENTS ....... 1 SNOW PLOW .... . 5

FRAME ................................ 22
BUMPERS AND FRAME COMPONENTS
INDEI
page page
Front Bumper 1 Rear Bumper 3

Front Bumper Air Dam 2 Skid Plate 2
Front Bumper Lower Fascia . 1 Spare Tire Winch 2
Front Bumper Upper Fascia 1 frailer Hitch 3
FRONT B U M P E R
REMOVAL (FIG. fj
(1) Support front bumper on a suitable lifting de
vice.
(2) Remove bolt holding front bumper brace to
frame rail.
(3) Remove nuts and stud plates holding front
bumper to end of frame rail.
(4) Disengage wire connectors from horns.
(5) Disengage wire connectors from fog lamps, if
equipped.
(6) Separate front bumper from vehicle.
INSTALLATION
Reverse the preceding operation.
FRONT B U M P E R U P P E R FASCIA
REMOVAL (FIG. 2)
(1) Remove bumper.
(2) Disengage clips holding upper fascia to bumper
Fig. I Front Bumper
face bar.
(3) Separate fascia from bumper. (2) Disengage clips holding end of upper fascia to
bumper face bar.
INSTALLATION (3) Disengage clips holding lower fascia to bumper
Reverse the preceding operation. face bar.
(4) Separate lower fascia from bumper.
FRONT B U M P E R L O W E R FASCIA
INSTALLATION
REMOVAL {FIG. 3) Reverse the preceding operation.
(1) Remove bumper.
13 - 2 BUMPERS AND FRAME
Fig. 2 Front Bumper Upper Fascia Fig. 4 Front Bumper Air Dam
SKID PLATE
LOWER BUMPER
MEMOWAL (FIG. 5 )
(1) Hoist and support vehicle on safety stands.
(2) Remove bolts holding skid plate to frame rails.
(3) Separate skid plate from vehicle.
INSTALLATION
J9413-2
Fig. 3 Front Bumper Lower Fascia

FRONT BUMPER AIR DAM
REMOVAL (FIG. 4} Fig. 5 Skid Plate

(1) Remove Pin-type fasteners holding air dam to
SPARE TIRE WINCH
bottom of front bumper.
(2) Remove screws holding air dam to bottom of MEMOWAL (FIG. 6|
front bumper. (1) Remove spare tire from under vehicle.
(3) Separate air dam from vehicle. (2) Remove bolts holding spare tire winch to spare
INSTALLATION tire bracket.
Reverse the preceding operation. (3) Separate spare tire winch from vehicle.
BR BUMPERS AND FRAME 13 - 3
INSTALLATION REAR BUMPER

REMOVAL (FIG. 7)
(1) Support rear bumper on a suitable lifting de
vice.
(2) Remove bolts holding rear bumper braces to
frame rails.
(3) Disengage license plate lamp wire connector
from body wire harness, if equipped.
(4) Separate rear bumper from vehicle.
INSTALLATION
Fig. 6 Spare Tire Winch
Fig. 7 Rear Bumper

13 - 4 BUMPERS AND FRAME BR
TRAILER HITCH
REMOVAL (PIG. 8)
(1) Support trailer hitch on a suitable lifting de
vice.
(2) Remove fasteners holding trailer wiring connec
tor to trailer hitch, if equipped.
(3) Remove bolts holding trailer hitch to frame
rails.
(4) Separate trailer hitch from vehicle.
INSTALLATION
HITCH
Fig. 8 Trailer Hitch

1UMPERS AND FRAME 13 - 5
SNOW PLOW
INDEX
page page
Power Angling Cylinder Service 18 Snow Plow Malfunction Diagnosis and Tests ...... 6
Power Unit 15 Snow Plow Pivot Bracket 18
Service Information 5 Snow Plow Wiring Diagrams 6
Snow Plow Control Module . . . . . . . . . . . . . . . . . . 19 System Description and Operation . 5
Snow Plow Frame 18
SERVICE INFORMATION If the blade impacts obstructions, the pin will

shear to protect the snow plow and the vehicle
The snow plow option is available on four wheel
from damage. The pin is not used with power
drive BR vehicles. Refer to figure 1 for primary me
angle plowing.
chanical components.
• Power Angling Cylinders—Enable the operator to
LIFT ARM move the moldboard either straight ahead or to the side.
• Hinge Pins—Allows the A-Frame to pivot up and
down. The pins act as moldboard attaching points.
© Cutting Edge—Replaceable blade edge extends
the life of the blade.
• Runners—Adjustable runners retain the cutting
edge at the proper height.
• Sno-Flo Paint—Specially developed high-
• visibility, yellow paint provides fast, smooth snow-
rolling action.
• Hydraulic Pump/Motor—Hy draulically lifts,
lowers and angles the snow plow.
• A-frame—Provides the means for attaching the
snow plow to the vehicle.
© Lift Arm—Raises and lowers the snow plow.
SYSTEM DESCRIPTION AND OPERATION
HYDRAULIC CYLINDER AND MOTOR

The hydraulic cylinder and motor unit is designed
to raise, lower and angle the blade.
The power unit is a high torque, 12-volt motor that
is coupled to a gear-type hydraulic pump.
The toggle switches operate the solenoid valves.
RUNNERS J9001-2
The following components control the snow plow
blade positioning:
Fig. 1 Snow Plow Components
• Solenoid valves designated A,B, and C.
COMPONENT DESCRIPTION © Mechanical hydraulic check valves.
The primary snow plow components are described • Pilot check valve.
within the following list: • Crossover relief valve.
• Moldboard—Snow blade constructed from high
tensile steel. SOLENOID (ELECTROMECHANICAL! VALVES
• Trip Springs—Allow the moldboard to tilt forward Three solenoid valves are used for snow plow con
and slide over obstructions without losing the snow load. trol. Each valve is comprised of two components:
© Sector—Used for positioning the moldboard • Cartridge—Comprised of a valve and a solenoid.
© straight ahead or angling it to the right or left. • Coil—The electrical component that retracts the
© Sector Shear Pin—Self-locking pin that locks the cartridge solenoid.
moldboard in either a straight ahead or an angled With power applied, the solenoid retracts and pulls
plowing position. the poppet valve into the OPEN position.
When power is turned off, the spring forces the so The other check valve is located between valve B
lenoid back to its normal, CLOSED position. and valve C. It prevents fluid from being forced
through solenoid valve B.
SOLENOID VALVE A
The solenoid valve A cartridge contains a poppet PILOT CHECK VALVE
valve. This valve is normally de-energized in the A pilot check valve has a piston in addition to a ball
CLOSED position. When closed, the valve retains seat and spring. A pilot check valve is located between
pressure in the lift cylinder. When it is energized solenoid valve C and the reservoir. It has two functions:
(valve opened), it allows the fluid to flow from the lift • Prevents the hydraulic fluid in either angling cyl
cylinder back to the reservoir. This enables the plow inder from leaking back to the reservoir.
blade to lower via gravity. • Allows the hydraulic fluid from a retracting an
Solenoid valve A is designed to remain energized gling cylinder to return to the reservoir.
(valve open) The valve action is done by fluid moving the piston,
during plowing to provide a floating blade position. which forces the check ball off its seat.
This ensures that the plow blade is guided up-down
by the surface deviations. CiQSSOVEi RELIEF VALVE
This valve protects against damage by a sudden
SOLENOID VALVE B
impact against the end of the blade. This will cause
The solenoid valve B cartridge contains a spool
high hydraulic pressure to accumulate in one of the
valve. This valve is normally in the de-energized
angling cylinders.
CLOSED position. This allows the fluid to flow to the
The hydraulic pressure increases enough to open
C solenoid. In the energized OPEN position, the fluid
is diverted to the lift cylinder. This causes the plow the crossover relief valve. The valve allows the highly
blade to be raised. pressurized hydraulic fluid to flow to the other cylin
der. This cushions the impact and changes the posi
SOLENOID VALVE C tion of the blade.
The solenoid valve C cartridge contains a spool
SYSTEM OPERATION
valve that is normally in the de-energized CLOSED
position. This allows the fluid to flow to the right- Refer to Figures 2 through 5 for voltage application
side power angling cylinder. This angles the blade to and hydraulic fluid flow for each snow plow function.
the left. At the same time, it allows the fluid from Each figure shows the components that are actuated
the retracting left-side power angling cylinder to re for each function.
turn to the pump reservoir.
Energizing the solenoid valve will route fluid to the SNOW PLOW WIRING DIAGRAMS
left side angling cylinder. This angles the plow blade Refer to Figures 6, 7 and 8 for wiring diagrams.
to the right. Also, the fluid is forced from the retract Refer to Specifications chart at the end of this group.
ing right side cylinder. It flows through the C car
tridge valve and returns to the pump reservoir. SNOW PLOW MALFUNCTION DIAGNOSIS AND
TESTS
MECHANICAL HYDRAULIC VALVES
Refer to the charts and illustrations for proper di
The mechanical hydraulic valves all have the same agnosis.
function: they control the direction of the hydraulic
fluid flow. SOLENOID VALVE COIL FUNCTIONAL TEST
CHECK VALVES Test the coils for proper operation, according to the
following procedure.
Check valves allow fluid to flow freely in one direc (1) Hold a screwdriver blade about 0.125 inch
tion while preventing fluid from flowing in the oppo above the nut on the coil to be tested.
site direction. (2) Have a helper operate the control switch that
A pump check valve is used to prevent fluid from energizes the applicable coil.
leaking back through the pump to the reservoir.
Two additional check valves are necessary because CAUTION: Do not connect an ohmmeter to a coil
solenoid valves B and C have some leakage. when it is applied. This can cause internal damage
One check valve is located between solenoid valve to the ohmmeter.
B and the lift cylinder. It prevents fluid in the lift
cylinder from leaking back through solenoid valve B. (3) If the coil is working, the electromagnetic ac
If fluid leaks back, it could angle the blade to the tion will pull the screwdriver down to the retaining
left. This would force fluid through solenoid valve C nut. If this does not occur, use an ohmmeter to check
into the right side cylinder. the coil for continuity.
BR BUMPERS AND FRAME 13
TAN- ORANGE WITH IGNITION SWITCH

WHITE
TRACER
•o
SWITCH
0 Q
SWITCH ANGLE
RAISE
AND O ORANGE BATTERY
LOWER WITH
WHITE TRACER
TAN
BLACK
FUSE
LIGHT + •O
"GREEN
RED <
' SOLENOID SWITCH

• MOTOR
ENERGIZED: MOTOR AND "B" COIL
PRESSURE RELIEF B
" " SOLENOID SOLENOID
^_JTTL ^
ANGLING CYLINDER
l^m OPERATING PRESSURE

EXHAUST
INTAKE OR DRAIN
METERED FLOW
RB525
Fig. 2 Raise Blade—Voltage Application & Hydraulic Fluid Flow

- 8 BUMPERS AND FRAME BR
IGNITION SWITCH
BATTERY
•o
ENERGIZED: "A" COIL
"B" SOLENOID C" SOLENOID

PRESSURE
RELIEF
CHECK
POWER
ANGLING
CYLINDER
LOWER AND FLOAT

(FORCE APPLIED AGAINST LIFT RAM)
OPERATING PRESSURE
EXHAUST
INTAKE OR DRAIN
METERED FLOW
RB526
Fig. 3 Lower & Fioat Blade—Voitage Application & Hydraulic Fluid Flow
BR BUMPERS AND FRAME 13 -
""7" IGNITION SWITCH
E?4
TAN t
-O
ORANGE
WITH
SWITCH
WHITE
TRACER
o
RAISE AND
LOWER
0
o
TAN
3
SWITCH I ANGLE
ORANGE WITH
WHITE TRACER
FUSE
f
BATTERY
-4\
-o
RED LIGHT GREEN
\ MOTOR
SOLENOID
SWITCH
ENERGIZED: MOTOR AND " C " COIL
Fig. 4 Angle Blade Right—Voltage Application & Hydraulic Fluid Flow

13 -10 BUMPERS AND FRAME mm
ORANGE
TAN- ORANGE
WITH WHITE WITH WHITE
TRACER TRACER
O
• IGNITION SWITCH
SWITCH
6
o o SWITCH ANGLE
RAISE
O BATTERY
AND LOWER FUSE
BLACK-
i
0
i TAN
o
LIGHT
RED- "GREEN
-SOLENOID SWITCH
MOTOR
ENERGIZED: MOTOR
C" SOLENOID
wsmrn OPERATING PRESSURE

EXHAUST
INTAKE OR DRAIN
METERED FLOW
J9001-1
Fig. 5 Angle Blade Left—Voltage Application & Hydraulic Fluid Flow

BR BUMPERS AND FRAME 13-11
SNOW PLOW DIAGNOSIS
Possible Cmum
Condition
PLOW B L A D I WILL NOT LIFT Oft 0) low hydraulic fluid level. (a) Add fluid to C©rr©€fl®n
proper level.
LIFTS SLOWLY b) Discharged battery. (b) Recharge battery.
c) Leaking or open "A" cartridge. (c) Clean or replace "A" cartridge.
d) No voltage at "B" coil. (d) Locate malfunction and repair.
e) Inoperative "B" coil. (e) Replace "B" coil.
1) Malfunctioning motor, (!) Repair or replace motor,
g) Malfunctioning pump. (g) Replace pump.
PLOW BLADE WILL MOT ANGLE R I G H T - a) Improper coupler engagement. (a) Engage coupler properly.
M O T O R IS O P E R A T I O N A L b) Mechanical bind or interference. (b) Eliminate mechanical bind or
interference.
c) Malfunctioning coupler. (c) Repair or replace coupler.
d) No voltage at "C" coil. (d) Locate malfunction and repair.
e) Inoperative "C" coil. (e) Replace "C" coil.
f) Inoperative "C" cartridge. (!) Clean or replace "C" cartridge.
P L O W BLADE WILL N O T ANGLE LEFT- a) Improper coupler engagement. (a) Engage coupler properly.
M O T O R IS O P E R A T I O N A L b) Mechanical bind or interference. (b) Eliminate mechanical bind or
interference.
c) Malfunctioning coupler. (c) Repair or replace coupler.
d) Leaking or open crossover relief (d) Clean or replace crossover relief
valve. valve.
PLOW BLAD1 WILL NOT ANGLE- a) Improper coupler engagement, (a) Engage coupler properly.
M O T O R IS O P E R A T I O N A L 'b) Mechanical bind or interference. (b) Eliminate mechanical bind or
interference.
c) Leaking or open crossover relief (c) Clean or replace crossover relief
valve. valve.
PLOW WILL N O T R E M A I N IN a) Air in cylinders and hoses. (a) Purge cylinders and hoses.
ANGLED P O S I T I O N b) Leaking "C" cartridge O-ring seals. (b) Replace O-ring seals.
c) Leaking or open pilot check valve. (c) Clean or replace pilot check valve.
d) Leaking crossover relief valve. (d) Clean or replace crossover relief
valve.
e) Crossover relief valve opening (e) Replace crossover relief valve.
pressure too low.
M O T O R DOES N O T OPERATE a) Discharged or defective battery. (a) Recharge or replace battery.

b) Loose or corroded electrical (b) Clean and tighten electrical
connections. connections.
c) Inoperative solenoid switch. (c) Replace solenoid switch.
d) Malfunctioning control switch. (d) Replace control switch.
e) Malfunctioning motor. (e) Repair or replace motor.
P L O W BLADE WILL N O T LOWER a) No voltage at "A" coil. (a) Locate malfunction and repair.
b) "A" cartridge jammed in closed
position. (b) Clean or replace "A" cartridge.
c) Inoperative "A" coil.
(c) Replace "A" coil.
P L O W BLADE CREEPS D O W N W A R D a) Leaking "A" cartridge.
b) Leaking "A" cartridge O-ring seal. (a) Clean or replace "A" cartridge.
c) Leaking B-Check Valve. (b) Replace O-ring seal.
[d) Leaking Ram Packing Cup. (c) Clean or replace Pump Check Valve.
e) Leaking O-ring seal at bottom of (d) Replace Ram Packing Cup.
cylinder. (e) Replace O-ring seal.
PLOW HAD! WILL NOT a) Runner height incorrect.

CLEAN SURFACE b) Cutting edge unevenly worn.
(a) Adjust runners.
(b) Replace.
BLADE WILL N O T FOLLOW a) Not in "Lower Float Position".
SURFACE D E V I A T I O N S (a) Position switch at "Lower Float"
b) Insufficient slack in lift chain.
(b) Adjust lift chain.
S N O W STICKS T O FACE (a) Sno-Flo paint worn off. (a) Refinish.
OF BLADE
J9001-3
13 -12 BUMPERS AND FRAME BR
TO TURN FUSE #5
SIGNAL FLASHER < (20 AMP)
V -Dl 18RD/YL*
(SEE SHEET 27)
Dl 18RD/YL*
TO R.W.A.L.
j MODULE
(SEE SH 51, 53)
BLACK
TO
IGNITION
SWITCH
(SEE SH 10)
-SP4 18WT/BR*- -SP4 18WT/BR*-
-SP4 18WT/BR*
-SP4 18WT/BR*
-Dl 18RD/YL*- '{{ f\ • DOWN

-SP1 18WT/BK* I
PLOW
CONTROL Dl 18RD/YL*
DOWN SWITCH
UP & DOWN L. -SP3 18 WT/RD*
-SP3 18WT/RD*-
-SP1 18WT/BK*-
Dl SP4 18WT/BR*
18RD SP4 18WT/BR*
YL*
-Dl 18RD/YL*
PLOW SP4 18WT/BR*
CONTROL j
SWITCH 1 Dl 18RD/YL*
LEFT TO
SP5 18WT/LG*
RIGHT
-SP4 18WT/BR* -SP5 18WT/LG*-
-Dl 18RD/YL*- -T2 18LG/RD*-
TRANSMISSION OIL
TEMPERATURE LAMP
8901-3
Fig. 6 Snow Plow Control Wiring Diagram

FUSE *5
(15 AMP) TO BATTERY ^NATURAL
CABLE 6RD
(REAR OF'
BATTERY)
NATURAL -Al 6RD-

^8> Al 6RD
TO CHARGING i
IGNITION 1 -SP4 18WT/BR*-
SYSTEM
ACCESSORY (REAR OF SNOW PLOW MOTOR
FEED BATTERY) SOLENOID (LEFT
WHEELHOUSE) ^
Ml 6RD-
BODY i—Ml 6RD-

GROUND SNOW PLOW MOTOR
(FRONT SNOW (FRONT SNOW
PLOW FRAME) PLOW FRAME)
-SP4 18WT/BR*- -SP4 18WT/BR
G9 6BK :
i— SP4 18WT/BR*
SP4 18WT/BR* j
UP
Dl 18RD/YL*
* DOWN
J I BLACK SNOW PLOW
SP1 18WT/BK*' (FRONT SNOW UP SOLENOID
UP PLOW FRAME) (FRONT SNOW
Dl 18RD/YL*
DOWN SP3 18WT/RD* PLOW FRAME)
-SP3 18WT/RD* ^ 16RD—FW1—-j_
PLOW
CONTROL
SWITCH -SP1 18WT/BK* fltZ 16BK—pgFI 2_
UP & DOWN
-SP3 18WT/RD*- BLACK SNOW PLOW DOWN
(FRONT SNOW SOLENOID (FRONT
-SP1 18WT/BK* PLOW FRAME) SNOW PLOW FRAME)
L
S P 4 18WT/BR*
SP4 18WT/BR*
SP4 18WT/BR*
SP4 18WT/BR*
BLUE
L
D 1 18RD/YL*- SP5 18WMG*-§ 16LG-fWf
SP4 18WT/BR* "1
Dl 18RD/YL*
SNOW PLOW
SP5 18WT/LG* BLACK RIGHT SOLENOID
PLOW (FRONT SNOW (FRONT SNOW
CONTROL PLOW FRAME) PLOW FRAME)
, SWITCH
L
S P 4 18WT/BR*-J LEFT TO
RIGHT TRANSMISSION OIL
-SP5 18WT/LG*- . TEMPERATURE SWITCH
-Dl 18RD/YL*- (RIGHT SIDE
TRANSMISSION OIL T2 18LG/RD*-
BELOW RADIATOR) 8901-4
TEMPERATURE LAMP
Fig. 7 Snow Plow Control Wiring Diagram (Continued)

13 -14 BUMPERS l i i PRIME
TO. FRONT TO FRONT

END WIRING END WIRING
TO HEADLAMP 5" -L2 14LG (SEE SH 22)
(SEE SH 21)
SWITCH
T (SEE SH 25) y
L9
18BK
BLACK
(RIGHT
SIDE
RADIATOR
YOKE
PANEL)
BLACK
BLACK
BLACK
LEFT AUXILIARY
PARK AND TURN RIGHT AUXILIARY
SIGNAL LAMP LEFT AUXILIARY PARK AND TURN
RIGHT AUXILIARY
HEADLAMP SIGNAL LAMP
HEADLAMP
8901-2
Fig. 8 Snow Plow Auxiliary Lighting Wiring Diagram

m m — ^ — ^ — — ^ — — — BUMPERS AND FRAME 13 - 15
POWEi UNIT (23) Disassemble the three-way valve (Fig. 9). Dis
card the O-ring seal.
DISASSEMBLY/INSPECTION (24) Remove and clean solenoid valve C with spe
(1) Remove the drain plug (Fig. 9). Drain the unit. cial tool J-25399 (Fig. 9). Inspect the solenoid valve
(2) Extend the ram and piston rod completely. for external damage.
Drain the remaining oil from the cylinder. (25) Disassemble the four-way valve (Fig. 12). Dis
(3) Remove the cover lock nuts (Fig. 9). Remove card the O-ring seals (Fig. 12).
the cover. (26) Test solenoid valve B and C coils for electrical
(4) Inspect the casting for damage and cracks. In continuity. The normal coil DC resistance is 3.7 ohms.
spect the seal for cuts (Fig. 9). (27) Remove the pilot check valve plug, the spring
(5) Remove the ram and the piston. Inspect the ny and the ball from the bottom of the valve block.
lon sleeve, the piston, and the piston follower for ex (28) Inspect the spring for damage and the ball
cessive wear (Fig. 10). seat for nicks.
(6) Inspect the cylinder for pitting and scoring in (29) Remove the acorn nut for access to the cross
the bore (Fig. 10). over valve components (Fig. 9).
(7) Inspect the ram for nicks, scratches, and corro (30) Remove the crossover valve components (Fig. 13).
sion (Fig. 10). Inspect for external damage. Discard the O-ring seals.
(8) Inspect the piston packing cup for wear (Fig. 10). (31) Clean the block with compressed air to remove
(9) Clean and inspect the base strainer. all foreign material.
(10) Replace all the O-ring seals during assembly.
(11) Loosen the motor bolts. Do not remove the ASSEMBLY
bolts from the motor. Retain the motor end plate dur Verify that all components are clean, free of foreign
ing removal. Temporarily install two nuts on the mo material. Use replacement gaskets and seals during
tor bolts to retain the motor intact. assembly. Petroleum jelly should used for installing
Both Prestolite and American Bosch motors the rubber O-ring seals.
are used in snow plow power units. A Prestolite (1) Install the crossover valve components in the
motor can be identified b y a domed top cover valve block with replacement O-ring seals (Fig. 13)
and the trade name stamped on the body. Amer (2) Install the ball, spring and pressure plug with
ican Bosch motors have a flat top cover and no a replacement O-ring seal in the bottom of the valve
identifying name or marks. block (Fig. 13)
(12) Remove the pump drive shaft seal. (3) Assemble solenoid valve C with replacement O-
(13) Verify the seal kit components are correct for ring seals and nylon retainer rings (Fig. 12).
the unit. (4) Install solenoid valve C with Tool J-25399 (Fig. 9).
(14) Dip the new seal in oil. Install it over the (5) Assemble solenoid valve B with replacement O-
pump shaft with the seal lip facing down. ring seals.
(15) Position the seal in the pump housing slightly (6) Install the ball, spring and solenoid valve B
below the boss face. with Tool J-25399 (Fig. 9).
(16) Remove solenoid valve A coil from the base. (7) Install the valve block and the replacement O-
Test it for continuity. The normal coil DC resistance ring seals on the pump base.
is 9.0 ohms ±10%. (8) Install the retainer, the spring, the ball, the in
(17) Remove solenoid valve A cartridge. Inspect for sert valve and the pump housing with replacement
external damage. O-ring seals (Fig. 11). Tighten the pump housing
(18) Remove the filters. Clean the screens with base nuts to 11.3 N-m (100 in. lbs.) torque.
cleaning solvent and compressed air. Discard the CD- (9) Install the filters and the plugs with replace
ring seals and the nylon retaining rings. ment O-ring seals (Fig. 9).
(19) Remove the pump housing (Fig. 9). Remove the in (10) Install solenoid valve A cartridge in the pump
sert valve, the ball, the spring, and the. retainer from the base with replacement O-ring seals (Fig. 9).
pump housing (Fig. 11). Inspect all the components for (11) Install solenoid valve A coil (Fig. 9).
damage and contamination. Discard the O-ring seals. (12) Install the motor on the pump housing (Fig.
(20) Remove the socket-head screws. Remove the 9). Engage the gear shaft tang with the notch in the
valve block from the pump housing (Fig. 9). Discard motor output shaft. Tighten the motor housing cap
the O-ring seals. screws to 5 N-m (45 in. lbs.) torque.
(21) Remove solenoid valve B with special tool (13) Install the ram and piston with replacement
J-25399 (Fig. 9). O-ring seals (Fig. 9).
(22) Remove the ball and spring from the valve (14) Position the cover on the reservoir. Secure it
block (Fig. 9). Clean the solenoid valve. Inspect it for with lock nuts (Fig. 9). Tighten the lock nuts to 11.3
external damage. N-m (100 in. lbs.) torque.
Fig. 9 Power Unit—Exploded View
BR -—^ — BUMPERS AND FRAME 13 - 17
LEGEND FOR FIG. 9
l Plastic Washer 16. Pump Housing 31. Valve Block 46. 3-Way Coil
2, Locknut 17. Poppet 32. Socket Head Cap Screw 47. Cap Plug
3. Pressure Relief Valve 18. Spring 33. Filter 48. Check Spring
4 Filler Plug 19. Guide 34. Plug 49. Cylinder Tank
5, Cover and Seal 20. Retainer 35. Strainer 50. Valve Block
6, O-Ring Seal 21. Setscrew 36. Check Valve Retainer 51. Cage
7 Sleeve 22. Aluminum Washer 37. Ball 52. O-Ring Seal/Glide Ring
8 Washer 23. Jamnut 38. Insert Valve 53. Crossover Valve
9, Rom 24. Acorn N ut 39. Cylinder Tank 54. Pilot Check Valve
10. Piston 25. Stud 40. Cylinder 55. Spacer
11. Packing Cup 26. Brass Washer 41. 4-Way Solenoid 56. Disc
12, Piston Follower 27. 2-Way Solenoid 42. 4-Way Valve 57. Adjustment Screw
13, Locknut 28. 2-Way Coil 43. 4-Way Coil 59. Drain Plug
14, Motor 29. 2-Way Valve 44. 3-Way Solenoid
15, Shaft Seal 30. Base and Strainer 45. 3-Way Valve
J9001-6
COVER TANK
ASSEMBLY RESERVOIR CYLINDER
I
PISTON LOCKNUT
BRASS NUT LOCK NUT

O-RING JT f
x , '
k n PACKING
RAM WASHER c u p
COIL
PISTON
FOLLOWER
RB531
Fig. 10 Lift Cylinder Components

-VALVE CARTRIDGE
O-RINGS
SPRING
PLUNGER
BASE VALVE
RETAINER
SNAP RING
NYLON WASHER
O-RING SPRING
O-RINGS
NYLON WASHER
O-RING
INSERT NOTE: NYLON WASHERS NYLON WASHER
O T ^ " VALVE AND O-RINGS SHOULD
TAPER DOWN TO VALVE SHAPE —
O-RING FROM VALVE DOWN. RB533
RB532
Fig. 12 Solenoid Valve C/Four-Way Valve—Exploded
Fig. 11 Insert Valve—Exploded View View
13 -18 BUMPERS AND FRAME BR
SNOW PLOW F i A i E
REMOVAL
(1) Support the snow plow frame.
(2) Remove the nuts and bolts that attach the
bumper brackets to the snow plow frame (Fig. 15).
(3) Remove the nuts and bolts that attach the sup
port straps to the snow plow frame (Fig. 15).
(4) Remove the nuts, washers and bolts that attach
the snow plow frame to the vehicle frame side rails
and front crossmember (Fig. 15).
(5) Remove the snow plow frame and support from
the front of the vehicle frame (Fig. 15).
INSTALLATION
(1) Position and support the snow plow frame at
RB534
the front of the vehicle frame with the bolt holes
aligned (Fig. 15).
Fig. 13 Crossover Relief Valve—Disassembled (2) Install the snow plow frame attaching bolts,
washers and nuts finger-tight (Fig. 15).
POWER ANGLING CYLINDER SERVICE
(3) Install the support strap attaching bolts and
If angling cylinder fluid leakage occurs, the cause nuts finger-tight (Fig. 15).
could be a loose gland nut (Fig. 14). Tighten the (4) Install the bumper bracket attaching bolts and
gland nut. nuts finger-tight (Fig. 15).
CAUTION: Over-tightening the gland not can lock (5) Tighten all the attaching nuts to 68 N-m (50 ft.
the cylinder. Leakage will not cease immediately be lbs.) torque.
cause fluid has accumulated between the packing (6) Remove the support from under the snow plow
and the gland nut. If the leakage persists, replace frame.
the rod packing (Fig. 14).
SNOW PLOW PiWOT BRACKET
MEM0WAL
(1) Support the snow plow pivot bracket.
RN886
Fig. 14 Angling Cylinder—Exploded View

BR BUMPERS AND FRAME 13 -19
FRAME
SNOW
PLOW FRAME
BUMPER
BRACKET
BUMPER
BRACKET
J9101-2
Fig. 15 Snow Plow Frame Removal/installation

(2) Remove the nuts and bolts that attach the sup FRAME FRAME
port straps to the pivot bracket (Fig. 15). BOLT
(3) Remove the nuts, washers and bolts that attach
the pivot bracket to the vehicle frame side rails (Fig.
16). BOLT
(4) Remove the pivot bracket from the vehicle
frame rails (Fig. 16).
INSTALLATION
(1) Position and support the pivot bracket at the
vehicle frame rails with the bolt holes aligned (Fig. BRACE llBRACE
16).
(2) Install the pivot bracket attaching bolts, wash
ers and nuts finger-tight (Fig. 16).
(3) Install the support strap attaching bolts and
nuts (Fig. 15). Tighten the nuts to 68 N-m (50 ft. lbs.)
torque.
(4) Tighten the pivot bracket attaching nuts to 68
(5) Remove the support from under the pivot
bracket.
Fig. 16 Snow Plow Pivot Bracket Removal/
SNOW PLOW CONTROL iOitJLE Installation
REMOVAL/DISASSEMBLY (2) Remove the control module from the instru
(1) Remove the screws and module retainers from ment panel (Fig. 17).
the instrument panel (Fig. 17). (3) Remove the module housing attaching screws
(Fig. 18).
(4) Separate the switch cover from the housing INSTRUMENT

(Fig. 18). PANEL
(5) Detach the lamp holders from the switch cover.
Disconnect the wire harness connectors from the
switches (Fig. 18). WIRE
HARNESS
(6) Remove the nut, ring washer and lock washer
from each toggle switch (Fig. 18). AUXILIARY
(7) Remove the toggle switches from the switch HEADLAMP
cover (Fig. 18). SWITCH
(8) Carefully pry the auxiliary headlamp switch
outward from the switch cover face. Remove it from
the switch cover (Fig. 18).
SWITCH
ASSEMBLY/IHSTALLATION COVER AND BEZEL
(1) Insert the auxiliary headlamp switch in the BLADE HOUSING
switch cover opening. Carefully push inward until it RAISE/LOWER
SWITCH BLADE
is completely seated against the cover face (Fig. 18). ANGLE
(2) Position the toggle switches in the switch cover SWITCH
openings. Install the lock washers, ring washers and RETAINER
J9123-424
nuts (Fig. 18). Tighten the nuts with 5 N-m (45 in.
lbs.) torque. Fig. 17 Snow Plow Control Module Removal/
(3) Insert the lamp holders in the switch cover Installation
openings. Connect the wire harness connectors to the
BLADE SWITCH AUXILIARY
switches (Fig. 18). ANGLE COVER HEADLAMP
(4) Mate the switch cover with the module hous SWITCH I SWITCH
ing. Install the housing attaching screws (Fig. 18). TRANS OIL NUT
Tighten the screws until the screw heads are seated TEMP LAMP
against the housing. (AUTO TRANS)
RING
(5) Position the control module on the instrument WASHER
panel with the slots aligned with the holes. Install TO AUXILLARY
the retainers and screws (Fig. 17). Tighten the H/LAMP SWITCH
LOCKWASHER
screws until the module is tightly attached to the in
strument panel. WIRE
HARNESS
'ILLUMINATION*
HOUSING LAMP'
SCREW BLADE
RAISE/LOWER
SWITCH
TO SNO-PLOW CONTROL
SWITCH
(ANGLE)
TO SNO PLW CONTROL SWITCH
(RAISE/LOWER) J9l 23-425
Fig. 18 Snow Plow Control Module Disassembled

BUMPERS AND FRAME 13 - 21
SNOW PLOW SPECIFICATIONS
ELECTRICAL SPECIFICATIONS SOLEWOIP VALVES A , B, AMP C SPE€8F2CATiONS

MOTOR SPiCif ICATIONS A Coll
American Bosch M 0 5 5 1 M 6 A Applied Voltage — 12 Volts DC
No load (motor not attached to pump) operation: Current — 0.83 Amperes
CAUTION: Do not operate motor continuously for more Nominal resistance (one ohmmeter probe to coil wire, other
than 30 seconds. to metal coil cover)—9.0 ± 10% ohms.
Applied Voltage — 12 Volts DC S ami C Colls
Mom. Current — 24 Amperes Applied Voltage — 12 Volts DC
Speed (Min.) — 5900 rpm Current —• 1.24 Amperes
With load (pump operating): Nominal resistance (one ohmmeter probe to coil w i r e , other
C A U T I O N : Do not operate motor continuously for more to metal coil cover)—3.5 ± 10% ohms.
than 5 seconds.
Applied Voltage — 12 Volts DC SOLEWOIP S W I T C H
Max. Current ^— 230 Amperes Applied Voltage — 12 Volts DC
Prestolite M G L 4 1 0 3 M a x . Current — 5 Amperes
Nominal resistance (one ohmmeter probe to coil w i r e , other
No load (motor not attached Jo pump) operation:
to metal foot)—2.65-4.5 ohms.
C A U T I O N : Do not operate motor continuously for more
than 30 seconds.
H Y D R A U L I C FLUID CAPACITY
Applied Voltage — 10 Volts DC
Max. Current — 45 Amperes NOTE: 1 Quart = 32 Fluid Ounces
Speed (Min.) — 10,000 rpm A Reservoir and Pump 28 oz.
Under Load (pump operating): Hoses & 1-1/2 x 10 Cylinders 16 oz.
C A U T I O N : Do not operate motor continuously for more Total 1 qt., 12 oz.
than 5 seconds. (44 oz.)
Applied Voltage — 12 Volts DC B Reservoir and Pump 28 oz.
Max. Current — 230 Amperes Hoses & 1-1/2 x 12 Cylinders 19 oz.
Total 1 qt., 15 oz.
(47 oz.)
HYDRAULIC SPICIPICATIONS C Reservoir and Pump 1 qt., 4.5 oz.
mmp (36.5 oz.)
Pressure Output (pump relief valve opening pressure Hoses & 2 x 12 Cylinders 28 oz.
1650 + 50 psi Total 2 qt., 5 oz.
(64.5 oz.)
C R O S S O V E R RELIEF V A L V E
J9001-4
j Opening Pressyre 3800 ± 400 psi
13 - 22 BUMPERS AID FRAME mm
mm;m
INDEX
page page
Frame Dimensions 23 General Information . . . . . . . . . . . . . . . . . . . . . . . 22

Frame Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Safety Precautions and Warnings 22
Frame Straightening 23
SAFETY PRECAUTIONS AND WARNINGS
WARNING: USE E Y E PROTECTION WHEN GRIND

ING OR WELDING METAL, SERIOUS EYE INJURY
CAN RESULT.
BEFORE PROCEEDING WITH FRAME REPAIR IN
VOLVING GRINDING OR WELDING, VERIFY THAT
VEHICLE FUEL SYSTEM IS NOT LEAKING OR IN
CONTACT WITH REPAIR. A R E A , PERSONAL INJURY
CAN RESULT
DO NOT ALLOW OPEN FLAHE TO CONTACT
PLASTIC BODY PANELS. FIRE OR EXPLOSION CAN
RESULT. .,
WHEN WELDED FRAME COMPONENTS ARE RE
PLACED, 100% PENETRATION WELD MUST BE
ACHIEVED DURING INSTALLATION. IF NOT, DAN
GEROUS OPERATING CONDITIONS CAN RESULT. Fig. 1 Frame
STAND CLEAR OF CABLES OR CHAINS ON with rubber load cushions (Fig. 2) with through-bolts.
PULLING EQUIPMENT DURING FRAME STRAIGHT The cargo box or bed is attached to the frame with
ENING OPERATIONS, PERSONAL INJURY CAN RE bolts. Refer to Group 23, Body for cargo box service
SULT,
procedures.
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 re
sult.
When using heat to straighten frame components
do not exceed 566°C (1050°F), metal fatigue can re
sult.
Welding the joints around riveted cross members
and frame side rails can weaken frame.
Fig. 2 Cab Mounts
GENERAL INFORMATION The frame is designed to absorb and dissipate flex
BR trucks have a ladder-type frame (Fig. 1) with ing and twisting due to acceleration, braking, corner
Box-section front rails, dropped center section and ing and road surface variances without bending when
open-channel side rails in the rear. subjected to normal driving conditions. The frame is
Cross members attached to the frame side rails the mounting platform for the following systems and
with rivets, welds or bolts form a ladder-type con components:
struction (Fig. 1). The cab is isolated from the frame • Front and rear suspension systems.
• Engine, transmission, and transfer case. If a reinforcement channel is required, the

• Steering gear and linkage. top and bottom flanges should be 0.250 inches
• Fuel cell and fuel line tubing. narrower than the side rail flanges. Weld only
• Front end sheet metal and radiator closure panel. in the areas indicated (Fig. 3).
© Passenger cab.
• Cargo box or bed.
• Front and rear bumper systems.
FRAME STRAIGHTENING
When necessary, a conventional frame that is bent
or twisted can be straightened by application of heat.
The temperature must not exceed 566°C (1050°F).
The metal will have a dull red glow at the desired
temperature. Excessive heat will decrease the
strength of the metal and result in a weakened
frame.
Welding the joints around riveted cross members
and frame side rails is not recommended.
A straightening repair process should be limited to
frame members that are not severely damaged. The
replacement bolts, nuts and rivets that are used to
join the frame members should conform to the same Fig. 3 Frame Reinforcement
specifications as the original bolts, nuts and rivets. FRAME FASTENERS
Bolts, nuts and rivets can be used to repair frames
FRAME REPAIRS
or to install a reinforcement section on the frame.
DRILLING HOLES Bolts can be used in place of rivets. When replacing
Do not drill holes in frame side rail top and bottom rivets with bolts, install the next larger size diameter
flanges, metal fatigue can result causing frame fail bolt to assure proper fit. If necessary, ream the hole
ure. Holes drilled in the side of the frame rail must out just enough to sufficiently receive the bolt.
be at least 38 mm (1.5 in.) from the top and bottom Conical-type washers are preferred over the split-
flanges. ring type lock washers. Normally, grade-5 bolts are
Additional drill holes should be located away from adequate for frame repair. Grade-3 bolts or softer
existing holes. should not be used. Tightening bolts/nuts with the
correct torque, refer to the Introduction Group at the
WELDING front of this manual for tightening information.
Use MIG, TIG or arc welding equipment to repair
welded frame components. FRAME DIMENSIONS
Frame components that have been damages should Frame dimensions are listed in inch scale. All di
be inspected for cracks before returning the vehicle
mensions are from center to center of Principal Lo
to use. If cracks are found in accessible frame com
ponents perform the following procedures. cating Point (PLP), or from center to center of PLP
(1) Drill a hole at each end of the crack with a 3 and fastener location.
mm (0.125 in.) diameter drill bit. VEHICLE PREPARATION
(2) Using a suitable die grinder with 3 inch cut off Position the vehicle on a level work surface. Using
wheel, V-groove the crack to allow 100% weld pene screw or bottle jacks, adjust the vehicle PLP heights
tration. to the specified dimension above a level work surface.
(3) Weld the crack. Vertical dimensions can be taken from the work sur
(4) If necessary when a side rail is repaired, grind
face to the locations indicated (Fig. 4, 5, 6, 7, 8 or 9).
the weld smooth and install a reinforcement channel
(Fig. 3) over the repaired area.
WB A B
1187 39.6683.76
134.7 55.6699.76
W B (134 7 S H O W N )
ALL DIMENSIONS ARE SHOWN IN INCHES
BR 1500 and 2500

119" and 135"
WHEEL BASE
REAR-WHEEL-DRIVE
- CAB H O L D REAR S P R I N G H A N G E R
FRONT
D O W N BRKT SPRING HANGER
REAR TRANS C M E M B E R
REAR FRAME SECTION J9413-15

Fig. 4 BR 1500 and 2500 Rear- Wheel-Drive
BR BUMPERS AND FRAME 13
GS-
Wi A B
118.7 39.66 83.76
134.7 55.66 99.76
W B (134.7 S H O W N )
ALL DIMENSIONS ARE S H O W N IN INCHES
0 63
2 HOLES
BR 1500 and 2500
119" and 135"
WHEEL BASE
FOUR-WHEEL-DRIVE
- CAB HOLD FRONT REAR SPRING HANGER

D O W N BRKT SPRING HANGER
REAR T R A N S C / M E M B E R
REAR FRAME SECTION J9413-

Flg. 5 BR 1500 and 2500 Four-Wheel-Drive
13 - 26 BUMPERS AID FRAME
REAR FRAME SECTION J9413-17

Fig. 6 BR 3500 Rear-Wheel-Drive
WB A B
134.7 55.66 99.76
138.7 59.66 103.76
162.7 83.66 127.76
C F R O N T WHEELS
- W B (134.7 S H O W N )
BR 3500
135", 139" and 163"
WHEEL BASE
FOUR-WHEEL-DRIVE
- CAB H O L D ^ ^ — FRONT REAR S P R I N G HANGER

D O W N BRKT. S P R I N G HANGER
• REAR T R A N S C/MEMBER
REAR FRAME SECTION
J9413-18
Fig. 7 BR 3500 Four- Wheel-Drive
13 - 28 BUMPERS AND FRAME — — — — BR
FRONT
SPRING HANGER REAR
REAR TRANS C/MEMBER BOX TIE
SPRING HANGER
DOWN BRKTS. J9513-31
Pig, 8 BR 1500 Club Cab Rear- Wheel-Drive
66.90
= 30.25»
16.48-
ALL DIMENSIONS
S H O W N IN INCHES
37.92
* ™ 2 2
. 2 6
SS'S!
f 1 0 5 6
y
34^7 I 32 5 4
0-
t -0 (48.07
32.54
20.59 35.51 37.63 BR 1500 )55" WHEEL BASE
CLUB CAB REAR WHEEL DRIVE
. 34 9 0 — ^ 2 5 . 1 5 - * J
[^—50.90——^^ 41.02-
REAR AXLE
58.97 — 18 84
^3.66
REAR FRAME SECTION
i LEI
FRONT
SPRING HANGER
BOX TIE REAR

REAR TRANS C/MEMBER D O W N BRKTS. SPRING HANGER
J9513-32
Fig. 9 BR 1500 Club Cab Rear-Wheel-Drive
BR FUEL SYSTEM 14 - 1
FUEL SYSTEM
CONTENTS
page page
ACCELERATOR PEDAL AND THROTTLE GENERAL INFORMATION 1

CABLE . . . . . 24 MULTI-PORT FUEL INJECTION (MFI)—
DIESEL ENGINE—COMPONENT DESCRIPTION/ COMPONENT DESCRIPTION/SYSTEM
SYSTEM OPERATION 87 OPERATION—EXCEPT DIESEL 28
DIESEL ENGINE—COMPONENT REMOVAL/ MULTI-PORT FUEL INJECTION (MFI)—
INSTALLATION 125 COMPONENT REMOVAL/INSTALLATION—
DIESEL ENGINE—GENERAL DIAGNOSIS . . . . . 18 EXCEPT DIESEL 73
FUEL DELIVERY SYSTEM—DIESEL ENGINE .. 11 MULTI-PORT FUEL INJECTION (MFI)—
FUEL DELIVERY SYSTEM—EXCEPT DIESEL . . . 2 GENERAL DIAGNOSIS—EXCEPT DIESEL . . . 5 3
FUEL TANKS 20 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 1 4 8
QENERAL INFORMATION
Throughout this group, references are made to par nents of the fuel system. Refer to the Powertrain
ticular vehicle models by alphabetical designation or Control Module sections for additional information.
by the particular vehicle nameplate. A chart showing The Fuel Delivery System consists of: the electric
a breakdown of the alphabetical designations is in fuel pump (gas), fuel injection pump (diesel), fuel
cluded in the Introduction section at the beginning of transfer pump (diesel), fuel filter, fuel tubes/lines/
this manual. hoses, fuel rail, fuel injectors and fuel pressure regu
All vehicles are equipped with either a 3.9L (V-6) lator.
engine, a 5.2L (V-8) engine, two different 5.9L (V-8) A Fuel Return System is used on all vehicles (all
engines, an 8.0L (V-10) engine or a 5.9L (Cummins engines). On gas powered engines, fuel is returned
in-line 6 cylinder diesel) engine. through the fuel pump module and back to the fuel
The 3.9L. (V-6) and 5.2L (V-8) engines will be re tank. A separate fuel return line from the tank to the
ferred to in this group as: LDC (Light Duty Cycle) engine is not used on any gas powered engine.
engines. The 5.9L (V-8) gas powered engine will be On diesel powered engines, a separate fuel return
referred to as either: LDC (Light Duty Cycle) or HDC line from the tank to the engine is used.
(Heavy Duty Cycle) engine. The 8.0L (V-10) and die The Fuel Tank Assembly consists of: the fuel
sel engines will be referred to as: HDC (Heavy Duty tank, filler tube, fuel gauge sending unit/electric fuel
Cycle) engine. pump module (electric fuel pump on gas powered en
Either of the HDC gas powered engines can be eas gines only), a pressure relief/rollover valve and a
ily identified by the use of an engine mounted air in pressure-vacuum filler cap.
jection pump. The 3.9L/5.2L/5.9L LDC gas engines or Also to be considered part of the fuel system is the
the diesel engine will not use an air injection pump. Evaporation Control System. This is designed to
The Fuel System consists of: the fuel tank, an reduce the emission of fuel vapors into the atmo
electric fuel tank mounted fuel pump (gas powered sphere. The description and function of the Evapora
engines), a fuel injection pump (diesel engine), a me tive Control System is found in Group 25, Emission
chanical fuel transfer (lift) pump (diesel) and a fuel Control Systems.
filter. It also consists of fuel tubes/lines/hoses and fit
tings, vacuum hoses, throttle body and fuel injec FUEL REQUIREMENTS
tors). The powertrain control module (PCM) will Refer to Group 0, Lubrication and Maintenance for
either directly operate or regulate certain compo information.
14 - 2 FUEL DELIVERY SYSTEM—EXCEPT DIESEL BR
FUEL DELIVERY S Y S T E M — E X C E P T D I E S E L
INDEX
page page
Fuel Filter . .5 Fuel System Pressure Release Procedure 5

Fuel Filter/Fuel Pressure Regulator 3 Fuel System Pressure Test—Gas Powered
Fuel Line with Latch Clip . 10 Engines 5
Fuel Pressure Leak Down Test—Gas Powered Fuel Tubes/Lines/Hoses and Clamps . 7
Engines 6 General Information . 2
Fuel Pump Capacity Test—Gas Powered Engines . . 6 Quick-Connect Fittings 7
Fuel Pump Module—All Gas Powered Engines . . . . 2
GENERAL INFORMATION PLASTIC FUEL FILTER/ FUEL

LOCKNUT FUEL PRESSURE SUPPLY TOP OF
A separate fuel return line or a separate frame
J
REGULATOR CONNECTION FUEL TANK
mounted fuel filter will not be used with any gasoline
powered engine.
The fuel delivery system for gas powered engines is
controlled by the powertrain control module (PCM). PRESSURE RELIEF/
For additional information, also refer to Powertrain ROLLOVER VALVE
Control Module (PCM) in the Multi-Port Fuel Injec
tion (MFI) sections of this group.
The fuel pump module contains a combination fuel
pressure regulator and fuel filter. Refer to the follow
ing Fuel Pump Module—All Gas Powered Engines AUXILIARY
PUMP/GAUGE
for additional information. ELEC. CONNECTION
FUEL SUPPLY
FITTING FRONT OF
FUEL P U M P M O D U L E — A L L GAS P O W E R E D (SOME ENGINES) TANK J9414-32
ENGINES
The fuel pump module on all gas powered engines is Fig. 1 Top View Fuel Pump Module -Gas Powered
installed in the top of the fuel tank (Fig. 1). The fuel Engines—Typical
pump module (Figs. 1 or 2) contains the following: FUEL GAUGE LOCKING
• A combination fuel filter/fuel pressure regulator FLOAT SENDING UNIT TABS
® Electric fuel pump ELECTRIC
o Fuel pump reservoir FUEL PUMP
o A separate in-tank fuel filter
• Pressure relief/rollover valve
• Fuel gauge sending unit
© Fuel supply line connection
o Auxiliary fuel supply fitting (not all engines)
ELECTRIC FUEL PUMP
The electric fuel pump is located in and is part of,
the fuel pump module (Fig. 2). It is equipped with a
permanent magnet electric motor. The fuel pump
module is suspended in fuel in the fuel tank. Fuel is MOUNTING IN-TANK
SCREWS FUEL FILTER J9414-33
drawn in through a separate filter (located on bottom
of module) and pushed through the electric motor to Fig. 2 Fuel Pump Module Components—Gas
the fuel filter/fuel pressure regulator. Powered Engines—Typical
FUEL P U i P ELECTRICAL COlIiOL FUEL PUMP HEPlACEiElI
Voltage to operate the electric pump is supplied The electric fuel pump is not serviceable. If the fuel
through the fuel pump relay. For an electrical operational pump needs replacement, the complete fuel pump module
description of the fuel pump, refer to Fuel Pump Relay—
PCM Pin #51-PCM Output. This can be found in the
Multi-Port Fuel Injection (MFI) System—Component De
scription/System Operation section of this group.
FUEL DELIVERY SYSTEM—EXCEPT DIESEL 14 - 3
must be replaced. Refer to Fuel Pump Module Removal AUXILIARY FUEL SUPPLY FITTING
for procedures. Perform the Fuel System Pressure Re An auxiliary (capped) fuel supply fitting is located
lease procedure before servicing the fuel pump. on the top of the fuel pump module (Fig. 1). This fit
ting will be available only on diesel powered models,
FUEL PUMP MODULE REMOVAL and models with either a 5.9L V-8 heavy duty or 8.0L
V-10 engine, and all cab-chassis models. This fitting
WARNING: THE F U E L S Y S T E M IS UNDER A CON
supplies a non-pressurized auxiliary fuel source.
STANT P R E S S U R E ( E V E N WITH THE ENGINE OFF).
B E F O R E SERVICING THE F U E L P U M P MODULE,
FUEL FILTER/FUEL PRESSURE REGULATOR
F U E L S Y S T E M P R E S S U R E MUST B E R E L E A S E D .
A combination fuel filter and fuel pressure regula
tor is used on all gas powered engines. It is pressed
CAUTION: Whenever the fuel pump module is ser into a rubber grommet located on the top of the fuel
viced, the locknut and gasket must be replaced. pump module (Fig. 4). A separate frame mounted fuel
filter is not used with gas powered engines.
(1) Drain the fuel tank. Refer to Draining Fuel Fuel Pressure Regulator Operation: The pres
Tank in the Fuel Tank section of this group. sure regulator is a mechanical device that is not con
(2) Remove fuel tank. Refer to the Fuel Tank sec trolled by the powertrain control module (PCM).
tion of this group. The regulator is calibrated to maintain fuel system
(3) Note the direction of the fuel filter/fuel pres operating pressure of approximately 241-310 kPa (35-45
sure regulator, the pressure relief/rollover valve and psi) at the fuel injectors. It contains a diaphragm, cali
the fuel pump electrical connector. These should all brated springs and a fuel return valve. The internal fuel
be pointed to the drivers side of the vehicle. filter (Fig. 3) is also part of the assembly.
(4) The fuel pump module locknut is threaded onto Fuel is supplied to the filter/regulator by the elec
the fuel tank. Remove the fuel pump module locknut tric fuel pump through an opening tube at the bot
(Fig. 1). The fuel pump module will spring up when tom of filter/regulator (Fig. 3).
the locknut is removed. The fuel pump module contains a check valve to
(5) Remove module from fuel tank. maintain some fuel pressure when the engine is not
operating. This will help to start the engine.
DISASSEMBLY—FUEL IAUGE SENDING UNIT If fuel pressure at the pressure regulator exceeds
(1) Remove sending unit mounting screws (Fig. 2). approximately 45 psi, an internal diaphragm closes
(2) Mark the sending unit electrical wires before re and excess fuel pressure is routed back into the tank
moval for correct installation. Carefully disconnect elec through the pressure regulator. A separate fuel re
trical wires from sending unit. Remove sending unit. turn line is not used with any gas powered engine.
(3) Reverse order of removal for installation.
INTERNAL
FUEL FILTER
IN-TANK FUEL FILTER
The in-tank filter is attached to the bottom of the
fuel pump module (Fig. 2).
(1) Pry the mounting tabs back and remove the in-
tank fuel filter.''
(2) Install new fuel filter into retaining tabs.
FUEL PUMP MODULE INSTALLATION
CAUTION: Whenever the fuel pump module is ser

viced, the locknut and gasket must be replaced.
(1) Using a new gasket, position fuel pump module

into opening in fuel tank. The fuel filter/fuel pressure
regulator, the pressure relief/rollover valve and the fuel
pump electrical connector should all be pointed to the
drivers side of the vehicle before tightening locknut.
(2) Position new locknut over top of fuel pump module.
(3) Tighten locknut. FUEL INLET J9314-170
(4) Install fuel tank. Refer to Fuel Tank Installa
tion in this section. Fig. 3 Side View—Filter/Regulator
14 - 4 FUEL DELIVERY SYSTEfVS—EXCEPT DIESEL — — — — — BR
REMOVAL— ~L FILTER OB F U E L PRESSURE

RE&VLAWm
WARNING; THE FUEL SYSTEM IS UNDER A CON

STANT PRESSURE, EVEN WITH ENGINE OFF. BEFORE
SERVICING THE FUEL FILTER/FUEL P R E S S U R E R E G
ULATOR, THE FUEL SYSTEM P R E S S U R E MUST B E
RELEASED,
Refer to Fuel System Pressure Release in the Fuel

Delivery System section of this group.
The fuel filter/fuel pressure regulator is located on
the top of fuel pump module (Fig. 4).
PLASTIC FUEL FILTER/ FUEL RUBBER
LOCKNUT FUEL PRESSURE SUPPLY TOP OF GROMMET J9314-173
REGULATOR CONNECTION FUEL TANK
Fig. 5 Filter/Regulator Removal and Installation
FUEL FILTER/FUEL
PRESSURE RELIEF/ PRESSURE REGULATOR
ROLLOVER VALVE
PLASTIC
TUBE
PUMP/GAUGE (COVER)
AUXILIARY ELEC CONNECTION
FUEL SUPPLY
FITTING
(SOME ENGINES) J9414-32
Fig. 4 Fitter/Regulator Location

Fuel pump module removal is not necessary.
(1) Drain fuel tank and remove tank. Refer to Fuel J9314-174
Tanks in this group.
(2) The fuel filter/regulator is pressed into a rubber Fig. 6 Plastic Tube and Snap Ring
grommet. Remove by twisting and pulling straight up
(Fig. 5). FUEL FILTER/FUEL
PRESSURE REGULATOR
CAUTION: D© not pull the filter/regulator more than
three inches from the fuel pump module. Damage to
the coiled fuel tube (line) may result.
(3) Remove the snap ring retaining the convoluted

tube (cover) to the filter/regulator (Fig. 6). Slide the
plastic tube down the fuel tube to clear the fuel tube
clamp.
(4) Gently cut the old fuel tube (line) clamp (Fig. 7)
taking care not to damage the plastic fuel tube. Re
move and discard the old fuel tube clamp.
(5) Remove the plastic fuel tube from the filter/reg
ulator by gently pulling downward. Remove filter/reg
ulator from fuel pump module.
Fig. 7 Fuel Tube and Clamp
BR FUEL DELIVERY SYSTEM—EXCEPT DIESEL 14 - 5
INSTALLATION (3) Remove (unscrew) the protective plastic cap

(1) Install a new clamp over the plastic fuel tube. from the pressure test port on the fuel rail (Fig. 9).
(2) Install filter/regulator to fuel tube. Rotate the On the 8.0L V-10 engine, this test port is located at
filter/regulator in the fuel tube (line) until it is the front of the engine.
pointed to the drivers side of vehicle.
(3) Tighten line clamp to fuel line using special
Hose Clamp Pliers number C-4124 or equivalent
(Fig. 8). Do not use conventional side cutters to
tighten this type of clamp.
Fig. 9 Typical Fuel Pressure Test Port

W A R N I N G : D O NOT A L L O W F U E L T O S P I L L ONTO
THE ENGINE INTAKE O R EXHAUST MANIFOLDS.
PLACE S H O P T O W E L S U N D E R AND AROUND T H E
PRESSURE PORT TO ABSORB FUEL WHEN THE
Fig. 8 Tightening Fuel Tube Clamp P R E S S U R E I S R E L E A S E D F R O M T H E F U E L RAIL.
(4) Slide the convoluted plastic tube (cover) up to
the bottom of filter/regulator and install snap ring WARNING: WEAR PROPER EYE PROTECTION
(Fig. 6). WHEN RELEASING FUEL SYSTEM PRESSURE.
(5) Press the filter/regulator (by hand) into the
rubber grommet. The assembly should be pointed to (4) Obtain the fuel pressure gauge/hose assembly
the drivers side of the vehicle. from fuel pressure gauge tool set 5069. Remove the
(6) Install fuel tank. Refer to Fuel Tanks in this gauge from the hose.
group. (5) Place one end of hose (gauge end) into an ap
proved gasoline container.
FUEL FILTER (6) Place a shop towel under the test port. On the
Refer to Fuel Filter/Fuel Pressure Regulator for in 8.0L V-10 engine, this test port is located at the front
formation. of the engine.
(7) To release fuel pressure, screw the other end of
FUEL SYSTEM PRESSURE RELEASE PROCEDURE hose onto the fuel pressure test port.
(8) After fuel pressure has been released, remove
ALL GAS POWERED ENGINES the hose from the test port.
The fuel system is under constant fuel pressure (9) Install protective cap to fuel test port.
(even with the engine off).
FUEL SYSTEM PRESSURE TEST—GAS POWERED
WARMING: BECAUSE THEFUEL SYSTEM IS UN ENGINES
DER CONSTANT FUEL PRESSURE, THIS PRES Fuel systems on gas powered engines are equipped
SURE MUST B E RELEASED BEFORE SERVICING with a fuel tank module mounted, combination fuel
ANY FUEL SUPPLY OR FUEL RETURN SYSTEM filter/fuel pressure regulator (Fig. 10). The fuel pres
COMPONENT. T H I S D O E S N O T A P P L Y TO T H R O T sure regulator is a mechanical device that is not con
TLE BODY REMOVAL. trolled by the powertrain control module (PCM) or
engine vacuum.
(1) Disconnect negative battery cable. With engine at idle speed, system fuel pressure
(2) Remove the fuel tank filler tube cap to release should be approximately 241-310 kPa (35-45 psi).
fuel tank pressure. (1) Remove (unscrew) the protective plastic cap
from the pressure test port on the fuel rail (Fig. 9).
14 - S FUEL DELIVERY SYSTE1—EICEPT DIESEL
PLASTIC FUEL FILTER/ FUEL FUEL PUMF CAPACITY TEST—SIS POWERED

FUEL PRESSURE SUPPLY TOP OF
LOCKNUT
REGULATOR CONNECTION
FUEL TANK ENGINES
Before performing this test, verify fuel pump pres
sure by performing the previous tests.
(1) Release the fuel system pressure from fuel sys
PRESSURE RELIEF/ tem. Refer to the previous Fuel Pressure Release
ROLLOVER Procedure in this group.
(2) Disconnect the fuel supply line at fuel rail.
On the 8.0L V-10 engine, the fuel line-to-fuel rail
connection is made at the rear of the engine. Refer to
Fuel Tubes/Lines/Hoses and Clamps in this section of
P U M P / G A U G E
AUXILIARY ELEC C O N N E C T I O N
the group for procedures. Remove air cleaner housing
FUEL SUPPLY before tool connection.
FITTING
(SOME ENGINES) J9414-32 (3) Connect Fuel Line Pressure Test Adapter Tool
number 6631 (3/8 in.), or number 6539 (5/16 in.) into
Fig. 10 Fuei Fiiter/Fuei Pressure Regulator—Typical the disconnected fuel supply line (tube). Insert the
other end of Adapter Tool 6631 or 6539 into an ap
On the 8.0L V-10 engine, this test port is located at proved gasoline container.
the front of the engine. Connect the 0-414 kPa (0-60 (4) To activate the fuel pump and pressurize the
psi) fuel pressure gauge (from Gauge Set 5069) to system, obtain the DRB scan tool. Refer to the appro
test port pressure fitting on fuel rail (Fig. 11). priate Powertrain Diagnostic Procedures service
FUEL PRESSURE
manual for DRB operation.
TEST G A U G E (5) A good fuel pump will deliver approximately 2
liters of fuel per minute.
FUEL PRESSURE LEAK DOWN TEST—GAS
POWERED ENGINES
ENGINE OFF
Abnormally long periods of cranking to restart a
hot engine that has been shut down for a short pe
riod of time may be caused by:
• Fuel pressure bleeding past a fuel injector(s).
• Fuel pressure bleeding past the. check valve in the
fuel pump module.
(1) Disconnect the fuel inlet line at fuel rail. On
the 8.0L V-10 engine, the fuel line-to-fuel rail connec
tion is made at the rear of the engine. Refer to Fuel
Tubes/Lines/Hoses and Clamps in this section of the
group for procedures. Remove air cleaner housing be
fore tool connection.
J9214-28 (2) Connect Fuel Line Pressure Test Adapter Tool
number 6539 (5/16 in.), or Adapter Tool number 6631
Fig. 11 Fuel Pressure Test—Typical (3/8 in.) between the disconnected fuel line and fuel
rail (Fig. 12).
(2) Note pressure gauge reading. Fuel pressure Adapter Tool connection on the 8.0L V-10 engine is
should be approximately 241-310 kPa (35-45 psi) at made at rear of engine.
idle. (3) Connect the 0-414 kPa (0-60 psi) fuel pressure
(3) If pressure is at O psi, connect DRB scan tool test gauge (from Gauge Set 5069) to the test port on
and refer to operating instructions in the appropriate either tool 6631 or 6539. The fittings on both tools
Powertrain Diagnostics Procedures service manual. must be in good condition and free from any
If operating pressure is above 45 psi, fuel pump is small leaks before performing the proceeding
OK. Replace fuel filter/fuel pressure regulator assem test.
bly. (4) Start engine and bring to normal operating
temperature.
(5) Observe test gauge. Normal operating pressure
should be 241-310 kPa (35-45 psi).
MUST B E RELEASED. REFER TO THE FUEL P R E S

SURE R E L E A S E PROCEDURE IN THIS GROUP,
Inspect all hose connections such as clamps, cou

plings and fittings to make sure they are secure and
leaks are not present. The component should be re
placed immediately if there is any evidence of degra
dation that could result in failure.
Never attempt to repair a plastic fuel line/tube. Re
place as necessary.
Avoid contact of any fuel tubes/hoses with other vehi
cle components that could cause abrasions or scuffing.
Be sure that the plastic fuel lines/tubes are properly
routed to prevent pinching and to avoid heat sources.
The lines/tubes/hoses used on fuel injected vehicles
are of a special construction. This is due to the higher
Fig, 12 Connecting Adapter Tool—Typical fuel pressures and the possibility of contaminated fuel
(6) Shut engine off. in this system. If it is necessary to replace these lines/
(7) Pressure should not fall below 24 psi for five tubes/hoses, only those marked EFM/EFI may be used.
minutes. The hose clamps used to secure rubber hoses on
(8) If pressure falls below 24 psi, it must deter fuel injected vehicles are of a special rolled edge con
mined if a fuel injector, the fuel module mounted fuel struction. . This construction is used to prevent the
pressure regulator or a fuel tube/line is leaking, edge of the clamp from cutting into the hose. Only
(9) Again, start engine and bring to normal operat these rolled edge type clamps may be used in this
ing temperature. system. All other types of clamps may cut into the
(10) Shut engine off. hoses and cause high-pressure fuel leaks.
(11) Checking for fuel injector leakage: Clamp Use new original equipment type hose clamps.
off the rubber hose portion of either tool 8539 or 6631 Tighten hose clamps to 1 N-m (15 in. lbs.) torque.
between the disconnected fuel tube (line) and test
QUICK-CONNECT FITTINGS
port inlet. If pressure now holds at or above 24 psi, a
fuel injector or the fuel rail is leaking. Also refer to the previous Fuel Tubes/Lines/Hoses
Checking for fuel pump module or fuel tube and Clamps section.
Different types of quick-connect fittings are used to
leakage: Clamp off the rubber hose portion of either
attach various fuel system components. These are: a
tool 6539 or 6631 between the fuel rail and test port single-tab type, a two-tab type or a plastic retainer
inlet. If pressure now holds at or above 24 psi, a leak ring type.
can be found at a fuel tube/line. If no leaks are found
at fuel tubes or lines, replace the fuel pump module. BINGtE-mB TYPE
This type of fitting is equipped with a single pull
MECHANI&&-L MALFtm&Tl&NS tab (Fig. 13). The tab is removable. After the tab is
Mechanical malfunctions are more difficult to diag removed, the quick-connect fitting can be separated
nose with this system. The powertrain control mod from the fuel system component.
ule (PCM) has been programmed to compensate for
some mechanical malfunctions such as incorrect cam CAUTION: The interior components (o-rings, spac
timing, vacuum leaks, etc. If' engine performance ers) of this type of quick-connect fitting are not ser
problems are encountered and a diagnostic trouble viced separately, but new pull tabs are available. Do
code (DTC) is not displayed, the problem may be me not attempt to repair damaged fittings or fuel lines/
chanical rather than electronic. tubes. If repair is necessary, replace the complete
fuel tube assembly.
FUEL TUBES/LINES/HOSES AND CLAMPS
Also refer to the proceeding section on Quick-Con WARNING: THE F U E L S Y S T E M IS UNDER A CON
nect Fittings. STANT P R E S S U R E (EVEN WITH THE ENGINE OFF).
B E F O R E SERVICING ANY F U E L S Y S T E M H O S E S ,
WARNING: TKZ FUEL SYSTEM IS UNDER A CON FITTINGS OR LINES, THE F U E L S Y S T E M P R E S
STANT P R E S S U R E (EVEN WiTH THE ENGINE OFF). S U R E MUST B E R E L E A S E D . R E F E R TO THE F U E L
BEFORE SIRViCiNG ANY FUEL SYSTEM HOSES, FIT PRESSURE RELEASE PROCEDURE m THIS
TINGS OR LIMES, THE FUEL SYSTEM P R E S S U R E GROUP.
14 - 8 FUEL DELIVERY SYSTEM—EXCEPT DIESEL mm
INSERTED TO REMOVE TUBE

TUBE END PULL TAB J9414-24 STOP J9414-26
Fig. 13 Single-Tab Type Fitting Fig. 15 Removing Pull Tab

DISCONNECTION/CONNECTION (9) Prior to connecting the quick-connect fitting to
(1) Disconnect negative battery cable from battery. component being serviced, check condition of fitting
(2) Perform the fuel pressure release procedure. and component. Clean the parts with a lint-free
Refer to the Fuel Pressure Release Procedure in this cloth. Lubricate them with clean engine oil.
section. (10) Insert the quick-connect fitting into the fuel
(3) Clean the fitting of any foreign material before tube or fuel system component until the built-on stop
disassembly. on the fuel tube or component rests against back of
(4) Press the release tab on the side of fitting to re fitting.
lease pull tab (Fig. 13). (11) Obtain a new pull tab. Push the new tab down
until it locks into place in the quick-connect fitting.
CAUTION: If this release tab is not pressed prior to (12) Verify a locked condition by firmly pulling on
releasing the pull tab, the pull tab will be damaged. fuel tube and fitting (15-30 lbs.).
(5) While pressing the release tab on the side of (13) Connect negative cable to battery.
the fitting, use a screwdriver to pry up the pull tab (14) Start engine and check for leaks.
(Fig. 14).
TWO-TAB TYPE FITTING
This type of fitting is equipped with tabs located on
both sides of the fitting (Fig. 16). These tabs are sup
plied for disconnecting the quick-connect fitting from
component being serviced.
QUICK-CONNECT
FITTING J9414-25
Fig. 14 Disconnecting Single-Tab Type Fitting

(6) Raise the pull tab until it separates from the
quick-connect fitting (Fig. 15). Discard the old pull
tab. RAIL ( J9414-30
(7) Disconnect the quick-connect fitting from the
Fig. 16 Typical Two-Tab Type Quick-Connect Fitting
fuel system component being serviced.
(8) Inspect the quick-connect fitting body and fuel
system component for damage. Replace as necessary.
CAUTION: The interior components (o-rings, spac PLASTIC RETAINER RING TYPE PITTING
ers) of this type of quick-connect fitting are not ser This type of fitting can be identified by the use of a
viced separately, but new plastic retainers are full-round plastic retainer ring (Fig. 17) usually black
available. Do not attempt to repair damaged fittings in color.
or fuel lines/tubes. If repair is necessary, replace
FUEL TUBE REMOVAL QUICK CONNECT
the complete fuel tube assembly.
FITTING

STANT P R E S S U R E ( E V E N WITH THE ENGINE OFF).
PUSH
FITTINGS OR LINES, THE F U E L S Y S T E M P R E S
S U R E MUST B E R E L E A S E D . R E F E R TO THE F U E L
PRESSURE RELEASE PROCEDURE IN THIS
GROUP.
INSTALLATION
DISCONNECTION/CONNECTION
(1) Disconnect negative battery cable from the bat
tery.
PUSH- •PUSH
(2) Perform the fuel pressure release procedure.
Refer to the Fuel Pressure Release Procedure in this
section.
(3) Clean the fitting of any foreign material before /
PLASTIC
disassembly. RETAINER J9314-100
(4) To disconnect the quick-connect fitting, squeeze
the plastic retainer tabs against the sides of the Fig. 17 Plastic Retainer Ring Type Fitting
quick-connect fitting with your fingers. Tool use is CAUTION: The interior components (o-rings, spac
not required for removal and may damage plastic re ers, retainers) of this type of quick-connect fitting
tainer. Pull the fitting from the fuel system compo are not serviced separately. Do not attempt to repair
nent being serviced. The plastic retainer will remain damaged fittings or fuel lines/tubes. If repair is nec
on the component being serviced after fitting is dis essary, replace the complete fuel tube assembly.
connected. The o-rings and spacer will remain in the
quick-connect fitting connector body.
(5) Inspect the quick-connect fitting body and com WARNING: THE FUEL S Y S T E M IS UNDER A CON
ponent for damage. Replace as necessary. STANT P R E S S U R E (EVEN WITH THE ENGINE OFF).
CAUTION: When the quick-connect fitting was dis FITTINGS OR LINES, THE F U E L SYSTEM P R E S
connected, the plastic retainer will remain on the S U R E MUST BE R E L E A S E D . R E F E R TO THE F U E L
component being serviced. If this retainer must be PRESSURE RELEASE PROCEDURE IN THIS
removed, very carefully release the retainer from GROUP.
the component with two small screwdrivers. After
removal, inspect the retainer for cracks or any dam
age. DISCONNECTION/CONNECTION
(1) Disconnect negative battery cable from the bat
(6) Prior to connecting the quick-connect fitting to tery.
component being serviced, check condition of fitting (2) Perform the fuel pressure release procedure.
and component. Clean the parts with a lint-free Refer to the Fuel Pressure Release Procedure in this
cloth. Lubricate them with clean engine oil. section.
(7) Insert the quick-connect fitting to the compo (3) Clean the fitting of any foreign material before
nent being serviced and into the plastic retainer. disassembly.
When a connection is made, a click will be heard. (4) To release the fuel system component from the
(8) Verify a locked condition by firmly pulling on quick-connect fitting, firmly push the fitting towards
fuel tube and fitting (15-30 lbs.). the component being serviced while firmly pushing
(9) Connect negative cable to battery. the plastic retainer ring into the fitting (Fig. 17).
(10) Start engine and check for leaks. With the plastic ring depressed, pull the fitting from
the component. The plastic retainer ring must be
14 - 1 0 FUEL DELIVERY SYSTEM—EXCEPT DIESEL BR
pressed squarely into the fitting body, if this re

tainer is cocked during removal, it may be dif
ficult to disconnect fitting/ Use an open-end
wrench on the shoulder of the plastic retainer
ring to aid in disconnection.
After disconnection, the plastic retainer ring will
remain with the quick-connect fitting connector body.
(5) Inspect fitting connector body, plastic retainer
ring and fuel system component for damage. Replace
as necessary.
(6) Prior to connecting the quick-connect fitting to
component being serviced, check condition of fitting
and component. Clean the parts with a lint-free
cloth. Lubricate them with clean engine oil.
(7) Insert the quick-connect fitting into the compo mu-s
nent being serviced until a click is felt. Fig. 19 Latch Clip Removal—Typical
(8) Verify a locked condition by firmly pulling on
fuel tube and fitting (15-30 lbs.).
(10) Start engine and check for leaks.
FUEL LINE WITH LATCH CLIP

iiSCillECTiil/CONlECTiOl IT FUEL RAIL
A latch clip is used to secure the fuel line to the
fuel rail on the 3.9L/5.2L and 5.9L engines (Fig. 18).
A special tool will be necessary to separate the fuel
line from the fuel rail after the latch clip is removed.
(1) Disconnect the negative battery cable from bat
tery.
(2) Perform the fuel pressure release procedure. j< FUEL RAIL J9514-6
Refer to the Fuel Pressure Release Procedure in this
section. Fig. 20 Fuel Line Disconnection—Typical
(3) Clean the fitting of any foreign material before
disassembly. (7) Insert special fuel line removal tool (Snap-On
(4) Pry up on the latch clip with a screwdriver number FIH 9055-1 or equivalent) into the fuel line
(Fig. 19). (Fig. 20). Use this tool to release the locking fingers
in the end of the line.
(8) With the special tool still inserted, pull the fuel
line from the fuel rail.
After disconnection, the locking fingers will remain
within the quick-connect fitting at the end of the fuel
line.-
(9) Inspect fuel line fitting, locking fingers and fuel
rail fitting for damage. Replace as necessary.
(10) Prior to connecting the fuel line to the fuel rail,
check condition of both fittings. Clean the parts with a
lint-free cloth. Lubricate them with clean engine oil.
(11) Insert the fuel line onto the fuel rail until a
click is felt.
(12) Verify a locked condition by firmly pulling on
fuel line and fitting (15-30 lbs.).
(13) Install latch clip (snaps into position). If the
latch clip will not fit, this indicates the fuel line
Fig. 18 Latch Clip Location—Typical is not properly installed to the fuel rail. Re
(5) Slide the latch clip toward the fuel rail while check the fuel line connection.
lifting with the screwdriver. (14) Connect negative battery cable to battery.
(6) Remove the latch clip from fuel rail. (15) Start engine and check for leaks.
BR FUEL DELIVERY SYSTEM—DIESEL ENGINE 14-11
FUEL DELiWERY SYSTEM—DIESEL ENGINE
NDEX
page page
Diesel Fuel System Operation 19 Fuel Tank 14

Fuel Drain Manifold 19 Fuel Tank Module—Diesel Engine 13
Fuel Filter 16 Fuel Transfer Pump 14
Fuel Filter—In Tank . . . . . . . . . . . . . . . . . . . . 16 Fuel Transfer Pump Capacity Test—Diesel Engine . 16
Fuel Filter/Water Separator . 15 Fuel Tubes/Lines/Hoses and Clamps—Low-
Fuel Heater 14 Pressure Type 16
Fuel Heater Relay 14 General Information 11
Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . 16 High-Pressure Fuel Lines . . . . . . . . . . . . . . . . . . . 16
Fuel Injectors 17 Intake Manifold Air Heater 16
Fuel Shutdown Solenoid 18 Intake Manifold Air Heater Relays 16
Fuel Shutdown Solenoid Relay 19 Intake Manifold Air Temperature Sensor . 16
Fuel System Pressure Test—Diesel Engine 16 Powertrain Control Module 19
Fuel System Pressure Warning . . . . . . . . . . . . . . . 16 Quick-Connect Fittings 16
GENERAL INFORMATION • Low-pressure, mechanical, fuel transfer pump (fuel

lift pump)
This section of the group will cover diesel fuel de
livery components not controlled by the powertrain • High-pressure fuel injection pump
control module (PCM). Various components, relays • Fuel heater
and switches are operated by the PCM. Refer to the • Fuel heater relay
Diesel Engine sections of this group for components • Fuel shutdown solenoid
that are operated by the PCM. • Fuel shutdown solenoid relay
Diesel fuel delivery (except for operation of • High-pressure fuel injectors
the intake manifold air heater and manifold air • Fuel return line
heater relays) is not directly regulated by the • Fuel filter/water separator
PCM. • In-tank fuel filter
The fuel delivery system of the 5.9L turbo-diesel • Pre-filter (in fuel heater)
engine consists of the: • Fuel drain manifold
• Fuel tank For information regarding fuel requirements of the
• Fuel tank module 5.9L turbo diesel engine, refer to Group 0, Lubrica
• Low and high-pressure fuel supply lines tion and Maintenance.
12 FUEL DELIVERY SYSTEM—DIESEL ENGINE mm
WASTEGATED TURBOCHARGER
TURBOCHARGER OIL SUPPLY
HIGH PRESSURE
FUEL TUBES
FUEL DRAIN
LINE (MANIFOLD)
FUEL INJECTORS (6)
TURBOCHARGER
WASTEGATE
RIGHT SIDE
OF ENGINE
FUEL SUPPLY NTAKE MANIFOLD

LINE (TO
INJECTION PUMP)
WATER TEMPERATURE
SENSOR (FOR I.P. GAUGE)
HIGH PRESSURE FUEL FILTER/

FUEL LINES WATER SEPARATOR
FUEL/WATER
SEPARATOR AND
HIGH PRESSURE DRAIN VALVE
FUEL INJECTION
PUMP
RUBBER PRIMER
BUTTON
THROTTLE POSITION
SENSOR (AUTO. FUEL TRANSFER
TRANS. ONLY) PUMP (FUEL
LIFT PUMP)
* STARTER
FUEL MOTOR
SHUTDOWN
SOLENOID
OIL PRESSURE LEFT SIDE DRAIN

SENSOR OF ENGINE TUBE J9414-69
Fig. 1 Fuel System Components—Diesel Engine

BR FUEL DELIVERY SYSTEM—DIESEL ENGINE 14 -13
FUEL TANK MODULE—DIESEL ENGINE mechanically operated. Refer to either: Fuel Transfer
Pump or Fuel Injection Pump for information.
An electric fuel pump is not used in the fuel tank
module for diesel powered engines. Fuel is supplied FUEL TANK MODULE REMOVAL
by the fuel transfer pump and the fuel injection
pump. CAUTION: Whenever the fuel tank module is ser
The fuel tank module is installed in the top of the viced, the plastic locknut and rubber gasket must
fuel tank (Fig. 2). The fuel tank module (Figs. 2 or 3) be replaced.
contains the following components:
• Fuel reservoir (1) Drain the fuel tank. Refer to Draining Fuel
• A separate in-tank fuel filter Tank in the Fuel Tank section of this group.
• Pressure relief/rollover valve (2) Remove fuel tank. Refer to the Fuel Tank sec
• Fuel gauge sending unit tion of this group.
• Fuel supply line connection (3) Note the direction of the: fuel line connectors,
• Fuel return line connection the pressure relief/rollover valve and the fuel gauge
• Auxiliary fuel supply fitting electrical connector. These should all be pointed to
the drivers side of the vehicle.
PRESSURE RELIEF/ AUX. FUEL (4) The plastic locknut on the fuel tank module is
ROLLOVER VALVE threaded onto the fuel tank. Remove the locknut
SUPPLY FITTING
(Fig. 2). The tank module will spring up when the
PLASTIC locknut is removed.
LOCKNUT (5) Remove module from fuel tank.
FUEL
SUPPLY DISASSEMBLY—FUEL GAUGE SEIDING UNIT
LINE
FUEL (1) Remove sending unit mounting screws (Fig. 3).
RETURN (2) Mark the sending unit electrical wires before
LINE removal for correct installation. Carefully disconnect
FRONT FUEL GAUGE
OF TANK SENDING electrical wires from sending unit. Remove sending
UNIT unit.
ELECTRICAL
CONNECTOR
(3) Reverse order of removal for fuel gauge unit in
stallation.
J9414-70
IN-TANK FUEL FILTER
Fig. 2 Top View of Fuel Tank Module—Diesel The in-tank filter is attached to the bottom of the
FUEL GAUGE LOCKING fuel tank module (Fig. 3).
FLOAT SENDING UNIT TABS (1) Pry the mounting tabs back and remove the in-
ELECTRIC tank fuel filter.
FUEL PUMP (2) Install new fuel filter into retaining tabs.
FUEL TANK MODULE INSTALLATION
CAUTION: Whenever the fuel tank module is ser

viced, the locknut and rubber gasket must be re
placed.
(1) Using a new gasket, position the fuel tank

module into the opening in fuel tank. The fuel line
connectors, the pressure relief/rollover valve and the
MOUNTING IN-TANK fuel gauge electrical connector should all be pointed
SCREWS FUEL FILTER J9414-33
to the drivers side of the vehicle before tightening
locknut.
Fig. 3 Fuel Gauge Sending Unit—Typical
(2) Position new locknut over top of fuel tank mod
ILECTmC FUEL PUMP ule.
The electric fuel pump, normally mounted in the (3) Tighten locknut.
fuel pump module on gas powered engines, is not (4) Install fuel tank. Refer to Fuel Tank Installa
used with diesel powered engines. tion in this section.
The low-pressure, fuel transfer pump (fuel lift
AUXILIARY FUEL SUPPLY FITTING
pump) and high- pressure fuel injection pump are
An auxiliary (capped) fuel supply fitting is located
14 -14 FUEL DELIVERY SYSTEM—DIESEL ENGINE — — - B R
on the top of the fuel tank module (Fig. 2). This fit FUEL HE1TER RELAY •• . ,
ting will be available only on: diesel powered models,
Voltage to operate the fuel heater is supplied from
and models with either a 5.9L V-8 heavy duty or 8.0L
the ignition switch through the fuel heater relay. The
V-10 engine, and all cab-chassis models. This fitting
powertrain control module (PCM) is not used to con
supplies a non-pressurized auxiliary fuel source.
trol this relay.
FUEL HEATER The fuel heater relay is located in the engine com
partment near the brake master cylinder (Fig. 5).
The fuel heater is used to prevent diesel fuel from FUEL SHUT-OFF
waxing during cold weather operation. The fuel FUEL HEATER SOLENOID RELAY
heater is located on the left side of the engine above
the starter motor (Fig. 4).
The heater assembly is equipped with a built-in
sensor (thermostat) (Fig. 4) that senses fuel temper
ature. When the temperature is below 40 degrees F,
the built-in sensor allows current to flow to the
built-in heater element warming the fuel. When the
temperature is above 80 degrees F, the sensor stops
current flow to the heater element.
Fig. 5 Fuel Heater Relay—Diesel

For diagnosis, refer to the Diesel Engine—General
Diagnosis section of this group.
For removal and installation procedures, refer to
the Diesel Engine—Component Removal/Installation
FUEL TANK
Refer to the Fuel Tank section of this group for in
formation.
Fig. 4 Fuel Heater and Temperature Sensor Location
FUEL TRANSFER PUMP
Voltage to operate the fuel heater is supplied from The fuel transfer pump (fuel lift pump) is located
the ignition switch and through the fuel heater relay on the left-rear side of the engine cylinder block
(Fig. 5) (also refer to Fuel Heater Relay). above the starter motor (Fig. 1). This mechanically
The fuel heater and fuel heater relay are not con operated pump is not controlled by the powertrain
trolled by the powertrain control module (PCM). control module (PCM).
The built-in heater element operates on 12 volts, The purpose of the fuel transfer pump is to supply
300 watts at 0 degrees F. (transfer) a low-pressure fuel source of approximately
The fuel heater assembly contains a pre-filter to 172 Kpa (25 psi) to the injection pump and fuel filter/
prevent contaminants from entering the fuel transfer water separator from the fuel tank. Here, the low-
pump. pressure is raised by the fuel injection pump for
For diagnosis, refer to the Diesel Engine—General operation of the high-pressure fuel injectors. The
Diagnosis section of this group. transfer pump is driven by an eccentric on the engine
For removal and installation procedures, refer to camshaft that actuates a spring loaded piston within
the Diesel Engine—Component Removal/Installation the pump (Fig. 6). Check valves within the pump,
BR FUEL DELIVERY SYSTEM—DIESEL ENGINE 14 - 15
control direction of fuel flow and prevent fuel Meed- housing. The purpose of the button is to prime and
back during engine shut down. bleed air from the fuel system if the vehicle has run
The fuel transfer pump should never be operated out of fuel. To prime the system up to the fuel injec
without the pre-filter installed. tor pump, continually press on the button (Fig. 8) un
The fuel volume of the transfer pump will vary til resistance is felt. This resistance will indicate that
with engine rpm, but will always provide more fuel priming is completed and air has been removed.
than the fuel injection pump requires. Excess fuel is If the primer button feels as if it is not pumping,
returned to the fuel tank through an overflow valve. rotate (crank) the engine approximately 90 degrees.
The valve is located on the side of the injection pump This will position the engine camshaft lobe away
(Fig. 7) and is used to connect the fuel return line to from the pump piston (Fig. 6). Continue pumping un
the side of the injection pump. This valve opens at til air is removed.
approximately 152 kPa (22 psi) and returns fuel to
the fuel tank through the fuel return line.
FUEL
CHECK TRANSFER
LOW PRESSURE PUMP
VALVES
/
/ SUPPLY UNE RUBBER
A B C PRIMER PUMP
BUTTON
FUEL LINE
ENGINE
CAMSHAFT INLET J9414-71
RUBBER
Fig. 6 Transfer Pump Operation PRIMER
BUTTON
FUEL RETURN LINE
J9414-72
Fig. 8 Fuel Transfer Pump—Manual Operation

OVERFLOW For removal and installation procedures of the
VALVE
transfer pump, refer to Fuel Transfer Pump in the
Diesel Engine—Component Removal/Installation sec
tion of this group.
FUEL FILTER/WATER SEPARATOR

The fuel filter/water separator protects the fuel in
jection pump by removing water and contaminants
from the fuel. The separator filter construction allows
fuel to pass through it, but prevents moisture (water)
from doing so. Moisture collects at the bottom of the
separator filter.
The fuel filter/water separator is located on the left
FUEL INJECTION side of the engine above the starter motor (Fig. 1).
PUMP J9414-102
Refer to the maintenance schedules in Group 0 in
Fig. 7 Injection Pump Overflow Valve
this manual for the recommended fuel filter/water
separator replacement intervals.
MANUAL OPERATION OF TRANSFER PUMP For diagnosis, refer to the Diesel Engine—General
The transfer pump has a primer button (Fig. 8). Diagnosis section of this group. -
This rubber primer button is located on the pump
14 •• 16 FUEL DELIVERY SYSTEM—DIESEL ENGINE
For removal and installation procedures, refer to repair lines that are damaged. Only use the recom
the Diesel Engine —Component Removal/Installation mended lines when replacement of high-pressure
section of this group. fuel line is necessary.
For draining of water, refer to the Diesel Engine—
Component Removal/Installation section of this High-pressure fuel lines deliver fuel under pressure
group. See Fuel Filter/Water Separator. of up to approximately 120,000 kPa (17,405 PSI)
from the injection pump to the fuel injectors. The
FUEL FILTER lines expand and contract from the high-pressure
Refer to Fuel Filter/Water Separator for informa- :
fuel pulses generated during the injection process. All
tion. high-pressure fuel lines are of the same length and
inside diameter. Correct high-pressure fuel line usage
FUEL FILTER—IN TANK and installation is critical to smooth engine opera
Refer to Fuel Tank Module—Diesel Engine for re tion.
moval and installation. This can be found in the Fuel
WARNING: U S E E X T R E M E CAUTION W H E N IN
Delivery—Diesel Engine section of this group.
SPECTING FOR H I G H - P R E S S U R E F U E L L E A K S . IN
FUEL SYSTEM PRESSURE WARNING S P E C T FOR H I G H - P R E S S U R E F U E L L E A K S WITH A
S H E E T OF CARDBOARD. HIGH F U E L INJECTION
WARNING: H I G H - P R E S S U R E F U E L LINES DELIVER P R E S S U R E CAN C A U S E P E R S O N A L INJURY IF
D I E S E L F U E L UNDER E X T R E M E P R E S S U R E FROM CONTACT IS MADE WITH THE SKIN.
THE INJECTION PUMP TO THE F U E L I N J E C T O R S .
THIS MAY B E A S HIGH A S 120,000 KPA (17,405 PSI). For removal and installation procedures, refer to
U S E E X T R E M E CAUTION W H E N INSPECTING FOR the Diesel Engine—Component Removal/Installation
H I G H - P R E S S U R E F U E L L E A K S . INSPECT FOR section of this group.
H I G H - P R E S S U R E F U E L L E A K S WITH A S H E E T OF
CARDBOARD. HIGH F U E L INJECTION P R E S S U R E INTAKE MANIFOLD AIR HEATER
CAN C A U S E P E R S O N A L INJURY IF CONTACT IS The intake manifold air heater is controlled by the
MADE WITH THE SKIN. powertrain control module (PCM). Refer to the Diesel
Engine—Component Description/System Operation
section of this group for an operational description.
FUEL SYSTEM PRESSURE TEST—DIESEL ENGINE Refer to the Diesel Engine—General Diagnosis sec
For fuel pressure tests, refer to the Diesel Engine— tion for diagnosis. Refer to the Diesel Engine—Com
General Diagnosis section of this group. ponent Removal/Installation section for removal/
installation procedures.
FUEL TRANSFER PUMP CAPACITY TEST—DIESEL
ENGINE INTAKE MANIFOLD AIR HEATER RELAYS
For fuel pump capacity tests, refer to the Diesel The relays for the intake manifold air heater are
Engine—General Diagnosis section of this group. controlled by the powertrain control module (PCM).
Refer to the Diesel Engine—Component Description/
FUEL TUBES/LINES/HOSES AND CLAMPS—LOW- System Operation section of this group for an opera
PRESSURE TYPE tional description. Refer to the Diesel Engine—
Refer to Fuel Tubes/Lines/Hoses and Clamps. Also General Diagnosis section for diagnosis. Refer to the
refer to the section on Quick-Connect Fittings. These Diesel Engine—Component Removal/Installation sec
can be found in the Fuel Delivery—Except Diesel sec tion for removal/installation procedures.
tion of this group.
QUICK-CONNECT FITTINGS The intake manifold air temperature sensor is con
Refer to Quick-Connect Fittings. These can be trolled by the powertrain control module (PCM). Re
found in the Fuel Delivery—Except Diesel section of fer to the Diesel Engine sections of this group for an
this group. operational description, diagnosis and removal/instal
lation procedures.
HIGH-PRESSURE FUEL LINES
FUEL INJECTION PUMP
CAUTION: The high-pressure fuel lines must be The fuel injection pump is a Bosch P7100 series in
held securely in place in their holders. The lines line type (Fig. 9). The injection pump is driven by the
cannot contact each other or other components. Do engine camshaft. A gear on the end of the pump shaft
not attempt to weld high-pressure fuel lines or to meshes with the camshaft gear. The pump is timed
BR FUEL DELIVERY SYSTEM—DIESEL ENGINE 14 - 17
to the engine. Fuel injection occurs near the end of AIR FLOW
the compression stroke for each cylinder. CONTROL (AFC)
DELIVERY OIL FILL PLUG

VALVES
AFC
RQV-K
GOVERNOR
P7100 INLINE
FUEL INJECTION
PUMP J9414-104
P7100 INLINE
FUEL INJECTION
PUMP ACCESS Fig. 10 Injection Pump Governor and AFC
PLUG J9414-75
adjustable. Refer to Idle Speed Adjustment in the
Fig. 9 Fuel Injection Pump Diesel Engine—General Diagnosis section of this
group for procedures.
The RQV-K governor (Fig. 10) has a pump timing
feature. This will allow the pump shaft to be oriented
in a position corresponding to top dead center (TDC)
for the compression stroke of cylinder number one. For removal and installation procedures, refer to
Indexing the governor flyweight assembly to the the Diesel Engine—Component Removal/Installation
shaft during assembly establishes pump timing. section of this group.
For injection pump timing, refer to Fuel Injection
As engine speed increases, the internal pump pres
Pump Timing in the Diesel Engine — General Diagno
sure increases. An air-flow control (AFC) (Fig. 10) on
sis section of this group.
the governor ensures that regulated fuel delivery is
matched to intake manifold pressure (turbocharger
FUEL INJECTORS
boost) for emission control.
The mechanical fuel transfer pump delivers fuel The fuel injectors are mounted on the left side of
under a low-pressure of approximately 172 Kpa (25 the cylinder head (Fig. 11). The injectors are con
psi) to the injection pump through the fuel filter/wa nected to the fuel injection pump by the high-pres
ter separator. The injection pump then supplies high- sure fuel lines. A separate injector is used for each
pressure fuel of approximately 120,000 kPa (17,400 cylinder.
psi) to each injector in precise metered amounts at The injectors consist of the nozzle holder, o-ring
the correct time. water seal, shims, spring, needle valve and nozzle.
Excess fuel is returned to the fuel tank by an over Fuel enters the injector at the fuel inlet (top of injec
flow valve (Fig. 7) on the injection pump. This vent tor) and is routed to the needle valve bore. When fuel
opens at approximately 152 kPa (22 psi) and returns pressure rises to approximately 26,252 kPa (3,822
fuel to the fuel tank through the fuel return line. psi), the needle valve spring tension is overcome. The
Diesel fuel and engine oil are used to cool the fuel needle valve rises and fuel flows through the spray
injection pump. A separate oil feed line from the en holes in the nozzle tip into the combustion chamber.
gine supplies engine oil to the pump. The oil returns The pressure required to lift the needle valve is the
to the engine through an opening at the front of operating pressure setting. This is sometimes re
pump. ferred to as the "pop" pressure setting.
Fuel pressure in the injector circuit decreases after
A KSB (cold start) solenoid is not used.
injection. The injector needle valve is immediately
The injection pump high idle speed is factory-
closed by the needle valve spring and fuel flow into
sealed and is not adjustable. The low idle speed is
14 -18 FUEL DELIVERY SYSTEM—DIESEL ENGINE BR
HIGH FRONT OF ENGINE AIR TEMPERATURE SENSOR

PRESSURE SENSOR ELECTRICAL
FUEL LINE CONNECTOR
(6)
J9114-74^
Fig. 11 Fuel Injectors—Typical

INTAKE
the combustion chamber is stopped. Exhaust gases MANIFOLD
FUEL
(UPPER HALF) SOLENOID
are prevented from entering the injector nozzle by SHUTDOWN
SOLENOID ELECTRICAL
the needle valve. CONNECTOR J9414-93
Diagnosis section of this group. Fig. 12 Fuel Shutdown Solenoid Location
For removal and installation procedures, refer to shaft in the up position. Accelerator pedal position
the Diesel Engine—Component Removal/Installation then controls fuel lever position for fuel control at the
section of this group. injection pump.
FUEL SHUTDOWN SOLENOID
SHUTDOWN
The fuel shutdown solenoid and fuel shut POSITION RUN POSITION
down solenoid relay are not controlled by the
powertrain control module (PCM).
The fuel shutdown (shut-off) solenoid is used to
electrically shut off the diesel fuel supply to the high-
pressure fuel injection pump. The solenoid is
mounted to the side of the pump and is connected to
the pump with a lever (Figs. 1 or 12).
The solenoid controls starting and stopping of the
engine regardless of the position of the accelerator
pedal. When the ignition switch is off, the solenoid
plunger is spring loaded (down) in the shutdown po
sition (Fig. 13) and fuel is shut off to the injection
pump.
Two different coils are located within the solenoid
and a three-wire pigtail wire harness is attached to FUEL
the solenoid. SHUTDOWN
SOLENOID
When the ignition switch is turned to the CRANK J9414-80
(starter engaged) position, high-amperage current
(approximately 40 amps at 12 volts) is supplied to
Fig. 13 Fuel Shutdown Solenoid Positions
one of the coils in the shutdown solenoid from the
fuel shutdown solenoid relay. This high-amperage Voltage to operate the solenoid is supplied from the
current allows the solenoid shaft to pull up on the in ignition switch and through the fuel shutdown sole
jection pump lever. The injection pump shutdown le noid relay (Fig. 14) (also refer to Fuel Shutdown So
ver is then positioned to the run position (Fig. 13). lenoid Relay).
When the ignition key is released to the ON posi For solenoid diagnosis, refer to Fuel Shutdown So
tion, a low-amperage current is supplied to the other lenoid in the Diesel Engine—General Diagnosis sec
coil in the solenoid. This is used to hold the solenoid tion of this group.
If the shutdown solenoid is being replaced, its shaft
BR FUEL DELIVERY SYSTEM—DIESEL ENGINE 14 -19
length must be adjusted. For fuel shutdown solenoid FUEL SHUT-OFF

removal, installation and solenoid shaft adjustment FUEL HEATER SOLENOID RELAY
procedures, refer to the Diesel Engine—Component
Removal/Installation section of this group.
FUEL SHUTDOWN SOLENOID RELAY

Voltage to operate the fuel shutdown (shut-off) so
lenoid is supplied from the ignition switch and
through the fuel shutdown solenoid relay. The fuel
shutdown solenoid relay is located in the engine com
FUEL DRAIN MANIFOLD
Some fuel is continually vented from the fuel injec
tion pump to cool the pump and the fuel injectors.
During injection, a small amount of fuel flows past
the injector nozzle and is not injected into the com
bustion chamber. This fuel drains into the fuel drain Fig. 14 Fuel Shutdown Solenoid Relay—Diesel
manifold (Fig. 15). Fuel in the drain manifold is then
routed back to the fuel filter/water separator.
Refer to the Diesel Engine sections of this group for
information.
DIESEL FUEL SYSTEM OPERATION
Refer to this section (Fuel Delivery—Diesel Engine)
for components not operated by the powertrain con
trol module (PCM). Refer to the Diesel Engine—Com
ponent Description/System Operation section for
components operated by the PCM.
Fig. 15 Fuel Drain Manifold—Typical
14 - 20 F U E L TANKS — — — — — — — — — — — — — - BR
FUEL T I N I S
1NDE1
page page
Fuel Gauge Sending Unit . . . . . . . . . . . . . . . . . . . 22 Fuel Tanks 20
Fuel Pump 22 General Information 20
Fuel Tank Capacities 22 Heat Shields 22
Fuel Tank Filler Tube Cap 22 No-Lead Fuel Tank Filler Tube 22
Fuel Tank Pressure Relief/Rollover Valve . . . . . . . . 22
GENERAL INFORMATION FUEL TAN I S

All Dodge trucks pass a full 360 degree rollover
without fuel leakage. To accomplish this, fuel and va D R A I N I N G FUEL TANK
por flow controls are required for all fuel tank con (1) Remove fuel tank filler tube cap to release fuel
nections. tank pressure.
All models have a pressure relief/rollover valve (2) Perform Fuel System Pressure Release proce
mounted in the top of the fuel tank. In addition to dure as described in this group.
the valve, improved flow control is used in the fuel (3) Raise vehicle on hoist.
pump. Fuel flow is controlled if pump is subjected to (4) While working over the left rear tire/wheel, dis
higher than normal pressure during rollover. For the connect the rubber fuel fill hose and clamp at fuel
same reason, a fuel tank filler tube cap (gas cap) tank (Fig. 1). Position fuel siphoning/drain hose into
with higher pressure setting is used to control fuel this opening at tank.
flow on vehicles with side fill.
An evaporation control system is used to reduce FUEL FUEL
emissions of fuel vapors into atmosphere by evapora PUMP VENT TUBE
MODULE, TANK
tion and to reduce unburned hydrocarbons emitted AND HOSE
by vehicle engine. When the fuel evaporates from
fuel tank, vapors pass through vent hoses or tubes to
a charcoal canister. The are temporarily held in the
canister. When the engine is running, the vapors are
drawn into intake manifold. Eefer to Group 25, Emis
sion Control System for additional information.
Inspect all hose connections to make sure they are
secure and not leaking. Fuel tank hoses, tubes and
lines should be replaced immediately if there is any
evidence of degradation that could result in .failure.
Avoid contact with clamps or other components
that cause abrasions or scuffing. Be sure that the
rubber hoses are properly routed to prevent pinching CLAMPS (4)
FUEL TANK
and to avoid heat sources. FILLER TUBE
The hoses used on fuel injected vehicles are of a CAP FUEL FILL
special construction due to higher fuel pressures in TUBE AND HOSE
volved in system. If hoses need replacement, only use DRIVER'S mm
hoses marked EFM/EFI. OF VEHICLE J9414-36
The hose clamps used on fuel injected vehicles have
a special rolled edge construction. This prevents the Fig. 1 Fuel Tank Fill and Vent Hoses
edge of the clamp from cutting into the hose. Only (5) Drain fuel into an approved portable holding
these rolled edge type clamps may be used on this tank or a properly labeled gasoline safety container.
system. Other clamps may cut into the hoses. This
could cause high- pressure fuel leaks. Refer to Fuel TANK REMOVAL
Tubes/Lines/Hoses and Clamps in this group for ad (1) Disconnect negative battery cable at battery.
ditional information. Also refer to Quick-Connect Fit (2) Remove fuel tank filler tube cap.
tings in this group.
mm FUEL TANKS 14 - 21
FUEL UNE ELECTRICAL

(3) Drain fuel tank. Refer to the previous Draining
( T O FUEL RAIL)
DRIVER'S SIDE CONNECTOR Fuel Tank section.
(4) Disconnect both the fuel fill and fuel vent rub
ber hoses at the fuel tank (Fig. 1).
EVAP (5) Gas Powered Engines: While working over
HOSE the left rear tire/wheel:
(a) Disconnect the electrical connector from the
fuel pump module (Fig. 2).
(b) Disconnect the EVAP hose at the pressure re
lief/rollover valve (Fig. 2).
(c) Disconnect the fuel supply line at the fuel fil
ter/fuel pressure regulator (Fig. 2). Refer to Fuel
Tubes/Lines/Hoses and Clamps in this group for ad
ditional information about fuel line removal and in
stallation. Also refer to Quick-Connect Fittings in
this group.
FUEL FILTER/ Diesel Powered Engines: While working over the
FUEL PRESSURE
REGULATOR
left rear tire/wheel:
* (a) Disconnect the electrical connector from the
FUEL TANK fuel tank module (Fig. 3).
(GAS P O W E R E D ) J9414-37 (b) Disconnect the fuel supply and fuel return
lines at the fuel tank module (Fig. 3). Refer to Fuel
Fig. 2 Fuel Tank Connections—Gas Powered
Engines
FUEL RETURN stallation. Also refer to Quick-Connect Fittings in
A N D SUPPLY LINES DRIVER'S mm this group.
OF VEHICLE ELECTRICAL (6) Place a transmission jack under the center of
, CONNECTOR the fuel tank. Apply a slight amount of pressure to
77\ fuel tank with transmission jack.
WARNING: W R A P SHOP TOWELS AROUND HOSES
TO CATCH ANY GASOLINE SPILLAGE.
(7) Remove the fuel tank mounting strap nuts at
the mounting straps (Fig. 4). If equipped, remove the
fuel tank heat shield bolts (Fig. 4).
(8) Lower fuel tank for removal.
TANK INSTALLATION
(1) Place fuel tank on top of transmission jack.
(2) Raise tank into position in the frame cross-
members.
(3) Connect the two mounting straps and mounting
strap nuts.
FUEL
TANK (4) Remove transmission jack. Tighten strap nuts
(DIESEL)
J9414-38 to 41 N-m (30 ft. lbs.) torque. Do not over tighten re
taining strap nuts.
Fig. 3 Fuel Tank Connections—Diesel Powered (5) Gas Powered Engines:
Engines (a) Connect the electrical connector to the fuel
pump module (Fig. 2).
WARNING: THE F U E L S Y S T E M I S UNDER A CON
(b) Connect the EVAP hose at the pressure relief/
STANT P R E S S U R E (EVEN WITH THE ENGINE OFF).
rollover valve (Fig. 2).
B E F O R E SERVICING THE F U E L TANK, FUEL S Y S (c) Connect the fuel supply line at the fuel filter/
TEM P R E S S U R E MUST B E R E L E A S E D . R E F E R TO fuel . pressure regulator (Fig. 2). Refer to Fuel
THE F U E L S Y S T E M P R E S S U R E R E L E A S E P R O C E Tubes/Lines/Hoses and Clamps in this group for ad
DURE B E F O R E SERVICING THE F U E L TANK. ditional information about fuel line removal and in
stallation. Also refer to Quick-Connect Fittings in
this group.
HEAT
sel powered engines. Refer to either of the Fuel De
SHIELD livery System sections of this group for fuel gauge
sending unit service.
FUEL TANK CAPACITIES

Refer to the Specifications section at the end of this
group.
HEAT SHIELDS
Some fuel line components are covered by sheet
metal heat shields. They may have to be removed
when servicing the fuel tank, fuel tubes/lines or va
por vent line, it is very important that these heat
shields be reinstalled after service. They are
used to protect lines and tank from heat of exhaust
system. See Group 11 in this manual for proper in
stallation.
FUEL TANK FILLER TUBE CUP
STRAP MOUNTING The loss of any fuel or vapor out of filler neck is
NUTS J9414-39 prevented by the use of a pressure-vacuum fuel tank
filler tube cap. Relief valves inside cap will release
Fig, 4 Fuel Tank Mounting—Typical
only under significant pressure of 6.58 to 8.44 kPa
Diesel Powered Engines: (1.95 to 2.5 psi). The vacuum release for all gas caps
(a) Connect the electrical connector to the fuel is between .97 and 2.0 kPa (.14 and .29 psi). This cap
tank module (Fig. 8). must be replaced by a similar unit if replacement is
(b) Connect the fuel supply and fuel return lines necessary. This is in order for the system to remain
at the fuel tank module (Fig. 8). Refer to Fuel effective.
CAUTION: Remo e f"f~; ^.nk ftibw ^.ibe osp bmom
servicing any fuel system mmponrnt " H T I S is clone
stallation. Also refer to Quick-Connect Fittings in to help relieve tank pressure.
this group.
(6) Install the rubber fill and vent lines to tank.
Tighten hose clamps to 2.3 N-m (20 in. lbs.) torque. NO-LEAD FUEL T i l l FILLER TUBE
(7) Refill fuel tank and inspect all hoses and lines
for leaks. GAS POWERED ENGINES
(8) Connect negative battery cable to battery. All catalyst equipped vehicles have a special fuel
tank filler tube. The fuel filler opening is smaller in
FUEL PUMP ' diameter than those used for non-catalyst vehicles to
Gas Powered Engines; An electric in-tank permit entry of only the smaller no-lead fuel nozzles.
mounted fuel pump is used with gas powered en A deflector is installed in the fuel filler opening. The
gines. Refer to' Fuel Pump Module in the Fuel Deliv deflector is opened by the no-lead fuel nozzle.
ery System—Except Diesel section of this group. The fuel filler tube on these models has a one-way
Diesel Powered Engines: A mechanically oper ball check valve. The valve is designed to prevent
ated low-pressure fuel transfer pump and a mechan fuel back splash which may occur while filling the
ically operated high-pressure fuel injection pump are tank.
used to supply fuel for the diesel engine. Refer to the A label is attached to instrument panel under fuel
Fuel Delivery—Diesel Engine section of this group gauge that reads UNLEADED FUEL ONLY as a re
minder to driver. A similar label is located near fuel
for information on the fuel injection pump and fuel
tank filler.
transfer pump.
FUEL TANK PRESSURE RELIEF/ROLLOVER VALVE
FUEL GAUGE SENDING UNIT
The fuel tanks of all vehicles have a pressure relief/
The fuel gauge sending unit is attached to the side rollover valve. The valves relieve fuel tank pressure
of the fuel pump module on gas powered engines. It and prevent fuel flow through fuel tank vent hoses
is attached to the side of the fuel tank module on die during rollover. All vehicles pass a full 360 degree
rollover without fuel leakage.
BR FUEL TANKS 14-23
The pressure relief/rollover valve (Figs. 5. or 6) is FUEL UNE ELECTRICAL

mounted at the top of fuel pump module (gas pow (TO FUEL RAIL) DRIVER'S MM CONNECTOt
ered engines), or fuel tank module (diesel powered OF VEHICLE
engines).
On gas powered engines, the valve is connected to
the EVAP canister with a rubber hose. On diesel
powered engines, the top of the valve is open to at
mosphere. Refer to Group 25, Emission Control Sys
tems for more information.
REMOVAL
(1) Remove fuel tank. Refer to Fuel Tanks section
in this group.
(2) Wedge the blade of a straight screwdriver be
tween the rubber valve grommet and fuel pump mod
ule where support rib is located. Do not wedge FUEL FILTER/
between valve and grommet or damage to valve FUEL PRESSURE
may result upon removal. REGULATOR
(3) Use a second screwdriver as a support to pry FUEL TANK

valve and grommet assembly from tank. (GAS POWERED) J9414-37'
(4) To remove grommet from valve, place valve up
Fig. 5 Pressure Relief/Rollover Valve—Gas Powered
right on a flat surface. Push down on the grommet.
Engines
Peel the grommet off the valve.
FUEL RETURN
INSTALLATION
AND SUPPLY LINES DRIVER'S mm
(1) Install the rubber grommet in fuel tank and ELECTRICAL
OF WHICH
work it around the curled lip. CONNECTOR
(2) Lubricate the grommet with power steering
fluid and push valve downward into grommet. Twist
the valve until it is pointed to the drivers side of ve
hicle.
(3) Install fuel tank. Refer to Fuel Tank Installa
tion.
FUEL
TANK
(DIESEL)
J9414-38
Fig. 6 Pressure Relief/Rollover Valve—Diesel

Powered Engines
14 - 24 ACCELERATOR PEDAL AND THROTTLE CABLE BR
ACCELERATOR PEDAL A N D THROTTLE CABLE
INDEX
page page
Accelerator Pedal 24 Throttle Cable 25

General Information 24 Throttle Linkage Adjustment—Diesel Engine 26
GENERAL INFORIATION PEDAL

RETURN
All gas powered engines are equipped with torsion SPRING
(MANUAL TRANS. THROTTLE
return springs located on the throttle body shaft. On BODY
ONLY)
the diesel powered engine, the torsion springs are lo
cated on the fuel injection pump lever (Fig. 1). 3.917
5.2L and 5.9L gas powered engines equipped with a
manual transmission have an additional pedal return
spring (Fig. 2). All of these springs are designed to
give positive throttle return while meeting safety re
quirements.
FRONT OF VEHICLE
CABLE RUBBER
CABLE
SOCKET GROMMET
MOUNTING
BRACKET CABLE
PIN
LEVER THROTTLE
BODY CAM
BALL
THROTTLE
CABLE J9414-45
Fig. 2 Throttle Return Spring—3.9U5.2U5.9L Gas

Engines with Man. Trans.
(2) Insert a small screwdriver into the square holes
located on the pivots/bushings (Fig. 4). Twist the
FUEL screwdriver to disengage the pivot locks from the
INJECTION pivot pin. Pivots will be damaged when removing.
PUMP Discard old pivots.
(3) Remove pedal/bracket assembly from vehicle.
TORSION
SPRING J94U-43 INSTALLATION
(1) Position pedal/bracket assembly over the pivot
Fig. 1 Throttle Cable at Injection Pump—Diesel- pin (Fig. 4).
Typical (2) Install two new pivots/bushings. Using large
ACCELERATOR PEDAL pliers, press both of the bushings together until they
bottom on the sides of the pedal/bracket assembly.
REM
Bushing retaining ears will snap into position when
properly installed.
CAUTION: Be careful not to damage or kink the c a (3) From inside the vehicle, hold up the accelerator
ble core wire (within the cable sheathing) while ser pedal. Install the throttle cable core wire and plastic
vicing accelerator pedal or cables. cable retainer into and through the upper end of the
pedal arm (the plastic retainer is snapped into the
(1) From inside the vehicle, hold up the accelerator pedal arm). When installing the plastic retainer to
pedal. Remove the plastic cable retainer and throttle the accelerator pedal arm, note the index tab on the
cable core wire from upper end of pedal arm (Fig. 3). pedal arm (Fig. 3). Align the index slot on the plastic
The plastic cable retainer snaps into pedal the arm. cable retainer to this index tab.
B R ACCELERATOR PEDAL AID THROTTLE CABLE 14 - 25
CABLE FRONT OF cable core wire from upper end of pedal arm (Fig. 3).
STOP W - V VEHICLE The plastic cable retainer snaps into pedal the arm.
PINCH TWO (2) Remove the cable core wire at the pedal arm.
TABS (3) All Gas Powered Engines: Remove the air
FOR cleaner housing.
CABLE REMOVAL (4) From inside the vehicle, pinch both sides of the
plastic cable housing retainer tabs at the dash panel
(Fig. 3).
(5) Remove cable housing from dash panel and pull
the cable into the engine compartment.
(6) 3.9L/5.2L/5.9L Gas Powered Engines: Dis
connect the cable from the routing/holddown clip at
the radiator fan shroud.
(7) 8.0L V-10 Engine and/or Diesel Engine: Re
move the throttle cable socket at fuel injection lever
ball (Fig. 1-Diesel) or throttle body lever ball (Fig.
6-8.0L V-10) (snaps off).
3.9L/5.2L/5.9L Gas Powered Engines: Operate
the throttle body cam (by hand) to the full open
THROTTLE throttle position. Slip the pin on the end of cable
PEDAL
ARM J9414-42 from the hole in the throttle body cam (Fig. 5). Re
move cable from cam.
Fig. 3 Cable Removal/installation TORSION
SPRING
PEDAL MOUNTING
BRACKET
CABLE
PIN
THROTTLE
CABLE
PRESS
TAB
PIVOTS/ FOR CABLE
PEDAL/ BUSHINGS REMOVAL
BRACKET
CAM
J9414-40
Fig. 4 Accelerator Pedal—Removal or Installation ROTATE

VIEW OF WIDE
THROTTLE CABLE OPEN THROTTLE
J9414-41
CAUTION: B e careful not to damage or kink the ca
ble core wire (within the cable sheathing) while ser Fig. 5 Throttle Cable at Throttle Body—3.9U5.2U
vicing accelerator pedal or cables. 5.9L Gas Engines—Typical
(8) All Gas Powered Engines: Remove cable
REMOVAL housing at throttle body mounting bracket by press
(1) From inside the vehicle, hold up the accelerator ing on release tab with a small screwdriver (Figs. 5
pedal. Remove the plastic cable retainer and throttle or 6). To prevent cable housing breakage, press
on the tab only enough to release the cable
14 - 26 ACCELERATOR PEDAL AND THROTTLE CABLE
PRESS TAB FOR (4) Install the remaining cable housing end into
CABLE REMOVAL and through the dash panel opening (snaps into po
sition). The two plastic pinch tabs (Fig. 3) should lock
THROTTLE the cable to dash panel.
CABLE
(5) From inside the vehicle, hold up the accelerator
CABLE
SOCKET pedal. Install the throttle cable core wire and plastic
cable retainer into and through the upper end of the
pedal arm (the plastic retainer is snapped into the
pedal arm). When installing the plastic retainer to
the accelerator pedal arm, note the index tab on the
pedal arm (Fig. 3). Align the index slot on the plastic
cable retainer to this index tab.
THROTTLE LINKAGE ADJUSTMENT—DIESEL

LEVER ENGINE
BALI The linkage rod (Fig. 7) connecting the throttle le
ver to the fuel injection pump lever is adjustable.
CAUTION: Before adjusting the fuel injection pump
MOUNTING throttle linkage, verify that engine is set at correct
BRACKET J9414-44 low idle speed. Refer to Idle Speed Adjustment.
This can be found in the Diesel Engine—General Di
Fig. 6 Throttle Cable at Throttle Body—S.OL V-10 agnosis section of this group.
Engine
from the bracket. Lift the cable housing straight (1) Verify low idle speed.
up from bracket while pressing on release tab. Re (2) Disconnect throttle cable socket from lever ball
move throttle cable from vehicle. stud on throttle lever (Fig. 8).
(9) Diesel Engine: A rubber/plastic grommet is
molded to the cable (Fig. 1). This grommet is pressed THROTTLE THROTTLE LEVER-TO-
LEVER INJECTION PUMP LEVER
into the back of the cable mounting bracket. Apply BALL LINKAGE ROD
lubricant to the rubber grommet (Fig. 1) on both
sides of the cable mounting bracket. Work the rubber
grommet (rearward) through the mounting bracket
with two small screwdrivers. Remove throttle cable
from vehicle.
INSTALLATION
(1) S.9L/5.2L/5.9L Gas Engines:
(a) Rotate and hold the throttle cam in the full
wide open position. Fit the pin on the end of cable
into the hole on the throttle body cam (Fig. 5).
(b) Connect cable to throttle body mounting
bracket (push down and lock).
(c) Connect cable to fan shroud routing clip.
(2) 8.0L V-10 Engine:
(a) Connect cable end socket to throttle body le
ver ball (snaps on) (Fig. 6). THROTTLE
(b) Connect cable to throttle body mounting LEVER
bracket (push down and lock).
(3) Diesel Engine: RIGHT-HAND-
(a) Feed the cable through the rear of its mount THREADED
THROTTLE FLAT NUT
ing bracket (Fig. 1) until the rubber/plastic grom POSITION
i r r T l l A k i r N
LEFT-HAND-
met locks into position on the bracket. SENSOR THREADED
NUT J9414-67
(b) Connect cable end socket to the fuel injection
pump lever ball (snaps on). Fig. 7 Diesel Throttle Lever Linkage Adjustment-
Typical
SR ^ _ ^ _ — ACCELERATOR PEDAL AND THROTTLE CAILE 14 - 27
FRONT OF VEHICLE
126.5 MM
(5.0 INCHES)
Fig. 8 Diesel Throttle Cable at Injection Pump-

Typical
(3) Measure the distance between the center of the
lever ball and the rear face of the cable mounting CENTER REAR FACE
bracket (Fig. 9). Dimension should be 126.5 mm (5.0 OF BALL OF BRACKET J9414-68
inches.) If not, proceed to following step.
(4) To prevent damage to ends of linkage, attach Fig. 9 Diesel Linkage Measurement—Typical
locking-type pliers to the flat (Fig. 7) located on the throttle lever and throttle lever-to-injection pump
linkage rod before loosening locknuts. lever linkage rod (Fig. 7) should be observed.
(5) Loosen the right-hand-threaded nut (Fig. 7). (c) Continue to press the accelerator pedal to the
(6) Loosen the left-hand-threaded nut (Fig. 7). floor. If throttle lever breakover is operating cor
(7) Rotate the flat on the linkage rod (lengthen or rectly, the throttle lever-to-injection pump lever
shorten) to achieve proper linkage adjustment (Fig. linkage rod should have stopped moving while the
9). Tighten both nuts after adjustment. throttle lever continues to move towards the rear of
(8) With the engine OFF, operate the throttle from vehicle.
accelerator pedal and check for throttle lever action (10) Again, check and verify low idle speed. Adjust
and binding. Be sure throttle lever stop is against
if necessary.
the low idle speed screw after throttle is released.
(9) Be sure of wide open throttle (WOT) when ac (11) Diesel engines equipped with an auto
celerator pedal is pressed to the floor. This is checked matic transmission: A throttle' position sensor
by observing throttle lever breakover position. Pro (TPS) is used with this driveline combination. TPS
ceed to the following: voltage must now be tested. Refer to Throttle Posi
(a) Key OFF and engine OFF for this test. tion Sensor. This can be found in the Diesel Engine—
(b) Two people are needed for this test. From in Component Removal/Installation section of this
side of the vehicle, press the accelerator pedal group.
about half-way to the floor. Movement of both the
14 - 28 COMPONENT DESCRIPTION/SYSTEM OPERATION—EXCEPT DIESEL BR
M U L T I - P O R T F U E L I N J E C T I O N (MFI)—COMPONENT DESCRIPTION/SYSTEM
OPERATION—EXCEPT D I E S E L
INDEX
page page
Air Conditioning (A/C) Controls—PCM Pins #27 and
#28—PCM Input .. ... 41 Ignition Circuit Sense—PCM Pin #9—PCM Input . . 36
Air Conditioning Relay—PCM Pin #34—PCM Ignition Coil Driver—PCM Pin #17—PCM Output . . 38
Output . 42 Ignition Coil Driver—PCM Pin #18—PCM Output . . 38
Automatic Shutdown (ASD) Relay—PCM Pin Ignition Coil Driver—PCM Pin #19—PCM Output . . 38
#51—PCM Output 46 Intake Manifold Air Temperature Sensor—PCM Pin
Automatic Shutdown (ASD) Sense—PCM Pin #21-—PCM Input 39
#57—PCM Input . . 48 Malfunction Indicator Lamp—PCM Pin #32—PCM
Battery Temperature Sensor 36 Output . . . . .. 42
Battery Voltage—PCM Pin # 3 — P C M input . . . . . . 35 Manifold Absolute Pressure (MAP) Sensor—PCM
Brake Switch—PCM Pin #29—PCM input ... 41 Pin #1—PCM Input 35
Camshaft Position Sensor—PCM Pin #44—PCM Open Loop/Closed Loop Modes of Operation 50
Input 45 Overdrive Lamp—PCM Pin #31—PCM Output . . . . 42
CCD Bus(+)—PCM Pin #26—PCM Output . . . . . . . 41 Overdrive Lamp—PCM Pin #37—PCM Output . . . . 43
CCD Bus(-)—PCM Pin #46—PCM Output . . . . . . . 45 Overdrive Solenoid—PCM Pin #55—PCM Output . 47
Crankshaft Position Sensor—PCM Pin #24—PCM Overdrive/Override Switch—PCM Pin #10—PCM
Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Input 36
Data Link Connector—PCM Pin #25—PCM Output . 41
Data Link Connector—PCM Pin #45—PCM input . . 45 Oxygen (02S) Sensor—PCM Pin #23—PCM Input . 40
E G R Valve Control Solenoid—Pin #35—PCM Oxygen (02S) Sensor—PCM Pin #41—PCM Input . 44
Output 43 Park/Neutral Switch—PCM Pin #30—PCM Input . . 41
Eight Volt Power—PCM Pin #7—PCM Input 36 PCM System Schematics—Except Diesel . . 30
Engine Coolant Temperature Sensor—PCM Pin Power Ground—PCM Pin #11 36
#2—PCM Input 35 Power Ground—PCM Pin #12 36
EVAP Canister Purge Solenoid—PCM Pin Powertrain Control Module (PCM) 29
#52—PCM Output 46 Sensor Return—PCM Pin #4—PCM Input 36
Five Volt Power—PCM Pin #6—PCM Input . . . . . . 36 Speed Control—PCM Pins #33 and #53—PCM
Fuel Filter . . . 48 Output 42
Fuel Injectors—PCM Pin #13—PCM Output 36 Speed Control—PCM Pins #48, #49 and #50—
Fuel Injectors—PCM Pin #14—PCM Output 37 PCM Input 46
Fuel Injectors—PCM Pin #15—PCM Output 37 Speed Control—PCM Pins #53 and #33—PCM
Fuel Injectors—PCM Pin #16—PCM Output . . . . . . 37 Output 47
Fuel Injectors—PCM Pin #17—PCM Output 38 Sri Lamp—PCM Pin #56—PCM Output . . . . . . . . . 47
Fuel Injectors—PCM Pin #18—PCM Output . . . . . . 38 Tachometer—PCM Pin #43—PCM Output . . . . . . . 45
Fuel Injectors—PCM Pin #38—PCM Output 43 Throttle Body 48
Fuel Injectors—PCM Pin #58—PCM Output . . 48 Throttle Position Sensor—PCM Pin #22—PCM Input . 39
Fuel Pressure Regulator 48 Torque Convertor Clutch (TCC) Solenoid—PCM Pin
Fuel Pump Relay—PCM Pin #51—PCM Output . . . 46 #54—PCM Output 47
Fuel Rail 49 Transmission Temperature Sensor—PCM Pin
General Information . 28 #42—PCM Input 44
Generator Field—PCM Pin #20—PCM Output . . . . 39 Transmission Temperature Warning Lamp—PCM
Idle Air Control (IAC) Motor—Pin #39—PCM Output . . 43 Pin #31—PCM Output 42
Idle Air Control (IAC) Motor—Pin #40—PCM Output . . 44 Transmission Temperature Warning Lamp—PCM
Idle Air Control (IAC) Motor—Pin #59—PCM Output . . 48 Pin #36—PCM Output . 43
Idle Air Control (IAC) Motor—Pin #60—PCM Output . . 48 Vehicle Speed Sensor—PCM Pin #47—PCM Input . 45
GENERAL INFORMATION Duty Cycle) engine. The 8.0L V-10 engine will be re
All vehicles are equipped with either a 3.9L V-6 en ferred to as: HDC (Heavy Duty Cycle) engine.
gine, a 5.2L V-8 engine, two different 5.9L V-8 en Either of the HDC gas powered engines can be eas
gines, an 8.0L V-10 engine or a 5.9L Cummins in-line ily identified by the use of an engine mounted air in
6 cylinder diesel engine. Refer to the Diesel sections jection pump. The 3.9L V-6, 5.2/5.9L V-8 LDC gas
of this group for diesel information. engines or the diesel engine will not use an air injec
The 3.9L V-6 and 5.2L V-8 engines will be referred tion pump.
to in this group as: LDC (Light Duty Cycle) engines. A sequential multi-port fuel injection (MFI) system
The 5.9L V-8 gas powered engine will be referred to is used on all 3.9L V-6 or 5.2/5.9L V-8 gas powered
as either: LDC (Light Duty Cycle) or HDC (Heavy engines. On the 8.0L V-10 engine, a multi-port fuel
COMPONENT DESCRIPTION/SYSTEM OPERATION—EXCEPT DIESEL 14 - 29
injection system is also used, although the fuel injec erator charge rate through control of the generator
tors are simultaneously fired in pairs. field and provides speed control operation.
The MFI system provides precise air/fuel ratios for The PCM contains a voltage convertor. This con
all driving conditions. verts battery voltage to a regulated 8.0 volts. It is
used to power the crankshaft position sensor, cam
POWERTRAIN CONTROL MODULE (PCM) shaft position sensor and vehicle speed sensor. The
The powertrain control module (PCM) is located in PCM also provides a five (5) volt supply for the man
the right-rear side of the engine compartment (Fig. ifold absolute pressure (MAP) sensor and throttle po
1). It is mounted to the dash panel cowl with three sition sensor (TPS).
bolts. The PCM was formerly referred to as the The PCM Inputs represent the instantaneous en
SBEC or engine controller. gine operating conditions. Air-fuel mixture and igni
tion timing calibrations for various driving and
atmospheric conditions are pre-programmed into the
PCM. The PCM monitors and analyzes various in
puts. It then computes engine fuel and ignition tim
ing requirements based on these inputs. Fuel
delivery control and ignition timing will then be ad
justed accordingly.
Other inputs to the PCM are provided by the brake
switch, air conditioning select switch and the speed
control switches. All inputs to the PCM are converted
into signals.
Electrically operated fuel injectors spray fuel in
precise metered amounts into the intake port directly
POWERTRAIN CONTROL above the intake valve. The injectors are fired in a
MODULE (PCM) J9414-11 specific sequence by the PCM. In the Closed Loop
mode, the PCM maintains an air/fuel ratio of 14.7 to
1 by constantly adjusting injector pulse width. Injec
The PCM operates the fuel system. The PCM is a tor pulse width is the length of time that the injector
pre-programmed, dual microprocessor digital com opens and sprays fuel into the chamber. The PCM
puter. It regulates ignition timing, air-fuel ratio, adjusts injector pulse width by opening and closing
emission control devices, charging system, speed con the ground path to the injector.
trol, A/C compressor clutch engagement, overdrive Manifold absolute pressure and engine rpm (speed)
operation, torque convertor clutch and idle speed. are-the primary inputs that determine fuel injector
The PCM can adapt its programming to meet chang pulse width. The PCM also monitors other inputs
ing operating conditions. when adjusting air-fuel ratio.
The PCM receives input signals from various The PCM adjusts ignition timing by controlling ig
switches and sensors. Based on these inputs, the nition coil operation. The ignition coil(s) receives bat
PCM regulates various engine and vehicle operations tery voltage when the ignition key is in the run or
through different system components. These compo start (crank) position. The PCM provides a ground
nents are referred to as PCM Outputs. The sensors for the ignition coil. The coil(s) discharges when the
and switches that provide inputs to the PCM are con PCM removes a ground. By switching the ground
sidered PCM Inputs. path on and off, the PCM regulates ignition timing.
The PCM adjusts ignition timing based upon in Refer to Group 8D, Ignition System for more infor
puts it receives from sensors that react to: engine mation.
crankshaft position, manifold absolute pressure, en PCM Inputs That Effect Fuel Injector Pulse
gine coolant temperature, throttle position, transmis Width:
sion gear selection (automatic transmission), vehicle © Battery voltage
speed, intake manifold air temperature and the • EGR
brake switch. • Engine coolant temperature
The PCM adjusts idle speed based on inputs it re @ Engine speed (rpm)
ceives from sensors that react to: throttle position, © Evaporative emissions purge
vehicle speed, transmission gear selection, engine ® Exhaust gas oxygen content from oxygen (02S)
coolant temperature and from inputs it receives from sensor
the air conditioning clutch switch and brake switch. • Intake manifold air temperature
Based on inputs that it receives, the PCM adjusts © Manifold absolute pressure (MAP)
ignition coil(s) dwell. The PCM also adjusts the gen • Throttle position (TPS)
14 - 30 COMPONENT DESCRIPTION/SYSTEM OPERATION—EXCEPT DIESEL
• Transmission gear selection (auto, trans.) • Overdrive solenoid electrical operation (auto,
Other POM Inputs: trans, only)
o A/C request (if equipped with factory A/C) • Overdrive warning lamp (auto, trans, only)
• Auto shutdown (ASD) sense • SCI transmit (DRB scan tool connection)
• Brake switch • Service reminder indicator lamp
• Camshaft position sensor signal • Shift indicator lamp (manual transmission only)
• Crankshaft position sensor • Speed control vacuum solenoid
• Engine coolant temperature sensor • Speed control vent solenoid
• Ignition circuit sense (ignition switch in run posi • Tachometer (on instrument panel, if equipped)
tion) • Torque convertor clutch electrical operation (auto,
o Manifold absolute pressure (MAP) sensor trans, only)
• Overdrive/override switch • Transmission oil temperature warning lamp (cer
• Park/neutral switch (auto, trans, only) tain HD models with auto, trans, only)
• SCI receive (DRB scan tool connection)
• Speed control resume switch SYSTEM DIAGNOSIS
• Speed control set switch The powertrain control module (PCM) tests many
© Speed control on/off switch of its own input and output circuits. If a diagnostic
• Vehicle speed sensor trouble code (DTC) is found in a major system, this
Powertrain Control Module (PCM) Outputs:
information is stored in the PCM memory. Refer to
After inputs are received by the PCM, certain com
ponents are controlled by the PCM. These are consid On-Board Diagnostics in the Multi-Port Fuel Injec
ered PCM Outputs. These outputs are for: tion—General Diagnosis—Except Diesel section of
o A/C clutch relay (A/C clutch operation) this group for DTC information.
o Auto shutdown (ASD) relay
• Data link connectors (for DRB and MDS test PCM SYSTEM SCHEMATICS—EXCEPT DIESEL
equipment) Powertrain control system schematics for gas pow
© EGR valve control solenoid ered fuel injected engines are shown in figures 2, 3, 4
• EVAP canister purge solenoid and 5.
• Fuel injectors (pulse width) These schematics are displayed as a quick refer
• Fuel pump relay (electric fuel pump) ence only. They are not intended to be all-inclusive.
® Generator field (charging system operation) Refer to the Wiring Diagrams section for detailed in
• Idle air control (IAC) motor formation.
• Ignition coil(s) and ignition timing After the schematics, a description is given for each
© Malfunction indicator lamp (check engine lamp) circuit (pin/cavity) of the PCM 60-way connector.
- GENERATOR
J9414-49
Fig. 2 System Schematic—3.9L (V-6) Engine

- GENERATOR J9414-50
Fig. 3 System Schematic—5.2L/5.9L LDC (V-8) Engine

o
o
S
•o
o
THROTTLE
POSITION
SENSOR
©0
o
z
00
o
m
ZD
X
O
GENERATOR
J9414-52
Fig. 5 System Schematic—S.OL HDC (V-10) Engine m

BR - — — — — COMPONENT DESCRIPTION/SYSTEM OPERATION—EXCEPT DIESEL 14 - 35
MANIFOLD ABSOLUTE PRESSURE (MAP)

SENSOR—PCM PIN #1—PCM INPUT
The MAP sensor reacts to absolute pressure in the
intake manifold and provides an input voltage to the
powertrain control module (PCM). As engine load
changes, manifold pressure varies, causing the MAP
sensor voltage to change. This change results in a
different input voltage to the PCM. The input voltage
level supplies the PCM with information. This relates
to ambient barometric pressure before engine start
up, during engine start-up (cranking) and to engine
load while the engine is running. The PCM uses this
input, along with inputs from other sensors, to adjust
air-fuel mixture.
3.9L V-6 or 5.2/5.9L V-8 Engines: The MAP sen
sor is mounted to the throttle body (Fig. 6). It is con Fig. 7 MAP Sensor—8.0L V-10 Engine—Typical
nected to the throttle body with an L-shaped rubber
fitting and to the PCM electrically. changes. At cold coolant temperatures, its resistance
S.OL V-10 Engine: The MAP sensor is mounted is high. As temperatures increase, its resistance will
into the right side of the intake manifold (Fig. 7). decrease.
The coolant sensor provides an input voltage to the
powertrain control module (PCM) relating engine
coolant temperature. The PCM uses this input, along
with inputs from other sensors, to determine injector
pulse width and ignition timing. As coolant tempera
ture varies, the coolant temperature sensor resis
tance will change, resulting in a different input
voltage to the PCM.
When the engine is cold, the PCM will operate in
the Open Loop Mode. It will demand slightly richer
air-fuel mixtures and higher idle speeds, until nor
mal operating temperatures are reached. Refer to
Open Loop/Closed Loop Modes Of Operation in this
group for a description of operation.
On the 3.9L V-6 or 5.2/5.9L V-8 engines, the sensor
is installed in the intake manifold near the thermo
stat housing (Fig. 8).
On the 8.0L V-10 engine, the sensor is installed in
the thermostat housing (Fig. 9).
Fig. 6 MAP Sensor—3.9L V-6 or 5.2/5.9L V-8 fer to the Component Removal/Installation section of
Engines—Typical this group.
vice Procedures section of this group. BATTERY VOLTAGE—PCM PIN #3—PCM INPUT
For removal and installation of this component, re The battery voltage input provides power to the
fer to the Component Removal/Installation section of powertrain control module (PCM). It also informs the
this group. PCM what voltage level is supplied to the ignition
coil(s) and fuel injectors.
ENGINE COOLANT TEMPERATURE SENSOR—PCM If battery voltage is low, the PCM will increase in
PIN #2—PCM INPUT jector pulse width (period of time that the injector is
The engine coolant temperature sensor is a vari energized). This is done to compensate for the re
able, thermistor type. It reacts to temperature duced flow through injector caused by the lowered
voltage.
14 - 3 6 COMPONENT DESCRIPTION/SYSTEM OPERATION—EXCEPT DIESEL BR
: GENERATOR COOLANT IGNITION CIRCUIT SENSE—PCM PIN #9—PCM

TEMPERATURE
SENSOR INPUT
The ignition circuit sense input tells the powertrain
control module (PCM) the ignition switch has ener
gized the ignition circuit. Refer to the wiring dia
grams for circuit information.
OVERDRIVE/OVERRIDE SWITCH—PCM PIN
#10—PCM INPUT
On vehicles equipped with an automatic transmis
sion and overdrive, the powertrain control module
(PCM) regulates the 3-4 overdrive up-shift and down
shift through the overdrive solenoid. This solenoid is
located in the transmission. An overdrive/override
J9314-78
push-button switch is located on the instrument
Fig. 8 Coolant Temperature Sensor—3.9L V-6 or
panel.
5.2/5.9L V-8 Engines—Typical The PCM circuit for overdrive is controlled by in
puts from the engine coolant temperature sensor and
^ ^ ^ ' ^ ^ ^ ^ X ^ ^ V TEMP. GAUGE
R
^ vehicle speed sensor. If coolant temperature and ve
ENGINE COOLANT TEMP. SENSOR I 5!^^?lf£ J^;~ hicle speed are not within the preset PCM specifica
tions, the PCM will not allow the transmission to
shift into overdrive. These preset PCM specifications
must be met before the push-button switch will be al
lowed to control overdrive operation.
The overdrive/override push-button switch is nor
mally closed (overdrive allowed) when the lamp is
not illuminated. It opens (overdrive not allowed)
when the operator presses the switch and the lamp is
illuminated. The switch will revert to its normally
closed position (lamp off) each time the ignition
switch in turned on. The transmission downshifts if
the operator presses the override switch while in
J948D-9 overdrive.
Also refer to: Overdrive Solenoid—PCM Pin #55—
Fig. 9 Coolant Temperature Sensor—8.0L V-10 PCM Output, Transmission Temperature Warning
Engine Lamp-PCM Pin #31-PCM Output and Transmis
BATTERY TEMPERATURE SENSOR sion Temperature Sensor—PCM Pin #42—PCM Input
for additional information.
This input is internal to the powertrain control
Refer to Group 21 for more transmission informa
module (PCM). A thermistor located within the tion.
PCM's printed circuit board is used to sense under
hood temperature. This temperature is used to vary POWER GROUND—PCM PIN #11
the battery charging rate in relationship to the tem Provides a common ground for power devices (sole
perature. noid and relay devices).
SENSOR RETURN—PCM PIN #4—PCM INPUT POWER GROUND—PCM PIN #12
Sensor Return provides a low noise ground refer Provides a common ground for power devices (sole
ence for all system sensors. noid and relay devices).
FIVE VOLT POWER—PCM PIN #6—PCM INPUT FUEL INJECTORS—PCM PIN #13—PCM OUTPUT
This circuit supplies approximately 5 volts to power
the MAP and TPS sensors. 3.BU5.2L/B.BL ENGINES
Pin #13 is used as the ground control circuit for the
EIGHT VOLT POWER—PCM PIN #7—PCM INPUT fuel injector on cylinder #4 on 3.9L/5.2L/5.9L engines.
This circuit supplies approximately 8 volts to power The injectors (Fig. 10) are energized individually in
the vehicle speed, camshaft position and crankshaft a sequential order by the powertrain control module
position sensors. (PCM). The PCM will adjust injector pulse width by
BR COMPONENT DESCRIPTION/SYSTEM OPERATION—EXCEPT DIESEL 14 - 37
switching the ground path to each individual injector

on and off. Injector pulse width is the period of time
that.the injector is energized. The PCM will adjust
injector pulse width based on various inputs it re
ceives.
FUEL
INJECTOR J9214-30
Fig. 10 Fuel injector internal Components—Typical
Fig. 11 Fuel Injectors—Typical
During start up, battery voltage is supplied to the engine (both injectors are fired simultaneously—one
injectors through the ASD relay. When the engine is cylinder on compression stroke and one cylinder on
operating, voltage is supplied by the charging sys exhaust stroke).
tem. The PCM determines injector pulse width based
on various inputs. FUEL INJECTORS—PCM PIN #15—PCM OUTPUT
The fuel injectors are attached to the fuel rail (Fig.
11). 3.9L V-6 engines use six injectors. 5.2L and 5.9L 3.BL/5.21/S.BL ENGINES
V-8 engines use eight injectors. Pin #15 is used as the ground control circuit for the
The nozzle ends of the injectors are positioned into fuel injector on cylinder #2 on 3.9L/5.2L/5.9L engines.
openings in the intake manifold just above the intake Refer to Fuel Injectors-PCM Pin #13-PCM Output
valve ports of the cylinder head. The engine wiring for information.
harness connector for each fuel injector is equipped
with an attached numerical tag (INJ 1, INJ 2 etc.). 8 . 0 L V-10 ENGINE
This is used to identify each fuel injector with its re Pin #15 is used as the ground control circuit for the
spective cylinder number. fuel injectors on cylinders #9 and #4 on the 8.0L V-10
engine (both injectors are fired simultaneously—one
S.OL 1MO ENGINE cylinder on compression stroke and one cylinder on
Pin #13 is used as the ground control circuit for the exhaust stroke).
fuel injectors on cylinders #5 and #8 on the 8.0L V-10
engine (both injectors are fired simultaneously—one FUEL INJECTORS—PCM P I N #16—PCM OUTPUT
cylinder on compression stroke and one cylinder on
exhaust stroke). 3.BL/S.2U5.BL ENGINES
FUEL INJECTORS—PCM PIN #14—PCM OUTPUT fuel injector on cylinder #1 on 3.9L/5.2L/5.9L engines.
Refer to Fuel Injectors-PCM Pin #13-PCM Output
3.9L/5.2L/5.9L ENGINES for information.
fuel injector on cylinder #3 on 3.9L/5.2L/5.9L engines. 8.0L V-fO ENGINE
Refer to Fuel Injectors-PCM Pin #13--PCM Output Pin #16 is used as the ground control circuit for the
for information. fuel injectors on cylinders #1 and #10 on the 8.0L
V-10 engine (both injectors are fired simultaneous
S.OL V-fO ENGINE ly—one cylinder on compression stroke and one cyl
Pin #14 is used as the ground control circuit for the inder on exhaust stroke).
FUEL INJECTORS—PCM P I N #17—PCM OUTPUT IGNITION COIL DRIVER—PCM PIN #19—PCM

OUTPUT
S.2L/5.9L ENGINES
Pin #17 is used as the ground control circuit for the BL/5.2L/5.9L ENGINES
fuel injector on cylinder #7 on 5.2L/5.9L engines. Re Pin #19 is used as the ground control circuit for the
fer to Fuel Injectors-PCM Pin #13-PCM Output for ignition coil.
information. System voltage is supplied to the ignition coil pos
itive terminal. The powertrain control module (PCM)
IGNITION COSL DRIVER—PCM PIN #17—PCM then operates the ignition coil through an on/off
OUTPUT ground signal. Base (initial) ignition timing is
not adjustable. The PCM adjusts ignition timing to
8.0L V-10 ENGINE meet changing engine operating conditions.
Pin #17 is used as the ground control circuit for the The ignition coil is located near the front of the
ignition coils operating cylinders #8 and #9 on the 8.0L right cylinder head (Fig. 13 or 14).
V-10 engine (both coils are fired simultaneously). Refer to Group 8D, Ignition System for additional
Two separate coil packs containing a total of five information.
cover (Fig. 12). The coil packs are not oil filled. The
front coil pack contains three independent epoxy
filled coils. The rear coil pack contains two indepen
dent epoxy filled coils.
Refer to Group 8D, Ignition System for additional
information.
Fig. 13 Ignition Coll—3.9U5.2U5.9L LDC-Gas

Engine
Fig. 12 ignition Coil Packs—S.OL V-10 Engine

FUEL INJECTORS—PCM PIN #18—PCM OUTPUT
5.21/5.9L ENGINES
fuel injector on cylinder #8 on 5.2L/5.9L engines. Re
fer to Fuel Injectors-PCM Pin #13-PCM Output for
information.
IGNITION COIL DRIVER—PCM PIN #18—PCM

OUTPUT Fig. 14 Ignition Coll—5.9L HDC-Gas Engine
a O L V-fO ENGINE
8.0L V-10 ENGINE Pin #19 is used as the ground control circuit for the
Pin #18 is used as the ground control circuit for the ignition coils operating cylinders #1 and #6 on the
ignition coils operating cylinders #2 and #3 on the 8.0L 8.0L V-10 engine (both coils are fired simultaneous-
V-10 engine (both coils are fired simultaneously). ly).
Refer to Group 8D, Ignition System for additional

information.
GENERATOR FIELD—PCM PIN #20—PCM OUTPUT

The powertrain control module (PCM) regulates the
charging system voltage within a range of 12.9 to
15.0 volts. Refer to Group 8A for charging system in
formation.
INTAKE MANIFOLD AIR TEMPERATURE SENSOR—
PCM PIN #21—PCM INPUT
The intake manifold air temperature sensor is a
variable, thermistor type. It reacts to temperature
changes. At cold air temperatures, its resistance is
high. As temperatures increase, its resistance will de
crease. Fig. 16 Sensor Location—5.2U5.9L V-8 Engines-
The air temperature sensor element extends into Typical
the intake manifold air stream. It provides an input
voltage to the powertrain control module (PCM) indi
cating intake manifold air temperature. The input
from this sensor is used along with inputs from other
sensors to determine injector pulse width. As the
temperature of the air-fuel stream in the manifold
varies, the sensor resistance will change. This will
result in a different input voltage to the PCM.
On 3.9L V-6 or 5.2/5.9L V-8 engines, the sensor is
threaded into the right-front side of the intake man
ifold (Figs. 15 or 16).
On 8.0L V-10 engines, the sensor is threaded into
the left side of the intake manifold near the front of
the throttle body (Fig. 17).
Fig. 17 Sensor Location—S.OL V-10 Engine—Typical

The TPS is connected to the throttle blade shaft
and is a variable resistor. It provides the powertrain
control module (PCM) with an input signal (voltage)
that represents throttle blade position. As the posi
tion of the throttle blade changes, the resistance of
the sensor changes.
The PCM supplies approximately 5 volts to the
sensor. The sensor output voltage (input signal to the
PCM) represents the throttle blade position. The
PCM receives an input signal voltage from the sen
sor. This will vary in an approximate range of from 1
volt at minimum throttle opening (idle), to 4 volts at
Fig. 15 Sensor Location—3.9L V-6 Engine—Typical wide open throttle. Along with inputs from other sen
THROTTLE POSITION SENSOR—PCM PIN sors, the PCM uses the TPS sensor output to deter
mine current engine operating conditions. It also will
#22—PCM INPUT adjust fuel injector pulse width and ignition timing.
The throttle position sensor (TPS) is located on the
left side of the throttle body on the 3.9L V-6 or 5.2/ For component testing, refer to the Diagnostics/Ser
5.9L V-8 engines (Fig. 18). vice Procedures section of this group.
The TPS is located on the rear of the throttle body For removal and installation of this component, re
just below the idle air control motor on the 8.0L V-10 fer to the Component Removal/Installation section of
engine (Fig. 19). Group 14, Fuel Systems.
The 02S sensor produces voltages from 0 to 1 volt.

This voltage will depend upon the oxygen content of
the exhaust gas in the exhaust manifold. When a
large amount of oxygen is present (caused by a lean
air-fuel mixture), the sensor produces a low voltage.
When there is a lesser amount present (rich air-fuel
mixture) it produces a higher voltage. By monitoring
the oxygen content and converting it to electrical
voltage, the sensor acts as a rich-lean switch.
The oxygen sensor is equipped with a heating ele
ment that keeps the sensor at proper operating tem
perature during all operating modes. Maintaining
correct sensor temperature at all times allows the
system to enter into Closed Loop operation sooner.
In Closed Loop operation, the powertrain control
module (PCM) monitors the 02S sensor input (along
with other inputs). It then adjusts the injector pulse
width accordingly. During Open Loop operation, the
PCM ignores the 02S sensor input and adjusts injec
tor pulse width to a preprogrammed value (based on
other sensor inputs).
Fig. 18 Sensor Location—3.9L V-6 or 5.2/5.9L V-8
Refer to Open Loop/Closed Loop Modes of Opera
tion in this group for additional information.
Engines—Typical
EXHAUST
PIPE J9214-5
Fig. 20 Oxygen Sensor Location—3.9U5.2U5.9L

Fig. 19 Sensor Location—S.OL ¥-10 Engine—Typical LDC Engine
OXYGEN (028) SENSOR—PCI PIN #23—PCM 8 J L ¥-10 AND S.9L V-8 HiC ENGINES
INPUT Dual, heated 02S sensors are used on both the
8.0L V-10 and 5.9L V-8 heavy duty cycle (HDC) en
PGM PINS # 2 3 O R # 4 1 gines (Fig. 21). Each sensor will monitor the oxygen
3.8L/5.2L/5.9L LDC ENGINE
content in each exhaust downpipe.
On the 5.9L HDC V-8 engine, the left 02S sensor
A single, heated 02S sensor is used on the 3.9L V-6
monitors the odd numbered cylinders (1-3-5-7) and
and the 5.2L/5.9L V-8 light duty cycle (LDC) engines.
fuel is controlled on the left side (bank) of the engine.
It is located in the exhaust down pipe (Fig. 20). The
The right sensor monitors the even numbered cylin
02S sensor provides an input voltage to the power-
ders (2-4-6-8) and fuel is controlled on the right side
train control module (PCM) relating the oxygen con
(bank) of the engine.
tent of the exhaust gas. The PCM uses this
information to fine tune the air-fuel ratio by adjust On the 8.0L V-10 engine, pairs of fuel injectors are
ing injector pulse width. fired (one on each side of the engine). Because of
this, both 02S sensor readings are averaged by the
powertrain control module (PCM). This will deter DATA LINK

mine a common fuel injection rate for all ten cylin CONNECTOR
ders.
For additional sensor operational information, refer
to the paragraphs in the previous 3.9L/5.2/5.9L LDC
oxygen sensor section.
POWERTRAIN CONTROL

is in the proper range for A/C application. The PCM
uses this input to cycle the A/C compressor clutch
(through the A/C relay). It will also determine the
correct engine idle speed through the idle air control
(IAC) motor position.
Fig. 21 02S Location—8.0U5.9L HDC Engine—
If the A/C low-pressure switch opens (indicating a
Typical
low refrigerant level), the PCM will not receive an
A/C select signal. The PCM will then remove the
CRANKSHAFT POSITION SENSOR—PCM PIN ground from the A/C relay. This will deactivate the
#24—PCM INPUT A/C compressor clutch.
Refer to Group 8D, Ignition System for informa If the evaporator switch opens, (indicating that
tion. evaporator is not in proper temperature range), the
PCM will not receive the A/C request signal. The
DATA LINK CONNECTOR—PCM PIN #25—PCM PCM will then remove the ground from the A/C relay,
OUTPUT deactivating the A/C compressor clutch.
The data link connector (diagnostic scan tool con
nector) links the Diagnostic Readout Box (DRB) scan BRAKE SWITCH—PCM PIN #29—PCM INPUT
tool or the Mopar Diagnostic System (MDS) with the When the brake light switch is activated, the pow
powertrain control module (PCM). The data link con ertrain control module (PCM) receives an input indi
nector is located in the engine compartment (Fig. 22). cating that the brakes are being applied. After
For operation of the DRB scan tool, refer to the ap receiving this input, the PCM maintains idle speed to
propriate Powertrain Diagnostic Procedures service a scheduled rpm through control of the idle air con
manual. trol (IAC) motor. The brake switch input is also used
The data link connector uses two different pins on to control the speed control system and electrical op
the PCM. Pin #25 is for Data Link Transmit and pin eration of the transmission torque converter.
#45 is for Data Link Receive.
PARK/NEUTRAL SWITCH—PCM PIN #30—PCM
CCD BUS(+)—PCM PIN #26—PCM OUTPUT INPUT
Various modules exchange information through a The park/neutral switch provides an input to the
communications port called the CCD BUS(+). powertrain control module (PCM). This will indicate
that the automatic transmission is in Park, Neutral
AIR CONDITIONING (A/C) CONTROLS—PCM PINS or a Drive gear selection. This input is used to deter
#27 AND #28—PCM INPUT mine idle speed (varying with gear selection), fuel in
The A/C control system information applies to fac jector pulse width, ignition timing advance and
tory installed air conditioning units. vehicle speed control operation. Refer to Group 21,
A/C REQUEST SIGNAL: Once A/C has been se Transmissions, for testing, replacement and adjust
lected, the powertrain control module (PCM) receives ment information.
the A/C request signal from the evaporator switch.
The input indicates that the evaporator temperature
TRANSMISSION TEMPERATURE WARNING MALFUNCTION INDICATOR LAMP—PCM PIN

LAMP—PCM PIN #31—PCM OUTPUT #32—PCM OUTPUT
The malfunction indicator lamp illuminates on the
CERTAIN HEAVY DUTY ENGINES WITH instrument panel each time the ignition key is
AUTOMATIC TRANSMISSIONS ONLY turned on. This lamp is displayed on the instrument
An instrument panel mounted lamp (Fig. 23) is panel as the CHECK ENGINE lamp (Fig. 24). Note
used to warn of a possible transmission overheating that the lamp will illuminate for approximately two
condition. When transmission temperature has been seconds each time the key is initially turned to the
determined to be above approximately 280 degrees F ON position. This feature is used as a bulb check.
by the transmission temperature sensor, a signal is
sent to the powertrain control module (PCM). The
PCM will then control warning lamp operation. The
lamp will illuminate for about two seconds each time
the ignition key is initially turned to the ON position
as a bulb check.
Also refer to Transmission Temperature Sensor—
PCM Pin #42-PCM Input for additional informa
tion.
INSTRUMENT
Fig. 24 Check Engine Lamp—Typical Location

If the powertrain control module (PCM) receives an
incorrect signal, or no signal from certain sensors or
emission related systems, the lamp is turned on. This
is a warning that the PCM has recorded a system or
sensor malfunction. In some cases, when a problem is
declared, the PCM will go into a limp-in mode. This
is an attempt to keep the system operating. It signals
an immediate need for service.
Fig. 23 Transmission Temperature Warning
Lamp—Typical Location
The lamp can also be used to display a diagnostic
trouble code (DTC). Cycle the ignition switch On-Off-
SML V-10 ENGINE—AUTOMATIC On-Off-On within three seconds and any codes stored
TRANSMISSIONS ONLY in the PCM memory will be displayed. This is done
On the 8.0L V-10 engine, pin #36 performs the in a series of flashes representing digits. Refer to On-
same function as pin #31 on 3.9L/5.2L/5.9L engines. Board Diagnostics in the General Diagnosis section
Also refer to Transmission Temperature Sensor— of this group for more information.
tion. SPEED CONTROL—PCM PINS #33 AND #53—PCM
OUTPUT
OVERDRIVE LAMP—PCM PIN #31—PCM OUTPUT
These two circuits control vent and vacuum opera
8.0L V-10 ENGINE—AUTOMATIC tion of the speed control solenoids.
TRANSMISSIONS ONLY
This circuit controls a signal for the operation of AIR CONDITIONING RELAY—PCM PIN #34—PCM
the instrument panel mounted overdrive lamp. On OUTPUT
3.9L/5.2L/5.9L engines, this circuit is controlled by This circuit controls a ground signal for operation
pin #37. When the lamp is illuminated, the overdrive of the A/C clutch relay. Also refer to Air Conditioning
is disengaged. (A/C) Controls-PCM Pins #27 and #28-PCM Input
The A/C relay is located in the power distribution
center (PDC). The PDC is located next to the battery
IR COMPONENT DESCRIPTION/SYSTEM OPERATION—EXCEPT DIESEL 14-43
in the engine compartment (Fig. 25). For the location 8.0L V-10 ENGINE
of the relay within the PDC, refer to PDC cover. Pin #37 is used to supply a dwell gate signal for
operation of the ignition control module. The dwell
gate signal selects which coil is to be fired.
FUEL INJECTORS—PCM PIN #38—PCM OUTPUT

3 9L/5«2U5»9L
m ENGINES
fuel injector on cylinder #5 on 3.9L/5.2L/5.9L engines.
for information.
8.0L V-10 ENGINE
Pin #38 is used to supply a dwell signal for opera
tion of the ignition control module to energize the ig
nition coil.
IDLE AIR CONTROL (IAC) MOTOR—PIN #39—PCM

Fig. 25 Power Distribution Center (PDC) Location OUTPUT
EGR VALVE CONTROL SOLENOID—PIN #35—PCM Pin #39 controls one of the circuits for operation of
the IAC motor.
OUTPUT The IAC motor is mounted to the throttle body
This circuit controls operation of the exhaust gas (Figs. 26 or 27) and is controlled by the powertrain
recirculation (EGR) valve solenoid. control module (PCM).
Refer to Group 25, Emission Control System for in
formation.
TRANSMISSION TEMPERATURE WARNING

LAMP—PCM PIN #36—PCM OUTPUT
8.0L ENGINE—AUTOMATIC TRANSMISSIONS

ONLY
An instrument panel mounted lamp (Fig. 23) is
used to warn of a possible transmission overheating
condition. When transmission temperature has been
determined to be above approximately 280 degrees F
by the transmission temperature sensor, a signal is
PCM will then control lamp operation. The lamp will
illuminate for about two seconds each time the igni
tion key is initially turned to the ON position as a
bulb check.
On 3.9L/5.2L/5.9L engines, pin #31 performs the
same function.
tion.
Fig. 26 IAC Motor—3.9U5.2U5.9L Engines—Typical
OVERDRIVE LAMP—PCM PIN #37—PCM OUTPUT The throttle body has an air control passage that
provides air for the engine at idle (the throttle plate
3.9L/5.2L/5.9L ENGINES—AUTOMATIC is closed). The IAC motor pintle protrudes into the
TRANSMISSIONS ONLY air control passage (Figs. 28 or 29) and regulates air
This circuit controls a signal for the operation of flow through it. Based on various sensor inputs, the
the instrument panel mounted overdrive lamp. On powertrain control module (PCM) adjusts engine idle
the 8.0L V-10 engine, this circuit is controlled by pin speed by moving the IAC motor pintle in and out of
#31. When the lamp is illuminated, the overdrive is the air control passage. The IAC motor is positioned
engaged. when the ignition key is turned to the ON position.
IDLE Alt INTAKE MANIFOLD VACUUM

fUPPER HALF) FITTING
CONTROL MOTOR
THROTTLE
POSITION
SENSOR
THROTTLE
BODY J9414-2
THROTTLE
Fig. 27 IAC Motor—S.OL Engine—Typical BODY
A (factory adjusted) set screw is used to mechani IDLE AIR

IDLE AIR
cally limit the position of the throttle body throttle PASSAGE CONTROL (IAC)
plate. Never attempt to adjust the engine idle MOTOR
VIEW FROM BOTTOM
speed using this screw. All idle speed functions are J9414-48
controlled by the PCM.
Fig. 29 Air Control Passage—8.0L V-10 Engine
MOUNTING SCREWS TRANSMISSION TEMPERATURE SENSOR—PCM
MAP SENSOR PIN #42—PCM INPUT
CERTAIN HEAWY DUTY ENGINES WITH

RUBBER FITTING AUTOMATIC TRANSMISSIONS ONLY
The transmission temperature sensor is a variable,
thermistor type. It reacts to temperature changes. At
cold transmission oil temperatures, its resistance is
high. As temperatures increase, its resistance will de
crease.
The transmission temperature sensor is used on
models equipped with certain heavy-duty options and
an automatic transmission. Its purpose is to help
J9314-87 control transmission overheating. If transmission
overheating has been determined by this sensor
Fig. 28 Air Control Passage—3.9U5.2U5.9L (temp, above approximately 280 degrees F), an input
is sent to the powertrain control module (PCM). The
Engines—Typical
PCM will then force a 4-3 downshift. Once transmis
IDLE AIR CONTROL (SAC) MOTOR—PIN #40—PCM sion temperature has cooled below specifications, a
OUTPUT 3-4 upshift will be allowed. An instrument panel
Pin #40 controls one of the circuits for operation of mounted transmission temperature warning lamp
the IAC motor. Refer to Idle Air Control (IAC) Mo (Fig. 23) is also used.
tor—Pin #39—PCM Output for information. The PCM will prevent overdrive engagement when
the temperature of the transmission oil is below ap
OXYGEN (02S) SENSOR—PCM PIN #41—PCM proximately 60° F. The PCM will also prevent torque
INPUT converter engagement when the temperature of the
Refer to Oxygen (02S) Sensor-PCM Pin transmission oil is below approximately 70° F.
#23—PCM Input for information. This sensor is located in the transmission cooling
line on the side of the transmission (Fig. 30).
BR — — — — COMPONENT DESCRIPTION/SYSTEM OPERATION—EXCEPT DIESEL 14 - 45
CAMSHAFT \
TEMPERATURE SENSOR J9414-46
Fig. 30 Transmission Temperature Sensor Fig. 32 Camshaft Position Sensor—S.OL ¥-10 Engine
Location—Typical
DATA LINK CONNECTOR—PCM PIN #45—PCM
TACHOMETER—PCM PIN #43—PCM OUTPUT INPUT
The powertrain control module (PCM) supplies en Refer to Data Link Connector-PCM PIN
gine rpm values to the instrument cluster mounted #25-PCM Output for information.
tachometer (if equipped). Refer to Group 8E for ta
chometer information. CCD BUS(-)—PCM PIN #46—PCM OUTPUT
CAMSHAFT POSITION SENSOR—PCM PIN Various modules exchange information through a
communications port called the CCD BUS(-).
#44—PCM INPUT
A fuel sync signal is provided by the camshaft po VEHICLE SPEED SENSOR—PCM PIN #47—PCM
sition sensor. The sync signal from this sensor works INPUT
in conjunction with the crankshaft position sensor to The speed sensor (Fig. 33) is located in the exten
provide the powertrain control module (PCM) with sion housing of the transmission (2WD) or on the
inputs. This is done to establish and maintain correct transfer case extension housing (4WD). The sensor
injector firing order. The sensor is located in the dis input is used by the powertrain control module
tributor (Fig. 31-3.9L/5.2L/5.9L engine), or in the (PCM) to determine vehicle speed and distance trav
timing chain case/cover on the left-front side of the eled.
engine (Fig. 32-8.0L V-10 engine). The speed sensor generates 8 pulses per sensor
Refer to Camshaft Position Sensor in Group 8D, Ig revolution. These signals, in conjunction with a
nition System for more information. closed throttle signal from the throttle position sen
sor, indicate a closed throttle deceleration to the
PCM. When the vehicle is stopped at idle, a closed
throttle signal is received by the PCM (but a speed
sensor signal is not received).
Under deceleration conditions, the PCM adjusts the
idle air control (IAC) motor to maintain a desired
MAP value. Under idle conditions, the PCM adjusts
the IAC motor to maintain a desired engine speed.
In addition to determining distance and vehicle
speed, the output from the sensor is used to help con
trol:
• Speed control operation
• Transmission overdrive operation
• Transmission torque converter electrical operation
© Idle air control (IAC) motor for engine idle speed
• Fuel injector pulse width
Fig. 31 Camshaft Position Sensor—3.9U5.2L/5.9L
Engine
SENSOR
ELECTRICAL
CONNECTOR

received by the PCM after approximately one second
of engine cranking (start-up), the ASD relay will be
J9414-60 shut down.
The ground circuit for the coil in the ASD relay is
Fig. 33 Vehicle Speed Sensor—Typical controlled by the powertrain control module (PCM).
The PCM operates the relay by switching the ground
SPEED CONTROL—PCM PINS #48, #49 AND
circuit ON and OFF.
#50—PCM INPUT Also refer to Fuel Pump Relay—PCM Pin
The speed control system provides three separate #51—PCM Output for additional information.
inputs to the powertrain control module (PCM); On/
Off, Set and Resume. The On/Off input informs the FUEL PUMP RELAY—PCM PIN #51—PCM
PCM that the speed control system has been acti OUTPUT
vated. The Set input informs the PCM that a fixed
The PCM energizes the electric fuel pump and the
vehicle speed has been selected. The Resume input
oxygen sensor (02S) heating element through the
indicates to the PCM that the previous fixed speed is
fuel pump relay. Battery voltage is applied to the fuel
requested.
pump relay when the ignition key is ON. The relay is
The speed control operating range is from 50 km/h energized when a ground signal is provided by pin
to 142 km/h (35 to 85 mph). Inputs that effect speed #51 on the PCM.
control operation are: Refer to Automatic Shutdown Relay—PCM Pin
® Brake switch position #51—PCM Output for additional information.
• Park/neutral switch
The fuel pump will operate for approximately one
© Vehicle speed sensor
second unless the engine is operating or the starter
® Throttle position sensor
motor is engaged.
Refer to Group 8H for further speed control infor The fuel pump relay is located in the power distri
mation. bution center (PDC). The PDC is located next to the
battery in the engine compartment (Fig. 34). For the
AUTOMATIC SHUTDOWN (ASD) RELAY—PCM PIN
location of the relay within the PDC, refer to PDC
#51—PCM OUTPUT cover.
This circuit (pin #51) controls operation of both the
ASD and fuel pump relays. EVAP CANISTER PURGE SOLENOID—PCM PIN
The ASD relay is located in the power distribution #52—PCM OUTPUT
center (PDC). The PDC is located next to the battery This circuit controls a ground signal for operation
in the engine compartment (Fig. 34). For the location of the EVAP Canister Purge Solenoid.
of the relay within the PDC, refer to PDC cover. Refer to Group 25, Emission Control System. See
The ASD relay, after receiving signals from the EVAP Canister Purge Solenoid.
crankshaft and camshaft position sensors, will supply
battery voltage to the fuel injectors, ignition coil(s)
and generator field winding. If these signals are not
SPEED CONTROL—PCM PINS #53 AND #33—PCM when the engine is started up. With the engine run
OUTPUT ning, the lamp is turned ON/OFF depending upon
These two circuits control vent and vacuum opera engine speed and load.
tion of the speed control solenoids.
OVERDRIVE SOLENOID—PCM PIN #55—PCM
TORQUE CONVERTOR CLUTCH (TCC) SOLENOID— OUTPUT
PCM PIN #54—PCM OUTPUT
AUTOMATIC TRANSMISSION
AUTOMATIC TRANSMISSION This circuit controls operation of the transmission
This circuit (Fig. 35) controls operation of the mounted overdrive solenoid (Fig. 35) used for over
transmission mounted torque convertor (TCC) sole drive operation. The powertrain control module
noid used for torque convertor engagement. (PCM) will determine when to engage and disengage
the solenoid by monitoring engine rpm versus output
TORQUE CONVERTER CLUTCH voltage of the throttle position sensor. Also needed
AND OVERDRIVE SOLENOID
ELECTRICAL CONNECTOR are various inputs from:
• Engine coolant temperature
© Transmission temperature sensor (certain heavy-
duty applications only)
© Module timer
• Vehicle speed
© MAP sensor
SRI LAMP—PCM PIN #56—PCM OUTPUT

This circuit controls operation of the SRI lamp.
The instrument panel mounted service reminder
VEHICLE
SPEED indicator (SRI) lamp is used only on vehicles
SENSOR J9414-59 equipped with 5.9L V-8 or 8.0L V-10 heavy duty cycle
(HDC) engines. The lamp is displayed on the instru
Fig. 35 Electrical Connections at Transmission— ment panel as the MAINT REQ'D lamp (Fig. 36).
TCC and Overdrive Solenoids When the lamp has been activated, certain service/
The powertrain control module (PCM) will deter maintenance must be performed.
mine when to engage and disengage the solenoid by For required service/maintenance stated in time or
monitoring vehicle miles per hour (mph) versus the mileage, refer to Group 0, Lubrication and Mainte
output voltage of the throttle position sensor. Also nance. Also refer to Group 25, Emission Control Sys
needed are various inputs from: tem for additional information.
© Engine coolant temperature The SRI lamp is not used with the diesel engine.
® Module timer
© Engine rpm
© MAP sensor
MANUAL TRANSMISSION
If equipped with a manual transmission, pin #54
will control operation of the shift indicator lamp (if
equipped with lamp). The lamp is controlled by the
powertrain control module (PCM). The lamp illumi
nates on the instrument panel to indicate when the
driver should shift to the next highest gear for best
fuel economy. The PCM will turn the lamp OFF after
3 to 5 seconds if the shift of gears is not performed.
SERVICE REMINDER
The lamp will remain off until vehicle stops acceler INDICATOR LAMP
ating and is brought back to range of up-shift lamp
operation. This will also happen if vehicle is shifted
Fig. 36 SRI (MAINT REQ'D) Lamp Location
into fifth gear.
The indicator lamp is normally illuminated when
the ignition switch is turned on and it is turned off
14 - 48 COMPONENT DESCRIPTION/SYSTEM OPERATION—EXCEPT DIESEL — _ BR
AUTOMATIC SHUTDOWN (ASD) SENSE—PCM PIN Pressure Regulator in the Fuel Delivery System—Ex
#57—PCM INPUT cept Diesel section of this group.
A 12 volt signal at this input indicates to the PCM The fuel pressure regulator is a mechanical device
that the ASD has been activated. The ASD relay is not controlled by the powertrain control module
located in the power distribution center (PDC). The (PCM) or engine vacuum.
PDC is located next to the battery in the engine com
partment (Fig. 84). For the location of the relay THROTTLE BODY
within the PDC, refer to PDC cover. Filtered air from the air cleaner enters the intake
This relay is used to connect the ignition coil(s), manifold through the throttle body. Fuel does not en
generator field winding and fuel injectors to the 12 ter the intake manifold through the throttle body.
volt + power supply. Fuel is sprayed into the intake manifold by the fuel
The ASD relay is controlled by the PCM through injectors.
same circuit that the fuel pump relay is controlled. The throttle body is mounted on the top of the in
This input is used only to sense that the ASD relay take manifold on 3.9L/5.2L/5.9L engines (Fig. 37). On
is energized. If the powertrain control module (PCM) the 8.0L V-10 engine, a two-barrel side-mounted type
does not see 12 volts + at this input when the ASD throttle body is mounted to the upper half of the in
should be activated, it will set a diagnostic trouble take manifold (Fig. 38).
code (DTC). THROTTLE
FUEL INJECTORS—PGM PIN #58—PCM OUTPUT

3.9U5.2L/5.9L ENGINES
fuel injector on cylinder #6 on 3.9L/5.2L/5.9L engines.
for information.
8.0L 1MO ENGINE
engine (both injectors are fired simultaneously—one
cylinder on compression stroke and one cylinder on
exhaust stroke).
IDLE AIR CONTROL (IAC) MOTOR—PIN #59—PCM

OUTPUT
Pin #59 controls one of the circuits for operation of THROTTLE BODY
the IAC motor. Refer to Idle Air Control (IAC) Mo MOUNTING BOLTS
tor-Pin #39-PCM Output for information.
IDLE AIR CONTROL (IAC) MOTOR—PIN #60—PCM Fig. 37 Throttle Body—3.9U5.2U5.9L Engines
OUTPUT The throttle body contains an air control passage
Pin #60 controls one of the circuits for operation of (Figs. 39 or 40) controlled by the idle air control
the IAC motor. Refer to Idle Air Control (IAC) Mo (IAC) motor. The air control passage is used to sup
tor—Pin #39—PCM Output for information. ply air for idle conditions. A throttle valve (plate) is
used to supply air for above idle conditions. Refer to
FUEL FILTER Idle Air Control (IAC) Motor-Pin #39-PCM Output
A fuel tank mounted, combination, fuel filter/fuel in this group for more information.
pressure regulator is used for all gasoline powered On the 3.9L V-6 and 5.2L/5.9L V-8 engines, the
engines. For information, refer to Fuel Filter/Fuel throttle position sensor (TPS), idle air control (IAC)
Pressure Regulator in the Fuel Delivery System—Ex motor and manifold absolute pressure (MAP) sensor
cept Diesel section of this group. are attached to the throttle body. On the 8.0L V-10
engine, the TPS and IAC motor are attached to the
FUEL PRESSURE REiULATOR throttle body. The MAP sensor on the 8.0L engine is
A fuel tank mounted, combination, fuel filter/fuel attached to the intake manifold.
pressure regulator is used for all gasoline powered
engines. For information, refer to Fuel Filter/Fuel
INTAKE MANIFOLD VACUUM

UPPER HALF FITTING
IDLE AIR IDLE AIR

PASSAGE CONTROL (IAC)
MOTOR
NUTS (4f J9414-57 VIEW FROM BOTTOM l Q j n A A Q
Fig. 38 Throttle Body—S.OL V-10 Engine Fig. 40 Air Control Passage—8.0L V-10 Engine
pump module. Refer to Fuel Filter/Fuel Pressure
Regulator in the Fuel Delivery System—Except Die
sel section of this group.
Fig. 39 Air Control Passage—3.9U5.2U5.9L

Engines—Typical
The accelerator pedal cable, speed control cable and Fig. 41 Fuel Rail—3.9U5.2U5.9L Engines—Typical
transmission control cable (when equipped) are con
nected to the throttle arm. CAUTION: 3.9L/S.2L/5.9L ENGINES. The left and
A (factory adjusted) set screw is used to mechani right sections of the fuel rail are connected with a
cally limit the position of the throttle body throttle flexible connecting hose. Do not attempt to sepa
plate. Never attempt to adjust the engine idle rate the rail halves at this connecting hose (Fig. 41).
speed using this screw. All idle speed functions are Due to the design of this connecting hose, they do
controlled by the PCM. not use any clamps. Never attempt to install a
clamping device of any kind to the hose. When re
FUEL RAIL moving the fuel rail assembly for any reason, be
The fuel rail supplies the necessary fuel to each in careful not to bend or kink the connecting hose.
dividual fuel injector and is mounted to the intake
manifold (Figs. 41 or 42). The fuel pressure regulator
is not mounted to the fuel rail on any gas powered
engines. It is located on the fuel tank mounted fuel
14 - 50 COMPONENT DESCRIPTION/SYSTEM OPERATION—EXCEPT DIESEL -—^ - — BR
ELECTRICAL MOUNTING BOLTS ® Cruise

© Acceleration
• Deceleration
• Wide open throttle (WOT)
• Ignition switch OFF
The ignition switch On, engine start-up (crank), en
gine warm-up, acceleration, deceleration and wide
open throttle modes are Open Loop modes. The idle
and cruise modes, (with the engine at operating tem
perature) are Closed Loop modes.
IGNITION SWITCH MODE (KEY-ON/ENGINE
OFF)
This is an Open Loop mode. When the fuel system
is activated by the ignition switch, the following ac
tions occur:
• The powertrain control module (PCM) pre-posi-
tions the idle air control (IAC) motor.
• The PCM determines atmospheric air pressure
from the MAP sensor input to determine basic fuel
strategy.
© The PCM monitors the engine coolant temperature
Fig. 42 Fuel RailS.OL V-10 Engine—Typical
sensor input. The PCM modifies fuel strategy based
OPEN LOOP/CLOSED LOOP MODES OF on this input.
OPERATION • Intake manifold air temperature sensor input is
As input signals to the powertrain control module monitored.
(PCM) change, the PCM adjusts its response to the ® Throttle position sensor (TPS) is monitored.
output devices. For example, the PCM must calculate • The auto shutdown (ASD) relay is energized by the
different injector pulse width and ignition timing for PCM for approximately three seconds.
idle than it does for wide open throttle (WOT). There • The fuel pump is energized through the fuel pump
are several different modes of operation that deter relay by the PCM. The fuel pump will operate for ap
mine how the PCM responds to the various input sig proximately three seconds unless the engine is oper
nals. ating or the starter motor is engaged.
• The 02S sensor(s) heater element is energized
MODES through the fuel pump relay. The 02S sensor(s) input
• Open Loop is not used by the PCM to calibrate air-fuel ratio dur
< Closed Loop ing this mode of operation.
During Open Loop modes, the powertrain control • The up-shift indicator lamp is illuminated (manual
module (PCM) receives input signals and responds transmission only).
only according to preset PCM programming. Input
from the oxygen (02S) sensor(s) is not monitored ENGINE START-UP MODE
during Open Loop modes. This is an Open Loop mode. The following actions
During Closed Loop modes, the PCM will monitor occur when the starter motor is engaged.
the oxygen (02S) sensor input. This input indicates The powertrain control module (PCM) receives in
to the PCM whether or not the calculated injector puts from:
pulse width results in the ideal air-fuel ratio. This • Battery voltage
ratio is 14.7 parts air-to-1 part fuel. By monitoring © Engine coolant temperature sensor
the exhaust oxygen content through the 02S sensor, • Crankshaft position sensor
the PCM can fine tune the injector pulse width. This • Intake manifold air temperature sensor
is done to achieve optimum fuel economy combined © Manifold absolute pressure (MAP) sensor
with low emission engine performance. © Throttle position sensor (TPS)
The fuel injection system has the following modes • Starter motor relay
of operation: • Camshaft position sensor signal
• Ignition switch ON The PCM monitors the crankshaft position sensor.
® Engine start-up (crank) If the PCM does not receive a crankshaft position
® Engine warm-up sensor signal within 3 seconds of cranking the en
• Idle gine, it will shut down the fuel injection system.
The fuel pump is activated by the PCM through © Battery voltage

the fuel pump relay. • Park/Neutral Switch (Gear indicator signal—Auto,
Voltage is applied to the fuel injectors with the trans, only)
PCM. The PCM will then control the injection se o Oxygen sensor
quence and injector pulse width by turning the Based on these inputs, the following occurs:
ground circuit to each individual injector on and off. • Voltage is applied to the fuel injectors with the
The PCM determines the proper ignition timing ac powertrain control module (PCM). The PCM will
cording to input received from the crankshaft posi then control injection sequence and injector pulse
tion sensor. width by turning the ground circuit to each individ
ual injector on and off.
EffGfNE WARM-UP MODE • The PCM monitors the 02S sensor(s) input and
This is an Open Loop mode. During engine warm- adjusts air-fuel ratio by varying injector pulse width.
up, the powertrain control module (PCM) receives in It also adjusts engine idle speed through the idle air
puts from: control (IAC) motor.
® Battery voltage • The PCM adjusts ignition timing by increasing
• Crankshaft position sensor and decreasing spark advance.
• Engine coolant temperature sensor • The PCM operates the A/C compressor clutch
© Intake manifold air temperature sensor through the clutch relay. This happens if A/C has
• Manifold absolute pressure (MAP) sensor been selected by the vehicle operator and requested
• Throttle position sensor (TPS) by the A/C thermostat.
• Camshaft position sensor signal (in the distribu
tor) CRUISE MODE
o Park/Neutral Switch (Gear indicator signal—auto, When the engine is at operating temperature, this
trans, only) is a Closed Loop mode. At cruising speed, the power-
• Air conditioning request signal (if equipped) train control module (PCM) receives inputs from:
Based on these inputs the following occurs: • Air conditioning request signal (if equipped)
• Voltage is applied to the fuel injectors with the • Battery voltage
powertrain control module (PCM). The PCM will • Engine coolant temperature sensor
then control the injection sequence and injector pulse © Crankshaft position sensor
width by turning the ground circuit to each individ • Intake manifold air temperature sensor
ual injector on and off. • Manifold absolute pressure (MAP) sensor
• The PCM adjusts engine idle speed through the • Throttle position sensor (TPS)
idle air control (IAC) motor and adjusts ignition tim • Camshaft position sensor signal (in the distribu
ing. tor)
• The PCM operates the A/C compressor clutch • Park/Neutral switch (gear indicator signal—auto,
through the clutch relay. This is done if A/C has been trans, only)
selected by the vehicle operator and requested by the © Oxygen (02S) sensor(s)
A/C thermostat. • Transmission temperature sensor (certain HD
• If the vehicle has a manual transmission, the up models with auto, trans.)
shift lamp is operated by the PCM. Based on these inputs, the following occurs:
• When engine has reached operating temperature, • Voltage is applied to the fuel injectors with the
the PCM will begin monitoring 02S sensor(s) input. PCM. The PCM will then adjust the injector pulse
The system will then leave the warm-up mode and go width by turning the ground circuit to each individ
into closed loop operation. ual injector on and off.
• The PCM monitors the 02S sensor(s) input and
IDLE MODE adjusts air-fuel ratio. It also adjusts engine idle
When the engine is at operating temperature, this speed through the idle air control (IAC) motor.
is a Closed Loop mode. At idle speed, the powertrain • The PCM adjusts ignition timing by turning the
control module (PCM) receives inputs from: ground path to the coil(s) on and off.
• Air conditioning request signal (if equipped) • The PCM operates the A/C compressor clutch
• Battery voltage through the clutch relay. This happens if A/C has
• Crankshaft position sensor been selected by the vehicle operator and requested
• Engine coolant temperature sensor by the A/C thermostat.
• Intake manifold air temperature sensor
• Manifold absolute pressure (MAP) sensor ACCELERATION MODE
• Throttle position sensor (TPS) This is an Open Loop mode. The powertrain control
® Camshaft position sensor signal (in the distribu module (PCM) recognizes an abrupt increase in
tor) throttle position or MAP pressure as a demand for
increased engine output and vehicle acceleration. The WIDE OPEN THROTTLE MODE
PCM increases injector pulse width in response to in This is an Open Loop mode. During wide open
creased throttle opening. throttle operation, the powertrain control module
(PCM) receives the following inputs.
DECELERATION MODE • Battery voltage
When the engine is at operating temperature, this • Crankshaft position sensor
is an Open Loop mode. During hard deceleration, the • Engine coolant temperature sensor
powertrain control module (PCM) receives the follow
ing inputs.
• Manifold absolute pressure (MAP) sensor
© Air conditioning request signal (if equipped)
• Battery voltage • Throttle position sensor (TPS)
© Engine coolant temperature sensor • Camshaft position sensor signal (in the distribu
• Crankshaft position sensor tor)
• Intake manifold air temperature sensor During wide open throttle conditions, the following
® Manifold absolute pressure (MAP) sensor occurs:
• Throttle position sensor (TPS) © Voltage is applied to the fuel injectors with the
@ Camshaft position sensor signal (in the distribu powertrain control module (PCM). The PCM will
tor) then control the injection sequence and injector pulse
• Park/Neutral switch (gear indicator signal—auto, width by turning the ground circuit to each individ
trans, only) ual injector on and off. The PCM ignores the oxygen
If the vehicle is under hard deceleration with the sensor input signal and provides a predetermined
proper rpm and closed throttle conditions, the PCM amount of additional fuel. This is done by adjusting
will ignore the oxygen sensor input signal. The PCM injector pulse width.
will enter a fuel cut-off strategy in which it will not • The PCM adjusts ignition timing by turning the
supply battery voltage to the injectors. If a hard de ground path to the coil(s) on and off.
celeration does not exist, the PCM will determine the • The PCM opens the ground circuit to the A/C
proper injector pulse width and continue injection. clutch relay to disengage the A/C compressor clutch.
Based on the above inputs, the PCM will adjust en This will be done for approximately 15 seconds (if the
gine idle speed through the idle air control (IAC) mo air conditioning system is operating).
tor. If the vehicle has a manual transmission, the up
The PCM adjusts ignition timing by turning the shift lamp is operated by the PCM.
ground path to the coil(s) on and off.
The PCM opens the ground circuit to the A/C IGNITION SWITCH OFF MODE
clutch relay to disengage the A/C compressor clutch. When ignition switch is turned to OFF position,
This is done until the vehicle is no longer under de the PCM stops operating the injectors, ignition
celeration (if the A/C system is operating). coil(s), ASD relay and fuel pump relay.
mm GENERAL DIAGNOSIS—EXCEPT DIESEL 14- 53
MULTI-PORT F U E L I N J E C T I O N ( M F ! ) — G E N E R A L DIAGNOSIS—EXCEPT D I E S E L
page page
Automatic Shutdown (ASD) Relay Test 57 Oxygen (02S) Sensor Heating Element Test . . . . . 62
Camshaft Position Sensor Test 57 Powertrain Control Module (PCM) 60-Way
Crankshaft Position Sensor Test 57 Connector - 57
Diagnostic Trouble Code (DTC) . . . . . . . . ... 68 Powertrain Control Module Testing . . . . . . . . . . . . . 65
DRB Scan Tool 68 Relays—Operation/Testing 64
Engine Coolant Temperature Sensor Test . . . . . . . 57 Starter Motor Relay Test 65
Fuel Injector Test 66 System Schematics 57
Fuel Pump Pressure Test 66 Throttle Body Minimum Air Flow Check . . . . . . . . . 61
Fuel Pump Relay Test 59 Throttle Position Sensor Test 61
Idle Air Control (IAC) Motor Test . . . . . . . . . . . . . . 63 Transmission Temperature Sensor Test 58
Intake Manifold Air Temperature Sensor Test 59
Vehicle Speed Sensor Test 62
Manifold Absolute Pressure (Map) Sensor Test . . . 59
Visual Inspection 53
On-Board Diagnostics (OBD)—Gas Powered
Vehicles 66
WISUAL INSPECTION (2) Inspect the battery cable connections. Be sure

A visual inspection for loose, disconnected, or incor that they are clean and tight.
rectly routed wires and hoses should be made. This (3) Inspect fuel pump relay and air conditioning
should be done before attempting to diagnose or ser compressor clutch relay (if equipped). Inspect the
vice the fuel injection system. A visual check will ASD relay connections. Inspect starter motor relay
help spot these faults and save unnecessary test and connections. Inspect relays for signs of physical dam
diagnostic time. A thorough visual inspection will in age and corrosion. The relays are located in the
clude the following checks: power distribution center (PDC). The PDC is located
(1) Verify that the 60-way connector is fully in in the engine compartment (Fig. 2). For the location
serted into the connector of the powertrain control of this relay within the PDC, refer to PDC cover.
module (PCM) (Fig. 1). Verify that the connector
mounting screw is tightened to 4 N-m (35 in. lbs.)
torque.
PCM
MOUNTING

(4) Inspect ignition coil connections. Verify that coil
secondary cable(s) is firmly connected to coil (Fig. 3,
4 or 5).
(5) 3.9L/5.2L/5.9L Engines: Verify that distributor
PCM CONNECTOR cap is correctly attached to distributor. Be sure that
CONNECTOR MOUNTING spark plug cables are firmly connected to the distrib
BOLT J9414-9 utor cap and the spark plugs are in their correct fir
ing order. Be sure that coil cable is firmly connected
Fig. 1 Powertrain Control Module (PCM) to distributor cap and coil. Be sure that camshaft po-
14 - 54 GENERAL DIAGNOSIS—EXCEPT DIESEL BR
(6) Verify that generator output wire, generator

connector and ground wire are firmly connected to
the generator.
(7) Inspect the system body grounds for loose or
dirty connections. Refer to Group 8, Wiring for
ground locations.
(8) 3.9L/5.2L/5.9L Engines: Verify positive crank
case ventilation (PCV) valve operation. Refer to
Group 25, Emission Control System for additional in
formation. Verify PCV valve hose is firmly connected
to PCV valve and manifold (Fig. 6).
8.0L V-10 Engine: Verify firm connections at fixed
orifice fitting and connecting tube (Fig. 7).
COIL
J [CONNECTOR J92I4-7
Fig. 3 Ignition CoU—3.9U5.2U5.9L LDC-Gas Engine
Fig. 6 PCV Valve and Hose Connections—3.9U5.2U

COIL
CONNECTOR 5.9L Engines—Typical
VACUUM
Fig. 4 ignition Coil—5.9L HDC-Gas Engine HE
' J9414-64
ENGINE COIL
- CYLINDER^ "MOUNTING Fig. 7 Fixed Orifice Fitting Hose Connections—8. OL
s
NUMBER BOLTS (8) J948D-6
V-10 Engine—Typical
Fig. 5 Ignition Coil Packs—S.OL V-10 Engine (9) Verify that the fuel line, vacuum hose and elec
sition sensor wire connector (at the distributor) is trical connector are firmly connected to the fuel
firmly connected to harness connector. Inspect spark pump module. These can be inspected from over the
plug condition. Refer to Group 8D, Ignition. Connect top of the left-rear wheel.
vehicle to an oscilloscope and inspect spark events
for fouled or damaged spark plugs or cables.
GENERAL DIAGNOSIS—EXCEPT DIESEL 1 4 - 51
(10) Inspect fuel line quick-connect fitting-to-fuel rail

connection. On the 8.0L V-10 engine, the fuel line-to-
fuel rail connection is made at the rear of the engine.
(11) Verify that hose connections to all ports of vac
uum fittings on intake manifold are tight and not leak
ing.
(12) Inspect accelerator cable, transmission throt
tle cable (if equipped) and cruise control cable con
nections (if equipped). Check their connections to the
throttle arm of throttle body for any binding or re
strictions.
(13) If equipped with vacuum brake booster, verify
that vacuum booster hose is firmly connected to fit
ting on intake manifold. Also check connection to
brake vacuum booster.
(14) Inspect the air cleaner inlet and air cleaner el
ement for dirt or restrictions. Fig. 10 Sensor Location—S.OL ¥-10 Engine—Typical
(15) Inspect radiator grille area, radiator fins and
(17) Verify that MAP sensor electrical connector is
air conditioning condenser for restrictions.
(16) Verify that the intake manifold air tempera firmly connected to MAP sensor (Figs. 11 or 12). On
ture sensor wire connector is firmly connected to har 3.9L/5.2L/5.9L engines, also verify that rubber
ness connector (Figs. 8, 9 or 10). L-shaped fitting from MAP sensor to the throttle
body is firmly connected (Fig. 13).
Fig. 8 Sensor Location—3.9L V-6 Engine—Typical
Fig. 11 MAP Sensor—3.9U5.2U5.9L Engines-

Typical
(18) Verify that fuel injector wire harness connec
tors are firmly connected to injectors in the correct
order. Each harness connector is numerically tagged
with the injector number (INJ 1, INJ 2 etc.) of its
corresponding fuel injector and cylinder number.
(19) Verify harness connectors are firmly connected
to idle air control (IAC) motor, throttle position sen
sor (TPS) and manifold absolute pressure (MAP) sen
Fig. 9 Sensor Location—5.2U5.9L ¥-8 Engines- sor (Fig. 11).
Typical
Fig. 12 MAP Sensor—S.OL ¥-10 Engine—Typical Fig. 14 Coolant Temperature Sensor—3.9U5.2U5.9L

Engines—Typical
Fig. 13 Rubber Fitting—MAP SensoMo-Throttle Fig. 15 Coolant Temperature Sensor—8.0L ¥-10

Body— 3.9U5.2U5.9L Engines—Typical Engine
(20) Verify that wire harness connector is firmly
connected to the engine coolant temperature sensor
(Figs. 14 or 15).
(22) Verify that oxygen sensor wire connector (or
connectors) are firmly connected to the sensor (or
sensors). Inspect sensor(s) and connector(s) for dam
age (Figs. 16 or 17).
(23) Inspect for pinched or leaking fuel lines/tubes.
Inspect for pinched, cracked or leaking fuel hoses.
(24) Inspect for exhaust system restrictions such
as pinched exhaust pipes, collapsed muffler or
plugged catalytic convertor.
(25) If equipped with automatic transmission, ver EXHAUST ^
ify that electrical harness is firmly connected to park/ PIPE J9214-5
neutral switch. Refer to Automatic Transmission Fig. 16 Single Oxygen Sensor Location—3.9U5.2U
section of Group 21. 5.9L LDC Engines—Typical
(26) Verify that the harness connector is firmly
connected to the vehicle speed sensor (Fig. 18).
BR GENERAL DIAGNOSIS—EXCEPT DIESEL 14 - 57
POWERTRAIN CONTROL MODULE (PCM) 60-WAY

CONNECTOR
For PCM 60-way connector wiring schematics, refer
to Group 8W, Wiring Diagrams.
SYSTEM SCHEMATICS
Refer to PCM System Schematics—Except Diesel
in the Multi-Port Fuel Injection (MFI)—Component
Description/System Operation—Except Diesel section
of this group.
AUTOMATIC SHUTDOWN (ASD) RELAY TEST
To perform a complete test of the ASD relay and its
circuitry, refer to the DRB scan tool and appropriate
the relay only, refer to Relays—Operation/Testing in
Fig. 17 Dual Oxygen Sensor Location—5.9L and
this section of the group.
8.0L HDC Engines—Typical
CAMSHAFT POSITION SENSOR TEST
SENSOR
ELECTRICAL Refer to Group 8D, Ignition Systems, for Camshaft
CONNECTOR Position Sensor testing.
CRANKSHAFT POSITION SENSOR TEST
Refer to Group 8D, Ignition Systems, for Crank
shaft Position Sensor testing.
iNGINE COOLANT TEMPERATURE SENSOR TEST
the sensor only, refer to the following:
(1) Disconnect wire harness connector from coolant
temperature sensor (Figs. 19 or 20).
3.9L/5.2L/5.9L Engines with Air Conditioning:
When removing the connector from sensor, do not
pull directly on wiring harness. Fabricate an
L-shaped hook tool from a coat hanger (approximate
J9414-60 ly eight inches long). Place the hook part of tool un
der the connector for removal. The connector is
Fig. 18 Vehicle Speed Sensor—Typical snapped onto the sensor. It is not equipped with a
lock type tab.
(27) Verify that electric fuel pump/gauge sender
(2) Test the resistance of the sensor with a high in
unit wire connector is firmly connected to harness
put impedance (digital) volt-ohmmeter. The resis
connector. These can be inspected from over the top
tance (as measured across the sensor terminals)
of the left-rear wheel. should be less than 1340 ohms with the engine
(28) Inspect fuel hoses at fuel pump/gauge sender warm. Refer to the Sensor Resistance (OHMS)—En
unit for cracks or leaks. gine Coolant, Intake Air and Transmission Tempera
(29) Inspect transmission torque convertor housing ture Sensors resistance chart. Replace the sensor if it
(automatic transmission) or clutch housing (manual is not within the range of resistance specified in the
transmission) for damage to timing ring on drive chart.
plate/flywheel. (3) Test continuity of the wire harness. Do this be
(30) Verify that battery cable and solenoid feed tween the powertrain control module (PCM) wire
wire connections to the starter solenoid are tight and harness connector terminal 2 and the sensor connec
clean. Inspect for chaffed wires or wires rubbing up tor terminal. Also test continuity of wire harness ter
against other components. minal 4 to the sensor connector terminal. Repair the
wire harness if an open circuit is indicated.
14 -18 GENERAL DIAGNOSIS—EXCEPT DIESEL mm
SENSOR RESISTANCE (ONMS)-ENGINE
GOOLANT,IMTAKE AIR AND TRANSMISSION
TEMPERATURE SENSORS
TEMPERATURI RESISTANCE ( O H M S )
C F mm 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
10 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
Fig. 19 Coolant Temperature Sensor—3.91 ¥-6 or 50 122 3,330 3,880
5.2/5.9L ¥-8 Engines—Typical 60 140 2,310 2,670
70 158 1,630 1,870
80 176 1,170 1,340
90 194 860 970
100 212 640 720
no 230 480 540
120 248 370 410
J928D-4
specifications, a 3-4 upshift will be allowed. An in

strument panel mounted transmission temperature
warning lamp (Fig. 21) is also used.
INSTRUMENT
Fig, 20 Coolant Temperature Sensor—8.0L ¥-10

Engine
(4) After tests are completed, connect electrical
connector to sensor. The sensor connector is symmet
rical (not indexed). It can be installed to the sensor
in either direction.
TRANSMISSION TEMPERATURE 5ENS01 TEST
4-SPEED AUTOMATIC TRANSMISSIONS ONLY

To perform a complete test of this sensor and its Fig. 21 Transmission Temperature Warning
circuitry, refer to DRB scan tool and appropriate Lamp—Typical Location
Powertrain Diagnostics Procedures manual. To test This sensor is located in the transmission cooling
the sensor only, refer to the following: line on the side of the transmission (Fig. 22).
The transmission temperature sensor is used on Test the resistance of the sensor with a high input
models equipped with certain heavy-duty options and impedance (digital) volt-ohmmeter. The resistance (as
a 4-speed automatic transmission. Its purpose is to measured across the sensor terminals) should be less
help control transmission overheating. If transmis than 1340 ohms with the engine and transmission
sion overheating has been determined by this sensor, warm. Refer to the Sensor Resistance (OHMS)—En
an input is sent to the powertrain control module gine Coolant, Intake Air and Transmission Tempera-
(PCM). The PCM will then force a 4-3 downshift.
Once transmission temperature has cooled below
TRANSMISSION COOLING i INTAKE MANIFOLD

LINE o AIR TEMPERATURE
SENSOR
TRANSMISSION
TEMPERATURE SENSOR J9414-46 J9314-162
Fig. 22 Transmission Temperature Sensor Fig. 24 Sensor Location—5.2L/5.9L V-8 Engines—

Location—Typical Typical
ture Sensors resistance chart. Replace the sensor if it

is not within the range of resistance specified in the INTAKE MANIFOLD
AIR TEMP.
chart. SENSOR
FUEL PUMP RELAY TEST VI K I

To perform a complete test of this relay and its cir
cuitry, refer to the DRB scan tool and appropriate
TEST
circuitry, refer to DRB scan tool and appropriate J948D-10
Powertrain Diagnostics Procedures manual. To test Fig. 25 Sensor Location—8.0L V-10 Engine—Typical
the sensor only, refer to the following:
(1) Disconnect the wire harness connector from the (2) Test the resistance of the sensor with an input
intake manifold temperature sensor (Figs. 23, 24 or impedance (digital) volt-ohmmeter. The resistance (as
25). measured across the sensor terminals) should be less
than 1340 ohms with the engine warm. Refer to the
THROTTLE - SUPPORT BRACKET INTAKE Sensor Resistance (OHMS)—Engine Coolant, Intake
BODY ^ MANIFOLD
BRACKET AIR Air and Transmission Temperature Sensors resis
TEMPERATURE tance chart. Replace the sensor if it is not within the
SENSOR range of resistance specified in the chart.
(3) Test the resistance of the wire harness. Do this
between the powertrain control module (PCM) wire
harness connector terminal 21 and the sensor con
nector terminal. Also check between terminal 4 to the
sensor connector terminal. Repair the wire harness
as necessary if the resistance is greater than 1 ohm.

TEST
J9414-12
To perform a complete test of MAP sensor and its
Fig. 23 Sensor Location—3.9L V-6 Engine—Typical Powertrain Diagnostics Procedures manual. To test
the MAP sensor only, refer to the following:
14 - 80 GENERAL DIAGNOSIS—EXCEPT DIESEL ™ ~ -
3.9L V-6 or 5.2/5.9L V-8 Engines: The MAP sen

MOUNTING SCREWS
sor is mounted to the throttle body (Fig. 26). It is
connected to the throttle body with an L-shaped rub MAP SENSOR
ber fitting and to the PCM electrically.
MAP r f ^ h R U B B E R FITTING
SENSOR
J9314-87
Fig. 28 Rubber Fitting—MAP Sensor-to-Throttle

Body—Except S.OL V-10 Engine—Typical
(2) 3.9L V-6 or 5.2/5.9L V-8 Engines: Test the MAP
sensor output voltage at the MAP sensor connector
between terminals A and B (Fig. 29). With the igni
tion switch ON and the engine OFF, output voltage
should be 4-to-5 volts. The voltage should drop to 1.5-
to-2.1 volts with a hot, neutral idle speed condition.
\T~r:J9414-47
Fig. 26 MAP Sensor—3.9L V-6 or 5.2/5.9L V-8
Engines—Typical
8.0L V-10 Engine: The MA? sensor is mounted
into the right side of the intake manifold (Fig. 27). It
senses direct manifold vacuum and is connected to
the PCM electrically.
A. Ground
B. Output Voltage
C.5 Volts
J8914-91
Fig. 29 MAP Sensor Connector Terminals—3.9L V-6

or 5.2/5.9L V-8 Engines
J9414-1 (3) Test powertrain control module (PCM) termi
nal-1 for the same voltage described above to verify
Fig. 27 MAP Sensor—8.0L V-10 Engine—Typical the wire harness condition. Repair as necessary.
(1) 3.9L V-6 or 5.2/5.9L V-8 Engines: Inspect the (4) Test MAP sensor supply voltage at sensor con
rubber fitting from the MAP sensor to the throttle nector between terminals A and C (Fig. 29) with the
body (Fig. 28). Repair as necessary. ignition ON. The voltage should be approximately 5
volts (±0.5V). Five volts (±0.5V) should also be at
CAUTION: When testing the MAP sensor, be sure terminal-6 of the PCM wire harness connector. Re
that the harness wires are not damaged by the test pair or replace the wire harness as necessary.
meter probes. (5) Test the MAP sensor ground circuit at sensor
connector terminal-A (Fig. 29) and PCM connector

terminal-4. Repair the wire harness if necessary.
(6) Test the MAP sensor ground circuit at the PCM
connector between terminal-4 and terminal-11 with
an ohmmeter. If the ohmmeter indicates an open cir
cuit, inspect for a defective sensor ground connection.
Refer to Group 8W, Wiring for location of this connec
tion. If the ground connection is good, replace the
PCM. If terminal-4 has a short circuit to 12 volts +,
correct this condition before replacing the PCM.
THROTTLE POSITION SENSOR TEST

ual. To test the sensor only, refer to the following:
The throttle position sensor (Figs. 30 or 31) can be
tested with a digital voltmeter. The sensor must be
checked on the vehicle with its three wire connector
engaged to the sensor. The center terminal wire of
the sensor connector is the output terminal.
(1) Remove the air cleaner housing assembly. Refer
to the Fuel System Component Removal/Installation Fig. 31 Throttle Position Sensor—3.9L ¥-6 or
section for procedures. 5.2/5.9L ¥-8 Engines—Typical
(2) Carefully attach a paper clip into the center THROTTLE BODY MINIMUM All FLOW CHECK
terminal of the sensor harness.
(3) Attach the positive (+) lead of the voltmeter to 3,9L V«6 AND 5.2L/5.9L F»8 ENGINES
this paper clip. The following test procedure has been developed to
(4) Attach the negative (-) lead of the voltmeter to check throttle body calibrations for correct idle condi
a good ground. tions. The procedure should be used to diagnose the
With the ignition key in the ON position and en throttle body for conditions that may cause idle prob
gine not running, check the sensor output voltage at lems. This procedure should be used only after
the center terminal wire of the connector. Check this normal diagnostic procedures have failed to
at idle (throttle plate closed) and at wide open throt produce results that indicate a throttle body re
tle (WOT). At idle, sensor output voltage should be lated problem. Be sure to check for proper op
greater than 200 millivolts. At wide open throttle, eration of the idle air control motor before
sensor output voltage must be less than 4.8 volts. performing this test.
The output voltage should increase gradually as the A special fixed orifice tool (number 6714) (Fig. 32)
throttle plate is slowly opened from idle to WOT. must be used for the following test.
SPECIAL TOOL 6714
J9414-7
Fig. 32 Fixed Orifice Tool

(1) Start the engine and bring to operating temper
ature. Be sure all accessories are off before perform
ing this test.
Fig. 30 Throttle Position Sensor—8.0L ¥-10 (2) Shut off the engine and remove the air cleaner
Engine—Typical element housing.
14 -12 GENERAL DIAGNOSIS—EXCEPT DIESEL BR
(3) Disconnect the vacuum line at the PCV valve

(Fig. 33).
POWERTRAIN CONTROL
Fig. 35 Data Link Connector

(8) Using the DRB scan tool, scroll through the
Fig. 33 install Orifice Tool menus as follows: select—System, select—Engine, se
(4) Install the 0.185 inch orifice tool (number 6714) lect—Fuel and Ignition, select—Actuator Tests, se
into the disconnected vacuum line in place of the lect—Engine rpm and select—Minimum Air Flow.
PCV valve (Fig. 33). The DRB scan tool will count down to stabilize the
(5) Disconnect the idle purge vacuum line from fit idle rpm and display the minimum air flow idle rpm.
ting at throttle body. This vacuum line is located on The idle rpm should be between 500 and 900 rpm.
the front of throttle body next to the MAP sensor If the idle speed is outside of these specifications, re
(Fig. 34). Cap the fitting at throttle body after vac place the throttle body. Refer to Throttle Body in the
uum line has been removed. Component Removal/Installation section of this
group.
^ FRONT OF ENGINE (9) Disconnect the DRB scan tool from the vehicle.
(10) Remove cap from idle purge fitting at throttle
body and install vacuum line.
(11) Remove orifice tool and connect vacuum line
to PCV valve.
(12) Install air cleaner element housing.
VEHICLE SPEED SENSOR TEST
To perform a complete test of the sensor and its cir
cuitry, refer to DRB scan tool and appropriate Pow
ertrain Diagnostics Procedures manual.
OXYGEN (02S) SENSOR HEATING ELEMENT TEST
To perform a complete test of single or dual 02S
sensor(s) and circuitry, refer to DRB scan tool and
ual. To test the 02S sensor only, refer to the follow
ing:
On 3.9L V-6 and 5.2/5.9L V 8 LDC engines, the sin
gle 02S sensor is located on the right exhaust down
BODY J9414-6 pipe (Fig. 36).
On both the 5.9L V-8 HDC and 8.0L V-10 engines,
Fig. 34 Idle Purge Line the dual 02S sensors are located on each (left and
(6) Connect the DRB scan tool to the data link con right) exhaust down pipe (Fig. 37).
nector (Fig. 35) on the vehicle. Refer to the appropri The 02S heating element can be tested with an
ate Powertrain Diagnostic Procedures service manual ohmmeter as follows:
for DRB operation. Disconnect the 02S sensor connector. Connect the
(7) Start the engine. ohmmeter test leads across the white wire terminals
of the sensor connector. Resistance should be be-
GENERAL DIAGNOSIS—EXCEPT DIESEL 14 - 63
tween 5 and 7 ohms. Replace the sensor if the ohm MAP

meter displays an infinity (open) reading. SENSOR
OXYGEN
SENSOR
EXHAUST
PIPE J9214-5
Fig. 36 Single Oxygen Sensor—3.9L V-6 or 5.2/5.9L

V-8 LDC Engines
J9414-47
IDLE AIR INTAKE MANIFOLD

/UPPER HALF)
CONTROL MOTOR
Fig. 37 Dual Oxygen Sensors—5.9U8.0L HDC THROTTLE

Engines—Typical BODY
IDLE AIR CONTROL (IAC) MOTOR TEST Fig. 39 IAC Motor—S.OL IMO Engine—Typical
To perform a complete test of IAC motor (Figs. 38 (1) With the ignition OFF, disconnect the IAC mo
or 39) and its circuitry, refer to DRB scan tool and tor wire connector at throttle body.
appropriate Powertrain Diagnostics Procedures man (2) Plug the exerciser tool (7558) harness connector
ual. To test the IAC motor only, special IAC motor into the IAC motor. A typical tool hook-up is shown
exerciser tool number 7558 (Fig. 40) may be used. in figure 40.
(3) Connect the red clip of exerciser tool (7558) to
CAUTION: Proper safety precautions must be taken battery positive terminal. Connect the black clip to
when testing the IAC motor. negative battery terminal. The red lamp on the exer
ciser tool will be illuminated when the exerciser is
• Set the parking brake and block the drive wheels properly connected to battery.
• Route all tester cables away from the cooling fans, (4) Start engine.
drive belt, pulleys and exhaust components When the switch is in the HIGH or LOW position,
• Provide proper ventilation while operating the en the lamp on the exerciser tool will flash. This indi
gine cates that voltage pulses are being sent to the IAC
• Always return the engine idle speed to normal be stepper motor.
fore disconnecting the exerciser tool (5) Move the switch to the HIGH position. The en
gine speed should increase. Move the switch to the
14 - 3 4 GENERAL D I A G N O S I S — E X C E P T D I E S E L BR
IAC IAC IDLE AIR WIRE HARNESS

MOTOR MOTOR CONTROL STEPPER CONNECTION
TOOL MOTOR
CONNECTOR
IAC
MOTOR
CONNECTOR
PINTLE J9314-116
Fig. 41 IAC Stepper Motor Pintle—Typical

TO SPECIAL RELAYS—OPERATION/TESTING
BATTERY TOOL 7558 To perform a complete test of a relay and its cir
J9314-115 cuitry, refer to DRB scan tool and appropriate Pow
ertrain Diagnostics Procedures manual. To test the
Fig. 40 IMC Motor Testing—Typical Tool Hook-Up relay only, refer to the following:
LOW position. The engine speed should decrease. OPERATION
(a) If the engine speed changes while using the The following operations/tests apply to these
exerciser tool, the IAC motor is functioning prop relays only: Automatic Shutdown (ASD) and Fuel
erly. Disconnect the exerciser tool and connect the Pump. For operations/tests on all other relays, refer
IAC stepper motor wire connector to the stepper to the appropriate section of this service manual.
motor. These relays are located in the power distribution
(b) If the engine speed does not change, turn the center (PDC). The PDC is located in the engine com
ignition OFF and proceed to step (6). Do not dis partment (Fig. 42). For the location of this relay
connect exerciser from the IAC stepper motor. within the PDC, refer to PDC cover.
(6) Remove the IAC stepper motor from the throt
POWER
tle body. DISTRIBUTION
CENTER
CAUTION: When checking IAC motor operation with (PDC)
the motor removed from the throttle body, do not
extend the pintle (Fig. 41) more than 8.35 mm (.250
in). If the pintle is extended more than this amount, it
may separate from the IAC stepper motor. The IAC mo
tor must be replaced if the pintle separates from the
motor.
(7) With the ignition OFF, cycle the exerciser tool

switch between the HIGH and LOW positions. Ob
serve the pintle. The pintle should move in-and-out
of the motor.
J9414-10
(a) If the pintle does not move, replace the IAC
motor. Start the engine and test the replacement
motor operation as described in step (5).
(b) If the pintle operates properly, check the IAC The relay terminal numbers (Fig. 43) can be found
motor bore in the throttle body bore for blockage on the bottom of the relay.
and clean as necessary. Install the IAC motor and • Terminal number 30 is connected to battery volt
retest. If blockage is not found, refer to the DRB age and can be switched or B+ (hot) at all times.
scan tool and the appropriate Powertrain Diagnos • The center terminal number 87A is connected (a
tics Procedures service manual. circuit is formed) to terminal 30 in the de-energized
(normally OFF) position.
mm — GENERAL DIAGNOSIS—EXCEPT DIESEL 14 - 65
BOTTOM VIEW RELAY

CONNECTOR
OF RELAY
85 30 85 30
86 86
87 87A 87 87A
DE-ENERGIZED ENERGIZED
RELAY
Fig. 43 Re Terminals
• Terminal number 87 is connected (a circuit is CAUTION:. Do not allow the ohmmeter to contact
formed) to terminal 30 in the energized (ON) posi terminals 85 or 86 during these tests. Damage to
tion. Terminal number 87 then supplies battery volt ohmmeter may result.
age to the component being operated.
• Terminal number 86 is connected to a switched (+) (7) Attach the other jumper wire (12V +) to termi
power source. nal number 86. This will activate the relay. Continu
• Terminal number 85 is grounded by the power- ity should now be present between terminals number
train control module (PCM). 87 and 30. Continuity should not be present between
terminals number 87A and 30.
TESTING (8) Disconnect jumper wires from relay and 12 Volt
(1) Remove relay before testing. power source.
(2) Using an ohmmeter, perform a resistance test If continuity or resistance tests did not pass, re
between terminals 85 and 86. Resistance value place relay. If tests passed, refer to Group 8W, Wiring
(ohms) should be 75 ±5 ohms for resistor equipped Diagrams for (fuel system) relay wiring schematics
relays. and for additional circuit information.
(3) Connect the ohmmeter between terminals num
ber 87A and 30. Continuity should be present at this STARTER 10T0R RELAY TEST
time. Refer to Group 8A, Battery/Starting/Charging Sys
(4) Connect the ohmmeter between terminals num tem Diagnostics, for starter motor relay testing.
ber 87 and 30. Continuity should not be present at
this time. POWERTRAIN CONTROL MODULE TESTING
(5) Use a set of jumper wires (16 gauge or small Operation of the powertrain control module (PCM)
er). Connect one jumper wire between terminal num is tested with the DRB scan tool. Refer to the appro
ber 85 (on the relay) to the ground side (-) of a 12 priate Powertrain Diagnostic Procedures service
Volt power source. manual for tests.
(6) Attach the other jumper wire to the positive
side (+) of a 12V power source. Do not connect this
jumper wire to relay at this time.
14 - I I GENERAL DIAGNOSIS—EICEPT DIESEL B R
FUEL INJECTOR TEST ON-BOARD DIAGNOSTICS (OBD)—GAS POWERED

To perform a complete test of the fuel injectors and VEHICLES
their circuitry, refer to DRB scan tool and appropri The powertrain control module (PCM) has been
ate Powertrain Diagnostics Procedures manual. To programmed to monitor many different circuits of the
test the injector only, refer to the following: fuel injection system. If a problem is sensed in a
Disconnect the fuel injector wire harness connector monitored circuit often enough to indicate an actual
from the injector (Figs. 44 or 45). Place an ohmmeter problem, a diagnostic trouble code (DTC) is stored.
across the injector terminals. Resistance reading The DTC will be stored in the PCM memory for even
should be approximately 14.5 ohms ±1.2 ohms at tual display to the service technician. If the problem
20°C (68°P). is repaired or ceases to exist, the PCM cancels the
DTC after 51 engine starts.
Certain criteria must be met for a diagnostic trou
ble code (DTC) to be entered into PCM memory. The
criteria may be a specific range of engine rpm, engine
temperature and/or input voltage to the PCM.
It is possible that a DTC for a monitored circuit
may not be entered into memory even though a mal
function has occurred. This may happen because one
of the DTC criteria for the circuit has not been met.
Example: assume that one of the criteria for the
MAP sensor circuit is that the engine must be oper
ating between 750 and 2000 rpm to be monitored for
a DTC. If the MAP sensor output circuit shorts to
ground when the engine rpm is above 2400 rpm, a 0
volt input will be seen by the PCM. A DTC will not
be entered into memory because the condition does
not occur within the specified rpm range.
A DTC indicates that the powertrain control mod
ule (PCM) has recognized an abnormal signal in a
circuit or the system. A DTC may indicate the result
INJECTOR J9214-30
of a failure, but never identify the failed component
Fig. 44 Typical Fuel Injector Wiring Connector
directly.
There are several operating conditions that the
PCM does not monitor and set a DTC for. Refer to
the following Monitored Circuits and Non-Monitored
Circuits in this section.
MONITORED CIRCUITS
The powertrain control module (PCM) can detect
certain problems in the fuel injection system.
Open or Shorted Circuit - The PCM can deter
mine if sensor output (which is the input to PCM) is
within proper range. It also determines if the circuit
is open or shorted.
Output Device Current Flow - The PCM senses
whether the output devices are hooked up.
SPACER J9414-58
If there is a problem with the circuit, the PCM
senses whether the circuit is open, shorted to ground
Fig. 45 Fuel Injector Internal Components—Typical
(-), or shorted to (+) voltage.
Oxygen Sensor - The PCM can determine if the
FUEL P U i P PRESSURE TEST oxygen sensor is switching between rich and lean.
Refer to Fuel Pump Pressure Test in the Fuel De This is, once the system has entered Closed Loop. Re
livery System section of this group. fer to Open Loop/Closed Loop Modes Of Operation in
the Component Description/System Operation section
for an explanation of Closed (or Open) Loop opera
tion.
m — — GENERAL DIAGNOSIS—EXCEPT DIESEL 14 - 67
NON-MONITORED CIRCUITS tablish high and low limits that are programmed into
The PCM does not monitor the following circuits, it for that device. If the input voltage is not within
systems or conditions that could have malfunctions specifications and other diagnostic trouble code
that result in driveability problems. A diagnostic (DTC) criteria are met, a DTC will be stored in mem
trouble code (DTC) may not be displayed for these ory. Other DTC criteria might include engine rpm
conditions. limits or input voltages from other sensors or
Fuel Pressure; Fuel pressure is controlled by the switches. The other inputs might have to be sensed
fuel pressure regulator. The PCM cannot detect a by the PCM when it senses a high or low input volt
clogged fuel pump inlet filter, clogged in-line fuel fil age from the control system device in question.
ter, or a pinched fuel supply or return line. However,
these could result in a rich or lean condition causing ACCESSING DIAGNOSTIC TROUBLE CODES
an oxygen sensor DTC to be stored in the PCM. A stored diagnostic trouble code (DTC) can be dis
Secondary Ignition Circuits The PCM cannot played by cycling the ignition key ON-OFF-ON-
detect an inoperative ignition coil, fouled or worn OFF-ON within three seconds and observing the
spark plugs, ignition cross firing, or open circuited malfunction indicator lamp. This lamp is displayed
spark plug cables. on the instrument panel as the CHECK ENGINE
Engine Timings The PCM cannot detect an incor lamp (Fig. 46).
rectly indexed timing chain, camshaft sprocket or
crankshaft sprocket. The PCM also cannot detect an
incorrectly indexed distributor. However, these could
result in a rich or lean condition causing an oxygen
sensor DTC to be stored in the PCM.
Cylinder Compressions The PCM cannot detect
uneven, low, or high engine cylinder compression.
Exhaust Systems The PCM cannot detect a
plugged, restricted or leaking exhaust system.
Fuel Injector Malfunctions: The PCM cannot de
termine if the fuel injector is clogged, or the wrong
injector is installed. However, these could result in a
rich or lean condition causing an oxygen sensor DTC
to be stored in the PCM.
Excessive OH Consumption: Although the PCM
monitors exhaust stream oxygen content through ox
ygen sensor (closed loop), it cannot determine exces
sive oil consumption. Fig, 46 Check Engine Lamp—Typical Location
Throttle Body Air Flow: The PCM cannot detect They can also be displayed through the use of the
a clogged or restricted air cleaner inlet or air cleaner Diagnostic Readout Box (DRB scan tool). The DRB
element.
scan tool connects to the data link connector in the
Evaporative System: The PCM will not detect a
engine compartment (Fig. 47). For operation of the
restricted, plugged or loaded EVAP canister.
DRB, refer to the appropriate Powertrain Diagnostic
Vacuum Assist: Leaks or restrictions in the vac
uum circuits of vacuum assisted engine control sys Procedures service manual.
tem devices are not monitored by the PCM. However,
EXAMPLES:
a vacuum leak at the MAP sensor will be monitored
and a diagnostic trouble code (DTC) will be gener • If the lamp (Fig. 46) flashes 1 time, pauses and
ated by the PCM. flashes 2 more times, a flashing Diagnostic Trouble
Powertrain Control Module (PCM) System Code (DTC) number 12 is indicated. If this code is
Ground: The PCM cannot determine a poor system observed, it is indicating that the battery has been
ground. However, a DTC may be generated as a re disconnected within the last 50 key-on cycles. It
sult of this condition. could also indicate that battery voltage has been dis
Powertrain Control Module (PCM) Connector connected to the PCM. In either case, other DTC's
Engagement: The PCM cannot determine spread or may have been erased.
damaged connector pins. However, a DTC may be • If the lamp flashes 4 times, pauses and flashes 1
generated as a result of this condition. more time, a diagnostic trouble code (DTC) number
41 is indicated.
H I O H AND LOW LIMITS • If the lamp flashes 4 times, pauses and flashes 6
The powertrain control module (PCM) compares in more times, a diagnostic trouble code (DTC) number
put signal voltages from each input device. It will es- 46 is indicated.
14-68 GENERAL DIAGNOSIS—EXCEPT DIESEL —~ _ - — BR
DATA LINK
CONNECTOR
f t
<kn| yJ M«
f t
In » .J f 'MBI D-l GROUND
D-2 N/C
D-3 SC! TRANS
D-4 SCI RECEIVE
D-5 IGNITION *
J9214-20 D-6 NOT USED
Fig. 48 Data Link Connector Schematic

POWERTRAIN CONTROL ERASING TROUBLE CODES
MODULE (PCM) J9414-11 After the problem has been repaired, use the DRB
scan tool to erase a Diagnostic Trouble Code (DTC). Re
Fig, 47 Data Link Connector Location—Typical fer to the appropriate Powertrain Diagnostic Procedures
After any stored DTC information has been ob service manual for operation of the DRB scan tool.
served, the display will end with a flashing DTC
number 55. This will indicate the end of all stored in DRB SCAN TOOL
formation. For operation of the DRB scan tool, refer to the ap
Refer to the Diagnostic Trouble Code (DTC) charts propriate Powertrain Diagnostic Procedures service
for DTC identification. manual.
If the problem is repaired or ceases to exist, the
powertrain control module (PCM) cancels the DTC DIAGNOSTIC TROUBLE CODE (DTC)
after 51 engine starts. On the following pages, a list of diagnostic trouble
Diagnostic trouble codes indicate the results of a codes is provided for all gas powered engines. A DTC
failure, but never identify the failed component di indicates that the powertrain control module (PCM)
rectly. has recognized an abnormal signal in a circuit or the
The circuits of the data link connector are shown in system. A DTC may indicate the result of a failure,
(Fig. 48). but never identify the failed component directly.
DIAGNOSTIC TROUBLE CODE DESCRIPTIONS

Diagnostic Description of Diagnostic Trouble Code
DRB Scan Tool Display
Trouble Code
11* No Crank Reference Signal at PCM No crank reference signal detected during en
gine cranking.
12* None Direct battery input to P C M was disconnected

within the last 50 Key-on cycles.
13** No Change in M A P From Start to Run No difference recognized between the engine
M A P reading and the barometric (atmospheric)
pressure reading at start-up.
14** M A P Sensor Voltage Too Low M A P sensor input below minimum acceptable
voltage.
or
M A P Sensor Voltage Too High M A P sensor input above maximum acceptable
voltage.
* Check Engine Lamp will not illuminate at all times if this Diagnostic Trouble Code was recorded. Cycle
Ignition key as described in manual and observe code flashed by Check Engine lamp.
** Check Engine Lamp will illuminate during engine operation if this Diagnostic Trouble Code was recorded.
BR GENERAL DIAGNOSIS—EXCEPT DIESEL 14-69
DIAGNOSTIC TROUBLE CODE DESCRIPTIONS—CONTINUED

Diagnostic
DRB Scan Tool Display Description of Diagnostic Trouble Code
Trouble Code
15* No Vehicle Speed Sensor Signal No vehicle distance (speed) sensor signal de
tected during road load conditions.
17* Engine is Cold Too Long Engine coolant temperature remains below
normal operating temperatures during vehicle
travel (thermostat).
2V Neither rich or lean condition detected from

0 2 S Stays at Center the oxygen sensor input. If equipped with dual
0 2 S sensors, the DRB scan tool will specify
left or right sensor.
or
Oxygen sensor input voltage maintained above
02S Shorted to Voltage the normal operating range. If equipped with
dual 0 2 S sensors, the DRB scan tool will
specify left or right sensor.
22* ECT Sensor Voltage Too High- Engine coolant temperature sensor input
above maximum acceptable voltage.
or
Engine coolant temperature sensor input below
ECT Sensor Voltage Too Low minimum acceptable voltage.
23* Intake manifold air temperature sensor input

Intake Air Temp Sensor Voltage Low below the minimum acceptable voltage.
or
Intake manifold air temperature sensor input
above the maximum acceptable voltage.
Intake Air Temp Sensor Voltage High
24* Throttle position sensor input above the maxi
mum acceptable voltage.
Throttle Position Sensor Voltage High
Throttle position sensor input below the mini

or
25* Throttle Position Sensor Voltage Low A shorted condition detected in one or more of
the idle air control motor circuits.
27* Idle Air Control Motor Circuits Injector #1 output driver does not respond
properly to the control signal.
Injector #1 Control Circuit

Injector #2 Control Circuit Injector #2 output driver does not respond
or properly to the control signal.
or
; - #1 GENERAL DIAGNOSIS—EXCEPT DSESEL B

Diagnostic
D R B S c a n Tool Display Description of Diagnostic Trouble Code
Trouble Code

or
or
Injector #6 Control Circuit Injector # 5 output driver does not respond
or
or
or
Injector #8 output driver does not respond
Injector #8 Control Circuit properly to the control signal.
31' An open or shorted condition detected in the

EVAP Solenoid Circuit EVAP solenoid circuit.
32* An o p e n or shorted condition detected in the

EGR Solenoid Circuit EGR solenoid circuit.
or
A mechanical problem found in EGR system
EGR System Failure
(vacuum line leak, defective EGR valve,
plugged EGR tube, etc.).
33* A/C Clutch Relay Circuit An open or shorted condition detected in the
A/C clutch relay circuit.
34* Speed Control Solenoid Circuits An open or shorted condition detected in the
Speed Control vacuum or vent solenoid cir
cuits.
or
Speed Control switch input below the mini
Speed Control Switch Always Low mum acceptable voltage.
or
Speed Control Switch Always High Speed Control switch input above the maxi

Diagnostic
DRB Scan Tool Display Description ©f Diagnostic Trouble Code
Trouble Code
37* Torque Converter Clutch Solenoid CKT An open or shorted condition detected in the
CKT circuit.
or
Trans Temp Sensor Voltage Too Low Voltage Low at Trans Temp Sensor
er
Trans Temp Sensor Voltage Too High Voltage High at Trans Temp Sensor
AY Generator Field Not Switching Properly An open or shorted condition detected in the
generator field control circuit.
42* Auto Shutdown Relay Control Circuit An open or shorted condition detected in the
auto shutdown relay circuit.
43* Ignition Coil Circuit #1 An open or shorted condition detected in the

#1 coil circuit.
or
An open or shorted condition detected in the

Ignition Coil Circuit #2 #2 coil circuit.
or
Ignition Coil Circuit #3 An open or shorted condition detected in the
#3 coil circuit.
or
#4 coil circuit.
or "

#5 coil circuit.
44* Battery Temp Sensor Volts out of Limit An open or shorted condition exists in the en
gine coolant temperature sensor circuit or a
problem exists in the PCM's battery tempera
ture voltage circuit.
45* Trans Overdrive Solenoid Circuit An open or shorted condition exists in the
transmission overdrive solenoid circuit.
46* Charging System Voltage Too High Battery voltage sense input above target
charging voltage during engine operation.
47* Charging System Voltage Too Low Battery voltage sense input below target
charging during engine operation. Also, no sig
nificant change detected in battery voltage
during active test of generator output.

Diagnostic
DRB Scan Tool Display Description of Diagnostic Trouble Code
Trouble Code
51* System Lean L-ldle Adap at Rich Limit Oxygen sensor signal input indicates lean air/
fuel ratio condition at the left 0 2 S sensor dur
ing engine operation. If equipped with dual
or
System Lean R-ldle Adap at Rich Limit Oxygen sensor signal input indicates lean air/
fuel ratio condition at the right 0 2 S sensor
during engine operation. If equipped with dual
52* System Rich L-ldle Adap at Lean Limit Oxygen sensor signal input indicates rich air/
fuel ratio condition at the left 0 2 S sensor dur
ing engine operation. If equipped with dual
or
System Rich R-ldle Adap at Lean Limit Oxygen sensor signal input indicates rich air/
fuel ratio condition at the right 0 2 S sensor
during engine operation. If equipped with dual
53* Internal PCM Failure PCM Internal fault condition detected.
or
PCM Failure SPI (Serial Peripheral Inter PCM Internal fault condition detected.
face) Communications
54* No fuel sync (camshaft signal) detected during

No Cam Sync Signal at PCM engine cranking.
55* A DTC #55 is used to end all DTC messages.

Display not shown on DRB scan tool This code indicates a completion of all DTC's
displayed on the Malfunction Indicator Lamp
(Check Engine Lamp).
62* PCM Failure SRI miles not stored Unsuccessful attempt to update SRI (service
reminder indicator) miles in the PCM EE
PROM.
63* PCM Failure EEPROM Write Denied Unsuccessful attempt to write to an EEPROM
location by the PCM.
Check Engine Lamp will illuminate during engine operation if this Diagnostic Trouble Code was recorded.
BR — — — — COMPONENT REMOVAL/INSTALLATION—EXCEPT DIESEL 14 - 73
MULTI-PORT FUEL INJECTION fl«FI!—COMPONENT REMOVAL/INSTALLATION

E X C E P T DIESEL
INDEX
page page
Accelerator Pedal and T irottle Cable 75 Fuel Tank Pressure Relief/Rollover Valve . 80
Air Cleaner Housing/Air Cleaner Element (Filter) . . 73 Fuel Tanks . 80
Air Conditioning (A/C) Clutch Relay . . . . . . . . . . . . 75 Fuel Tubes/Lines/Hoses and Clamps 80
Automatic Shutdown (ASD) Relay . 75 Idle Air Control (IAC) Motor 80
Brake Switch 75 Ignition Coil 80
Camshaft Position Sensor 75 Intake Manifold . 81
Crankshaft Position Sensor 75 Intake Manifold Air Temperature Sensor . 75
Engine Coolant Temperature Sensor . . . . . . . . . . . 76 Manifold Absolute Pressure (MAP) Sensor 81
EVAP Canister Purge Solenoid 76 Oxygen (02S) Sensor 82
Fuel Filter 76 Park/Neutral Switch 83
Fuel Injector(s) 76
Powertrain Control Module (PCM) . 83
Fuel Pressure Regulator 76
Quick-Connect Fittings 83
Fuel Pump 77
Fuel Pump Module . . 77 Throttle Body 83
Fuel Pump Relay 77 Throttle Position Sensor (TPS) 84
Fuel Rail 77 Transmission Temperature Sensor 85
Fuel System Pressure Release Procedure . . . . . . . 80 Vehicle Speed Sensor 86
AIR CLEANER HOUSING/AIR CLEANER ELEMENT AIR INLET

(FILTER)
3.9L/5.2L/5.9L GAS ENGINES
For air cleaner element required maintenance
schedules (listed in time or mileage intervals), refer
to Group 0, Lubrication and Maintenance.
iElOWAL/IlSIALLATlil
CAUTION: Do not attempt to remove the air cleaner

element from the housing by removing the top
cower only. To prevent damage to the air cleaner
housing, the entire air cleaner housing assembly
must be removed from the engine for air cleaner el
ement replacement.
(1) Remove the air inlet tube (Fig. 1) at the side of

the air cleaner housing.
(2) A band-type screw clamp secures the air
cleaner housing to the throttle body. Loosen, but do
not remove, this screw clamp (Fig. 1). Note the clamp
positioning tabs on the air cleaner housing.
(3) All Gas Powered Engines: Disconnect the
breather hose at the rear of air cleaner housing.
5.9L V-8 HDC Engine Only: Disconnect the air
pump hose at the air cleaner housing.
(4) The bottom/front of the air cleaner housing is
equipped with a rubber grommet (Fig. 1). A mounting Fig. 1 Air Cleaner Housing—3.9U5.2U5.9L Gas
stud is attached to the intake manifold (Fig. 1) and is Powered Engines—Typical
used to position the air cleaner housing into this
grommet. Lift the assembly from the throttle body (5) Check condition of gasket at throttle body and
while slipping the assembly from the mounting stud replace as necessary.
(Fig. 1).
14 - 7 4 COMPONENT REMOVAL/INSTALLATION—EXCEPT DIESEL BR
(6) The housing cover is equipped with three (3) HOUSING

spring clips (Fig. 1) and is hinged at the rear with
plastic tabs. Unlatch the clips from the top of air
cleaner housing and tilt the housing cover up and
rearward for cover removal.
(7) Remove the air cleaner element from air
cleaner housing.
(8) Before installing a new air cleaner element,
clean inside of air cleaner housing.
(9) Position air cleaner cover to tabs on rear of air
cleaner housing. Latch the three spring clips to seal
cover to housing.
(10) Position the air cleaner housing assembly to
the throttle body while guiding the rubber grommet
over the mounting stud. The lower part of the screw
clamp should be below the top lip of the throttle
body.
(11) Push down on air cleaner housing at rubber
grommet to seat housing at intake manifold.
(12) Tighten throttle body-to-air cleaner housing
clamp to 4 N-m (35 in. lbs.) torque.
(13) Install the air inlet tube at air cleaner hous Fig. 3 Air Cleaner Housing—8.0L V-10 Engine—
ing inlet. Typical
8.0L V-10 ENGINE cover to housing (Fig. 3). Unlatch the clips from the
For air cleaner element required maintenance air cleaner cover and remove cover from air cleaner
schedules (listed in time or mileage intervals), refer housing.
to Group 0, Lubrication and Maintenance. (3) Remove the air cleaner element from air
A small amount of engine oil wetting the inside of cleaner cover.
the air cleaner housing is normal. When servicing, (4) Before installing a new air cleaner element,
wipe out the oil from the air cleaner housing. clean inside of air cleaner housing.
(5) Position air cleaner element into air cleaner
iElOfAL/INSIALLATiON cover. Latch the spring clips to seal cover to housing.
(1) Loosen the clamp (Fig. 2) and remove the air (6) Install the air inlet tube at air cleaner housing
inlet tube (Fig. 3) at the front of the air cleaner hous inlet.
ing cover. (7) Install and tighten clamp at air inlet tube (Fig.
4).
CLAMP ADJUSTABLE PLIERS
CLAMP ADJUSTABLE PLIERS
J9314-136
Fig. 2 Clamp Removal

Fig. 4 Clamp Installation
(2) The air cleaner housing and air cleaner ele
ment cover are equipped with spring clips to seal the
BR COMPONENT REMOVAL/INSTALLATION—EXCEPT DIESEL 14 - 75
ACCELERATOR PEDAL AND THROTTLE CABLE

Refer to the Accelerator Pedal and Throttle Cable
section of this group for removal/installation proce
dures.
AIR CONDITIONING (A/C) CLUTCH RELAY

The A/C clutch relay is located in the power distri
bution center (PDC). The PDC is located in the en
gine compartment (Fig. 5). For the location of this
relay within the PDC, refer to PDC cover.
Fig. 6 Sensor Location—3.9L V-6 Engine—Typical

AUTOMATIC SHUTDOWN (ASD) RELAY
The relay is located in the power distribution cen
ter (PDC). The PDC is located next to the battery in
the engine compartment (Fig. 5). For the location of
the relay within the PDC, refer to PDC cover. Fig. 7 Sensor Location—5.2L/5.9L V-8 Engines
Typical
BRAKE SWITCH
Refer to Group 5, Brakes for removal/installation
procedures.
CAMSHAFT POSITION SENSOR

For removal/installation procedures, refer to Group
8D, Ignition System. See Camshaft Position Sensor.
CRANKSHAFT POSITION SENSOR
Refer to Group 8D, Ignition System for removal/in
stallation procedures.

On 3.9L V-6 or 5.2/5.9L V-8 engines, the sensor is
threaded into the right-front side of the intake man
ifold (Figs. 6 or 7).
On 8.0L V-10 engines, the sensor is threaded into Fig. 8 Sensor Location—8.0L V-10 Engine—Typical
the left side of the intake manifold near the front of (2) Disconnect electrical connector at sensor (Figs.
the throttle body (Fig. 8). 6, 7 or 8).
REMOWAL (3) Remove sensor from intake manifold.
(1) Remove air cleaner assembly.
14 - 71 COMPONENT REMOVAL/INSTALLATION—EXCEPT DIESEL mm
INSTALLATION (1) Partially drain cooling system. Refer to Group
(1) Install sensor to intake manifold. Tighten to 28 7, Cooling.
N-m (20 ft. lbs.) torque. (2) 3.9L/5.2L/5.9L Engines: Remove air cleaner
(2) Install electrical connector. housing assembly. Refer to Air Cleaner Element/
(3) Install air cleaner. Housing in this section of the group.
(3) Disconnect electrical connector from sensor.
ENGINE COOLANT TEMPERATURE SENSOR 3.9L/5.2L/5.9L Engines with air conditioning:
On the 3.9L V-6 or 5.2/5.9L V-8 engines, the sensor When removing the connector from sensor, do not
is installed in the intake manifold near the thermo pull directly on wiring harness. Fabricate an
stat housing (Fig. 9). L-shaped hook tool from a coat hanger (approximate
On the 8.0L V-10 engine, the sensor is installed in ly eight inches long). Place the hook part of tool un
the thermostat housing (Fig. 10). der the connector for removal. The connector is
snapped onto the sensor. It is not equipped with a
lock type tab.
(4) Remove sensor from intake manifold or thermo
stat housing.
INSTALLATION
(1) Install sensor.
(2) Tighten to 11 N-m (8 ft. lbs.) torque.
(3) Connect electrical connector to sensor.
The sensor connector is symmetrical (not indexed).
It can be installed to the sensor in either direction.
(4) 3.9L/5.2L/5.9L Engines: Install air cleaner
housing assembly.
(5) Replace any lost engine coolant. Refer to Group
7, Cooling System.
EVAP CANISTER PURGE SOLENOID

Refer to Group 25, Emission Control System for re
moval/installation procedures.
FUEL FILTER
The fuel filter and fuel pressure regulator are one
combined part. A separate in-line fuel filter is not
used. Refer to Fuel Filter/Fuel Pressure Regulator in
the Fuel Delivery System—Except Diesel section of
this group for removal and installation procedures.
FUEL PRESSURE REGULATOR
The fuel filter and fuel pressure regulator are one
combined part. Refer ' to Fuel Filter/Fuel Pressure
Regulator in the Fuel Delivery System—Except Die
sel section of this group for removal and installation
procedures.
Pig. 10 Coolant Temperature Sensor—8.01 ¥-10

FUEL INJECTOR(S)
Engine
REMOVAL STANT P R E S S U R E ( E V E N WITH THE ENGINE
TURNED OFF). B E F O R E SERVICING THE F U E L IN
WARNING: HOT, P R E S S U R I Z E D COOLANT CAN J E C T O R ^ ) , THE F U E L S Y S T E M P R E S S U R E MUST
CAUSE INJURY BY SCALDING. COOLING SYSTEM BE RELEASED.
MUST B E PARTIALLY DRAINED BEFORE REMOV
ING THE COOLANT TEMPERATURE SENSOR. RE To release fuel pressure, refer to the Fuel Delivery
FER TO GROUP 7, COOLING. System section of this group. See Fuel System Pres
sure Release.
BR COMPONENT REMOVAL/INSTALLATION—EXCEPT DIESEL 14-77
To remove one or more fuel injectors, the fuel rail POWER

assembly must be removed from engine. DISTRIBUTION
CENTER
(PDC)
CUP
FUEL RAIL
J9414-10
INJECTOR J9214-24
Fig. 11 Fuel injector and Retaining Clip
TURNED OFF). B E F O R E SERVICING THE F U E L
REMOVAL RAIL ASSEMBLY, THE F U E L S Y S T E M P R E S S U R E
(1) Remove air cleaner assembly. MUST B E R E L E A S E D .
(2) Remove fuel rail assembly. Refer to Fuel Rail
removal in this section. To release fuel pressure, refer to the Fuel Delivery
(3) Remove the clip(s) retaining the injector(s) to System section of this group. See Fuel System Pres
fuel rail (Fig. 11). sure Release.
(4) Remove injector(s) from fuel rail.
REMOVAL—3.BL/5.2L/5*9L ENGINES
INSTALLATION
CAUTION: The left and right fuel rails are replaced
(1) Apply a small amount of engine oil to each fuel
as an assembly. Do not attempt to separate the rail
injector o-ring. This will help in fuel rail installation.
halves at the connecting hose (Fig. 13). Due to the
(2) Install injector(s) and injector clip(s) to fuel
rail. design of this connecting hose, it does not use any
(3) Install fuel rail assembly. Refer to Fuel Rail in clamps. Never attempt to install a clamping device
stallation. of any kind to the hose. When removing the fuel rail
(4) Install air cleaner. assembly for any reason, be careful not to bend or
(5) Start engine and check for leaks. kink the connecting hose.
FUEL RAIL
FUEL PUMP MODULE CONNECTING
HOSE
Refer to Fuel Pump Module in the Fuel Delivery
System section of this group for removal/installation
procedures.
FUEL PUMP
The electric fuel pump is not serviced separately.
The fuel pump module must be replaced. Refer to
Fuel Pump Module in the Fuel Delivery System sec
tion of this group for removal/installation procedures.
FUEL PUMP RELAY

The relay is located in the power distribution cen
ter (PDC). The PDC is located next to the battery in LATCH CLIP
J9514-7
the engine compartment (Fig. 12). For the location of
the relay within the PDC, refer to PDC cover. Fig. 13 Fuel RaH—3.9U5.2U5.9L Engines—Typical
FUEL RAIL (1) Remove negative battery cable at battery.

(2) Remove air cleaner tube and housing.
WARNING: THE F U E L S Y S T E M I S UNDER A CON
STANT P R E S S U R E (EVEN WITH THE ENGINE
14 - 78 COMPONENT REMOVAL/INSTALLATION—EXCEPT DIESEL BR
(3) Perform the fuel pressure release procedure. (7) 3.9L (V-6) engine only: Disconnect electrical
Refer to the Fuel Delivery System section of this connector at intake manifold air temperature sensor.
group. Do not remove sensor.
(4) Remove throttle body from intake manifold. Re (8) Remove EVAP canister purge solenoid/bracket
fer to Throttle Body removal in this group. assembly (Fig. 16) from intake manifold (one nut on
(5) If equipped with air conditioning, remove the 3.9L, one bolt on 5.2L/5.9L).
A/C compressor-to-intake manifold support bracket
(three bolts) (Fig. 14).
Fig. 16 EVAP Canister Purge Solenoid—3.9U5.2U

5.9L Engines—Typical
Fig. 14 A/C Compressor Support Bracket—3.9U5.2U
5.9L Engines—Typical (9) Disconnect the main fuel line at side of fuel rail
(Fig. 17). Refer to Fuel Tubes/Lines/Hoses and
(6) Disconnect electrical connectors at all fuel in Clamps in the Fuel Delivery System section of this
jectors (Fig. 15). The factory fuel injection wiring har group for procedures.
ness is numerically tagged (INJ 1, INJ 2, etc.) for
injector position identification. -
Fig. 17 Fuel Line at Fuel Rail—3.9U5.2U5.9L

Engines—Typical
(10) Remove the remaining fuel rail mounting
bolts (Fig. 13).
FUEL (11) Gently rock and pull the left fuel rail until
INJECTOR J9214-30 the fuel injectors just start to clear the intake mani
fold. Gently rock and pull the right fuel rail until
Fig. 15 Injector Connectors—3.9L/5.2U5.9L the fuel injectors just start to clear the intake mani
Engines—Typical fold. Repeat this procedure (left/right) until all fuel
injectors have cleared the intake manifold.
COMPONENT REMOVAL/INSTALLATION—EXCEPT DIESEL 14-78
(12) Remove fuel rail (with injectors attached) from (3) Perform "the fuel pressure release procedure.
engine. Refer to the Fuel Delivery System section of this
(13) Remove the clip(s) retaining the injector(s) to group.
fuel rail (Fig. 18). (4) Disconnect throttle body linkage and remove
throttle body from intake manifold. Refer to Throttle
Body removal in this group.
(5) Remove ignition coil pack and bracket assembly
(Fig. 19) at intake manifold and right engine valve
CUP
cover (four bolts).
COIL PACKS
AND BRACKET
INJECTOR J92I4-24
Fig, 18 Fuel injector Clip—Typical

INSTALLATION—3.BL/5.2L/5.9L ENGINES MOUNTING
(1) Apply a small amount of engine oil to each fuel BOLTS (4) '
injector o-ring. This will help in fuel rail installation.
(2) Install injector(s) and injector clip(s) to fuel
rail.
(3) Position the fuel rail/fuel injector assembly to
the injector openings on the intake manifold.
(4) Guide each injector into the intake manifold.
Be careful not to tear the injector o-ring.
(5) Push the right fuel rail down until fuel injec FRONT OF ENGINE J9414-55
tors have bottomed on injector shoulder. Push the
left fuel rail down until fuel injectors have bottomed Fig, 19 Ignition Coil Pack and Mounting Bracket—
on injector shoulder. S.OL ¥-10 Engine
(6) Install fuel rail mounting bolts. (6) Remove upper half of intake manifold. Refer to
(7) Install EVAP canister purge solenoid to intake Group 11, Exhaust System and Intake Manifold for
manifold. procedures.
(8) Connect electrical connector to intake manifold (7) Disconnect electrical connectors at all fuel in
air temperature sensor. jectors. The factory fuel injection wiring harness is
(9) Connect wiring to all fuel injectors. The injector numerically tagged (INJ 1, INJ 2, etc.) for injector
wiring harness is numerically tagged. position identification.
(10) Install the A/C support bracket (if equipped). (8) Disconnect main fuel line at fuel rail. On the
(11) Install throttle body to intake manifold. Refer 8.0L V-10 engine, the fuel line-to-fuel rail connection
to Throttle Body installation in this section of the is made at the rear of the engine. Refer to Fuel
group. Tubes/Lines/Hoses and Clamps in the Fuel Delivery
(12) Install main fuel line at fuel rail (Fig. 17). Re System section of this group for procedures.
fer to Fuel Tubes/Lines/Hoses and Clamps in the (9) Remove the six fuel rail mounting bolts from
Fuel Delivery System section of this group for proce the lower half of intake manifold (Fig. 20).
dures. (10) Gently rock and pull the left fuel rail until
(13) Install air cleaner tube and housing. the fuel injectors just start to clear the intake mani
(14) Connect battery cable to battery. fold. Gently rock and pull the right fuel rail until
(15) Start engine and check for leaks. - the fuel injectors just start to clear the intake mani
fold. Repeat this procedure (left/right) until all fuel
REMOVAL—8.0L V-10 ENGINE injectors have cleared the intake manifold.
(1) Remove negative battery cable at battery. (11) Remove fuel rail (with injectors attached) from
(2) Remove air cleaner housing and tube. engine.
14-80 COMPONENT REMOVAL/INSTALLATION—EXCEPT DIESLL - — BR
ELECTRICAL MOUNTING BOLTS (11) Install throttle body to intake manifold. Refer
to Throttle Body removal in this group.
(12) Install throttle body linkage to throttle body.
(13) Install air cleaner tube and housing.
(14) Install negative battery cable at battery.
(15) Start engine and check for leaks.
FUEL SYSTEM PRESSURE RELEASE PROCEDURE
WARNING: THE FUEL S Y S T E M IS UNDER A CON

STANT P R E S S U R E (EVEN WITH THE ENGINE
TURNED OFF). B E F O R E SERVICING THE F U E L
PUMP, F U E L LINES ( T U B E S ) , F U E L FILTER, F U E L
PRESSURE REGULATOR OR F U E L INJECTOR(S),
THE FUEL S Y S T E M P R E S S U R E MUST B E R E
LEASED.
To release fuel pressure, refer to the Fuel Delivery

System section of this group. See Fuel System Pres
sure Release Procedure.
FUEL TANKS
Fig. 20 Fuel Rail Mounting Bolts—8.0L V-10
Refer to the Fuel Tank section of this group for re
Engine—Typical
moval/installation procedures.
(12) Remove the clip(s) retaining the injector(s) to
fuel rail (Fig. 18). FUEL TANK PRESSURE RELIEF/ROLLOVER VALVE
Refer to the Fuel Tank section of this group for re
INSTALLATION—8.0L W-10 ENGINE moval/installation procedures.
(1) Apply a small amount of engine oil to each fuel
injector o-ring. This will help in fuel rail installation. FUEL TUBES/LINES/HOSES AND CLAMPS
(2) Install injector(s) and injector clip(s) to fuel Refer to Fuel Tubes/Lines/Hoses and Clamps in the
rail. Fuel Delivery System section of this group for remov
The fuel injector electrical connectors on all al/installation procedures.
10 injectors should be facing to the right (pas Also refer to Quick-Connect Fittings in the Fuel
senger) side of the vehicle (Fig. 2 0 ) . Delivery System section of this group for removal/in
(3) Position the fuel rail/fuel injector assembly to stallation procedures.
the injector openings on the intake manifold.
(4) Guide each injector into the intake manifold. IDLE AIR CONTROL (IAC) MOTOR
Be careful not to tear the injector o-ring. The idle air control (IAC) motor is mounted to the
(5) Push the right fuel rail down until fuel injec throttle body (Figs. 21 or 22).
tors have bottomed on injector shoulder. Push the
left fuel rail down until fuel injectors have bottomed REMOVAL
on injector shoulder. (1) Remove air cleaner housing and tube assembly.
(6) Install the six fuel rail mounting bolts into the (2) Disconnect electrical connector from IAC motor.
lower half of intake manifold. Tighten bolts to 15 (3) Remove two mounting bolts (screws) (Fig. 23).
N-m (136 in. lbs.) torque. (4) Remove IAC motor from throttle body.
(7) Connect wiring to all fuel injectors. The injector
wiring harness is numerically tagged. INSTALLATION
(8) Install upper half of intake manifold. Refer to (1) Install IAC motor to throttle body.
Group 11, Exhaust System and Intake Manifold for (2) Install and tighten two mounting bolts (screws)
procedures. to 7 N-m (60 in. lbs.) torque.
(9) Connect main fuel line at fuel rail. Refer to (3) Install electrical connector.
Fuel Tubes/Lines/Hoses and Clamps in the Fuel De (4) Install air cleaner assembly.
livery System section of this group for procedures.
(10) Install ignition coil pack and bracket assembly IGNITION COIL
(Fig. 19) at intake manifold and right engine valve Refer to Group 8D, Ignition Systems for removal/
cover (four bolts). installation procedures.
^ COMPONENT REMOVAL/INSTALLATION—EXCEPT DIESEL 14 - 81
J9214-23
Fig. 23 Typical Mounting Bolts (Screws)—SAC Motor
Fig. 24 MAP Sensor L-Shaped Rubber Fitting—3.9U

5.2U5.9L Engines—Typical
(3) Remove two MAP sensor mounting bolts
(screws) (Fig. 24).
(4) While removing MAP sensor, slide the rubber
Fig. 22 IAC Motor—S.OL Engine—Typical L-shaped vacuum fitting (Fig. 24) from the throttle
INTAKE MANIFOLD body fitting.
(5) Remove rubber L-shaped fitting from MAP sen
Refer to Group 11, Exhaust System and Intake
sor.
Manifold for removal/installation procedures.
INSTALLATION
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR (1) Install rubber L-shaped fitting to MAP sensor.
REMOVAL—3„BL V-6 OR 5.2/5.9 L V-8 ENGINES (2) Position sensor to throttle body while guiding
The MAP sensor is located on the front of the rubber fitting over throttle body vacuum fitting.
throttle body (Fig. 21). An L-shaped rubber fitting is (3) Install MAP sensor mounting bolts (screws).
used to connect the MAP sensor to throttle body (Fig. Tighten screws to 3 N-m (25 in. lbs.) torque.
24). (4) Install throttle body. Refer to Throttle Body in
The throttle body must be removed from the stallation in this section.
intake manifold for MAP sensor removal. (5) Install air cleaner assembly.
(1) Remove air cleaner assembly and tube. REMOVAL—8.0L V-10 ENGINE
(2) Remove throttle body. Refer to Throttle Body The MAP sensor is mounted into the right upper
removal in this section. side of the intake manifold (Fig. 25). A rubber gasket
14 - 82 COMPONENT REMOVAL/INSTALLATION—EXCEPT DIESEL
is used to seal the sensor to the intake manifold. The

rubber gasket is part of the sensor and is not ser
viced separately.
EXHAUST
PIPE J9214-5
Fig. 26 Single Oxygen Sensor—3.9U5.2U5.9L LDC

Engine
Fig. 25 MAP Sensor Location—8.0L ¥-10 Engine-

Typical
(1) Remove the electrical connector at the sensor.
(2) Clean the area around the sensor before re
moval.
(3) Remove the two sensor mounting bolts.
(4) Remove the sensor from the intake manifold.
INSTALLATION
(1) Check the condition of the sensor seal. Clean
the sensor and lubricate the rubber gasket with clean
engine oil.
(2) Clean the sensor opening in the intake mani
fold.
(3) Install the sensor into the intake manifold. Fig. 27 Dual Oxygen Sensors—5.9L and 8.0L HDC
(4) Install sensor mounting bolts. Tighten bolts to Engine—Typical
2 N-m (20 in. lbs.) torque. CAUTION: When disconnecting the sensor electrical
(5) Install the electrical connector to sensor. connector, do not pull directly on wire going into
sensor.
OXYGEN (02S) SENSOi
On 3.9L/5.2L/5.9L LDC engines, the single 02S (3) Remove the 02S sensor from the exhaust man
sensor is located on the right exhaust down pipe (Fig. ifold. Snap-On oxygen sensor wrench (number YA
26). On 5.9L V-8 HDC and 8.0L V-10 HDC engines, 8875) may be used for removal and installation.
the dual 02S sensors are located on each (left and
right) exhaust down pipe (Fig. 27). INSTALLATION
Threads of new oxygen sensors are factory coated
REMOVAL with anti-seize compound to aid in removal. DO
NOT add any additional anti-seize compound to
WARNING: THE EXHAUST MANIFOLD B E C O M E S the threads of a new oxygen sensor.
V E R Y HOT DURING ENGINE OPERATION. A L L O W If threads in exhaust pipe are damaged, they may
ENGINE TO COOL B E F O R E REMOVING O X Y G E N be rethreaded with an 18 mm x 1.5 pitch +6E tap.
SENSOR. Blow off metal material in exhaust pipe before in
stalling 02S sensor.
(1) Raise and support the vehicle. (1) Install the 02S sensor into the exhaust mani
(2) Disconnect the wire connector(s) from the 02S fold. Tighten to 30 N-m (22 ft. lbs.) torque.
sensor(s). (2) Connect the 02S sensor wire connector.
BR COMPONENT REMOVAL/INSTALLATION—EXCEPT DIESEL 14 - 83
PARK/NEUTRAL SWITCH (3) Remove the three PCM mounting bolts (Fig.
Refer to Group 21, Transmission and Transfer Case 29).
for removal/installation procedures. (4) Remove PCM from vehicle.
POWERTRAIN CONTROL MODULE (PCM) INSTALLATION

(1) Check pins in PCM 60-way connector for dam
REMOVAL age. Repair as necessary.
The powertrain control module (PCM) is located in (2) Position PCM and install mounting bolts.
the right-rear side of the engine compartment (Fig. Tighten bolts to 1 N-m (9 in. lbs.) torque.
28). It is mounted to the dash panel cowl with three (3) Connect 60-way electrical connector to PCM.
bolts (Fig. 29). The PCM was formerly referred to as Tighten bolt to 4 N-m (35 in. lbs.) torque.
the SBEC or engine controller. (4) Connect negative battery cable to battery. *
QUICK-CONNECT FITTINGS
Refer to the Fuel Delivery System section of this
group for removal/installation procedures.
THROTTLE BODY
A (factory adjusted) set screw is used to mechani
cally limit the position of the throttle body throttle
plate. Never attempt to adjust the engine idle
speed using this screw. All idle speed functions are
controlled by the powertrain control module (PCM).
The throttle body is mounted on the top of the in
take manifold on 3.9L/5.2L/5.9L engines (Fig. 30). On
POWERTRAIN CONTROL
the 8.0L V-10 engine, a two-barrel side-mounted type
throttle body is mounted to the upper half of the in
take manifold (Fig. 31).
THROTTLE
PCM
MOUNTING
THROTTLE BODY
PCM CONNECTOR MOUNTING BOLTS
CONNECTOR MOUNTING
BOLT J9414-9
Fig. 30 Throttle Body Mounting—3.9U5.2U5.9L
Fig. 29 PCM Mounting Engines
(1) Disconnect negative battery cable at battery. REMOVAL
(2) Remove 60-way electrical connector from PCM (1) Remove the air cleaner assembly.
(one screw) (Fig. 29). (2) 3.9L/5.2L/5.9L Engines: Disconnect throttle
body electrical connectors at MAP sensor, IAC motor
14 - 84 COMPONENT REMOVAL/INSTALLATION—EXCEPT DIESEL
INTAKE MANIFOLD THROTTLE POSITION SENSOR (TPS)

UPPER HALF
The throttle position sensor (TPS) is located on the
left side of the throttle body on the 3.9L V-6 or 5.2/
5.9L V-8 engines (Fig. 32).
The TPS is located on the rear of the throttle body
just below the idle air control motor on the 8.0L V-10
engine (Fig. 33).
NUTS (4) J9414-57
Fig. 31 Throttle Body Mounting—S.OL ¥-10 Engine

and TPS. 8.0L V-10 Engine: Disconnect throttle
body electrical connectors at IAC motor and TPS.
(3) 3.9L/5.2L/5.9L Engines: Remove vacuum line
at throttle body.
(4) Remove (unsnap) all control cables from throt
tle body (lever) arm. Refer to the Accelerator Pedal
and Throttle Cable section of this group for addi Fig. 32 TPS Location—3.9L ¥-6 or 5.2/5.9L ¥-8
tional information. Engines—Typical
(5) 3.9L/5.2L/5.9L Engines: Remove the four
throttle body mounting bolts (Fig. 30). 8.0L V-10 En
gine: Remove the four throttle body mounting nuts
(Fig. 31).
(6) Remove throttle body from intake manifold.
(7) Discard old throttle body-to-intake manifold
gasket.
INSTALLATION
(1) Clean the mating surfaces of the throttle body
and the intake manifold.
(2) Install new throttle body-to-intake manifold
gasket.
(3) Install throttle body to intake manifold.
(4) 3.9L/5.2L/5.9L Engines:Install four mounting
bolts. Tighten bolts to 23 N-m (200 in. lbs.) torque.
8.0L V-10 Engine: Install four mounting nuts and Fig. 33 TPS Location—8.0L ¥-10 Engine—Typical
tighten to 11 N-m (96 in. lbs.) torque. REMOVAL
(5) Install control cables. (1) Remove the air cleaner housing assembly. Refer
(6) Install vacuum line to throttle body. to the Component Removal/Installation section for
(7) Install electrical connectors. procedures.
(8) Install air cleaner assembly. (2) Disconnect TPS electrical connector.
(3) Remove two TPS mounting bolts (Figs. 34 or
35).
(4) Remove TPS from throttle body.
COMPONENT REMOWAL/1NSTALLAT10N—EXCEPT DIESEL 14 - 81
THROTTLE THROTTLE THROTTLE

BODY POSITION
THROTTLE SOCKET L O C A T I N G
SHAFT TANGS J9214-52
Fig. 34 TPS Mounting Bolts—3.91 V-6 or 5.2/5.9L ¥-8 Fig. 36 TPS Installation—Typical
Engine—Typical
TRANSMISSION TEMPERATURE SENSOR
IDLE AIR This sensor is located in the transmission cooling
CONTROL MOTOR line on the side of the transmission (Fig. 37).
THROTTLE Fig. 37 Transmission Temperature Sensor

POSITION
Location—Typical
SENSOR J9414-3
REMOVAL
Fig. 35 TPS Mounting Bolts—S.OL ¥-10 Engine- (1) Raise and support the vehicle.
Typical (2) Place a drain pan below the sensor.
INSTALLATION (3) Clean the area around sensor before removal.
The throttle shaft end of the throttle body slides (4) Disconnect the electrical connector at sensor.
into a socket in the TPS (Fig. 36). The TPS must be (5) Remove (unthread) the sensor from transmis
installed so that it can be rotated a few degrees. If sion cooling line. To prevent twisting and damage
the sensor will not rotate, install the sensor with the to cooling line, be sure to use a backup wrench
throttle shaft on the other side of the socket tangs. on cooling line.
The TPS will be under slight tension when rotated.
INSTALLATION
(1) Install the TPS and two retaining bolts.
(2) Tighten bolts to 7 N-m (60 in. lbs.) torque. (1) Install the sensor into the transmission cooling
(3) Manually operate the throttle control lever by line. Tighten sensor to 11 N-m (8 ft. lbs.) torque.
hand to check for any binding of the TPS. (2) Connect the electrical connector at sensor.
(4) Connect TPS electrical connector to TPS. (3) Lower the vehicle.
(5) Install air cleaner. Refer to Group 25, Emission (4) Check and adjust automatic transmission fluid
Control Systems for procedures. level.
•
14 - 86 COMPONENT REMOVAL/INSTALLATION—EXCEPT DIESEL BR
VEHICLE SPEED SENSOR SPEEDOMETER

The vehicle speed sensor (Pig. 38) is located on the PINION GEAR
extension housing of the transmission on 2WD mod ELECTRICAL
els. It is located on the transfer case on 4WD models. CONNECTOR
O-RING
REMOVAL
SENSOR
SENSOR MOUNTING
ELECTRICAL BOLT
CONNECTOR
SPEEDOMETER PINION
GEAR ADAPTER
VEHICLE
O-RING
SPEED
TRANSMISSION
SENSOR J9314-188
EXTENSION
HOUSING
Fig. 39 Sensor Removal/Installation—Typical
J9414-60
Fig. 38 Vehicle Speed Sensor Location—Typical

(2) Clean the area around the sensor before re
moval.
(3) Disconnect the electrical connector from the
sensor (Fig. 39).
(4) Remove the sensor mounting bolt (Fig. 39).
(5) Pull the sensor from the speedometer pinion
gear adapter for removal. ^
INSTALLATION
(1) Install new sensor into speedometer gear
adapter.
(2) Tighten sensor mounting bolt. To prevent dam
age to sensor or speedometer adapter, be sure the
sensor is mounted flush to the adapter before tight
ening.
(3) Connect electrical connector to sensor.
mm -—- _ COMPONENT DESCRIPTION/SYSTEM OPERATION—DIESEL ENGINE 14 - 87
DIESEL E N G I N E — C @ i * P O t l E I I T DESCRIPTION/SYSTEM O P E R A T I O N
INDE1
page page
Air Conditioning (A/C) Controls—PCM Pin
#27—PCM Input . . . . . 93 Park/Neutral Switch—PCM Pin #30—PCM Input . . 94
Air Conditioning Relay—PCM Pin #34—PCM PCM System Schematics—Diesel . . . . . . . . . . . . . 88
Output 95 Power Ground—PCM Pin #11 . . . . . . . 90
Automatic Shutdown (ASD) Relay—PCM Pin Power Ground—PCM Pin #12 90
#51—PCM Output 97 Powertrain Control Module (PCM)—Diesel . . . . . . . 87
Automatic Shutdown (ASD) Sense—PCM Pin Sensor Return—PCM Pin #4—PCM Input 90
#57—PCM Input 97 Speed Control—PCM Pins #33 and #53—PCM
Battery Temperature Sensor 90 Output 95
Battery Voltage—PCM Pin #3—PCM Input . . . . . . 90 Speed Control—PCM Pins #48, #49 and #50—
Brake Switch—PCM Pin #29—PCM Input . . . 94 PCM Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
CCD Bus(-)—PCM Pin #46—PCM Output . 96 Speed Control—PCM Pins #53 and #33—PCM
Data Link Connector—PCM Pin #25—PCM Output . 93 Output 97
Data Link Connector—PCM Pin #45—PCM Input . . 96 System Diagnosis 87
Eight Volt Power—PCM Pin #7—PCM Input 90 Tachometer—PCM Pin #43—PCM Output . 96
Engine Speed Sensor—PCM Pin #24—PCM Input . 93 Throttle Position Sensor—PCM Pin #22—PCM
Five Volt Power—PCM Pin #6—PCM Input 90 Input 93
General Information 87 Torque Convertor Clutch (TCC) Solenoid—PCM Pin
Generator Field—PCM Pin #20—PCM Output 92 #54—PCM Output . . . . . 97
Ignition Circuit Sense—PCM Pin #9—PCM Input . . 90 Transmission Temperature Sensor—PCM Pin
Intake Manifold Air Heater . . . . . . . . . . . . . . . . . . . 90 #42—PCM Input . 96
Intake Manifold Air Heater Relays—PCM Pins #15 Transmission Temperature Warning Lamp—PCM
and #16—PCM Output 91 Pin #31—PCM Output 94
Intake Manifold Air Temperature Sensor—PCM Pin Vehicle Speed Sensor—PCM Pin #47—PCM Input . 96
#21—PCM Input 92 Wait-To-Start Lamp Warning Lamp—PCM Pin
Malfunction Indicator Lamp—PCM Pin #32—PCM #36—PCM Output 95
Output 94 Water-ln-Fuel Sensor—PCM Pin #1—PCM Input . . 90
Overdrive Lamp—PCM Pin #37—PCM Output . . . . 96 Water-ln-Fuel Warning Lamp—PCM Pin #35—PCM
Overdrive Solenoid—PCM Pin #55—PCM Output . 97 Input 95
GENERAL INFORMATION • Fuel return line

Various components, relays and switches are • Fuel filter (strainer)
operated by the powertrain control module • Fuel drain manifold
(PCM). This section of the group will cover a
description and operation of components con SYSTEM DIAGNOSIS
trolled by the PCM for vehicles equipped with The powertrain control module (PCM) tests many
diesel powered engines. of its own input and output circuits. If a diagnostic
Diesel fuel injection system components (except for trouble code (DTC) is found in a major system, this
the intake manifold air heater elements) are not di information is stored in the PCM memory. Refer to
rectly regulated by the PCM. On-Board Diagnostics in the Diesel Engine—General
Refer to the Fuel Delivery—Diesel Engine section Diagnosis section of this group for DTC information.
of this group for fuel components not operated or reg For components not operated by the PCM, refer to
ulated by the PCM. These components are the: the Fuel Delivery—Diesel Engine section of this
• Fuel tank group.
® Fuel tank module
• Low and high-pressure fuel supply lines POWERTRAIN CONTROL MODULE (PCM)—DIESEL
• Low-pressure, mechanical, fuel transfer pump (fuel The powertrain control module (PCM) is located in
lift pump) the right-rear side of the engine compartment (Fig.
© High-pressure fuel injection pump 1). It is mounted to the dash panel cowl with three
• Fuel filter/water separator
bolts. The PCM was formerly referred to as the
• Fuel heater
• Fuel heater relay SBEC or engine controller. Except for operation of
• Fuel shutdown solenoid the intake manifold air heater elements, the PCM
• Fuel shutdown solenoid relay does not regulate or control fuel system operation on
• High-pressure fuel injectors the diesel engine.
14 - S I COMPONENT DESCRIPTION/SYSTEM OPERATION—DIESEL ENGINE BR

• Overdrive/override switch
© Park/neutral switch (auto, trans, only)
© Power ground
© SCI receive (DRB scan tool connection)
• Sensor return
• Throttle position sensor (auto, trans, only)
• Transmission temperature sensor (auto, trans,
only)
® Vehicle speed sensor
• Water-in-fuel sensor
• Ignition switch sense
PCM Outputs:
POWERTRAIN CONTROL After inputs are received by the PCM, certain sen
MODULE (PCM) J9414-11 sors, switches and components are controlled or reg
ulated by the PCM. These are considered PCM
Fig. 1 PCM Location—Typical Outputs. These outputs are for:
The PCM is a pre-programmed, dual micro-proces © A/C clutch relay (A/C clutch operation)
sor digital computer. Although it does not regulate or O Auto shutdown (ASD) relay
control the fuel system on the diesel powered engine, • Data link connectors (for DRB and MDS test
it does operate or regulate the: equipment)
© Speed control system • Generator field (charging system operation)
® Charging system • Malfunction indicator lamp (check engine lamp)
© Certain warning lamps • Overdrive solenoid electrical operation (auto,
• Transmission overdrive solenoid trans, only)
• Torque convertor engagement • Overdrive/Override warning lamp (auto, trans,
© ASD relay only)
• Air conditioning operation • SCI transmit (DRB scan tool connection)
• Tachometer • Speed control vacuum solenoid
© Intake manifold air heater • Speed control vent solenoid
The PCM can adapt its programming to meet • Tachometer
changing operating conditions. • Torque convertor electrical operation (auto, trans,
The PCM receives input signals from various only)
switches and sensors. Based on these inputs, the • Transmission oil temperature warning lamp (auto,
PCM regulates various engine and vehicle operations trans, only)
through different system components. These compo » Wait-to-start lamp
nents are referred to as PCM Outputs. The sensors • Water-in-fuel lamp
and switches that provide inputs to the PCM are con • Intake Manifold Air Heater Element #1
sidered PCM inputs. • Intake Manifold Air Heater Element #2
PCM Inputs:
• Air conditioning selection PCM SYSTEM SCHEMATICS—DIESEL
• Battery voltage A powertrain control system schematic for diesel
9 Brake light switch powered vehicles is shown in figure 2.
© Engine speed sensor (rpm) The schematic is displayed as a quick reference
• Speed control switch position only. It is not intended to be all-inclusive. Refer to
© Auto shutdown (ASD) sense the Wiring Diagrams section for detailed information.
• Battery voltage input used to measure generator After the schematic, a description is given for each
output circuit (pin/cavity) of the PCM 60-way connector.
TRANSMISSION
OVERDRIVE
SWITCH
(AUTO ONLY)
THROTTLE
POSITION
SENSOR
(AUTO. TRANS.
ONLY)
A/C
COMPRESSOR
CLUTCH
J9414-84
Fig. 2 System Schematic—5.9L Diesel Engine

14 - 90 COMPONENT DESCRIPTION/SYSTEM OPERATION—DIESEL ENGINE
WATER-IN-FUEL SENSOR—PCM PIN #1—PCM in the ON position. The PCM continues to monitor
INPUT the input at the end of the intake manifold air heater
The water-in-fuel (WIF) sensor is located at the post-heat cycle.
bottom of the fuel filter/water separator (Fig. 3).
BATTERY VOLTAGE—PCM PIN #3—PCM INPUT
FUEL FILTER/ The battery voltage input provides power to the
powertrain control module (PCM). It also informs the
PCM what voltage level is being supplied by the gen
erator once the vehicle is running.
The battery input also provides the voltage that is
needed to keep the PCM memory alive. The memory
stores diagnostic trouble code (DTC) messages, mini
mum and maximum TPS value from the previous
key-on and speed control adaptive memory.
DRAIN
VALVE
BATTERY TEMPERATURE SENSOR
This input is internal to the powertrain control
module (PCM). A thermistor located within the
J9414-90 PCM's printed circuit board is used to sense under
hood temperature. This temperature is used to vary
Fig. 3 Water-in-Fuel Sensor the battery charging rate in relationship to the tem
perature.
WAIT-TO-
START
WARNING LAMP SENSOR RETURN—PCM PIN #4—PCM INPUT
Sensor Return provides a low noise ground refer
ence for all system sensors.
FIVE VOLT POWER—PCM PIN #6—PCM INPUT
HEAT-A/C the throttle position sensor (TPS) sensor.
TEMPERATURE
' CONTROL
KNOB EIGHT VOLT POWER—PCM PIN #7—PCM INPUT
the vehicle speed and engine speed sensors.
IGNITION CIRCUIT SENSE—PCM PIN #9—PCM
INPUT
The ignition circuit sense input tells the powertrain
control module (PCM) the ignition switch has been
turned to the ON position. Refer to the wiring dia
grams for circuit information.
WARNING LAMP WARNING LAMP J9414-63 POWER GROUND—PCM PIN #11
Fig. 4 Wait-to-Start and Water-in-Fuel Warning Lamp
Provides a common ground for power devices (sole
Location
noid and relay devices).
The sensor sends an input to the powertrain con POWER GROUND—PCM PIN # 1 2
trol module (PCM) when it senses water in the fuel Provides a common ground for power devices (sole
filter/water separator. As the water level in the filter/ noid and relay devices).
separator increases, the resistance across the WIF
sensor decreases. This decrease in resistance is sent INTAKE MANIFOLD AIR HEATER
as a signal to the PCM and compared to a high water The intake manifold air heater block/element as
standard value. Once the value reaches 30 to 40 ki- sembly is located on the top of the intake manifold
lohms, the PCM will activate the instrument panel (Fig. 5).
mounted, water-in-fuel warning lamp (Fig. 4). This The air heater is used to heat incoming air to the
all takes place when the ignition key is initially put intake manifold to help engine starting and improve
driveability with cool or cold outside temperatures.
BR COMPONENT DESCRIPTION/SYSTEM OPERATION—DIESEL ENGINE 14 - 9 1
Electrical supply for the 2 air heater elements is

controlled by the powertrain control module (PCM)
through the 2 air heater relays. Refer to the follow
ing Intake Manifold Air Heater Relays for more in
formation.
INTAKE MANIFOLD AIR HEATER RELAYS—PCM

PINS # 1 5 AND #16—PCM OUTPUT
The 2 relays are located in the engine compartment
below the left battery (Fig. 7).
BATTERY
(LEFT SIDE)
UPPER PART OF
INTAKE MANIFOLD J9414-105
Fig. 5 Air Heater Location

CABLE
MOUNTING
STUDS
Fig. 7 Intake Manifold Air Heater Relays

The powertrain control module (PCM) operates the
2 heating elements within the air heater assembly
through the 2 intake manifold air heater relays. The
air heater elements are used to heat incoming air
flowing into the intake manifold. This will help en
gine starting and improve driveability with cool or
cold outside temperatures.
The relays may be energized by the PCM before
and after cranking. This will depend on inputs the
PCM receives from: the intake manifold air tempera
ture sensor, the engine speed sensor and the vehicle
speed sensor.
With a cool or cold engine, the air heater relays
and the air heater elements may be activated for a
J95U-76 maximum time of approximately 3 1/2 minutes. Refer
to the following Air Heater Cycle Chart for a temper
Fig. 6 Heater Elements—Typical ature/time comparison of relay engagement.
In this chart, Pre-Heat and Post-Heat times are
Two heavy-duty cables (Fig. 5) connect the 2 air mentioned. Pre-heat is the amount of time the relay
heater elements to the 2 air heater relays. Each of circuits are activated when the ignition (key) switch
these cables will supply approximately 95 amps at 12 is ON, but the engine has yet to be started. Post-heat
volts to an individual heating element within the is the amount of time the relay circuits are activated
heater block assembly (Fig. 6). after the engine is operating.
14 - 92 COMPONENT DESCRIPTION/SYSTEM OPERATION—OIESEL ENGINE
The wait-to-start warning lamp is tied to this cir The post-heat cycle will continue for up to 3 1/2
cuit. Lamp operation is also controlled by the PCM. minutes unless the PCM determines one or more of
The wait-to-start warning lamp will not be illumi these preceding features interrupts the cycle strat
nated during the post-heat cycle. egy.
The relays are not energized during engine crank AIR HEATER CYCLE CHART
ing. When initially energized, they will make a click
ing noise. mmimmmB
-OfflONOtirBNONS wmmmm,
PiEHEAT CYCLE mmmmm NOTINNMNG •
The PCM will supply a signal to the 2 relays when

the ignition (key) switch is initially turned to the ON Above 15° C 0 seconds No
(59° F)
position. When this signal is supplied, electrical cur
rent is passed through the relays for operation of the -10°Cfo 15° C 10 seconds Yes
2 heating elements. (15° F to 59° F)
If the intake manifold air temperature is 15°C -18° Cto-10° F 15 seconds Yes
(59°F) or below, the air heater elements are ener (0° F to 15° F)
gized and the wait-to-start warning lamp is illumi
nated. The heater is energized for a specific amount Below-18° C 30 seconds Yes
of time. Refer to the following Air Heater Cycle Chart (0° F)
for a temperature/time comparison of relay engage
ment.
Once the heater has cycled, the wait-to-start warn
ing lamp goes out.
While the engine is cranked, the heater relays are
not energized.
J9414-133
POST-HEAT CYCLE
After the pre-heat cycle is completed, the PCM GENERATOR F1ELD™PCM PIN #21—PCi OUTPUT
must receive an engine crank signal (engine speed
The powertrain control module (PCM) regulates the
between 32 and 475 rpm) followed by an engine run
charging system voltage within a range of 12.9 to
signal (engine speed above 475 rpm). Intake manifold
15.0 volts. Refer to Group 8A for charging system in
air temperature must also be below 15°C (59°F). All
formation.
of these signals must be seen by the PCM before ini
tiating the post-heat cycle. INTAKE MANIFOLD AIR TEMPERATURE SENSOR—
Depending upon intake manifold air temperature, PCM PIN #21—PCM INPUT
engine rpm and predetermined PCM values, one or This pin provides an input signal to the powertrain
both of the relays and one or both of the heating el control module (PCM).
ements may be activated. This may be observed as a The intake manifold air temperature sensor is a
large needle swing on the vehicle voltmeter and is variable, thermistor type. It reacts to temperature
due to the high-amperage draw of the heating ele changes. At cold air temperatures, its resistance is
ments. Each heating element will draw approxi high. As temperatures increase, its resistance will de
mately 95 amps at 12 volts. This voltmeter crease.
movement is a normal condition during the The air temperature sensor element extends into
post-heat cycle. the intake manifold air stream. It provides an input
Refer to the following Air Heater Cycle Chart for a voltage to the PCM indicating intake manifold air
temperature/time comparison of relay engagement. temperature. The input from this sensor is used by
The PCM is also programmed with battery saving the PCM to determine if and how long to activate the
features. It will shut down the air heater relays if: intake manifold air heater relays. When the relays
• the engine starter is operated during the pre-heat are activated, current will flow through the relays to
cycle. the intake manifold air heater.
• the engine stalls during the post-heat cycle. As the temperature of the air-fuel stream in the
• the engine starter is operated for more than 10 manifold varies, the sensor resistance will change.
seconds during the post-heat cycle. This will result in a different input voltage to the
• the vehicle speed is above 10 mph during the post- PCM.
heat cycle.
BR COMPONENT DESCRIPTION/SYSTEM OPERATION—DIESEL ENGINE 14 - 93
The sensor is located on the top of the intake man

ifold and to the rear of the intake manifold air heater
(Fig. 8).
FRONT OF ENGINE A I R TEMPERATURE SENSOR
SENSOR ELECTRICAL
CONNECTOR
ELECTRICAL THROTTLE
CONNECTOR POSITION
SENSOR
CENTER TERMINAL MOUNTING

IS OUTPUT WIRE BOLTS (2) J9414-91
INTAKE
MANIFOLD
(UPPER H A L F ) SHUVBOWN SOLENOID Fig. 9 Throttle Position Sensor Location—Diesel
SOLENOID ELECTRICAL
mi 4-93
ENGINE SPEED SENSOR—PCM PIN #24—PCM
CONNECTOR
INPUT
Fig. 8 Mir Temperature Sensor Location—Diesel
The engine speed (rpm) sensor is mounted to the
Also refer to Intake Manifold Heater Relays—-PCM front of engine (Fig. 10). It generates an rpm signal
Pin #15—PCM Output for additional information. to the PCM. The engine speed sensor input is used
Refer to the Diesel Engine—General Diagnosis sec along with the vehicle speed sensor and throttle po
tion of this group for diagnostic procedures. sition sensor (TPS) inputs to determine when to shift
the automatic transmission into and out of overdrive.
THROTTLE POSITION SENSOR—PCM PIN The speed sensor signal is also used as an input for
#22—PCM INPUT the ASD relay (for control of generator field), vehicle
The throttle position sensor (TPS) is used only on speed control, torque convertor electrical engagement
vehicles equipped with an automatic transmission if and instrument panel mounted tachometer.
equipped with a diesel engine. It is not used with the
manual transmission. DATA LINK CONNECTOR—PCM PIN #25—PCM
The TPS is mounted on the side of the fuel injec OUTPUT
tion pump (Fig. 9). The TPS provides an input to the The data link connector (diagnostic scan tool con
PCM. It senses how far the throttle is open (past the nector) links the Diagnostic Readout Box (DRB) scan
idle position). The PCM uses the TPS input, along tool or the Mopar Diagnostic System (MDS) with the
with vehicle speed sensor and engine speed sensor powertrain control module (PCM). The data link con
inputs to determine 3-4 upshift (overdrive) and 4-3 nector is located in the engine compartment (Fig. 11).
downshift. It is also used with the vehicle speed sen For operation of the DRB scan tool, refer to the ap
sor and engine speed sensor inputs to engage and propriate Powertrain Diagnostic Procedures service
disengage the torque convertor solenoid. This sole manual.
noid is used for torque convertor engagement. The data link connector uses two different pins on
The TPS is a linear potentiometer. The PCM sup the PCM. Pin #25 is for Data Link Transmit and pin
plies 5 volts to the sensor. TPS output voltage to the #45 is for Data Link Receive.
PCM will vary. At idle speed, the voltage should be
1.0 volt (± .2 volts). At wide open throttle (WOT), the AIR CONDITIONING (A/C) CONTROLS—PCM PIN
output voltage must be 2.2-to-2.9 volts higher than at #27—PCM INPUT
idle speed. The A/C control system information applies to fac
tory installed air conditioning units.
A/C REQUEST SIGNAL: When either the A/C or
Defrost mode has been selected and the A/C low and
14 -14 COMPONENT DESCRIPTION/SYSTEM OPERITIOI—DIESEL ENGINE
PARK/NEUTRAL SWITCH—PCM PIN #30—PCM

INPUT
The park/neutral switch provides an input to the
powertrain control module (PCM). This will indicate
that the automatic transmission is in Park, Neutral
or a Drive gear selection. This input is used to deter
mine speed control strategy and electrical operation
of both the overdrive and torque convertor solenoids.
Refer to Group 21, Transmissions, for testing, re
placement and adjustment information.
TRANSMISSION TEMPERATURE WARNING

LAMP—PCM PIN #31—PCM OUTPUT
AUTOMATIC TRANSMISSION OMLY

An instrument panel mounted lamp (Fig. 12) is
used to warn of a possible transmission fluid over
heating condition. When transmission fluid tempera
ture has been determined to be above approximately
280 degrees F by the transmission temperature sen
sor, a signal is sent to the powertrain control module
Fig. 10 Engine Speed Sensor—Diesel (PCM). The PCM will then control warning lamp op
eration. The lamp will illuminate for about two sec
onds each time the ignition key is initially turned to
the ON position as a bulb check.
tion.
INSTRUMENT
POWERTRAIN CONTROL

high-pressure switches are closed, an input signal is
PCM uses this input to cycle the A/C compressor
through the A/C relay.
If the A/C low or high-pressure switch opens, the
PCM will not receive an A/C request signal. The Fig. 12 Transmission Temperature Warning
PCM will then remove the ground from the A/C relay. Lamp—Typical Location
This will deactivate the A/C compressor clutch. MALFUNCTION INDICATOR LAMP—PGM PIN
#32—PCM OUTPUT
BRAKE SWITCH—PCM PIN #29—PCM INPUT
The malfunction indicator lamp illuminates on the
When the brake light switch is activated, the pow
instrument panel each time the ignition key is
ertrain control module (PCM) receives an input indi
turned on. This lamp is displayed on the instrument
cating that the brakes are being applied. After
panel as the CHECK ENGINE lamp (Fig. 13). Note
receiving this input, the PCM is used to control the
that the lamp will illuminate for approximately two
speed control system and electrical operation of the
seconds each time the key is initially turned to the
transmission torque converter. ON position. This feature is used as a bulb check.
mm - COMPONENT DESCRIPTION/SYSTEM OPERATION—DIESEL ENGIIH U - SS
Fig.' 13 Check Engine Lamp—Typical Location Fig. 14 Power Distribution Center (PDC) Location
If the powertrain control module (PCM) receives an WAIT-TO-
incorrect signal, or no signal from certain sensors or START
components, the lamp is turned on. This is a warning WARNING LAMP
that the PCM has recorded a system or sensor mal
function. It signals an immediate need for service.
The lamp can also be used to display a diagnostic
trouble code (DTC). Cycle the ignition switch On-Off-
On-Off-On within three seconds and any codes stored HEAT-A/C
in the PCM memory will be displayed. This is done TEMPERATURE
' CONTROL
in a series of flashes representing digits. Refer to On- KNOB
Board Diagnostics in the General Diagnosis section
of this group for more information.
SPEED CONTROL—PCM PINS #33 AND #53—PCM

OUTPUT
tion of the speed control solenoids.
AIR CONDITIONING RELAY—PCM PIN #34—PCM

OUTPUT
WARNING LAMP WARNING LAMP J9414-63
This circuit controls a ground signal for operation
of the A/C clutch relay. Also refer to Air Conditioning Fig. 15 Wait-to-Start and WateNn-Fuel Warning
(A/C) Controls-PCM Pin #27-PCM Input for addi Lamp Location
tional information.
The A/C relay is located in the power distribution WAIT-TO-START LAMP WARNING LAMP—PCM
center (PDC). The PDC is located next to the battery PIN #36—PCM OUTPUT
in the engine compartment (Fig. 14). For the location The wait-to-start warning lamp is turned on and
of the relay within the PDC, refer to PDC cover.
off by the PCM based on the intake manifold air tem
WATER-IN-FUEL WARNING LAMP—PCM PIN perature sensor input. The lamp is located on the in
strument (Fig. 15).
#35—PCM INPUT
The lamp is turned on when the ignition is first ac
The PCM turns the water-in-fuel indicator lamp to tivated. If the PCM reads intake manifold air tem
the ON position if water is detected in the fuel. The
perature below 15°C (59°F), it will turn the wait-to-
water-in-fuel indicator lamp is located in the instru
ment panel (Fig. 15). The lamp will illuminate for start warning lamp on for the air heater preheat
about two seconds each time the ignition key is ini cycle. The lamp stays on until the preheat cycle is
tially turned to the ON position as a bulb check. over.
Also refer to Water-ln-Fuel Sensor—PCM Pin #1 — The wait-to-start lamp will flash on and off if the
PCM Input for additional information. intake manifold air temperature sensor input to the
14 - I S COMPONENT DESCRIPTION/SYSTEM OPERATION—DIESEL ENGINE mm
PCM is below minimum value or above maximum 1ATA LINK CONNECTOR—PCM PIN #45—PCM
value. The PCM stores a DTC when these conditions INPUT
occur. Refer to Data Link Connector-PCM PIN
#25-PCM Output for information.
OVERDRIVE LAMP—PCM PIN #37—PCM OUTPUT
This circuit controls a signal for the operation of CCD BUS(-)—PCM PIN #46—PCM OUTPUT
the instrument panel mounted overdrive lamp. When Various modules exchange information through a
the lamp is illuminated, the overdrive is engaged. communications port called the CCD BUS(-).
TRANSMISSION TEMPERATURE SENSOR—PCM VEHICLE SPEED SENSOR—PCM PIN #47—PCM
PIN #42—PCM INPUT
INPUT
DIESEL WITH AUTOMATIC TRANSMISSIONS The speed sensor (Fig. 17) is located in the exten
ONLY sion housing of the transmission (2WD) or on the
The transmission temperature sensor is a variable, transfer case extension housing (4WD). The sensor
thermistor type. It reacts to temperature changes. At input is used by the powertrain control module
cold transmission oil temperatures, its resistance is (PCM) to determine vehicle speed and distance trav
high. As temperatures increase, its resistance will de eled.
crease. The speed sensor generates 8 pulses per sensor
The transmission temperature sensor is used on revolution. These signals, in conjunction with a
models equipped with an automatic transmission. Its closed throttle signal from the throttle position sen
purpose is to help control transmission fluid over sor (auto, trans, only), indicate a closed throttle de
heating. If transmission overheating has been deter celeration to the PCM. When the vehicle is stopped
mined by this sensor (temp, above approximately 280 at idle, a closed throttle signal is received by the
degrees F), an input is sent to the powertrain control PCM (but a speed sensor signal is not received).
module (PCM). The PCM will then force a 4-3 down In addition to determining distance and vehicle
shift. Once transmission temperature has cooled be speed, the output from the sensor is used to help con
low specifications, a 3-4 upshift will be allowed. An trol:
instrument panel mounted transmission temperature • Speed control operation
warning lamp (Fig. 12) is also used. • Transmission overdrive operation
This sensor is located in the transmission cooling • Transmission torque converter electrical operation
line on the side of the transmission (Fig. 16). SENSOR
ELECTRICAL
CONNECTOR
Fig. 16 Transmission Temperature Sensor

Location—Typical
J9414-60
TACHOMETER—PCM PIN #43—PCM OUTPUT
The powertrain control module (PCM) supplies en
Fig. 17 Vehicle Speed Sensor—Typical
gine rpm values to the instrument cluster mounted
tachometer (if equipped). Refer to Group 8E for ta
chometer information.
COMPONENT DESCRIPTION/SYSTEM OPERATION—DIESEL ENGINE 14 - 97
SPEED CONTROL—PCM PINS #48, #49 AND TORQUE CONVERTER CLUTCH

AND OVERDRIVE SOLENOID
#50—PCM INPUT ELECTRICAL CONNECTOR
The speed control system provides three separate
inputs to the powertrain control module (PCM); On/
Off, Set and Resume. The On/Off input informs the
PCM that the speed control system has been acti
vated. The Set input informs the PCM that a fixed
vehicle speed has been selected. The Resume input
indicates to the PCM that the previous fixed speed is
requested.
The speed control operating range is from 50 km/h
to 142 km/h (35 to 85 mph). Inputs that effect speed
control operation are: VEHICLE
• Brake switch position SPEED
SENSOR J9414-59
• Park/neutral switch
© Vehicle speed sensor
• Engine speed sensor Fig. 18 Electrical Connections at Transmission—
• Throttle position sensor (auto, trans, only) TCC and Overdrive Solenoids
Refer to Group 8H for further speed control infor monitoring vehicle miles per hour (mph). Also needed
mation. are various inputs from the module timer, engine
rpm and throttle position sensor.
AUTOMATIC SHUTDOWN (ASD) RELAY—PCM PIN
#51—PCM OUTPUT OVERDRIVE SOLENOID—PCM PIN #55—PCM
This circuit controls operation of the ASD relay. It OUTPUT
provides the necessary power to operate the genera
tor field control for charging system operation. AUTOMATIC TRANSMISSION
The ASD relay is located in the power distribution This circuit controls operation of the transmission
center (PDC). The PDC is located next to the battery mounted overdrive solenoid (Fig. 18) used for over
in the engine compartment (Fig. 14). For the location drive operation. The powertrain control module
of the relay within the PDC, refer to PDC cover. (PCM) will determine when to engage and disengage
The ground circuit for the coil in the ASD relay is the solenoid by monitoring engine rpm and vehicle
controlled by the powertrain control module (PCM). speed, versus output voltage of the throttle position
The PCM operates the relay by switching the ground sensor. Also needed are various inputs from the mod
circuit ON and OFF. ule timer.
SPEED CONTROL—PCM PINS #S3 AND #33—PCi
AUTOMATIC SHUTDOWN (ASD) SENSE—PCM PIN
OUTPUT
#57—PCM INPUT
tion of the speed control solenoids. A 12 volt signal at this input indicates to the PCM
that the ASD has been activated. The ASD relay is
TORQUE CONVERTOR CLUTCH (TCC) SOLENOID— located in the power distribution center (PDC). The
PCM PIN #54—PCM OUTPUT PDC is located next to the battery in the engine com
partment (Fig. 14). For the location of the relay
AUTOMATIC TRANSMISSION within the PDC, refer to PDC cover.
This circuit (Fig. 18) controls operation of the This input is used only to sense that the ASD relay
transmission mounted torque convertor (TCC) sole is energized. If the powertrain control module (PCM)
noid used for torque convertor engagement. does not see 12 volts + at this input when the ASD
The powertrain control module (PCM) will deter should be activated, it will set a diagnostic trouble
mine when to engage and disengage the solenoid by code (DTC).
14 -18 GENERAL DIAGNOSIS—DIESEL ENGINE BR
DIESEL ENGINE—GENERAL DIAGNOSIS
INDEX
page page
Air in Fuel System 101 Intake Manifold Air Heater Relay Test 112
Automatic Shutdown (ASD) Relay Test . . . . . . . . 102 Intake Manifold Air Heater Test 110
Diagnostic Trouble Code (DTC) 117 Intake Manifold Air Temperature Sensor Test . . . . 112
DRB Scan Tool 117 On-Board Diagnostics (OBD)—Diesel Powered
Engine Speed Sensor Test 102 Vehicles 115
Fuel Filter/Water Separator Test 102 Powertrain Control Module (PCM) 60-Way
Fuel Heater Relay Test 104 Connector 101
Fuel Heater Test . 103 Powertrain Control Module Testing 113
Fuel Injection Pump Test 105 Relays—Operation/Testing 113
Fuel Injection Pump Timing 119 Starter Motor Relay Test . . . . . . . . . . . . . . . . . . . 114
Fuel Injector Test 104 System Diagnosis Charts 119
Fuel Shutdown Solenoid Relay Test 107
System Schematics 101
Fuel Shutdown Solenoid Test . . . . . . . . . . . . . . . 105
Fuel Supply Restrictions 105 Throttle Position Sensor Test . . . . . . . . . . . . . . . . 114
Fuel Transfer Pump Pressure Test 107 Transmission Temperature Sensor Test 114
General Information 98 Vehicle Speed Sensor Test 115
High-Pressure Fuel Line Leak Test . 109 Visual Inspection 100
Idle Speed Adjustment 110 Water-ln-Fuel Warning Lamp 115
GENERAL INFORMATION Although various components, relays and switches

This section of the group will cover a general diag are operated by the powertrain control module
nosis of diesel engine fuel system components. For an (PCM), the diesel fuel injection system (Fig. 1) is not
operational description, refer to the Diesel Engine— directly regulated by the PCM. Refer to Powertrain
Component Description/System Operation section of Control Module (PCM) for additional information.
this group. For component removal and installation
procedures, refer to the Diesel Engine—Component
Removal/Installation section of this group.
GENERAL DIAGNOSIS—DIESEL ENGINE 14 - I I
WASTEGATEO TURBOCHARGER
FUEL SUPPLY WAKE MANIFOLD

LINE (TO
INJECTION PUMP)
WATER TEMPERATURE
SENSOR (FOR LP. GAUGE)
HIGH PRESSURE FUEL FILTER/

FUEL LINES WATER SEPARATOR
FUEL/WATER
SEPARATOR AND
HIGH PRESSURE DRAIN VALVE
FUEL INJECTION
PUMP
RUBBER PRIMER
BUTTON
THROTTLE POSITION
SENSOR (AUTO. FUEL TRANSFER
TRANS. ONLY) PUMP (FUEL
LIFT PUMP)
STARTER
FUEL MOTOR
SHUTDOWN
SOLENOID FUEL HEATER
TEMP. SENSOR
OIL PRESSURE (THERMOSTAT)
LEFT SIDE DRAIN
SENSOR OF ENGINE TUBE J9414-69
Fig. 1 Fuel System Components—Diesel Engine

14-100 GENERAL DIAGNOSIS—DIESEL ENGINE ~ , _ _ BR
VISUAL INSPECTION BATTERY

(LEFT SIDE)
A visual inspection for loose, disconnected, or incor CABLES TO
rectly routed wires and hoses should be made before BATTERY (+)
attempting to diagnose or service the diesel fuel in
jection system. A visual check will help find these
conditions. It also saves unnecessary test and diag
nostic time. A thorough visual inspection of the fuel
injection system includes the following checks:
(1) Be sure that the battery connections (on both INTAKE AIR
batteries) are tight and not corroded. HEATER RELAYS (2)
(2) Be sure that the 60-way connector is fully en
gaged with the powertrain control module (PCM).
Verify that the connector mounting screw is tight
(Fig. 2).
DATA LINK
CONNECTOR
RELAY
TRIGGER RELAY MOUNTING ^
WIRES (4) BOLTS (3) J9414-85
FRONT OF ENGINE AIR TEMPERATURE SENSOR

SENSOR ELECTRICAL
CONNECTOR
POWERTRAIN CONTROL
(3) Be sure that the electrical connections at the

intake manifold air heater relays (Fig. 3) are tight
and not corroded.
(4) Inspect the starter motor and starter solenoid
connections for tightness and corrosion.
(5) Verify that the electrical connector is firmly
connected to the intake manifold air temperature
sensor. Inspect the connector for corrosion or dam
INTAKE
aged wires. The sensor is located on the top of the in MANIFOLD
take manifold (Fig. 4). (UPPER HALF) FUEL
SHUTDOWN SOLENOID
(6) Verify that the water-in-fuel (WIF) sensor elec SOLENOID ELECTRICAL
J9414-93
CONNECTOR
trical connector is firmly attached to the sensor (Fig.
5). Inspect the connector for corrosion or damaged Fig. 4 Air Temperature Sensor and Fuel Shutdown
wires. Solenoid
(7) Check for water in the fuel filter/water separa
tor. A water drain is supplied on the filter/separator. (9) Be sure that the intake manifold air heater
Refer to Fuel Filter/Water Separator in the Diesel electrical cable connections at the intake manifold
Engine—Component Removal/Installation section of are tight and free of corrosion (Fig. 6).
this group for draining water. (10) Inspect the throttle linkage and accelerator
linkage for binding.
(8) Verify that the electrical connector is firmly (11) Be sure that the throttle return spring is con
connected to the fuel shutdown solenoid on the injec nected.
tion pump (Fig. 4). Inspect the connector for corro (12) Inspect all fuel supply and return lines for
sion or damage. signs of leakage.
(13) Be sure that the ground connections are tight
BR GENERAL DIAGNOSIS—DIESEL ENGINE 14 -101
tube. Verify that the charge air cooler output hose is

connected to the cooler and the intake manifold.
(16) Be sure that the vacuum pump-to-brake
booster hose is connected and not damaged.
(17) Be sure that the accessory drive belt is not
damaged or slipping.
(18) Automatic Transmission Only: Raise the vehi
cle and check the electrical connection at the trans
mission temperature sensor (Fig. 7).
Fig. 5 Water-in-Fuel (WIF) Sensor
Fig. 7 Transmission Temperature Sensor Location—

Typical
(19) Automatic Transmission Only: Be sure the
electrical connector is firmly connected to the plug
leading to the overdrive solenoid in the transmission.
POWERTRAIN CONTROL MODULE (PCM) 60-WAY

CONNECTOR
For PCM 60-way connector wiring schematics, refer
to Group 8W, Wiring Diagrams.
SYSTEM SCHEMATICS
Refer to PCM System Schematics—Diesel in the
Diesel Engine—Component Description/System Oper
ation section of this group.
UPPER PART OF AIR IN FUEL SYSTEM
Air will enter the fuel system whenever fuel supply
Fig. 6 Air Heater Cable Connections lines, separator filters, injection pump, high-pressure
lines or injectors are removed or disconnected. Air
and free of corrosion. Refer to Group 8, Wiring for lo trapped in the fuel system can result in hard start
cations of ground connections. ing, a rough running engine, engine misfire, low
(14) Inspect the air cleaner element (filter) for re power, excessive smoke and fuel knock. After service
strictions by using the built-on Filter Minder™. Do is performed, air must be bled from the system be
not remove the top of air cleaner housing to inspect fore starting the engine.
condition of air cleaner element. Refer to Diesel En Inspect the fuel system from the fuel transfer
gine Component Removal/Installation section for Fil pump to the injectors for loose connections. Leaking
ter Minder information. fuel is an indicator of loose connections or defective
(15) Be sure that the turbocharger output hose is seals. Air can also enter the fuel system between the
connected to the charge air cooler (intercooler) inlet
14 - 1 0 2 GENERAL DIAGNOSIS—DIESEL ENGINE
fuel tank and the transfer pump. Inspect the fuel

tank and fuel lines for damage that might allow air
into the system.
For air bleeding, refer to the Air Bleed Procedure
in the Diesel Engine—Component Removal/Installa
AUTOMATIC SHUTDOWN (ASD) RELAY TEST

To perform a complete test of the ASD relay and its
circuitry, refer to the DRB scan tool and appropriate
ENGINE SPEED SENSOR TEST
circuitry, refer to the appropriate Powertrain Diag
nostic Procedures manual.
FUEL FILTER/WATER SEPARATOR TEST
A blocked or clogged fuel filter/water separator can
cause starting problems and prevent the engine from
revving up. It can also cause, low power and blue or
white fog like exhaust.
The maximum allowable fuel pressure drop across
the fuel filter/water separator is 35 kPa (5 psi). This
can be checked with a fuel pressure gauge connected
to the inlet and outlet sides of the upper part of the
filter base with special fuel line adapter fittings.
To test fuel pressure drop:
(1) Remove the clamp bolt retaining the fuel drain
manifold line to the cylinder head (Fig. 8).
(2) Remove the rear banjo fitting bolt at the inlet
line (Fig. 8).
(3) Position the fuel drain manifold line (Fig. 8) to
the rear.
(4) Install and tighten special adapter tool 6829
into the top of the fuel inlet line (Fig. 9).
(5) Install a 0-60 or 0-100 psi fuel pressure gauge
to adapter tool 6829 (Fig. 9).
(6) Start engine and record fuel pressure. Mini
mum pressure should be 172 kPa (25 psi). If not, re
fer to Fuel Transfer Pump Pressure Test for more
information
(7) Remove fuel pressure gauge and adapter tool.
(8) Connect banjo fittings together at fuel inlet line
with bolt.
(9) Remove the front banjo fitting bolt at the outlet
line (Fig. 8).
(10) Install and tighten special adapter tool 6829
Fig. 9 installing Special Tools
into the top of the fuel outlet line (Fig. 10).
(11) Install fuel pressure gauge to adapter tool If pressure specification has been exceeded, replace
6829 (Fig. 10). fuel filter and check for line restrictions.
(12) Start engine and record fuel pressure. If the instrument panel mounted water-in-fuel
(13) Compare the 2 pressures. It must not exceed warning lamp is illuminated with the ignition key
35 kPa (5 psi). ON, it indicates that excess water has collected in
GENERAL DIAGNOSIS—DIESEL ENGINE 14 -113
Fig, 10 installing Special Tools

the fuel filter/water separator. Excess water can be
drained. Refer to Fuel Filter/Water Separator in the
Diesel Engine—Component Removal/Installation sec
tion of this group for water draining procedures.
If excess water gathers in the filter/separator in a
short period of time, the fuel tank must be removed,
drained and cleaned.
FUEL HEATER TEST

The fuel heater is used to prevent diesel fuel from
waxing during cold weather operation.
The fuel heater element, fuel heater relay and
fuel heater temperature sensor are not con
trolled by the powertrain control module Fig. 12 Fuel Heater Assembly
(PCM). the fuel. When the fuel temperature is above 80 de
A malfunctioning fuel heater can cause a wax grees F, the sensor stops current flow to the heater
build-up in the fuel filter/water separator. Wax element (circuit is open).
build-up in the filter/separator can cause engine Voltage to operate the fuel heater element is sup
starting problems and prevent the engine from rev plied from the ignition switch, through the fuel
ving up. It can also cause blue or white fog-like ex heater relay (Fig. 13) (also refer to Fuel Heater Re
haust. If the heater is not operating in cold lay), to the fuel temperature sensor and on to the
temperatures, the engine may not operate due to fuel fuel heater element.
waxing. The built-in heater element operates on 12 volts,
The fuel heater is located on the left side of the en 300 watts at 0 degrees F. As temperature increases,
gine above the starter motor (Fig. 11). power requirements decrease.
The heater assembly is equipped with a built-in The fuel heater assembly contains a pre-filter (Fig.
fuel temperature sensor (thermostat) (Figs. 11 or 12) 12) to prevent contaminants from entering the fuel
that senses fuel temperature. When the fuel temper transfer pump.
ature is below 40 degrees F, the sensor allows cur
rent to flow to the built-in heater element to warm
14 -104 GENERAL DIAGNOSIS—DIESEL ENGINE
FUEL SHUT-OFF FUEL HEATER RELAY TEST

FUEL HEATER SOLENOID RELAY The fuel heater relay is located in the engine com
To test the relay only, refer to Relays—Operation/
Testing in this section of the group.
To test the fuel heater, refer to Fuel Heater Test in
FUEL INJECTOR TEST
A leaking fuel injector can cause fuel knock, poor
performance, black smoke, poor fuel economy and
rough engine idle. If the fuel injector needle valve
does not operate properly, the engine may misfire
and produce low power.
A leak in the injection pump-to-injector high-pres
sure fuel line can cause many of the same symptoms
as a malfunctioning injector. Inspect for a leak in the
high-pressure lines before checking for a malfunc
tioning fuel injector.
WARNING; THE INJECTION PUMP S U P P L I E S HIGH-
P R E S S U R E FUEL OF U P TO APPROXIMATELY
Fig. 13 Fuel Heater Relay—Diesel 120,000 KPA (17,400 PSI) TO EACH INDIVIDUAL IN
A minimum of 7 volts is required to operate the JECTOR THROUGH THE HIGH-PRESSURE LINES.
fuel heater. The resistance value of the heater ele FUEL UNDER THIS AMOUNT OF PRESSURE CAN
ment is less than 1 ohm (cold) and up to 1000 ohms PENETRATE THE SKIN AND C A U S E P E R S O N A L IN
warm. JURY. WEAR SAFETY GOGGLES AND ADEQUATE
PROTECTIVE CLOTHING. AVOID CONTACT WITH
TESTING FUEL SPRAY WHEN BLEEDING HIGH-PRESSURE
(1) Remove the electrical connector at the side of FUEL LINES.
the fuel heater (Fig. 11).
(2) Using an ohmmeter, check the resistance across WARNING: DO NOT BLEED AIR FROM THE FUEL
the two terminals on the side of the heater. Resis SYSTEM OF A HOT ENGINE. DO NOT ALLOW FUEL
tance should be approximately 1 ohm (cold) to 1000 TO SPRAY ONTO THE EXHAUST MANIFOLD WHEN
ohms (warm). BLEEDING AIR FROM THE FUEL SYSTEM.
(3) With the electrical connector still unplugged
from the fuel heater, check the electrical operation of To determine which fuel injector is malfunctioning,
the fuel temperature sensor (Fig. 12). Proceed to next run the engine and loosen the high-pressure fuel line
step: nut at the injector (Fig. 14). Listen for a change in
(4) Using an ohmmeter, check the resistance across engine speed. After testing, tighten the line nut to 30
the two terminals in the pigtail wire harness coming N-m (22 ft. lbs.) torque. If engine speed drops, the in
from the fuel temperature sensor. The sensor circuit jector was operating normally. If engine speed re
should be open if the fuel temperature is above 80 mains the same, the injector is malfunctioning. Test
degrees. The sensor circuit should be closed if the all injectors in the same manner one at a time.
fuel temperature is below 40 degrees. Once an injector has been found to be malfunction
(5) Check for 12 volts at the disconnected temper ing, remove it from the engine and test it. Refer to
ature sensor connector with the ignition key ON. Re the Diesel Engine—Component Removal/Installation
fer to Group 8W, Wiring for electrical schematics. section of this group for procedures.
(6) With ignition ON, check for 12 volts at the fuel After the injector has been removed, install it to a
heater relay connector. Refer to Group 8W, Wiring for typical bench-mount injector tester (Fig. 15). Position
electrical schematics. a container below the injector before testing. Refer to
(7) Check operation of the fuel heater relay (Fig. operating instructions supplied with tester for proce
13). Refer to Relays—Operation/Testing in this sec dures.
tion of the group. The opening pressure or "pop" pressure should be
For removal and installation procedures, refer to approximately 26,252 kPa (3822 psi). If the fuel in
the Diesel Engine—Component Removal/Installation jector needle valve is opening (popping) to early or to
section of this group. late, replace the injector.
BR GENERAL DIAGNOSIS—DIESEL ENGINE 14 - 105
® Poor performance
o Low power
o Black smoke from the exhaust
® Blue or white fog like exhaust
o Incorrect idle or maximum speed
Engine power is also effected by the governor set
ting and performance. Do not attempt to adjust
the governor. If the governor seals on the exter
nal adjustment screw are broken, the fuel rate
may be out of adjustment. The warranty of the
injection pump and the engine may be void if
the seals have been tampered with or removed.
Fig. 14 inspecting Injector Operation
FUEL SUPPLY RESTRICTIONS
FUEL
LOW-PRESSURE LINES
Fuel supply line restrictions or a defective fuel
transfer pump can cause starting problems and pre
vent the engine from revving up. The starting prob
lems include; low power and blue or white fog like
exhaust. Test all fuel supply lines for restrictions or
blockage. Flush or replace as necessary. Bleed the
fuel system of air once a fuel supply line has been re
placed. Refer to the Air Bleed Procedure section of
this group for procedures. Also refer to the Fuel
Transfer Pump Pressure Test section of this group for
restriction tests.
HIGH-PRESSURE LINES-
Restricted (kinked or bent) high-pressure lines can
cause starting problems, poor engine performance
CONTAINER
and black smoke from exhaust.
Examine all high-pressure lines for any damage.
J9514-71
Each radius on each high-pressure line must be
Fig. 15 Typical Fuel Injector Tester smooth and free of any bends or kinks.
Replace damaged, restricted or leaking high-pres
- FUEL INJECTION PUMP TEST sure fuel lines with the correct replacement line.
The fuel shutdown solenoid is the only serviceable
component of the fuel injection pump. The injection CAUTION: The high-pressure fuel lines must be
pump is not to be serviced or the warranty may clamped securely in place in the holders. The lines
be voided. If the injection pump requires ser cannot contact each other or other components. Do
vice, the complete assembly must be replaced. not attempt to weld high-pressure fuel lines or to
Incorrect injection pump timing can cause poor per repair lines that are damaged. Only use the recom
formance, excessive smoke and emissions and poor mended lines when replacement of high-pressure
fuel economy. fuel line is necessary.
A defective fuel injection pump or misadjusted
pump timing can cause starting problems or prevent
the engine from revving up. It can also cause: FUEL SHUTDOWN SOLENOID TEST
• Engine surge at idle For an operational description (electrical and me
• Rough idle (warm engine) chanical) of the solenoid, refer to the Diesel Engine—
• Low power Component Description/System Operation section of
• Excessive fuel consumption this group.
The fuel shutdown (shut-off) solenoid (Fig. 16) FUEL SHUT-OFF

and fuel shutdown solenoid relay (Fig. 18) a r e FUEL HEATER SOLENOID RELAY
RELAY
not controlled by t h e powertrain control mod
ule (PCM).
J9414-31
INTAKE
MANIFOLD p u E L
Fig. 18 Fuel Shutdown Solenoid Relay Location
(UPPER HALF) SHUTDOWN SOLENOID
SOLENOID ELECTRICAL retracted into the solenoid) and the pump lever
J9414-93 should be in the run position (fuel being supplied to
CONNECTOR
injection pump) (Fig. 17).
Fig. 16 Fuel Shutdown Solenoid Location (3) Release the ignition key from the CRANK to
the ON position.' The shaft should remain in the up
SHUTDOWN
position and the pump lever should remain in the
POSITION RUN POSITION run position (fuel being supplied to injection pump)
(Fig. 17). If the solenoid shaft is not moving, refer to
the following:
(4) Disconnect the solenoid three-wire pigtail wire
harness from the main engine harness.
(5) If the solenoid shaft did not move up when the
ignition switch was in the CRANK position, check for
12 volts at the three-way connector. This will be the
circuit coming from the fuel shutdown solenoid relay.
Refer to Group 8W, for wire connector pin location
and circuit identification. If 12 volts is not present at
this circuit when the key is in the CRANK position,
check the fuel shutdown solenoid relay. Refer to Re
lays —Operation/Testing in this section of the group.
Also check the wiring between the relay and the so
FUEL lenoid.
SHUTDOWN
SOLENOID (6) If the solenoid shaft moves up when the igni
J9414-80 tion switch is in the CRANK position, but moves
down when the key is released from the CRANK to
Fig. 17 Fuel Shutdown Solenoid Positions the ON position, check the circuit coming from the
(1) With the ignition switch off, the solenoid shaft ignition switch for 12 volts. Refer to Group 8W, for
should be down and the injection pump lever should wire connector pin location and circuit identification.
be in the shutdown position (no fuel supply to injec If the shutdown solenoid is being replaced, its shaft
tion pump) (Fig. 17). length must be adjusted. For fuel shutdown solenoid
(2) Turn the ignition switch to the CRANK (starter removal, installation and solenoid shaft adjustment
engage) position and observe the solenoid shaft and procedures, refer to the Diesel Engine—Component
injection pump lever. The shaft should pull up (shaft Removal/Installation section of this group.
GENERAL DIAGNOSIS—DIESEL ENGINE 14 - 107
FUEL SHUTDOWN SOLENOID RELAY TEST sure drop across the fuel filter/water separator will
Voltage to operate the fuel shutdown solenoid is increase.. Frequent replacement of the filter may in
supplied from the ignition switch and through the dicate a worn transfer pump. The filter/separator can
fuel shutdown solenoid relay. The fuel shutdown so be checked with a fuel pressure gauge. For test pro
lenoid relay is located in the engine compartment cedures, refer to Fuel Filter/Water Separator Tests in
near the brake master cylinder (Fig. 18). this section of the group.
To test the relay, refer to Relays—Operation/Test Refer to Group 0, Lubrication and Maintenance at
ing in this section of the group. the front of this manual for recommended replace
For removal and installation procedures, refer to ment intervals.
OUTPUT PRESSURE TEST
(1) Remove the clamp bolt retaining the fuel drain
FUEL TRANSFER PUMP PRESSURE TEST manifold line to the cylinder head (Fig. 20).
^ For operation of the fuel transfer pump primer but
ton, refer to Fuel Transfer Pump in the Fuel Deliv
ery—Diesel Engine section of this group.
The fuel transfer pump is located on the left side of
the engine and above the starter motor (Fig. 19).
FUEL
TRANSFER
PUMP
ELECTRICAL
CONNECTOR
FUEL
HEATER J9414-94
J9514-68
Fig. 19 Fuel Transfer Pump Location
Fig. 20 Fuel Line Fittings
An improperly operating fuel transfer pump can (2) Remove the rear banjo fitting bolt at the inlet
cause low engine power and/or hard engine starting. line (Fig. 20).
Inspect the fuel supply line to the pump for restric
tions, kinks or leaks.
the rear.
Fuel leaking from the weep hole in the pump cas (4) Install and tighten special adapter tool 6829
ing indicates a leaking pump. The transfer pump into the top of the fuel inlet line (Fig. 21).
must then be replaced or rebuilt. (5) Install a 0-60 or 0-100 psi fuel pressure gauge
Do not operate the fuel system with a fuel line or
to adapter tool 6829 (Fig. 21).
component suction restriction of more than 100 MM
Hg (4.0 inch Hg). (6) Start engine and record fuel pressure. Mini
Low transfer pump output can be caused by a worn mum pressure should be 172 kPa (25 psi).
eccentric on the engine camshaft. (7) If fuel pressure falls below specifications, test
The maximum allowable fuel pressure drop across for fuel line inlet restrictions before condemning the
the fuel filter/water separator is 35 kPa (5 psi). As fuel transfer pump. Proceed to step (a).
the filter removes contaminants in the fuel, the pres
14 -108 GENERAL DIAGNOSIS—DIESEL ENGINE SIR
Fig. 23 Installing Hose Adapter
Fig. 21 installing Special Tools
Fig. 24 installing Vacuum Gauge

vent. A partially clogged in-tank fuel filter can also
cause excess vacuum. Repair as necessary.
(8) Remove vacuum gauge and adapter hose tool.
(9) Install rubber fuel hose and clamps between
heater and pump.
Fig. 22 Rubber Fuel Hose—Pump to Heater
(a) Remove the rubber fuel hose and clamps lo FUEL VOLUME TEST
cated between the fuel heater and fuel transfer Fuel volume-versus-engine cranking rpm are used
pump (Fig. 22). for the test.
(b) Install special hose adapter tool 6837 be
tween the disconnected fittings on the heater and WARNING: TO P R E V E N T THE ENGINE FROM
transfer pump (Fig. 23). Install clamps to hose tool STARTING, DISCONNECT THE PIGTAIL H A R N E S S
6837. AT THE F U E L SHUTDOWN SOLENOID ( F I G . 25).
(c) Connect vacuum gauge 6828 to T-fitting as U S E CAUTION A S RESIDUAL F U E L IN THE F U E L
shown in figure 24. INJECTION PUMP MAY C A U S E THE ENGINE TO
(d) Start the engine and observe the vacuum START AND RUN TEMPORARILY. CONTINUE TO
gauge. The vacuum gauge will not indicate a vac RUN T H E ENGINE UNTIL IT QUITS B E F O R E P E R
uum until the transfer pump begins to operate at FORMING THE F U E L VOLUME TEST.
full capacity.
Inlet restriction m u s t not exceed 100 mm Hg (1) Connect a hand held tachometer to the engine.
(4 in. Hg). Use Cummins part number 3377462 or an equiva
If the restriction is higher than the specifications, lent.
check for a kinked fuel line or a plugged fuel tank

(7) Place the other end of this temporary hose into
SENSOR ELECTRICAL a graduated container (Fig. 26).
CONNECTOR (8) Crank the engine for 30 seconds. Measure the
fuel volume in the container after 30 seconds of en
gine cranking time. Do not crank the engine for
more than 30 seconds at a time. Starter motor
damage may result.
(9) To determine the correct fuel volume, refer to
figure 27—Fuel Volume Specification. To use the
chart in figure 27, refer to the following procedure:
• Draw a straight vertical line at the measured rpm.
• Draw a straight horizontal line at the measured
fuel volume.
• If these two lines intersect below the flow line
(Fig. 27), this indicates a defective transfer pump or
a line restriction.
• If these two lines intersect above the flow line
INTAKE (Fig. 27), this indicates acceptable fuel flow.
MANIFOLD P U E L
(UPPER HALF) SHUJDOWN SOLENOID ml FLOW LINE (oz)

SOLENOID ELECTRICAL
J9414-93 625 21.2
CONNECTOR
600 20.3
Fig. 25 Fuel Shutdown Solenoid Electrical 575
Connector
c
550 / 19.5
18.6
(2) Remove the clamp bolt retaining the fuel drain o 525
/ 17.8
manifold line to the cylinder head (Fig. 20). /
Ji
500 16.9
(3) Remove the rear banjo fitting bolt at the inlet /
line (Fig. 20).
the rear. o
CO
475
450
425
J <
16.1
15.3
14.4
(5) Install and tighten special adapter tool 6836 £ 400 /
k~ — 13.6
into the top of the fuel inlet line (Fig. 26). 375
(6) Connect a temporary rubber fuel hose to i 12.7
350 >
adapter 6836 (Fig. 26). \ 11.9
m
325 11.0
TEMPORARY 300 Vfciximuin Restric:tion —- 10.2
RUBBER
HOSE 275 9.3
200 225 250 275 300 400
Engine Cranking Speed (RPM) J9414-110
Fig. 27 Fuel Volume Specifications

HIGH-PRESSURE FUEL LINE LEAK TEST
High-pressure fuel line leaks can cause starting
problems and poor engine performance.
WARNING: DO TO E X T R E M E F U E L P R E S S U R E S OF
UP TO 120,000 K P A (17,400 PSI), U S E E X T R E M E
CAUTION W H E N INSPECTING FOR HIGH-PRES
S U R E F U E L L E A K S . DO NOT G E T YOUR HAND
NEAR A S U S P E C T E D LEAK. INSPECT FOR HIGH-
P R E S S U R E F U E L L E A K S WITH A S H E E T OF CARD
BOARD. HIGH F U E L INJECTION P R E S S U R E CAN
C A U S E P E R S O N A L INJURY IF CONTACT IS MADE
GRADUATED WITH THE SKIN.
J9514-75 CONTAINER
Start the engine. Move the cardboard over the
Fig. 26 Performing Fuel Volume Test high-pressure fuel lines and check for fuel spray onto
14 - 110 GENERAL DIAGNOSIS—DIESEL ENGINE BR
the cardboard (Fig. 28). If a high- pressure line con LEVER STOP
nection is leaking, bleed the system and tighten the
connection. Eefer to the Air Bleed Procedure in this
group for procedures. Replace damaged, restricted or
leaking high-pressure fuel lines with the correct re
placement line.
HIGH-PRESSURE CARDBOARD
LINE
LOW IDLE
ADJUSTING
SCREW
FACTORY HIGH IDLE LOCKNUT
SEAL STOP SCREW J9414-103
Fig. 29 Low Idle Speed Screw

IDLE SPEEDS—DIESEL ENGINES
FITTING LOW IDLE SPEED :-z$M mm

J9414-130
With automatic transmission... Do not attempt to adjust
high idle speed. High idle
Fig. 28 Typical Test for Leaks with Cardboard *75O-80O RPM with transmission speed adjustment screw
CAUTION; The high-pressure fuel lines must be in drive and air conditioning on. is factory sealed. Breaking
clamped securely in place in the holders. The lines seal will void injection pump
cannot contact each other or other components. Do With manual transmission... warranty.
not attempt to weld high-pressure fuel lines or to
*780 RPM with transmission in
repair lines that are damaged. Only use the recom neutral and air conditioning on.
mended lines when replacement of high-pressure
fuel line is necessary. • * With engine at normal operating temperature. Refer to text
for idle adjustment procedures.
1 r
J9414-66
IDLE SPEED ADJUSTMENT
INTAKE MANIFOLD AIR HEATER TEST
The high-speed idle screw is factory sealed and
cannot be adjusted. Low-speed idle can be adjusted. The intake manifold air heater (Fig. 30) is con
(1) Use an optical tachometer such as Snap-on No. trolled by the powertrain control module (PCM)
MT139 or MTE (Cummins tool division) No. 3377462 through the intake manifold air heater relays (Fig.
to read the engine rpm. 31). This is done after a specified signal is sent to the
(2) Bring the engine to normal operating tempera PCM from the intake manifold air temperature sen
ture. sor.
Two heating elements are located within the air
(3) Adjust the low idle speed at the low idle speed
heater assembly. A separate heavy-duty cable is con
screw. The screw and locknut are located at the rear
nected to a separate terminal to supply power for
of the fuel injection pump (Fig. 29).
each element.
(4) Loosen the idle screw lock nut (Fig. 29). Adjust
idle screw to obtain specified rpm. Refer to the Idle PREHEAT/POST-HEAT CYCLE
Speed—Diesel Engine specifications chart for idle Refer to the Diesel Engine—Component Descrip
rpm. tion/System Operation section of this group for pre
(5) Tighten the locknut after adjustment. heat and post-heat information. See Intake Manifold
Air Heater Relays-PCM Pins #15 and #16-PCM
Output.
ON position. When the ground is provided, the air

heater is energized to start the preheat cycle.
The preheat-cycle can be tested with a voltmeter or
test light. If the intake manifold air temperature is
above 15°C (59°F), the wait-to-start warning lamp
will not illuminate and the air heater will not be en
ergized.
(1) With the engine not running and ambient air
temperature below 15°C (59°F), turn the ignition key
to the ON position.
(2) The wait-to-start warning lamp will come on
and the air heater relays should click ON signaling
the start of the preheat cycle. If the engine starter
is engaged before the preheat cycle of the heat
ers is complete, the PCM will stop the remain
ing preheat cycle.
(3) Check for battery voltage at both air heater ter
minals (Fig. 30). The heater will only be ener
gized for 10 to 30 seconds. Refer to the following
Air Heater Cycle Chart for a time/temperature com
parison.
AIR HEATER CYCLE CHART
mmmmmcm PKWATCYOEIIME POST-HOT CYOE-

«Nm0N0H,MONE
UPPER PART OF mmmmim NOTRIMNNG
Above 15° C 0 seconds No
Fig. 30 intake Manifold Air Heater (59° F)
BATTERY -10°Cto 15° C 10 seconds Yes

(LEFT SIDE) (15° F to 59° F)
-18° C to -10° F 15 seconds Yes

( 0 ° F t o l 5 ° F)
Below-18° C 30 seconds Yes

(0° F)
J9414-133
HEATER TEST
batteries.
(2) Lift the rubber shields from each of the cable
connectors at the intake manifold air heater (Fig. 30)
to expose the cable terminals. Do not disconnect ca
ble nuts.
(3) Use an ohmmeter to test the resistance be
The PCM provides a ground path for the intake tween the cable terminal (not the mounting stud)
manifold air heater relays. The ground path is pro and a ground. The resistance should be zero (0). If
vided if intake manifold air temperature is 15°C not, inspect for corroded or dirty cable connections.
(59°F) when the ignition key is initially placed in the Clean or repair the connections and retest before re
placing heater. Also check both ends of the ground
cable at the rear of the heater for corroded or dirty FRONT OF ENGINE AIR TEMPERATURE SENSOR
connections. If resistance is now anything other than SENSOR ELECTRICAL
zero (0), proceed to next step. CONNECTOR
(4) Disconnect both cables from the intake mani
fold heater (two nuts) (Fig. 30).
(5) Measure the resistance from each of the air
heater terminal threaded studs to a ground. The re
sistance should be zero (0). If the ohmmeter is still
reading anything other than zero (0), replace the in
take manifold air heater.
(6) After testing and repairing, connect battery ca
bles to both batteries.
Intake Manifold Air Heater in the Diesel Engine—
Component Removal/Installation section of this
group.
INTAKE
INTAKE MANIFOLD AIR HEATER RELAY TEST MANIFOLD
To test the intake manifold air heater, refer to the (UPPER HALF) S H ^ o
U W N SOLENOID^
SOLENOID ELECTRICAL
previous Intake Manifold Air Heater Test. CONNECTOR J9414-93
To test the intake manifold air heater relays, refer
to the following: Fig. 32 Air Temperature Sensor Location—Diesel
SENSOR RESISTANCE (OHMS)—INTAKE
batteries.
(2) Disconnect the four small relay trigger wires at MANIFOLD AIR TEMPERATURE SENSOR
both relays (Fig. 31). Note position of wires before re
moval. TEMPERATURE RESISTANCE {OHMS}
(3) Disconnect the four large cables at each of the
relay terminals (four nuts—figure 31). Note position C F MIN mm
of cables before removal.
(4) Attach an ohmmeter across two of the large -40 -40 291,490 381,710
studs on one of the relays. -20 -4 85,850 108,390
(5) Attach a jumper wire (+ and -) to each of the -10 14 49,250 61,430
small terminals on one of the relays. Polarity is not 0 32 29,330 35,990
important. 10 50 17,990 21,810
(6) Momentarily touch the jumper wires to the ve 20 68 11,370 13,610
25 77 9,120 10,880
hicle battery (+ and -). The relay should click and the 30 86 7,370 8,750
ohmmeter should show a closed circuit across the 40 104 4,900 5,750
large terminals. If not, replace relay and bracket as 50 122 3,330 3,880
sembly. 60 140 2,310 2,670
(7) Repeat the same test on the opposite relay. 70 158 1,630 1,870
80 176 1,170 1,340
(8) After testing and repairing, connect battery ca 90 194 860 970
bles to both batteries. 100 212 640 720
For removal and installation procedures, refer to 110 230 480 540
the Diesel Engine—Component Removal/Installation 120 248 370 410
J928D-4
INTAKE MANIFOLD AIR TEMPERATURE SENSOR (2) Test the resistance of the sensor with an input
TEST impedance (digital) volt-ohmmeter. The resistance (as
To perform a complete test of this sensor and its measured across the sensor terminals) should be less
circuitry, refer to DRB scan tool and appropriate than 1340 ohms with the engine warm. Refer to the
Powertrain Diagnostics Procedures manual. To test Sensor Resistance (OHMS)—Intake Manifold Air
the sensor only, refer to the following: Temperature resistance chart. Replace the sensor if it
(1) Disconnect the wire harness connector from the is not within the range of resistance specified in the
intake manifold air temperature sensor. The sensor chart.
is located on the top of the intake manifold and to
the rear of the air heater (Fig. 32).
BR - GENERAL DIAGNOSIS—DIESEL ENGINE 14 -113
(3) Test the resistance of the wire harness. Do this FUEL SHUT-OFF
between the powertrain control module (PCM) wire FUEL HEATER SOLENOID RELAY
harness connector terminal 21 and the sensor con
nector terminal. Also check between terminal 4 to the
sensor connector terminal. Repair the wire harness
POWERTRAIN CONTROL MODULE TESTING

Operation of the powertrain control module (PCM)
is tested with the DRB scan tool. Refer to the appro
priate Powertrain Diagnostic Procedures service
manual for tests.
RELAYS—OPERATION/TESTING
To perform a complete test of a relay and its cir
cuitry, refer to DRB scan tool and appropriate Pow
ertrain Diagnostics Procedures manual. To test the
relay only, refer to the following:
OPERATION
The following operations/tests apply to these
relays only: automatic shutdown (ASD), fuel shut
Fig. 34 Fuel Heater and Fuel Shutdown Solenoid
down solenoid and fuel heater. For operations/tests
Relays—Diesel
on all other relays, refer to the appropriate section of
this service manual. • Terminal number 87 is connected (a circuit is
The ASD relay is located in the power distribution formed) to terminal 30 in the energized (ON) posi
center (PDC). The PDC is located in the engine com tion. Terminal number 87 then supplies battery volt
partment (Fig. 33). For the location of this relay age to the component being operated.
within the PDC, refer to PDC cover. • Terminal number 86 is connected to a switched (+)
The fuel heater and fuel shutdown relays are lo power source.
cated in the engine compartment near the brake • Terminal number 85 is grounded by the power-
master cylinder (Fig. 34). train control module (PCM).
TESTING
(1) Remove relay before testing.
(2) Using an ohmmeter, perform a resistance test
between terminals 85 and 86. Resistance value
(ohms) should be 75 ±5 ohms for resistor equipped
relays.
ber 87A and 30. Continuity should be present at this
time.
ber 87 and 30. Continuity should not be present at
this time.
(5) Use a set of jumper wires (16 gauge or small
er). Connect one jumper wire between terminal num
ber 85 (on the relay) to the ground side (-) of a 12
Fig. 33 Power Distribution Center (PDC) Location Volt power source.
(6) Attach the other jumper wire to the positive
The relay terminal numbers (Fig. 35) can be found
on the bottom of the relay. side (+) of a 12V power source. Do not connect this
• Terminal number 30 is connected to battery volt jumper wire to relay at this time.
age and can be switched or B+ (hot) at all times. CAUTION: Do not allow the ohmmeter to contact
• The center terminal number 87A is connected (a
terminals 85 or 86 during these tests. Damage to
circuit is formed) to terminal 30 in the de-energized
ohmmeter may result.
(normally OFF) position.
14 -114 G E N E R A L D I A G N O S I S — D I E S E L ENGINE BR
30
85 87A 86
87
BOTTOM VIEW RELAY
OF RELAY CONNECTOR
DE-ENERGIZED ENERGIZED
RELAY RELAY
9214-157
Fig, 35 Relay Terminals

(7) - Attach the other jumper wire (12V +) to termi TRANSMISSION TEMPERATURE SENSOR TEST
nal number 86. This will activate the relay. Continu
ity should now be present between terminals number AUTOMATIC TRANSMISSION ONLY
87 and 30. Continuity should not be present between To perform a complete test of this sensor and its
terminals number 87A and 30. circuitry, refer to DRB scan tool and appropriate
(8) Disconnect jumper wires from relay and 12 Volt Powertrain Diagnostics Procedures manual. To test
power source. the sensor only, refer to the following:
If continuity or resistance tests did not pass, re (1) Disconnect the wire harness connector from the
place relay. If tests passed, refer to Group 8W, Wiring temperature sensor. The sensor is located on the side
Diagrams for (fuel system) relay wiring schematics of the transmission in the transmission cooling line
and for additional circuit information. (Fig. 36).
(2) Test the resistance of the sensor with an input
STARTER MOTOR RELAY TEST impedance (digital) volt-ohmmeter. The resistance (as
Refer to Group 8A, Battery/Starting/Charging Sys measured across the sensor terminals) should be less
tem Diagnostics, for starter motor relay testing. than 1340 ohms with the engine warm. Refer to the
Sensor Resistance (OHMS)—Transmission Tempera
THROTTLE POSITION S E N S O R T E S T ture Sensor resistance chart. Replace the sensor if it
The throttle position sensor (TPS) is used on diesel is not within the range of resistance specified in the
engines only when equipped with an automatic chart.
transmission. (3) Test the resistance of the wire harness. Do this
To test and adjust the TPS, refer to Throttle Posi between the powertrain control module (PCM) wire
tion Sensor Testing. See Throttle Position Sensor in harness connector terminal 42 and the sensor con
the Diesel Engine—Component Removal/Installation nector terminal. Also check between terminal 4 to the
section of this group for procedures. sensor connector terminal. Repair the wire harness

section of this group for water draining procedures.
0N-B0ARD DIAGNOSTICS (OBD)—DIESEL
POWERED VEHICLES
The powertrain control module (PCM) has been
programmed to monitor many different circuits for
diesel powered vehicles. If a problem is sensed in a
monitored circuit often enough to indicate an actual
problem, a diagnostic trouble code (DTC) is stored.
The DTC will be stored in the PCM memory for even
tual display to the service technician. If the problem
is repaired or ceases to exist, the PCM cancels the
DTC after 51 engine starts.
TEMPERATURE SENSOR J9414-46 Certain criteria must be met for a diagnostic trou
ble code (DTC) to be entered into PCM memory. The
Fig. 36 Transmission Temperature Sensor criteria may be a specific range of engine rpm, engine
Location—Typical temperature and/or input voltage to the PCM.
SENSOR RESISTANCE (OHMS)— It is possible that a DTC for a monitored circuit
TRANSMISSION TEMPERATURE SENSOR may not be entered into memory even though a mal
function has occurred. This may happen because one
of the DTC criteria for the circuit has not been met.
TEMPERATURE RES6STANCE ( O H M S ) A DTC indicates that the powertrain control mod
ule (PCM) has recognized an abnormal signal in a
C F MIN mm circuit or the system. A DTC may indicate the result
of a failure, but never identify the failed component
-40 291,490 381,710 directly.
-^20 -4 85,850 108,390 There are several operating conditions that the
-10 14 49,250 61,430 PCM does not monitor and set a DTC for. Refer to
0 32 29,330 35,990
10 50 17,990 21,810
the following Monitored Circuits and Non-Monitored
20 68 11,370 13,610 Circuits in this section.
25 77 9,120 10,880
30 86 7,370 8,750 MONITORED CIRCUITS
40 104 4,900 5,750 The powertrain control module (PCM) can detect
50 122 3,330 3,880 certain problems in the electrical system.
60 140 2,310 2,670
70 158 1,630 1,870
Open or Shorted Circuit - The PCM can deter
80 176 1,170 1,340 mine if sensor output (which is the input to PCM) is
90 194 860 970 within proper range. It also determines if the circuit
100 212 640 720 is open or shorted.
no
120
230
248
480
370
540
410
Output Device Current Flow - The PCM senses
whether the output devices are hooked up.
J928D-4
If there is a problem with the circuit, the PCM
senses whether the circuit is open, shorted to ground
VEHICLE SPEED SENSOR TEST (-), or shorted to (+) voltage.
To perform a complete test of the sensor and its cir NON-MONITORED CIRCUITS
cuitry, refer to DRB scan tool and appropriate Pow The PCM does not monitor the following circuits,
ertrain Diagnostics Procedures manual. systems or conditions that could have malfunctions
that result in driveability problems. A diagnostic
WATER-IN-FUEL WARNING LAMP
trouble code (DTC) will not be displayed for these
If this warning lamp remains illuminated when the conditions.
ignition key is ON, it indicates that excess water has Fuel Pressure: Fuel pressure is controlled by the
collected in the fuel filter/water separator. (Note that fuel transfer pump and fuel injection pump. The
the lamp will be illuminated for approximately two PCM cannot detect problems in these components.
seconds when the ignition key is initially placed in" Cylinder Compression: The PCM cannot detect
the ON position for a bulb check). Excess water can uneven, low, or high engine cylinder compression.
be drained. Refer to Fuel Filter/Water Separator in Exhaust System: The PCM cannot detect a
plugged, restricted or leaking exhaust system.
14 - 116 GENERAL DIAGNOSIS—DIESEL ENGINE Bit
Fuel injector Malfunctions: The PCM cannot de DRB, refer to the appropriate Powertrain Diagnostic
termine if the fuel injector is clogged, or the wrong Procedures service manual.
injector is installed. The fuel injectors on the diesel
engine are not controlled by the PCM.
Vacuum Assist: Leaks or restrictions in the vac
uum circuits of vacuum assisted engine control sys
tem devices are not monitored by the PCM.
Powertrain Control Module (PCM) System
Ground: The PCM cannot determine a poor system
ground. However, a DTC may be generated as a re
sult of this condition.
Powertrain Control Module (PCM) Connector
Engagement: The PCM cannot determine spread or
damaged connector pins. However, a DTC may be
generated as a result of this condition.
HIGH AND LOW LIMITS POWERTRAIN CONTROL
The powertrain control module (PCM) compares in MODULE (PCM) J9414-11
put signal voltages from each input device. It will es
Fig. 38 Data Link Connector Location—Typical
tablish high and low limits that are programmed into
it for that device. If the input voltage is not within E1AMPLES;
specifications and other diagnostic trouble code • If the lamp (Fig. 37) flashes 1 time, pauses and
(DTC) criteria are met, a DTC will be stored in mem flashes 2 more times, a flashing Diagnostic Trouble
ory. Other DTC criteria might include engine rpm Code (DTC) number 12 is indicated. If this code is
limits or input voltages from other sensors or observed, it is indicating that the battery has been
switches. The other inputs might have to be sensed disconnected within the last 50 key-on cycles. It
by the PCM when it senses a high or low input volt could also indicate that battery voltage has been dis
age from the control system device in question. connected to the PCM. In either case, other DTC's
may have been erased.
ACCESSING DIAGNOSTIC TROUBLE CQDES
A stored diagnostic trouble code (DTC) can be dis • If the lamp flashes 4 times, pauses and flashes 1
played by cycling the ignition key ON-OFF-ON- more time, a diagnostic trouble code (DTC) number
OFF-ON within three seconds and observing the 41 is indicated.
malfunction indicator lamp. This lamp is displayed ® If the lamp flashes 4 times, pauses and flashes 6
on the instrument panel as the CHECK ENGINE more times, a diagnostic trouble code (DTC) number
lamp (Fig. 37). 46 is indicated.
After any stored DTC information has been ob
served, the display will end with a flashing DTC
number 55. This will indicate the end of all stored in
formation.
Refer to the Diagnostic Trouble Code (DTC) charts
for DTC identification.
If the problem is repaired or ceases to exist, the
powertrain control module (PCM) cancels the DTC
after 51 engine starts.
Diagnostic trouble codes indicate the results of a
failure, but never identify the failed component di
rectly.
Typical circuits of the data link connector are
shown in (Fig. 39).
ERASING TROUBLE CODES
Fig. 37 Check Engine Lamp—Typical Location After the problem has been repaired, use the DRB
scan tool to erase a Diagnostic Trouble Code (DTC).
They can also be displayed through the use of the Refer to the appropriate Powertrain Diagnostic Pro
Diagnostic Readout Box (DRB scan tool). The DRB cedures service manual for operation of the DRB
scan tool connects to the data link connector in the
scan tool.
engine compartment (Fig. 38). For operation of the
DRB SCAN TOOL

For operation of the DRB scan tool, refer to the ap D-l GROUND
propriate Powertrain Diagnostic Procedures service
manual.
D-2 N/C
DIAGNOSTIC TiOtJIlE CODE (DTC)
D-3 " SCI TRANS
On the following pages, a list of diagnostic trouble D-4 SCI RECEIVE |
codes is provided for all diesel powered vehicles. A
DTC indicates that the powertrain control module D-5 IGNITION
(PCM) has recognized an abnormal signal in a circuit
or the system. A DTC may indicate the result of a J9214-20 D-6 NOT USED !
failure, but never identify the failed component di
rectly. Fig. 39 Data Link Connector Schematic
DIAGNOSTIC TROUBLE CODE DESCRIPTIONS

Diagnostic
DRB Scan Tool Display Description ©f Diagnostic Trouble Code
Trouble Code
11* No Crank Reference Signal at PCM No crank reference signal detected during en
gine cranking.
12* None Direct battery input to PCM was disconnected

within the last 50 Key-on cycles.
15** No Vehicle Speed Sensor Signal No vehicle distance (speed) sensor signal de
tected during road load conditions.
23** Intake Air Temp Sensor Voltage Low Intake manifold air temperature sensor input
below the minimum acceptable voltage.
or
Intake manifold air temperature sensor input

Intake Air Temp Sensor Voltage High above the maximum acceptable voltage.
Throttle position sensor input above the maxi

24** Throttle Position Sensor Voltage High mum acceptable voltage (automatic transmis
sion only).
or
Throttle Position Sensor Voltage Low Throttle position sensor input below the mini
mum acceptable voltage (automatic transmis
sion only).
33* A/C Clutch Relay Circuit An open or shorted condition detected in the
A/C clutch relay circuit.
34* Speed Control Solenoid Circuits An open or shorted condition detected in the
Speed Control vacuum or vent solenoid cir
cuits.
or
Speed Control Switch Always Low Speed Control switch input below the mini
or
118 GENERAL DIAGNOSIS—DIESEL ENGINE B

Diagnostic D R B Scan Tool Display Description of Diagnostic Trouble Cod©
Trouble Code
Speed Control Switch Always High Speed Control switch input above the maxi
37** Torque Converter Clutch Solenoid CKT An open or shorted condition detected in the
CKT circuit.
or
Trans Temp Sensor Voltage Too Low Voltage Low at Trans Temp Sensor
or
Trans Temp Sensor Voltage Too High Voltage High at Trans Temp Sensor
41** Generator Field Not Switching Properly An open or shorted condition detected in the
generator field control circuit.
42* Auto Shutdown Relay Control Circuit An open or shorted condition detected in the
auto shutdown relay circuit.
44* Battery Temp Sensor Volts out of Limit An open or shorted condition exists in the en
gine coolant temperature sensor circuit or a
problem exists in the PCM's battery tempera
ture voltage circuit.
45* Trans Overdrive Solenoid Circuit An open or shorted condition exists in the
transmission overdrive solenoid circuit.
46** Charging System Voltage Too High Battery voltage sense input above target
charging voltage during engine operation.
47** Charging System Voltage Too Low Battery voltage sense input below target
charging during engine operation. Also, no sig
nificant change detected in battery voltage
during active test of generator output.
53* Internal PCM Failure PCM Internal fault condition detected.
or
PCM Failure SPI (Serial Peripheral Inter PCM Internal fault condition detected.
face) Communications
55* Display not shown on DRB scan tool A DTC #55 is used to end all DTC messages.
This code indicates a completion of all DTC's
displayed on the Malfunction Indicator Lamp
(Check Engine Lamp).
62* PCM Failure SRI miles not stored Unsuccessful attempt to update SRI (service
reminder indicator) miles in the PCM EE
PROM.
63* PCM Failure EEPROM Write Denied Unsuccessful attempt to write to an EEPROM
location by the PCM.
SYSTEM DIAGNOSIS CHARTS stroke) at cylinder number 1. Place a paint mark on

Refer to Engine Diagnosis in Group 9, Engine for the dampener to indicate TDC. Remove the pin.
diagnostic charts. This will prevent damage when barring (rotat
ing) the engine in later steps.
FUEL INJECTION PUMP TIMING The pin is located above the power steering
(1) Thoroughly clean the engine and fuel system pump, below and to the inside of the fuel injec
before attempting to remove any "components. Pay tion pump, on the rear of the cam gear housing
special attention to the top of the fuel injection (Fig. 42).
pump. Use compressed air to remove any water re MACHINED HOLE
maining on the fuel pump after the cleaning process.
CAUTION: DO NOT ALLOW ANY DIRT, D E B R I S , OR
PAINT CHIPS TO ENTER THE F U E L S Y S T E M WHILE
IT I S O P E N . IF FOREIGN MATERIAL OF ANY T Y P E
IS A L L O W E D INTO THE PUMP, LINES OR INJEC
TORS DURING THIS P R O C E S S IT COULD RESULT
IN AN INJECTION PUMP OR F U E L INJECTOR MAL
FUNCTION.
Locate top dead center (TDC) on cylinder #1.

(2) Remove the rubber access plug located in the
rear flange of the engine on the exhaust manifold
side. (Fig. 40).
Fig. 41 Back of Camshaft Gear
Fig. 40 Rotating Engine With Barring Tool

Removing the #6 cylinder valve cover and
first barring (rotating) the engine clockwise un
til both intake and exhaust valves are closed
will speed up locating engine TDC as described
later in step 4.
(3) Insert the barring tool number 7471B through
the access hole and into the flywheel housing (Fig.
40).
(4) While holding tension on the timing pin (to
ward front of engine), slowly rotate the engine with
the barring tool. Hold a slight rearward (pushing)
pressure on the barring tool and rotate the tool
counter-clockwise until the timing pin drops into the
machined hole in the back of the camshaft gear.
Fig. 42 Timing Pin and Location
When the pin aligns to the gear (Fig. 41), and the in
take and exhaust valves are closed at the #6 cylinder, (5) Remove #1 fuel injection line from the fuel
the engine is at the TDC position (compression pump (Fig. 43).
14 - 121 GENERAL DIAGNOSIS—DIESEL ENGINE BR
CAUTION: DO NOT BEND THE F U E L LINE. BEND

ING THE LINE WILL CAUSE LINE OR INJECTOR
FAILURE.
Fig. 45 Delivery Valve Holder Removal
Fig. 43 Number 1 injection Line

(6) With the engine at TDC, loosen but do not re
move, the front (#1) delivery valve holder using spe
cial socket #6804 (Fig. 44). Remove the socket from
the valve holder prior to removing the valve from the
injection pump.
There is an external o-ring on the holder to help
prevent debris from getting into the pump. This may
create a slight resistance as the holder is unscrewed.
(7) Remove the delivery valve holder by carefully
Fig. 46 Delivery Valve Assembly

careful not to scratch the top of the plunger/barrel
assembly during this process. Discard the used deliv
ery valve washer. A new washer (Fig. 47) will be used
during reassembly.
Fig. 44 Delivery Waive Holder Removal

tipping the holder outboard with one hand while us
ing the other hand to hold the spring, fill piece, and
any shims from slipping out of the holder. Place
J9514-81
these parts (Fig. 45) as an assembly to a clean sur
face. Fig. 47 Delivery Valve Washer
(8) Using a magnet, remove the two piece delivery
(10) Install the dial indicator adaptor tool #6842
valve assembly from the pump (Fig. 46). Place these
(Fig. 48) in place of the #1 delivery valve holder and
parts to a clean surface.
tighten finger tight.
(9) Using a pick, remove the copper delivery valve
washer from the top of the pumping element. Be
Fig. 48 Installing Special Adapter Tool

Fig. 30 Engine Data Plate
(11) Loosen the set screw on the dial indicator (b) Note the pump lift setting on the dial indica
adaptor (Fig. 48). Install the dial indicator #6859 and tor (Fig. 49).
dial indicator tip #6843 into the adapter. Position the (c) Note the "Timing-TDC" specification (in de
dial indicator to read between 7.0 and 9.0 mm and grees) stamped into the engine data plate. The en
tighten the set screw (Fig. 48). The dial indicator is gine data plate is located on the left side of the
capable of measuring from 0-20.00 mm lift. The small timing gear cover (Fig. 50).
inner dial is marked in increments of 1 mm. The (d) Compare these specifications to the chart
large outer dial is marked in increments of 0.01 mm. shown in figure 51 for automatic transmission, or
One revolution of the outer dial is equal to 1 mm. figure 52 for manual transmission.
The inner dial only indicates 0-10 mm, but will ro (e) If specifications match, a fuel timing adjust
tate twice as the indicator goes through the full ment will not be necessary. Proceed to step 27.
range. (f) If the specifications do not match, a fuel tim
(12) Using the engine barring tool #7471B, rotate ing adjustment will be necessary. Proceed to next
the engine in the direction opposite normal direction step.
of engine rotation (counterclockwise from front of en
gine) 1/4 turn or until you see the dial indicator read Degrees b e f o r e top Pump p l u n g e r
dead center (BTDC) lift setting (mm)

ing stop dropping. This is the inner base circle of the
11.0 5.4
injection pump cam. Zero the indicator and note the 11.5 5.5
reading on the small inner dial (Fig. 49). 12.0 5.6
12.5 5.7
13.0 5.8
13.5 5.9
J9514-67
Fig. 51 Pump Lift Settings—Automatic

Transmission
Degrees before top Pump plunger

dead center (BTDC) lift setting (mm)
Il.O 4.0
11 5 4.05
12.0 4.1
12.5 4.2
13.0 4.3
13.5 4.4
J9514-66
Fig. 49 Setting Dial Indicator
Fig. 52 Pump Lift Settings—Manual Transmission
(13) Be sure the timing pin is disengaged be
fore rotating the engine to avoid damage to the
timing pin. •
(a) Rotate the engine clockwise slowly to TDC.
Adjusting Timing:
(14) Remove the oil filler tube (Fig. 53) and
adapter elbow from the front of the timing gear hous
ing.
PUMP SHAFT
Fig. 58 Oil Filler Tube J9514-65
(15) Loosen the injection pump shaft nut (use the
barring tool to keep the engine from rotating). Before Fig. 54 Positioning Magnet to Pump Shaft
removing pump nut or washer, place a magnet to the BEARING
end of the injection pump shaft (Fig. 54). This will
prevent the nut or washer from falling into the tim
ing gear cover which will require engine disassembly
for recovery.
(16) Position a magnet to the end of the injection
pump shaft. Install the special bearing and thrust
washer kit #6862 (Fig. 55) over th^ injection pump
shaft in this order: 1 thrust washer-1 bearing-1
thrust washer. The thrust washer/bearing kit is used
to prevent the pump gear from rotating on the pump
shaft when tightening the pump nut (step 22). Rein
stall pump shaft nut allowing some clearance be WASHERS
tween the thrust washers. Do not tighten nut at this J9514-85
time.
Fig. 55 Bearing/Thrust Washer Tools
(17) Slowly rotate the engine clockwise until reach
ing the required lift setting on the dial indicator (re the gear onto the pump shaft. This will remove back
fer to charts figure 51 or 52). The injection pump lash between the injection pump and camshaft gears.
should rotate with the engine since the injection (21) Hand tighten the pump shaft nut (Fig. 59).
pump gear is still locked to the injection pump shaft. Remove the gear puller (Fig. 59).
(18) With the injection pump at the correct plunger (22) Tighten the pump shaft nut to 15 N-m (11 lb.
ft.) torque to seat the gear to the pump shaft taper
lift setting, use special gear puller tool #L-4407A to
(Fig. 60).
pull the injection pump gear off the taper of the in (23) Remove injection pump shaft nut. Use a mag
jection pump input shaft. Leave the gear puller in net on the end of the shaft while removing (Fig. 54).
stalled (Fig. 56). After the gear has been pulled, (24) Remove special bearing and thrust washers
ensure the lift setting has not changed. #6862 from pump shaft. Use a magnet on the end of
(19) Rotate the engine 20 to 30 degrees counter the shaft while removing.
clockwise, then rotate the engine back clockwise to (25) While preventing the engine from rotating
TDC (Fig. 57). This removes backlash from the with the barring tool, tighten the shaft nut to 195
geartrain. N-m (144 lb. ft.) torque (Fig. 60).
(20) Loosen, but do not remove the gear puller tool (26) Repeat steps 12 and 13 to verify that the final
bolts. Using the gear puller, rotate to pump gear timing setting is correct. If the setting is not correct,
counterclockwise by hand (Fig. 58), while pushing repeat steps 15 through 25.
THRUST
WASHERS
THRUST
WASHER
J9514-89
J9514-86
Fig. 56 Gear Puller Tool Installed Fig. 59 Removing Gear Puller Tool
95 N«m
[144 FT-LBS]
J9514-90
Fig. 60 Tightening Pump Nut

Fig. 57 Rotating Crankshaft
(28) Install a new copper delivery valve washer
into the fuel pump.
THRUST (29) Install the delivery valve assembly on top of
WASHER
the sealing washer as shown in figure 61.
J9514-8
Fig. 58 Rotating Injection Pump Gear J9514-91

(27) Remove the dial indicator and adaptor from
the injection pump.
CAUTION: THE FOLLOWING INSTALLATION AND Fig. 61 Delivery Valve Assembly
TORQUING P R O C E D U R E MUST B E F O L L O W E D E X
ACTLY. I M P R O P E R INSTALLATION OF THE DELIV
(30) Lubricate the threads and clamping surface of
ERY VALVE WILL RESULT IN DAMAGE OR L E A K S .
the delivery valve holder with a few drops of SAE 90
14 -124 GENERAL DIAGNOSIS—DIESEL ENGINE mm
hypoid gear oil. Do not Imbricate the copper de
livery valve washer or its seating area,
(31) Install the delivery valve holder assembly tak
ing care not to displace the delivery valve spring, fill
piece, or any shims as shown in figure 62.
Fig. 63 Tightening Delivery Waive Holder

J9514-92
Fig. 62 Delivery Waive Holder

(32) Pre-tighten the delivery valve holder to 40
N-m (29 lb. ft.) torque (Fig. 63). Next, in one motion,
tighten the holder to 115 N-m (85 ft. lbs.) torque (Fig.
63).
(33) Install remaining engine components removed
during the timing process. Leave the injector end of
the #1 high-pressure fuel line loose to facilitate
bleeding the air out of the system.
WARNING: THE PRESSURE OF THE FUEL IN THE
LINE IS SUFFICIENT TO PENETRATE THE SKIN
AND C A U S E S E R I O U S BODILY HARM.
(34) Crank the engine until fuel is observed at the

#1 injector. Tighten the high-pressure line at the in
jector. Start the engine and check for leaks.
BR COMPONENT REMOVAL/INSTALLATION—DIESEL ENGINE 14 - 1 2 5
D I E S E L ENGINE—COMPONENT REMOVAL/INSTALLATION
NDEX
page page
Air Bleed Procedure 126 Fuel Tank 142

Air Cleaner Housing/Air Cleaner Element 125 Fuel Tank Module 142
Engine Speed Sensor 127 Fuel Transfer Pump 142
Fuel Drain Manifold 128 High-Pressure Fuel Lines 142
Fuel Filter—In Tank 129 Idle Speed Adjustment . . . . . . . . . . . . . . . . . . . . 143
Fuel Filter/Water Separator 129 Intake Manifold 143
Fuel Gauge Sending Unit 130 Intake Manifold Air Heater 144
Fuel Heater 130 Intake Manifold Air Heater Relays 144
Fuel Heater Relay ...... 131 Intake Manifold Air Temperature Sensor . . . . . . . . 144
Fuel Injection Pump 131 Powertrain Control Module (PCM) 145
Fuel Injection Pump Supply Line 138 Throttle Position Sensor 145
Fuel Injectors 138 Transmission Temperature Sensor 147
Fuel Shutdown Solenoid 140
Vehicle Speed Sensor . . . . . . . . . . . . . . . . . . . . . 147
Fuel Shutdown Solenoid Relay 141
Fuel System Pressure Test—Diesel Engine . . . . . 141 Wastegate (Turbocharger) . 147
Fuel System Pressure Warning 141 Water-ln-Fuel Sensor . 147
AIR CLEANER HOUSING/AIR CLEANER ELEMENT will hold the yellow disc at the highest restriction
that the air cleaner element has experienced. A drop
TESTING AM CLEANER ELEMENT in air pressure due to an air cleaner element restric
Do not attempt to unnecessarily remove the tion moves the diaphragm and the yellow disc will
top of the air cleaner housing for air cleaner el indicate the size of the air drop.
ement inspection on diesel engines. CAUTION: Certain engine degreasers or cleaners
The air cleaner (filter) housing is equipped with an may discolor or damage the plastic housing of the
air Filter Minder™ gauge (Fig. 1). This air flow re Filter Minder. Cover and tape the Filter Minder if any
striction gauge will determine when the air cleaner engine degreasers or cleaners are to be used.
element is restricted and should be replaced.
PRESS BUTTON
TO RESET
Fig. 1 Filter Minder™ Location—Diesel Engine

TO AIR
The Filter Minder™ consists of a diaphragm and FILTER HOUSING
calibrated spring sealed inside of a plastic housing J9425-4
(Fig. 2). A yellow colored disc attached to the dia
phragm moves along a graduated scale on the side of Fig. 2 Filter Minder™ —Diesel Engine
the Filter Minder. After the engine has been shut off,
To test, turn the engine off. If the yellow disc (Fig.
a ratcheting device located within the Filter Minder 2) has reached the red colored zone on the graduated
14 -126 COMPONENT REMOVAL/INSTALLATION—DIESEL ENGINE BR
scale, the air cleaner element should be replaced. Re amount of air is vented automatically from the injec
fer to the proceeding removal/installation para tion pump through the fuel drain manifold. This is if
graphs. the filter was changed according to instructions.
Resetting t h e Filter Minder: After the air The system will have to be bleed manually if:
cleaner (filter) element has been replaced, press the ® The fuel filter is not filled before installation
rubber button on the top of the Filter Minder (Fig. ® The fuel injection pump is replaced
2). This will allow the yellow colored disc to reset. Af • High-pressure fuel line connections are loosened or
ter the button has been pressed, the yellow disc lines replaced
should spring back to the UP position. • Initial engine start-up or start-up after an ex
If the Filter Minder gauge has reached the red col tended period of no engine operation.
ored zone, and after an examination of the air (1) Loosen the low-pressure bleed bolt (Fig. 3).
cleaner (filter) element, the element appears to be
clean, the high reading may be due to a temporary
condition such as snow build-up at the air intake.
Temporary high restrictions may also occur if the air
cleaner (filter) element has gotten wet such as during
a heavy rain or snow. If this occurs, allow the ele
ment to dry out during normal engine operation. Re
set the rubber button on the top of the Filter Minder
and retest after the element has dried.
REMOVAL/INSTALLATION
(1) Loosen the air inlet tube clamp at air cleaner
housing inlet (Fig. 1). Remove this tube at air cleaner
housing cover.
(2) The housing cover is equipped with four (4)
spring clips (Fig. 1) and is hinged at the front with
plastic tabs. Unlatch the clips from the top of air
cleaner housing and tilt the housing cover up and
forward for cover removal.
(3) Remove the air cleaner element from air
cleaner housing.
(4) Before installing a new air cleaner element,
clean inside of air cleaner housing.
(5) Position air cleaner cover to tabs on front of air
cleaner housing. Latch the four spring clips to seal
cover to housing.
(6) Install the air inlet tube at air cleaner housing
inlet. Note the hose alignment notches at both the in
let hose and air cleaner cover (Fig. 1).
(7) Position the tube clamp to the inlet tube and Fig. 3 Low-Pressure Bleed Bolt
tighten to 3 N-m (25 in. lbs.) torque. (2) Operate the rubber push-button primer on the
fuel transfer pump (Fig. 4). Do this until the fuel ex
AIR BLEED PROCEDURE iting the low-pressure bleed bolt is free of air.
A certain amount of air becomes trapped in the fuel If the primer button feels as if it is not pumping,
system when fuel system components are serviced or rotate (crank) the engine approximately 90 degrees.
replaced. Bleed the system after fuel system service Continue pumping until air is removed.
according to the following procedures. (3) Tighten low-pressure bleed screw to 8 N-m (6 ft.
WARNING: DO HOT BLEED A I R F R O U THE FUEL
lbs.) torque.
SYSTEM O F k H O T E N G I N E . DO NOT A L L O W F U E L
FUEL INJECTION PUMP BLEEDING
TO S P R A Y O N T O T H E EXHAUST M A N I F O L D WHEN
BLEEDING MR FROM T H E F U E L S Y S T E M . WARNING: THE ENGINE MAY START WHEN
CRANKING TO BLEED AIR FROM T H E INJECTION
MANUAL BLEEDING PUMP. PLACE T H E TRANSMISSION iu NEUTRAL

Some air enters the fuel system when the filters or OR PARK AND SET PARKING BRAKE BEFORE EN
injection pump supply line are changed. This small GAGING T H E STARTER MOTOR.
BR COMPONENT REMOVAL/INSTALLATSON—DIESEL ENGINE 14 -121
FUEL
TRANSFER
PUMP
J9114-69
Fig. 5 Bleeding High-Pressure Fuel Lines

RUBBER (2) Crank the engine until all air is bled from the
PRIMER line. Do not operate the starter motor for longer
BUTTON
than 30 seconds. Wait two minutes between
J9414-72
cranking intervals.
Fig. 4 Fuel Transfer Pump—Manual Operation
(3) Start the engine and bleed one injector at a
time until the engine runs smoothly.
CAUTION: Do not engage the starter motor for more (4) Tighten fuel line(s) at injector(s) to 30 N-m (22
than 30 seconds at a time. Allow two minutes be ft. lbs.) torque.
tween cranking intervals.
ENGINE SPEED SENSOR
(1) Perform the previous procedure: Manual Bleed
ing. The engine speed (rpm) sensor is located on the
(2) Crank the engine for 30 seconds at a time to al front of engine (Fig. 6). Spacers located behind the
low air trapped in the injection pump to vent out the sensor are^ used to position sensor over the vibration
damper.
drain manifold. Observe the previous WARNING and
CAUTION. SENSOR MOUNTING BOLTS
mGW-PRESSURE FUEL LIME BLEEDING
WARNING: THE F U E L INJECTION PUMP S U P P L I E S

H I G H - P R E S S U R E F U E L O F A S HIGH AS 120,000
KPA (17,405 PSI) TO EACH INDIVIDUAL INJECTOR
THROUGH THE HIGH-PRESSURE LINES. F U E L UN
DER THIS AMOUNT OF P R E S S U R E CAN P E N E
TRATE THE SKIN AND C A U S E P E R S O N A L INJURY.
W E A R S A F E T Y G O G G L E S AND ADEQUATE P R O
TECTIVE CLOTHING AND AVOID CONTACT WITH
FUEL SPRAY WHEN BLEEDING HIGH-PRESSURE
F U E L LINES.
WARNING: DO NOT B L E E D AIR FROM THE F U E L

S Y S T E M OF A HOT ENGINE. DO NOT A L L O W F U E L
TO S P R A Y ONTO THE EXHAUST MANIFOLD W H E N
B L E E D I N G AIR FROM THE F U E L S Y S T E M .
VIBRATION
DAMPER J9214-69
Bleed air from one injector at time.
(1) Loosen the high-pressure fuel line fitting at the Fig. 6 Engine Speed Sensor—Diesel
injector (Fig. 5).
14 -128 COMPONENT REMOVAL/INSTALLATION—DIESEL ENGINE BR
REMOVAL FUEL DRAIN MANIFOLD
Before removing the sensor, note the position and
routing of the sensor wiring harness. This routing REMOVAL
must be maintained to prevent wiring from contact (1) Remove the two nuts retaining the nameplate/
ing belt or pulleys. cover to the top of the six engine valve covers (Fig.
(1) Disconnect the speed sensor pigtail harness 8). Remove nameplate/cover from engine.
from the main engine wiring harness near the front/ NAMEPLATE/COVER
top of engine. NAMEPLATE/COVER
(2) Remove the clip bolts from the sensor pigtail NUTS (2)
# 6 CYLINDER
wiring harness. VALVE COVER
(3) Remove the two speed sensor mounting nuts
(Fig. 6).
(4) Remove the speed sensor and its mounting
spacers from the vehicle.
INSTALLATION/ADJUSTMENT
The engine speed sensor uses a slotted hole on one
side (Fig. 7) to adjust its depth. A brass (non-magnet
ic) feeler gauge must be used to adjust the sensor.
RUBBER
METAL ADAPTER
CLAMPS (2) INTAKE
TUBE
J9414-73
Fig. 8 Nameplate/Cover—Diesel
(2) Remove drain manifold fitting screws (bolts) at
each of the six injectors (Fig. 9).
INJECTOR
^ ' Fig. 7 Engine Speed Sensor—Installation

(1) Sensor-to-vibration damper air gap is: 1.25 MM
(.049 in.) minimum to 1.30 MM (.051 in.) maximum.
(2) Position speed sensor, its mounting spacers and
two mounting nuts to the engine. Install mounting
nuts finger tight.
(3) Route sensor wiring harness behind engine pul
leys. Install and tighten wiring harness clip bolts.
(4) Place the feeler gauge between the sensor and DRAIN MANIFOLD
the vibration dampener. FITTING
SCREW
(5) Gently seat (push down) the sensor until it con J9114-44
tacts the feeler gauge. Be sure the sensor is not
Fig. 9 Fuel Drain Manifold Fittings—Typical
near either of the notches (Fig. 6) on the vibra
tion damper. If sensor is adjusted at or near (3) Remove the fuel drain manifold holddown
these notches, it will be damaged when engine clamp mounting bolt at the top/rear of intake mani
is started. fold.
(6) Tighten sensor mounting nuts to 24 N-m (18 ft. (4) Remove the fuel drain manifold banjo fitting at
lbs.) torque. the top of fuel filter/water separator (one bolt) (Fig.
(7) Remove feeler gauge. 10).
(8) Connect the sensor electrical connector to the (5) Remove fuel drain manifold fitting washers at
main engine wiring harness. each fuel injector.
BR — — — — — - COMPONENT REMOVAL/INSTALLATION—DIESEL ENGINE 14 -129
(6) Remove manifold from engine. following: D r a i n i n g Water f r o m Filter.

DRAINING WATER FROM FILTER: The filter
FUEL
DRAIN should be drained whenever t h e water-in-fuel w a r n
MANIFOLD i n g lamp remains illuminated. (Note t h a t t h e lamp
BOLT
w i l l be i l l u m i n a t e d for approximately t w o seconds
w h e n the i g n i t i o n key is i n i t i a l l y placed i n the O N
position for a bulb check). The d r a i n valve can also
be used to d r a i n excess fuel f r o m t h e f i l t e r when re
placement of the filter is necessary.
There is a d r a i n valve a n d d r a i n hose located a t
the bottom of t h e water-in-fuel ( W I F ) sensor (Fig.
11). Place a d r a i n p a n under t h e d r a i n hose. With
the engine not running, push u p on the drain
valve (Fig. 11) t o remove t h e water f r o m t h e filter/
separator. H o l d t h e d r a i n valve open u n t i l a l l water
and contaminants have been removed and clean fuel
exits the d r a i n . Dispose of m i x t u r e i n d r a i n pan ac
cording to applicable regulations.
FUEL FILTER/
WATER SEPARATOR
FUEL DRAIN
MANIFOLD
WIF
SENSOR
HOUSING
FUEL FILTER/
WATER SEPARATOR J9414-86
Fig. 10 Drain Manifold and Fuel Filter/Water

Separator
INSTALLATION DRAIN
(1) Using new seals/washers on a l l fittings, assem HOSE J9414-89
ble fuel d r a i n manifold i n reverse order of disassem
bly. Fig. 11 Drain Valve at Fuel Filter/Water Separator
(2) Tighten d r a i n manifold f i t t i n g screws (bolts) a t
(2) Remove t h e d r a i n hose at the d r a i n valve (Fig.
the injectors to 8 N-m (6 f t . lbs.) torque.
11).
(3) Tighten d r a i n manifold holddown clamp screws
(3) Disconnect t h e electrical connector from the
(bolts) to 13 N-m (10 ft. lbs.) torque.
W I F sensor at t h e bottom of the filter (Fig. 12).
(4) I n s t a l l nameplate/cover.
FILTER -Ht- FUEL FILTER/ -
FUEL FILTER—IN TANK \ r ~f\ HOUSING. X \ /WATER SEPARATOR
Refer to Fuel Tank Module—Diesel Engine for re
moval and installation. This can be found i n the Fuel
Delivery—Diesel Engine section of this group.
FUEL FILTER/WATER SEPARATOR

Refer to the maintenance schedules i n Group 0 i n
this manual for t h e recommended fuel filter/water
separator replacement intervals.
The combination water-in-fuel sensor a n d fuel f i l
ter/water separator is screwed onto a metal housing
located on t h e left/rear side of the engine and below
the intake manifold (Fig. 10). ELECTRICAL /
CONNECTOR J9414-87
REMOWAL
(1) Partially d r a i n the filter/separator. Refer to t h e Fig. 12 Electrical Connector—WIF Sensor
14 - 130 COMPONENT REMOVAL/INSTALLATION—DIESEL ENGINE B R
(4) Remove (unscrew) the filter/separator and WIF (3) Fill filter/separator with clean fuel.
sensor as one assembly from the filter housing (Fig. (4) Apply a light film of clean unused engine oil to
12). the filter/separator seal.
(5) Remove the o-ring seal from the filter housing (5) Install a new o-ring seal to the filter/separator
(Fig. 13). housing (Fig. 13).
(6) Install filter/separator to housing. Tighten fil
O-RING FILTER ter/separator one-half turn after it makes contact
with the housing. Tighten by hand only.
(7) Connect electrical connector to WIF sensor.
(8) Connect drain hose to drain valve.
FUEL GAUGE SENDING UNIT

Refer to the Fuel Delivery—Diesel Engine section
of this group for procedures.
FUEL HEATER
The fuel heater element assembly is located inside
of the fuel heater housing and above the pre-filter '
(Fig. 15). The fuel temperature sensor is located at
the top of the fuel heater housing (Fig. 15).
Fig. 13 Fuel Filter/Water Separator O-ring

(6) Drain the filter/separator.
(7) Remove the WIF sensor, o-ring and drain valve
assembly from the filter/separator (Fig. 14).
(8) Inspect the WIF sensor probes. Clean contami
nants from sensor probes if necessary. Replace sensor
if probes will not clean up.
:
i FUEL FILTER/
WATER SEPARATOR
DRAIN
VALVE
Fig. 15 Fuel Heater and Temperature Sensor

J9414-90 Location
REMOVAL
Fig. 14 WIF Sensor and Drain Valve Assembly (1) Disconnect both negative battery cables at both
INSTALLATION batteries.
(1) Install a new o-ring seal on WIF sensor. (2) Remove starter motor. Refer to Group 8B for
(2) Install WIF sensor/drain valve assembly into procedures.
new filter/separator. (3) Disconnect the electrical connector at the front
If the new fuel filter/water separator is not of fuel heater housing (Fig. 15).
filled with clean fuel before it is installed, man (4) Place a drain pan below the fuel heater.
ual air bleeding of the fuel system may be nec (5) A machined hex is located on the bottom of the
essary (temporary rough engine running may pre-filter housing (Fig. 16). From under the vehicle,
occur). If necessary, refer to the Air Bleed Pro attach a socket to this hex and remove (unscrew) the
cedure i n this section of the group for proce pre-filter.
dures. (6) Remove the fuel heater assembly from housing.
BR COMPONENT REMOVAL/INSTALLATION—DSESEL ENGINE 1 4 • 131
FROM FUEL FUEL INJECTION PUMP

TANK
REMOVAL
T O FUEL
TRANSFER (1) Disconnect both negative battery cables at both
PUMP batteries.
FUEL (2) Disconnect electrical connector at throttle posi
TEMPERATURE tion sensor on side of injection pump (if equipped
SENSOR
with automatic transmission) (Fig. 18).
MOUNTING
PRE-FILTER BRACKET/
SPACER
SCREEN
FUEL HEATER
ASSEMBLY
MACHINED
HEX J9414-95
Fig. 16 Fuel Heater and Pre-Filter
INSTALLATION
Reverse the removal procedure for heater element ELECTRICAL THROTTLE
installation. CONNECTOR POSITION

SENSOR
FUEL HEATER RELAY

The fuel heater relay is located in the engine com
FUEL SHUT-OFF
FUEL HEATER S O L E N O I D RELAY
RELAY
BRAKE M A S T E R
CYLINDER
CENTER TERMINAL MOUNTING
BOLTS (2)
IS O U T P U T WIRE J9414-91
Fig. 18 Throttle Position Sensor—Diesel

(3) Disconnect the electrical connector at fuel shut
down solenoid. (Fig. 19).
FRONT O F ENGINE AIR TEMPERATURE SENSOR
SENSOR ELECTRICAL
CONNECTOR
J9414-31
Fig. 17 Fuel Heater Relay—Diesel

REMOVAL
batteries.
(2) Disconnect the electrical connector at the relay.
(3) Remove the relay from the mounting bracket. INTAKE
MANIFOLD
FUEL
INSTALLATION (UPPER HALF)
SOLENOID
SHUTDOWN
(1) Install the relay to the mounting bracket. SOLENOID
ELECTRICAL
J9414-93
CONNECTOR
(2) Connect the electrical connector.
(3) Connect battery cables to both batteries. Fig. 19 Fuel Shutdown Solenoid Location
14 - 132 COMPONENT REMOVAL/INSTALLATION—DIESEL ENGINE
(4) Disconnect the main engine wiring harness at

top of injection pump and position to the side.
(5) Remove the metal intake manifold-to-inter-
cooler connecting tube.
(6) Remove the engine oil dipstick tube mounting
clamp and bolt (Fig. 20). Position dipstick tube to, the
side.
Fig. 21 Wastegate and Vacuum Lines
UPPER PART OF
Fig. 20 intake Manifold Air Heater

(7) Disconnect the air heater cables (two nuts—fig
ure 20) and remove the air heater assembly at intake
manifold (five bolts—figure 20). Discard both of the
old air heater base gaskets.
(8) Remove the throttle control bracket, cables and
linkage assembly from the side of pump (three bolts).
Position the assembly to the side.
(9) Disconnect turbocharger wastegate line and
vacuum line from air flow control (AFC) valve at rear
of injection pump (Fig. 21). Fig. 22 Fuel Injection Pump Supply Line
(10) Remove the fuel supply line at both ends (in
jection pump and fuel filter/water separator) (Fig.
22). For procedures, refer to Fuel Injection Pump
Supply Line in this group. Place a rag beneath the
fitting to catch excess fuel.
COMPONENT REMOVAL/INSTALLATION—DIESEL ENGINE 14 - 133
(11) Remove the overflow valve and fuel return (13) Disconnect the engine oil supply line at side of
line at pump (Fig. 23). Place a rag beneath the fitting pump (Fig. 25).
to catch excess fuel.
FUEL RETURN LINE
OVERFLOW
VALVE
OIL SUPPLY
LINE FITTING
J9414-112
FUEL INJECTION
PUMP J9414-102
Fig. 25 Engine Oil Supply Line—Pump Mounting
Fig. 23 injection Pump Overflow Valve Nuts
(12) Disconnect the six (6) high-pressure fuel lines (14) Remove the oil fill tube bracket mounting bolt
from the fuel delivery valve holders at the top of in (Fig. 26).
jection pump. For procedures, refer to High-Pressure (15) Remove oil fill tube from tube-to-gear housing
adapter (Fig. 26). Tube is removed by screwing coun
Fuel Lines in this group. Place a rag beneath the fit
terclockwise from adapter.
tings to catch excess fuel.
HIGH-PRESSURE FUEL DEUVERY

FUEL LINES (6) FITTINGS (6) VALVE HOLDERS (6) OIL FILL
TUBE
J9114-54
Fig. 26 Oil Fill Tube, Adapter and Mounting Bracket

(16) Remove oil fill tube adapter from gear housing
(Fig. 26). Adapter is removed by screwing counter
clockwise from gear housing.
INJECTION PUMP The engine is equipped with a built-on move
J9414-116
able timing pin. This pin is located above the power
steering pump, below and to the inside of the fuel in
Fig. 24 Fuel Delivery Valve Holders and Pressure
jection pump, on the rear of the cam gear housing
Lines
(Fig. 27). The pin will engage into a machined hole in
the back of the camshaft gear (Fig. 28). It is designed
14 - 131 COMPONENT REMOVAL/INSTALLATION—DIESEL ENGINE
to position the engine to TDC (Top Dead Center) on (18) The opening for the barring tool is located in
the compression stroke of number 1 cylinder. the rear flange of engine on exhaust manifold side
(Fig. 29). Remove the rubber access plug covering
this opening.
REAR
FLANG
TIMING
Pir
HOLDER
VACUUM TIMING
PUMP PIN
BARRING
TOOL J9114-5
Fig. 29 Rotating Engine with Barring Tool—Typica

(19) Insert the barring tool into the flywheel hous
J9414-74 ing opening (Fig. 29).
(20) While holding tension on the timing pin (to
Fig. 27 Timing Pin and Location wards front of engine), very slowly rotate the engine
(counter-clockwise as viewed from front) with the
MACHINED HOLE barring tool. Rotating the barring tool counter-clock
IN BACK OF
CAMSHAFT GEAR wise will rotate the crankshaft clockwise. Continue to
rotate until the timing pin drops into the machined
hole in the back of the camshaft gear. When the pin
aligns to the gear, the engine is now at the TDC po
sition (compression stroke) at cylinder number 1.
CAUTION: When installing the fuel injection pump
and to achieve proper injection pump timing, the
engine MUST be in the TDC position (compression
stroke) at cylinder number 1 .
Before proceeding to the next step, and to

prevent shearing of the timing pin, temporarily
remove the timing pin from the back of the
gear.
(21) Remove the nut and washer retaining the in
jection pump gear to the injection pump shaft (Fig.
30). "
Place a shop towel below the retainer nut in the
HOLDER J9414-83 gear housing cover opening to prevent the nut or
washer from falling into the gear housing.
Fig. 28 Back of Camshaft Gear—Typical
CAUTION: If the gear retainer nut or washer drops
(17) Remove the rubber air tube connecting the
into gear housing, cover must be removed to re
turbocharger to the air cleaner housing. trieve them before engine is started.
The engine can be rotated with a barring tool such
as SnapÔn No. SP371, MTE No. 3377371 (Cummins (22) Use a T-bar type puller (Fig. 31) to separate
Tool Division), or an equivalent. the injection pump gear from the injection pump
shaft. Attach two M8 X 1.24 MM (metric) screws
through the puller and into the two threaded holes
supplied in the pump gear. Pull the injection pump
COMPONENT REMOVAL/INSTALLATION—DIESEL ENGINE 14 -135
INJECTION
PUMP
GEAR
TIMING GEAR
COVER J9414-4
Fig. 30 injection Pump Gear Washer and Nut Fig. 32 Pump Mounting Bolts
gear forward until it loosens from the injection pump INSTALLATION
shaft. Pull on the gear only enough to loosen it
CAUTION: Before installing the injection pump, be
from the injection pump shaft. Pulling the gear
sure that number 1 cylinder is at the Top Dead Cen
to far may cause damage or breakage to the
ter (compression stroke) position. Engage the tim
gear cover.
ing pin on the rear of the gear cover (Fig. 27) into
the rear of the camshaft gear. Rotate crankshaft if
necessary.
Before injection pump installation, it must be set

(pump shaft rotated) to a certain position to attain
accurate pump timing. Remove the access plug from
the side of pump (Fig. 33). Stored behind this access
plug is a plastic timing pin tool (Fig. 34). This tool is
used to align the injection pump timing tooth (Fig.
35) to the center of access hole.
Installing Original Pump: If the original pump
is being reinstalled, the pin tool should already be
mounted with the slotted end facing outward (Fig.
34). When the position of this tool has been reversed,
with the slotted end facing inward, it is used as a
Fig. 31 Separating injection Pump Gear from Pump pump timing pin tool.
Shaft Installing New or Rebuilt Pump: If a new or re
(23) Remove the two" (2) injection pump-to-lower built pump is being installed, the pump should have
mounting bracket bolts (Fig. 32). been shipped with the slotted end of the timing pin
tool engaged to the timing tooth in the pump.
(24) Remove the four (4) injection pump-to-gear
To set injection pump timing on an original pump
housing mounting nuts (Fig. 25). or when checking timing on a new pump, rotate the
(25) Remove the injection pump from gear housing. pump shaft until the timing tooth appears in the cen
Take care not to nick the injection pump shaft ter of the plug opening (Fig. 35). Install the slotted
on the aluminum gear housing when removing end of the timing pin tool over the timing tooth. The
pump. pump shaft may have to be rotated slightly to align
(26) Clean the injection pump o-ring mounting sur the tool to the tooth. Do not force the slots in the tool
faces on both the gear housing and pump. over the timing tooth.
14 -131 COMPONENT REMOVAL/INSTALLATION—DIESEL ENGINE B R
DELIVERY OIL FILL PLUG ACCESS HOLE

VALVES O N SIDE
OF PUMP
TIMING
TOOTH
CENTERED
I N ACCESS HOLE
o
Fig. 35 Injection Pump Timing Tooth
J9414-77
gine oil to the pump o-ring seal at pump mounting

P7100 INLINE area. The injection pump shaft and its mounting
FUEL INJECTION
PUMP ACCESS area in the center of the injection pump gear,
J9414-75
* PLUG should be clean and free of any oil. This will en
sure of proper gear-to-shaft tightening.
Fig. 33 injection Pump Access Plug (3) Position the pump assembly to the mounting
After the tool has been temporarily installed to flange on gear cover while aligning the injection
the timing tooth, install and loosely tighten the ac pump shaft through the back of injection pump gear.
cess plug. New pumps should have been shipped with (4) Install the four pump mounting nuts finger
this tool already engaged. tight. Do not attempt to tighten (pull) the pump
(1) If the original pump is being installed, check to the gear cover using the mounting nuts.
the condition of the rubber o-ring at pump mounting Damage to pump or gear cover may occur. The
area. pump must be positioned flat to its mounting
(2) Apply clean engine oil to the injection pump flange before attempting to tighten mounting
mounting flange opening in gear cover housing to al nuts.
low easier pump installation (Fig. 36). Also apply en- (5) Install two (vertical) pump mounting bracket
bolts finger tight.
PUMP
TIMING
TOOTH
TIMING
PIN TOOL
TIMING
PIN TOOL
SLOT
'ACCESS
PLUG
ACCESS
PLUG
1PIN DISENGAGED! J9414-76
Fig. 34 Injection Pump Timing Pin Tool

COMPONENT REMOVAL/INSTALLATION—DIESEL ENGINE 1 4 - 137
INJECTION (c) If the timing pin tool will not fit into the tim
PUMP ing tooth in the pump, the pump gear nut must be
GEAR removed. Loosen the pump gear from the pump
shaft with the T-bar puller tool. With the gear loos
ened, rotate the injection pump shaft until it aligns
to the center of access hole on side of pump.
Tighten injection gear nut and remove barring tool.
(12) Remove the timing pin tool from the pump.
Reverse the position of this tool (Fig. 34). The slotted
part of tool should be facing outward and will be
stored in pump in this direction. Place tool back into
pump. Install access plug and its sealing washer.
Tighten plug to 15 N-m (11 ft. lbs.) torque.
(13) Install the engine oil supply line and fuel re
turn line/overflow valve to pump.
(14) Install the six high-pressure fuel lines to the
top of pump. Tighten lines to 30 N-m (22 ft. lbs.)
torque.
(15) Install the low-pressure fuel supply line to
PUMP MOUNTING pump.
FLANGE J9414-5 (16) Install the turbocharger wastegate line and
:
AFC sensing line at the pump.
Fig. 36 Apply Oil to Gear Cover'
(17) New or rebuilt P7100 series fuel injection
(6) Tighten the four pump mounting nuts to 24 pumps must be pre-lubricated before operation. Fail
N-m (18 ft. lbs.) torque. Tighten the two pump ure to do so may result in pre-mature governor wear.
mounting bracket bolts. To prevent damage to (a) Remove the 10 mm hex plug (oil fill plug) on
pump and mounting flange, tighten the pump the top of the injection pump governor (Fig. 33).
mounting nuts first. (b) Add 750 ml (25 ounces) of clean engine oil
(7) Install injection pump drive shaft-to-injection through this opening.
pump gear retaining nut and washer. Do a prelim (c) Install oil fill plug and tighten to 28 N-m (21
inary tightening of this nut to 10 to 15 N-m (7 to ft. lbs.) torque.
11 ft. lbs.) torque. Do not over tighten. This is (18) Install the throttle linkage assembly to pump.
not t h e final tightening torque. To prevent dam Tighten bolts to 24 N-m (18 ft. lbs.) torque.
age to the timing pin, do not exceed this (19) Connect electrical connector to fuel solenoid.
torque. (20) Connect the main engine wiring harness at
(8) Disengage the timing pin (Fig. 27) from the top of injection pump.
rear of camshaft gear by pulling it straight back. (21) Install the engine oil dipstick tube mounting
(9) Remove the access plug from injection pump clamp and bolt at the opening to the intake manifold.
(Fig. 33) and remove timing pin tool from pump. (22) Install oil fill tube and tube adapter.
(10) Do a final tightening of the injection pump (23) Install oil fill tube bracket and mounting bolt.
gear-to-injection pump shaft nut. Tighten to 195 N-m (24) Install electrical connector to throttle position
(144 ft. lbs.) torque. Use the barring tool to prevent sensor (if equipped).
the engine from rotating when tightening gear. (25) Install air cleaner housing-to-turbocharger
(11) After the injection pump gear has received a tube at air cleaner housing.
final tightening, verify injection pump timing. (26) Using a new gasket, install air heater assem
(a) Rotate the engine counter-clockwise with the bly (five bolts).
barring tool (clockwise as observed at the crank (27) Install intake manifold-to-intercooler tube.
shaft from the front of vehicle). Continue rotating (28) Check and adjust throttle linkage. Refer to
engine until the timing pin aligns into hole at rear Throttle Position Sensor in this group.
of camshaft gear (Fig. 28). The engine is now at (29) Bleed air from fuel system. Refer to the Air
TDC of number cylinder. Bleed Procedure in this section of the group.
(30) Adjust the low idle speed if required. Refer to
(b) With the timing pin aligned into the rear of
Idle Speed Adjustment.
the camshaft gear, the timing tooth should also be
(31) Inspect throttle linkage to be sure that the
centered in the access hole on the side of the injec control lever is opening to the full open position.
tion pump (Fig. 35). Install timing pin tool (Fig. 34) (32) Some engine oil was lost when removing
to verify. pump. Check and adjust engine oil level.
14 -138 COMPONENT REMOVAL/INSTALLATION—DIESEL ENGINE B R
FUEL INJECTION PUiP SUPPLY LINE can rotate in the cylinder head. This may cause
damage to the cylinder head bore. Use a rust pen
The fuel injection pump supply line is located be
etrating solvent before attempting to loosen a
tween the injection pump and the fuel filter/water
rusted holddown nut
separator housing (Fig. 37). It is attached at each
end with copper/or rubber sealed banjo fittings and
bolts.
J9414-97
Fig. 38 Loosening Injector Nut

(5) Hit the injector body with a brass drift to
loosen it (Fig. 39).
Fig. 37 Fuel Injection Pump Supply Line

REMOVAL
(1) Clean the area around the line.
(2) Remove the banjo fitting bolts at each end of
the supply line (Fig. 37).
(3) Remove line from engine.
INSTALLATION
(1) Install new copper/or rubber washers to the
banjo fittings at each end of the line.
(2) Install the line to the injection pump and fuel J9414-98
filter, lighten the injection pump end to 33 N-m (24
Fig. 39 Loosening Injector Body
ft. lbs.). Tighten the filter end to 24 N-m (18 ft. lbs.).
(3) Bleed the line of air. Refer to the Air Bleed Pro (6) Hold the injector body with one wrench while
cedure at the beginning of this group. removing the injector nut with another (Fig. 40).
(7) It may be necessary to tap the injector with an
FUEL INJECTORS injector puller tool (Fig. 41).
REMOVAL INSTALLATION
(1) Disconnect both negative battery cables from (1) Clean the injector cylinder head bore with spe
both batteries. cial Cummins wire brush tool or equivalent (Fig. 42).
(2) Remove the high-pressure fuel lines. Refer to (2) Install a new copper washer on injector (Fig.
High-Pressure Fuel Lines in this section. 43).
(3) Remove the fuel drain manifold. Refer to Fuel (3) Apply a coating of anti-seize compound to the
Drain Manifold in this section. threads of the injector holddown nut and between the
(4) Thoroughly clean the area around the injector. top of the nut and injector body (Fig. 44).
(4) Install the injector into the cylinder head. Align
CAUTION: When rust has formed on the fuel injec the tab on the injector to the notch in the cylinder
tor nut (Fig. 38), the injector (when being removed) bore (Fig. 45). Certain types of injectors m a y have an
BR COMPONENT REMOVAL/INSTALLATION—DIESEL ENGINE 14 -139
INJECTOR
COPPER
WASHER
J9114-50
J9414-99
Fig. 43 Injector Washer
Fig. 40 Loosening injector
BRUSH ANTI-
SEIZE
COMPOUND
FUEL
INJECTOR
PULLER
TOOL*
J9414-101
J9414-100
Fig. 44 Apply Anti-Seize Compound
Fig. 41 Removing injector with Puller Tool
O-RING
NOTCH J9114-51
Fig. 45 Installing Injector

Fig. 42 Cleaning Cylinder Head Injector Bore
(6) Connect the fuel drain manifold to the injec
o-ring located above the holddown nut (Fig. 45). After tors. Refer to Fuel Drain Manifold in this section.
tightening the injector, push the o-ring into the (7) Connect the high-pressure fuel lines. Refer to
groove on the top of the injector. High-Pressure Fuel Lines in this section.
(5) Tighten the injector holddown nut to 60 N-m
14 - 1 4 0 COMPONENT REMOVAL/INSTALLATION—DIESEL ENGINE
(8) Connect the negative battery cables to both FUEL SHUTDOWN MOUNTING
batteries. SOLENOID BOLTS
(9) Bleed the air from the high-pressure lines. Re
fer to High- Pressure Line Bleeding in the Air Bleed
Procedure section at the front of this section of the
group.
FUEL SHUTDOWN SOLENOID
SHUTDOWN
LEVER
REMOVAL
The fuel shutdown solenoid is mounted to a bracket
located on the side of the fuel injection pump (Fig.
46).
SENSOR ELECTRICAL
CONNECTOR
LOCKNUTS CLIP J9414-92
Fig. 47 Fuel Shutdown Solenoid Removal/

Installation
(2) Pull up (by hand) and hold on the solenoid le
ver (Fig. 48). If the' solenoid is operating cor
rectly, it should remain in the UP position with
the key in the ON position.
FUEL
SHUTDOWN
INTAKE SOLENOID
MANIFOLD FUEL
(UPPER HALF) SHUTDOWN SOLENOID
SOLENOID ELECTRICAL
CONNECTOR J9414-93
Fig. 46 Fuel Shutdown Solenoid Location

(1) Disconnect the solenoid electrical connector
(Fig. 46).
(2) Disconnect clip at injection pump shutdown le
ver (Fig. 47).
(3) Remove two solenoid mounting bolts.
(4) Remove solenoid from mounting bracket.
INSTALLATION . .
(1) Position solenoid to mounting bracket and in
jection pump lever.
(2) Install clip at injection pump lever. HOLD SOLENOID
(3) Install and tighten two mounting bolts. LEVER IN
"UP" POSITION J9414-81
(4) Check and adjust the shaft length of the sole
noid. Refer to the following procedure: Fig. 48 Fuel Shutdown Solenoid Lever in Up
Position
SOLENOID SHAFT ADJUSTMENT
After replacing the fuel shutdown solenoid, the so (3) Take a measurement from the bottom of the so
lenoid shaft length must be checked and (if neces lenoid mounting bracket to the top of the injection
sary) adjusted. pump shutdown lever pin (Fig. 49).
(1) Turn the ignition switch ON. (4) Dimension should be 66.9 mm (2.64 inches).
COMPONENT REMOVAL/INSTALLATION—DIESEL ENGINE 14 -141
FUEL SHUTDOWN SOLENOID RELAY

The fuel shutdown solenoid relay is located in the
BOTTOM OF BRACKET
engine compartment near the brake master cylinder
(Fig. 51).
FUEL SHUT-OFF
FUEL HEATER SOLENOID RELAY
Fig. 51 Fuel Shutdown Solenoid Relay—Diesel

REMOVAL
batteries.
(2) Disconnect the electrical connector at the relay.
(3) Remove the relay from the mounting bracket.
INSTALLATION
(1) Install the relay to the mounting bracket.
(2) Connect the electrical connector.
(3) Connect battery cables to both batteries.
FUEL SYSTEM PRESSURE WARNING
WARNING: H I G H - P R E S S U R E F U E L LINES DELIVER

DIESEL F U E L UNDER EXTREME P R E S S U R E FROM
THE INJECTION PUMP TO THE F U E L I N J E C T O R S .
THIS MAY B E A S HIGH A S 120,000 KPA (17,405
PSI). U S E E X T R E M E CAUTION W H E N INSPECTING
FOR H I G H - P R E S S U R E F U E L L E A K S . INSPECT FOR
H I G H - P R E S S U R E F U E L L E A K S WITH A S H E E T OF
CARDBOARD. HIGH F U E L INJECTION P R E S S U R E
LOCKNUT J9414-132 CAN C A U S E P E R S O N A L INJURY IF CONTACT IS
MADE WITH THE SKIN.
Fig. 50 Solenoid Adjustment
(5) If adjustment is necessary, loosen the shaft
locknut and rotate the adjustment nut (Fig. 50) to at FUEL SYSTEM PRESSURE TEST—DIESEL ENGINE
tain dimension. For fuel pressure tests, refer to the Diesel Engine—
General Diagnosis section of this group.
14 -142 COMPONENT REMOVAL/INSTALLATION—DIESEL ENGINE — BR
FUEL TANK
Refer to the Fuel Tank section of this group for pro
cedures.
FUEL TANK MODULE

Refer to Fuel Tank Module—Diesel Engine. This
can be found in the Fuel Delivery—Diesel Engine
FUEL TRANSFER PUMP
For operation of the fuel transfer pump primer but
ton, refer to Fuel Transfer Pump in the Fuel Deliv
ery—Diesel Engine section,of this group.
The fuel transfer pump is located on the left side of
the engine and above the starter motor (Fig. 52). The
mounting bracket/spacer for the fuel heater assembly
is located between the engine block and the fuel
PUMP INSTALLATION
transfer pump (Fig. 53). The fuel heater housing and
its bracket assembly must also be removed when re (1) Clean the mating surfaces of the fuel heater
mounting bracket, the fuel pump and the engine
moving fuel pump. block of any gasket material.
FUELTEMPERATURE SENSOR (2) Position the new gaskets, the fuel heater hous
ing mounting bracket and the fuel pump to the en
gine.
(3) Install the two mounting bolts into the engine.
Tighten to 24 N-m (18 ft. lbs.) torque. As these bolts
are tightened, the plunger within the fuel pump
is being compressed. Tighten these two bolts al
ternately to prevent damage to the fuel pump
housing.
(4) Install fuel line fittings to pump and fuel
heater. Tighten to 24 N-m (18 ft. lbs.) torque.
(5) Install starter motor. Refer to Group 8B for
procedures.
(6) Connect battery cables at both batteries.
(7) Bleed air from fuel system. Refer to the Air
Bleed Procedure at the beginning of this section of
the group.
HIGH-PRESSURE FUEL LINES

All high-pressure fuel lines are of the same length
and inside diameter. Correct high-pressure fuel line
usage and installation is critical to smooth engine op
Fig, 52 Fuel Transfer Pump Location eration.
PUMP REMOVAL
CAUTION: The high-pressure fuel lines must be
(1) Disconnect both negative battery cables at both clamped securely in place in the holders. The lines
batteries. cannot contact each other or other components. Do
(2) Remove starter motor. Refer to Group 8B for not attempt to weld high-pressure fuel lines or to
procedures. repair lines that are damaged. Only use the recom
(3) Place a drain pan below the pump. mended Sines when replacement of high-pressure
(4) Remove the fuel line fittings at the top of both fuel line is necessary
the fuel pump and fuel heater housing (Fig. 53).
(5) Remove the fuel hose clamps and rubber fuel
hose (fuel heater housing-to-fuel pump) (Fig. 53). REMOVAL
(6) Remove the two mounting bolts (Fig. 53). (1) Disconnect both negative battery cables from
(7) Remove the fuel pump and fuel heater assem both batteries.
bly from the engine as one unit. (2) Remove the nameplate/cover from the top of
COMPONENT REMOVAL/INSTALLATIONDIESEL ENGINE 14 - 143
the six engine valve covers (two nuts) (Fig. 54). HIGH-PRESSURE FUEL DELIVERY
FUEL LINES (6) FITTINGS (6) VALVE HOLDERS (
NAMEPLATE/COVER
. NAMEPLATE/COVER
NUTS (2)
#6 CYLINDER
VALVE COVER
RUBBER
METAL INJECTION PUMP
CLAMPS (2) INTAKE ADAPTER J9414-116
TUIE
J9414-73 Fig. 56 Fuel Delivery Waive Holders and Pressure
Fig. 54 Nameplate/Cover—Diesel Lines
CAUTION: B e sure that the high-pressure fuel lines
(3) Remove the necessary clamps holding the lines
are installed in the same order that they were re
to the engine.
moved. Prevent the injection, pump delivery valve
(4) Clean the area around each line. Disconnect
holders from turning when removing or installing
each line at the top of each fuel injector (Fig. 55).
high- pressure lines from injection pump.
FUEL HIGH-PRESSURE
DRAIN FITTING FUEL LINE
MANIFOLD INSTALLATION
(1) Carefully position each high-pressure fuel line
to the fuel injector and fuel injection pump delivery
valve holder in the correct firing order. Also position
each line in the correct line holder.
(2) Loosely install the line clamp isolator and
bracket holder bolts.
(3) Tighten each line at the delivery valve holder
(4) Tighten each line at the fuel injector to 30 N*m
Be sure t h e lines are not contacting each
other or any other component.
(5) Tighten the clamp bracket bolts to 24 N-m (18
ft. lbs.) torque.
(6) Bleed air from the fuel system. Refer to High-
Pressure Fuel Line Bleeding in the Air Bleed Proce
FUEL INJECTOR
J9414-117
dure portion of this section.
j
lDLE SPEED ADJUSTMENT
Fig. 55 Fuel Lines ai Fuel Injectors
Refer to the Diesel Engine—General Diagnosis sec
(5) Disconnect each high-pressure line fitting at tion for procedures.
each fuel injection pump delivery valve holder (Fig.
56). INTAKE MANIFOLD
(6) Very carefully remove each line from the en Refer to Group 11, Exhaust System and Intake
gine. Do not bend the line while removing. Manifold for procedures.
14 - 144 COMPONENT REMOVAL/INSTALLATION—I-DIESEL ENGINE BR
INTAKE MANEFOLD All TEMPERATURE SENSOR

The intake manifold air temperature sensor is lo
cated on the top of intake manifold and to the rear of
the intake manifold heater (Fig. 57).
SOLENOID ELECTRICAL J
.941 .4 9 3
, 4 y j
CONNECTOR * UPPER PART OF
Fig. 57 Air Temperature Sensor Location—Diesei
REMOVAL Fig. 58 Intake Manifold Air Heater
(1) Disconnect the electrical connector at the sen (5) Position the intake manifold and manifold con
sor. necting tube to the side.
(2) Remove the sensor (Fig. 57) the from intake (6) Remove the air heater from the intake mani
manifold. fold.
INSTALLATION INSTALLATION
(1) Install sensor to intake manifold. Tighten to 28 (1) Clean the mating surfaces of the air heater and
N-m (20 ft. lbs.) torque. intake manifold.
(2) Install electrical connector. (2) Install a new lower and upper gasket to the air
heater.
INTAKE MANIFOLD AIR HEATER (3) Position the air heater to the intake manifold.
The intake manifold air heater assembly (with in (4) Install and tighten five bolts to the intake man
ternal heating elements) is located between the up ifold. Tighten to 24 N-m (18 ft. lbs.) torque. (The
per and lower portions of the intake manifold (Fig. ground cable for the air heater is connected to one of
58). If the heating coils (elements) within the assem the intake manifold bolts).
bly have failed, the entire heater block assembly (5) Connect the two cables to the air heater.
must be replaced.
REMOVAL INTAKE MANIFOLD AIR HEATER RELAYS
(1) Disconnect both negative battery cables at both The relays are located in the engine compartment,
batteries. bolted to the left inner fender below the left battery
(2) Remove the engine oil dipstick tube mounting (Fig. 59).
bracket bolt at the side of the intake manifold (Fig.
58). REMOVAL
(3) Remove the two cable nuts and remove cables The mounting bracket and both relays are replaced
at the air heater electrical studs (Fig. 58). as an assembly.
(4) Remove the five bolts retaining the upper half (1) Disconnect both negative battery cables at both
of the intake manifold to the lower half of the intake batteries.
manifold (Fig. 58).
BH COMPONENT REMOVAL/INSTALLATION—DIESEL ENGINE 14 - 1 4 5
BATTERY REMOVAL
(LEFT SIDE) (1) Disconnect the electrical connector on bottom of
TPS (Fig. 60).
Fig. 59 intake Manifold Mir Heater Relays

(2) Disconnect the four relay trigger wires at both IS OUTPUT WIRE B ( J L , b
W J9414-91
relays (Fig. 59). Note the position of wiring before re
moving. Fig. 60 Throttle Position Sensor—Diesel
(3) Lift the four rubber shields from the four cables (2) Remove the two TPS mounting bolts.
(Fig. 59). (3) Remove the sensor from bracket.
(4) Remove the four nuts at the cable connectors
(Fig. 59). Note the position of wiring before removing. INSTALLATION
(5) Remove the three relay mounting bracket bolts (1) Position the TPS to the mounting bracket. The
(Fig. 59) and remove relay assembly. electrical connector should be facing downward.
The TPS is spring loaded. After positioning
INSTALLATION the TPS to its mounting bracket, rotate the TPS
(1) Install the relay assembly to the inner fender. on the bracket in a counter-clockwise direction
Tighten mounting bolts to 4.5 N-m (40 in. lbs.) until the two bolt holes align.
torque. (2) Install and tighten two bolts.
(2) Connect the eight electrical connectors to the (3) Connect the electrical connector on bottom of
relays. TPS.
(3) Connect battery cables to both batteries. (4) Operate the throttle by hand to check for bind
ing.
POWERTRAIN CONTROL MODULE (PCM) (5) The TPS voltage must now be tested and (if
Refer to the Multi-Port Fuel Injection (MFI)-Com necessary) adjusted. Refer to the following: Throttle
ponent Removal/Installation—Except Diesel section Position Sensor Testing.
of this group for procedures.
THROTTLE POSITION SENSOR TESTING
THROTTLE POSITION SENSOR
CAUTION: Before attempting to test the T P S , verify
AUTOMATIC TRANSMISSION ONLY the linkage adjustment dimension shown in figure
The throttle position sensor (TPS) is used on 61. This dimension MUST be 126.5 mm (5.0 inches)
the diesel powered engine only when equipped B E F O R E testing. For linkage adjustment proce
with an automatic transmission. If the TPS is to dures, refer to Throttle Linkage Adjustment—Diesel
be replaced on a diesel engine, it must be Engine. This can be found in the Accelerator Pedal
tested after replacement. and Throttle Cable section of this group.
Fig. 61 Linkage Measurement—Diesel Fig. 62 Throttle Lever Linkage Adjustment—Diesel
CAUTION: Before testing the T P S , verify that the volts) on the voltmeter with the linkage in the idle
engine is set at correct low idle speed. Refer to Idle position. At wide open throttle (WOT), the output
Speed Adjustment. This can be found in the Diesel voltage must be 2.2-to-2.9 volts higher than at idle
Engine—General Diagnosis section of this group. speed. DO NOT lengthen or shorten the linkage
rod more than 1 mm from the dimension shown
(1) After confirming the correct linkage adjustment in figure 61. If voltage requirements cannot be
and idle speed, proceed to the following: met by linkage adjustment (125.6 to 127.6 mm),
(2) Attach a paper clip into the center terminal replace the TPS.
(Fig. 60) of the TPS electrical connector. Do not re (10) Tighten both nuts after adjustment.
move the connector from the TPS for this test. (11) With the engine OFF, operate the throttle
(3) Attach the positive lead of a voltmeter to this from accelerator pedal and check for throttle lever
paper clip and the negative lead to a good ground. action and binding. Be sure throttle lever stop is
(4) Turn the ignition switch to the ON position. Do against the low idle speed screw after throttle is re
not start engine. leased.
(5) The voltage at the TPS center terminal should (12) Be sure of wide open throttle (WOT) when ac
be 1.0 volt (± .2 volt) with linkage at idle position. At celerator pedal is pressed to the floor. This is checked
wide open throttle (WOT), the output voltage must by observing throttle lever breakover position. Pro
be 2.2-to-2.9 volts higher than at idle speed. If volt ceed to the following:
age is not correct, proceed to adjusting linkage.
(a) Key OFF and engine OFF for this test.
(6) The linkage rod (Fig. 62) connecting the throt
tle lever to the fuel injection pump lever is adjust (b) Two people are needed for this test. From in
able. To prevent damage to the ends of linkage, side of the vehicle, press the accelerator pedal
attach locking-type pliers to the flat (Fig. 62) located about half-way to the floor. Movement of both the
on the linkage rod before loosening locknuts. throttle lever and throttle lever-to-inj ection pump
(7) Loosen the right-hand-threaded nut (Fig. 62). lever linkage rod (Fig. 62) should be observed.
(8) Loosen the left-hand-threaded nut (Fig. 62). (c) Continue to press the accelerator pedal to the
(9) Slowly rotate the flat (Fig. 62) on the linkage floor. If throttle lever breakover is operating cor
rod (lengthen or shorten) to achieve 1.0 volt (± .2 rectly, the throttle lever-to-inj ection pump lever
BR COMPONENT REMOVAL/INSTALLATION—DIESEL ENGINE 14 - 147
linkage rod should have stopped moving while the WASTEGATE (TURBOCHARGER)
throttle lever continues to move towards the rear of Refer to Group 11, Exhaust System and Intake
vehicle. Manifold for procedures.
(13) Again, check and verify low idle speed. Adjust
if necessary. WATER-IN-FUEL SENSOR
TRANSMISSION TEMPERATURE SENSOR The water-in-fuel sensor is located at the bottom of
Refer to the Multi-Port Fuel Injection (MFI)-Com the fuel filter/water separator. Refer to Fuel Filter/
ponent Removal/Installation—Except Diesel section Water Separator in this section of the group for re
of this group for removal and installation procedures. moval and installation procedures.

Refer to the Multi-Port Fuel Injection (MFI)-Com
ponent Removal/Installation—Except Diesel section
of this group for removal and installation procedures.
DIFFERENTIAL AND DRIVELINE 3 -1
DIFFERENTIAL AND DRIVELINE

CONTENTS
I t i
page page
FRONT AXLE—MODEL 44/60 15 PROPELLER SHAFTS 1

MODEL 60/70/80 AXLES 79 REAR AXLE—MODEL 9 1/4 51
PROPELLER SHAFTS
INDEX
page page
G E N E R A L INFORMATION REAR PROPELLER SHAFT . . . . . . . . . . . . . . . . . 7

CENTER BEARING 2 T W O PIECE PROPELLER SHAFT—REAR . . . . . . 8
LUBRICATION 2 DISASSEMBLY AND ASSEMBLY
PRECAUTIONS 2 CENTER BEARING 8
PROPELLER SHAFTS 1 DOUBLE CARDAN (CV) 10
UNIVERSAL JOINTS 2 SINGLE CARDAN . 9
DIAGNOSIS AND TESTING CLEANING AND INSPECTION
RUNOUT 4 SINGLE AND DOUBLE CARDAN JOINT . . . . . . . 13
UNBALANCE 3 ADJUSTMENTS
VIBRATION 3 ADJUSTMENT AT AXLE W I T H LEAF SPRINGS . 1 4
SERVICE PROCEDURES CENTER BEARING ADJUSTMENT—TWO
INSPECTION 5 PIECE SHAFT 14
MEASUREMENT—TWO-PIECE SHAFT 6 SPECIFICATIONS
PROPELLER SHAFT ANGLE MEASUREMENT . . . 5 TORQUE . . . . . . . . . . 14
UNIVERSAL JOINT ANGLE 4 SPECIAL TOOLS
REMOVAL AND INSTALLATION PROPELLER SHAFT . . . . . . . . . . . . . . . . . 14
FRONT PROPELLER SHAFT 7
GENERAL INFORMATION Tubular propeller shafts are balanced by the man

ufacturer with weights spot welded to the tube.
PROPELLER SHAFTS The propeller shaft is designed and built with the
The function of a propeller shaft is to transmit yoke lugs in line with each other which is called
power from one point to another in a smooth action. phasing. This design produces the smoothest running
The shaft is designed to send torque through an condition. An out of phase shaft can cause a vibra
angle from the transmission (transfer case on 4WD tion.
vehicles) to the axle. Before undercoating a vehicle, the propeller
The propeller shaft must operate through con shaft and the U-joints should be covered. This
stantly changing relative angles between the trans will prevent the undercoating from causing an
mission and axle. I t must also be capable of changing out of balance condition and vibration.
length while transmitting torque. The axle rides sus
pended by springs in a floating motion. This means CAUTION: Use exact replacement parts for attach
the propeller shaft must be able to change angles ing the propeller shafts. This will ensure safe oper
when going over various roads. This is accomplished ation. The specified torque must always be applied
through universal joints, which permit the propeller when tightening the fasteners.
shaft to operate at different angles. The slip joints (or
yokes) permit contraction or expansion.
3 -2 DIFFERENTIAL AND DRIVELINE BR
G E N E R A L I N F O R M A T I O N (Continued)
CENTER BEARING
The two-piece propeller shaft uses a center bearing
to support the shafts. Two types of center bearings
are used. Type 1 is used with the 9 1/4 axle. Type 2
is used with the Dana axles (Fig. 1). Both types are
mounted in the same location.
RETAINER J9416-11
TYPE 2 TYPE 1 Fig. 2 Single Cardan Universal Joint—Typical

— J9416-2
Fig. 1 Center Bearing S LINK YOKE
UNIVERSAL JOINTS
The front prop shaft uses a 7290 series universal
joints. The rear prop shaft uses a 7290 series univer
sal joint with a 9 1/4 axle. A 1410 series universal
joint is used with the Dana 60, 70 and 80 rear axles.
Shaft with 7290 series universal joints use external
snap rings. Shafts with 1410 series universal joints
use internal snap rings.
Two different types of universal joints systems are
used:
® Single cardan universal joint (Fig. 2)
• Double cardan universal joint (Fig. 3)
LUliiCATlON
The slip yoke on the Type 1 front shaft is equipped
with a lubrication fitting. Use a multi-purpose NLGI
Grade 2 EP lubricant.The factory installed U-joints
are lubricated for the life of the vehicle and do not
need lubrication. All U-joints should be inspected for
leakage and damage each time the vehicle is ser
viced. I f seal leakage or damage exists, the U-joint
should be replaced.
PRECAUTIONS
Use exact replacement hardware for attaching the
propeller shafts. Exact replacement will ensure safe
operation. The specified torque must always be
applied when tightening the fasteners.
Put reference marks on the propshaft yoke and
J9316-2
axle or transmission yoke before service (Fig. 4). This
will assure correct phasing and eliminate possible Fig. 4 Reference Marks on Yokes
vibration.
DIFFERENTIAL AND DRIVELINE 3-3
G E N E R A L I N F O R M A T I O N (Continued)
CAUTION: Do not allow the propeller shaft to drop UNBALANCE
or hang from either universal joint during removal If propeller shaft unbalance is suspected, i t can be
Attach it to the vehicle underside with wire to pre verified with the following procedure:
vent damage to the universal joints. Removing and re-indexing the propeller shaft
180° may eliminate some vibrations.
• Clean all the foreign material from the propeller
CAUTION: It is very important to .protect the
shaft and the universal joints.
machined, external surface of the slip yoke from
• Inspect the propeller shaft for missing balance
damage after propeller shaft removal, if damaged,
weights, broken welds, and bent areas. If the pro
the transmission extension seal could be damaged
peller shaft is bent, it must be replaced.
and cause a leak.
• Ensure the universal joints are not worn, are
properly installed, and are correctly aligned with the
shaft.
DIAGNOSIS AND T E S T I N G • Check the universal joint clamp screws torque
(1) Raise the vehicle.
VIBRATION (2) Remove the wheel and tires assembly. Install
Tires that are out-of-round or wheels that are the wheel lug nuts to retain the brake drums.
unbalanced will cause a low frequency vibration. (3) Mark and number the shaft six inches from the
Refer to Group 22, Wheels and Tires for additional yoke end at four positions 90° apart.
information. (4) Run and accelerate the vehicle until vibration
Brake drums that are unbalanced will cause a occurs. Note the intensity and speed the vibration
harsh, low frequency vibration. Refer to Group 5, occurred. Stop the engine.
Brakes for additional information. (5) Install a screw clamp at position 1 (Fig. 5).
Driveline vibration can also result from loose or (6) Start the engine and re-check for vibration. I f
damaged engine mounts. Refer to Group 21, Trans there is little or no change in vibration, move the
missions for additional information. clamp to one of the other three positions. Repeat the
Propeller shaft vibration will increase as the vehi vibration test.
cle speed is increased. A vibration that occurs within (7) I f there is no difference in vibration at the
a specific speed range is not caused by propeller other positions, the vibration may not be propeller
shaft unbalance. Defective universal joints or an shaft unbalance.
incorrect propeller shaft angle are usually the cause. (8) I f the vibration decreased, install a second
clamp (Fig. 6) and repeat the test.
DRIVELINE VIBRATION
D r i v e Condition Possible Cause Correction
PROPELLER SHAFT a. Undercoating or other foreign material a. Clean exterior of shaft and wash with
on shaft. solvent.
b. Loose U-joint clamp screws. b. Tighten screws properly.
c. Loose or bent U-joint yoke or excessive c. Install replacement yoke.
runout.
d. Incorrect drive line angularity. d. Correct angularity
e. Rear spring center bolt not in seat. e. Loosen spring U-bolts and seat center
bolts.
f. Worn U-joint bearings. f. Replace U-joint.
g. Propeller shaft damaged (bent tube) or g. Install replacement propeller shaft.
out of balance.
h. Broken rear spring. h. Replace rear spring.
i. Excessive runout or unbalanced i. Reindex propeller shaft 180°, test and
condition. correct as necessary.
j. Excessive drive pinion gear shaft yoke j . Reindex propeller shaft 180° and
runout. evaluate.
UNIVERSAL JOINT NOISE a. U-joint clamp screws loose. a. Tighten screws with specified torque.
b. Lack of lubrication. b. Replace U-joint.
mi 6-7
3 -4 DIFFERENTIAL AND DRIVELINE — ——^ —^ BR
D I A G N O S I S A N D T E S T I N G (Continued)
(10) Increase distance between the clamp screws
and repeat the test until the amount of vibration is
at the lowest level. Bend the slack end of the clamps
so the screws will not loosen.
: (11) Install the wheel and tires. Lower the vehicle.
(12) I f the amount of vibration remains unaccept
able, apply procedures at the front end of the propel
ler shaft.
RUNOUT
(1) Remove dirt, rust, paint, and undercoating
from the propeller shaft surface. Areas where the dial
indicator will contact the shaft must be clean.
(2) The dial indicator must be installed perpendic
ular to the shaft surface.
(3) Measure runout at the center and ends away
Fig. 5 Clamp Screw At Position 1 from welds.
(4) Refer to Runout Specifications chart.
(5) Replace the propeller shaft i f the runout
exceeds the limit.
RUNOUT SPECIFICATIONS
Front of shaft 0.010 in. (0.25 mm)
Center of shaft . . .". . . . . . . 0.015 in. (0.38 mm)
Rear of shaft . . . . . . ,, 0.010 in. (0.25 mm)
NOTE: Measure front/rear runout approximately 3 inches

(76 mm) from the weld seam at each end of the shaft tube
for tube lengths over 30 inches. Under 30 inches the max.
runout is 0.20 inch for full length of the tube.
RF488
J9116-15
Fig. 6 Two Clamp Screws At The Same Position
SERVICE PROCEDURES
(9) I f the clamps cause an additional unbalance,
separate the clamps (1/4 inch above and below the
UNIVERSAL JOINT ANGLE
mark). Repeat the vibration test (Fig. 7).
INFORMATION
When two shafts come together at any common
joint, the bend that is formed is called the operating
angle. The larger the angle, the larger the amount of
acceleration and deceleration of the joint. This speed
ing up and slowing down of the joint must be can
celled to produce a smooth power flow. This is done
through phasing and proper universal joint working
angles.
A propeller shaft is properly phased when the yoke
ends are on the same plane or in line. A twisted shaft
will throw the yokes out of phase and cause a notice
able vibration.
When taking universal joint angle measurements
1 or checking phasing with two piece shafts, consider
each shaft separately. On 4WD vehicles, the front
Fig. 7 Clamp Screws Separated shaft input (pinion shaft) angle has priority over the
caster angle.
Ideally the driveline system should have;
BR DIFFERENTIAL AND DRIVELINE 3-5
SERVICE PROCEDURES ( C o n t i n u e d )
• Angles that are in equal or opposite within 1
degree of each other
• Have a 3 degree maximum operating angle
• Have at least a 1/2 degree continuous operating
(propeller shaft) angle
Engine speed (rpm) is the main factor though in
determining maximum allowable operating angles.
As a guide to maximum normal operating angles
refer to the chart listed (Fig. 8).
PROPELLER SHAFT M A X « NORMAL

R.P.M. OPERATING ANGLES
5000 3°
4500 3°
4000 4°
3500 5°
3000 5°
2500 7°
2000 8°
1500 11°
J9316-4 (J-23498A) J9216-13
Fig. 9 Front (Output) Angle Measurement (A)

Fig. 8 Maximum Angles And Engine Speed
measurement. This measurement can also be taken
INSPECTION at the rear end of the shaft.
Before measuring universal joint angles, the This measurement will give you the Propeller
following must be done. Shaft Angle (C).
• Inflate all tires to correct pressure
• Check angles in the same loaded or unloaded
condition as when the vibration occurred. Propeller
shaft angles will change according to the amount of
load in the vehicle. Always check angles in loaded
and unloaded conditions.
• * Check the condition of all suspension compo
nents and verify all fasteners are torqued to specifi
cations.
• Check the condition of the engine and transmis
sion mounts and verify all fasteners are torqued to
specifications.
PROPELLER SHAFT ANGLE MEASUREMENT

To accurately check driveline alignment, raise and
support the vehicle at the axles as level as possible.
Allow the wheels and propeller shaft to turn. Remove
any external bearing snap rings (if equipped) from
universal joint so protractor base sits flat. J9216-9
(1) Rotate the shaft until transmission/transfer
case output yoke bearing is facing downward. Fig. 10 Propeller Shaft Angle Measurement (C)
Always make measurements from front to
(4) Subtract smaller figure from larger (C minus
rear.
A) to obtain Transmission Output Operating Angle.
(2) Place Inclinometer on yoke bearing (A) parallel
(5) Rotate propeller shaft 90 degrees and place
to the shaft (Fig. 9). Center bubble in sight glass and
Inclinometer on pinion yoke bearing parallel to the
record measurement.
shaft (Fig. 11). Center bubble in sight glass and
This measurement will give you the transmis
record measurement.
sion or Output Yoke Angle (A).
This measurement will give you the pinion
(3) Rotate propeller shaft 90 degrees and place
shaft or Input Yoke Angle (B).
Inclinometer on yoke bearing parallel to the shaft
(Fig. 10). Center bubble in sight glass and record
3 - i DIFFERENTIAL AND DRIVELINE BR
S E R V I C E P R O C E D U R E S (Continued)
• Operating angles less than 3°
© At least 1/2 of one degree continuous operating
(propeller shaft) angle
MEASUREMENT—TWO-PIECE SHAFT
A rear propeller shaft U-joint angle can be easily
measured with Special Tool 7663.
The front half-shaft must be parallel to the rear
axle pinion gear shaft. The front and rear half-shafts
must be offset by a minimum of 1/2 of .a degree. From
the transmission/transfer case output shaft and from
each other.
To accurately check driveline alignment, raise and
support the vehicle at the axles as level as possible.
PINION YOKE
BEARING CAP Allow the wheels and propeller shaft to turn. Remove
any external bearing snap rings (if equipped) from
universal joint so protractor base sits flat.
SPECIAL (1) Rotate the shaft until transmission/transfer
TOOL
7663 case output yoke bearing is facing downward.
(J-23498A) J9216-12 (2) Place Inclinometer on yoke bearing (A) parallel
to the shaft (Fig. 13). Center bubble i n sight glass
Fig. 11 Rear (input) Angle Measurement (B) and record measurement.
(6) Subtract smaller figure from larger (C minus (3) Repeat measurement procedure on bearing cap
B) to obtain axle Input Operating Angle. B and C. Record these measurements.
Refer to rules given below and the example in (Fig. (4) Excessive variation in measurement angles of
12) for additional information. A, B or C indicate propeller mis-alignment. Vertical
• Good cancellation of U-joint operating angles alignment of a two-piece shaft at the yokes
(within 1°) should be greater t h a n one-half degree and as
close to one degree as possible.
Output
Yoke
Horizontal Level
(A) Output Yoke = 3.0° 4.9° (B) Axle Input Yoke 3.2° 4.9°
or
(C) Prop. Shaft r
= 4.9° ° - 3 . 0 ° (C) Prop. Shaft 4.9° -3.2°
Transmission Output 1 9° Axle Input 1.7°

Operating Angle Operating Angle
Trans. Output Operating Angle 1.9°

Axle Input Operating Angle -1.7°
Amount of U-J6int Cancellation 0.2°

J9316-3
Fig. 12 Universal Joint Angle Example

BR — — — DIFFERENTIAL AND DRIVELINE 3 -7
YOKES MUST BE IN SAME PLANE
J9016-26
Fig. 13 Universal Joint Angle—Two-Piece Shaft

REMOVAL AND INSTALLATION (3) Remove the U-joint strap bolts at the pinion
shaft yoke.
FRONT PROPELLER SHAFT (4) Remove bolts from transfer case yoke flange
and remove the propeller shaft.
REMOVAL
(1) Shift the transmission and transfer case to INSTALLATION
their neutral positions. Raise and support vehicle. (1) Position the propeller shaft with the yoke ref
Remove skid plates (if equipped), refer, to Group 13 erence marks aligned. Install the propeller shaft (Fig.
Frames. 14).
(2) Scribe alignment mark on transfer case and Replacement U-joint straps and bolts must be
propeller shaft flanges. Scribe mark on pinion shaft installed.
yoke and propeller shaft. These marks will be used (2) Tighten the U-joint strap bolts at the pinion
for installation reference (Fig. 14). shaft to 19 N-m (14 ft. lbs.) torque.
Tighten the transfer case bolts to 88 N-m (65 ft.
TRANSFER
CASE
lbs.) torque.
(3) Install skid plates (if equipped), refer to Group
13, Frames. Remove support and lower the vehicle.
REAR PROPELLER SHAFT
REMOVAL
(1) Shift the transmission and transfer case (if
applicable) to their Neutral positions. Raise and sup
port vehicle.
(2) Scribe alignment marks on the pinion yoke.
(3) Remove the U-joint strap bolts at pinion shaft
yoke.
(4) Slide the slip yoke off of the transmission/
STRAP transfer case output shaft and remove the propeller
shaft (Fig. 15).
INSTALLATION
(1) Slide the slip yoke on the transmission/transfer
SLIP YOKE AXLE
case output shaft. Align the installation reference
BOOT YOKE J9416-1 marks at the axle yoke and install the propeller shaft
(Fig. 15).
Fig. 14 Front Propeller Shaft Replacement U-joint straps and bolts must be
installed.
3 -8 DIFFERENTIAL AND DRIVELINE en
R E M O V A L A N D I N S T A L L A T I O N (Continued)
SLIDING (4) Scribe alignment marks on the frame cross-

member for center bearing reference. Remove bolts
that attach the center bearing to the support bracket
(Fig. 16).
(5) Slide the slip yoke off transmission output
shaft and remove the propeller shaft.
INSTALLATION
(1) Slide the slip yoke on transmission output
shaft. Align the installation reference marks at the
axle yoke.
(2) Align and install the center bearing to the sup
port bracket. Install the bolts and tighten to 68 N-m
Replacement U-joint straps and bolts must be
installed.
(3) Tighten the U-joint strap bolts to;
• Dana Axle: 29 N-m (22 ft. lbs.) torque.
• 9 1/4 Axle: 19 N-m (14 ft. lbs.) torque.
SCREW
19 N-m
(14 ft-lbs). CLAMP J9216-6
DISASSEMBLY AND ASSEMBLY

Fig. 15 Rear Propeller Shaft
(2) Tighten the U-joint strap bolts to; CENTER BEARING
• Dana Axle: 29 N-m (22 ft. lbs.) torque. Vehicles equipped with a two-piece rear propeller
• 9 1/4 Axle: 19 N-m (14 ft. lbs.) torque. shaft have a rubber insulated center bearing. The
(3) Remove support and lower the vehicle. bearing supports the shafts where they join together.
The two-piece propeller shaft uses two types of cen
TWO PIECE PROPELLER SHAFT—REAR ter bearings. Type 1 is used with the 9 1/4 axle. Type
The two piece shaft has a center bearing which 2 is used with the Dana axles. Both types are
supports the shafts where they are joined together mounted in the same location and service the same.
(Fig. 16).
REMOVAL
(1) Remove rear two-piece shaft. Refer to two-
-piece removal.
(2) Remove slip joint boot clamp and separate the
two shafts. The slip joints are master splined.
(3) Use hammer and punch to tap slinger away
from shaft to provide room for bearing splitter.
(4) Position Bearing Splitter Tool 1130 between
slinger and shaft.
CAUTION: Do not damage shaft spline during

removal of center bearing.
(5) Set shaft in press and press bearing off the

TYPE 2 TYPE 1
shaft.
J9416-2
INSTALLATION
Fig. 16 Center Bearing (1) Install new slinger on shaft and drive into posi
REMOVAL
tion with 2 1/2 in. ID pipe for type 1 center bearing.
For type 2 center bearing use 2 1/4 in. ID pipe to
(1) Shift the transmission/transfer case to their
install slinger.
Neutral positions. Raise and support vehicle.
(2) Install new center bearing on shaft with Bear
(2) Scribe alignment marks on the pinion yoke.
ing Installer Tool 6052. Drive on shaft with hammer
(3) Remove the universal joint strap bolts at the
until bearing is seated.
pinion shaft yoke.
DIFFERENTIAL AND DRIVELINE 3- I
mm
D I S A S S E M B L Y AND A S S E M B L Y (Continued)
(3) Clean shaft splines and apply a coat of multi-
-purpose grease.
(4) Align master splines and slide front and rear
shafts together. Reposition slip yoke boot and install
new clamp.
(5) Install two-piece shaft in vehicle. Refer to
installation two-piece shaft.
SINGLE CARDAN
REMOVAL
Single cardan universal joints are not serviceable.
If worn or leaking, they must be replaced as a unit.
(1) Remove the propeller shaft. Refer to Propeller
Shaft Replacement in this Group.
(2) Paint or score alignment marks on the
yokes and propeller shaft for installation refer
ence.
(3) Using a soft drift, tap the outside of the bear
ing assembly to loosen snap ring.
(4) Remove snap rings from both sides of yoke J9316-2V
(Fig. 17).
Fig. 18 Press Out Bearing
CAUTION: If the cross or bearing assembly are
cocked when being pressed, the bearing assembly
will score the walls of the yoke bore and ruin the
yoke.
J9316-19
Fig. 17 Remove Snap Ring BEARING
(5) Set the yoke in an arbor press or vise with a

large socket beneath it. Position the yoke with the
grease fitting pointing up (if equipped). Place a
smaller socket on the upper bearing assembly and
press it through to release the lower bearing assem
bly (Fig. 18).
(6) I f the bearing assembly will not pull out by J9316-24
hand after pressing, tap the base of the lug near it to
Fig. 19 Press Out Remaining Bearing
dislodge.
(7) To remove the opposite bearing, turn the yoke
over and straighten the cross in the open hole. Then
carefully press the end of the cross until the remain
ing bearing can be removed (Fig. 19).
3 - 10 DIFFERENTIAL AND DRIVELINE BR
D I S A S S E M B L Y A N D A S S E M B L Y {Continued)
ASSEMBLY (4) Press the bearing assembly into the cross hole
(1) Apply extreme pressure (EP) N.L.G.I. Grade 1 enough to install a snap ring. Install a snap ring.
or 2 grease to aid in installation. (5) Repeat steps 3 and 4 to install the opposite
(2) Position the cross in the yoke with its lube fit bearing assembly. I f the joint is stiff, strike the yoke
ting (if equipped) pointing up (Fig. 20). with a soft hammer to seat the needle bearings.
Install a snap ring.
CROSS
(6) Add grease to lube fitting (if equipped),
(7) Install the propeller shaft.
DOUBLE CARDAN (CV)
REMOVAL
Cardan universal joints are not serviceable. I f worn
or leaking, they must be replaced as a unit.
(1) Remove the propeller shaft. Refer to Propeller
Shaft Replacement in this Group.
(2) Paint or score alignment marks on the
yokes and propeller shaft for installation refer
ence.
(3) Remove all the bearing assembly snap rings
(Fig. 22).
J9316-22
Fig, 20 install Cross in Yoke

(3) Place a bearing assembly over the trunnion
and align i t with the cross hole (Fig. 21). Keep the
needle bearings upright in the bearing assembly. A
needle roller, lying at the bottom will prevent proper
assembly.
J9316-5
Fig. 22 Remove Snap Rings
Fig. 21 install Bearing On Trunnion

BR DIFFERENTIAL ANU UKIVCLHU.
D I S A S S E M B L Y AND A S S E M B L Y {Continued)
(4) Press the bearing assembly partially from the (6) Flip assembly and repeat steps 4 and 5 for
outboard side of the center yoke, enough to grasp by removing the opposite side bearing. This will then
vise jaws (Fig. 23). Be sure to remove grease fittings allow removal of the cross centering kit assembly and
that interfere with removal. spring (Fig. 25).
J9316-8
J9316-6
Fig. 25 Remove Centering Kit
Fig. 23 Press Out Bearing
(7) Press the remaining bearing assemblies out the
(5) Grasp the protruding bearing by vise jaws. Tap other cross as described above to complete the disas
the tube yoke with a mallet and drift to dislodge sembly.
from the yoke (Fig. 24).
INSTALLATION
During installation, ensure that the spiders
and yokes are aligned to the reference marks.
(1) Fit a cross into the tube yoke (Fig. 26).
J9316-7 J9316-9
Fig. 24 Remove Bearing From Yoke Fig. 26 install Cross In Yoke

_ . ..1L.1MHML ANU DRIVELINE ^ ^ • ^ • ^ BR
D I S A S S E M B L Y AND A S S E M B L Y {Continued)
• (2) Place a bearing assembly in a tube yoke hole (4) Flip the tube yoke and bearing assembly instal
and over a trunnion. Keep the needle bearings lation on the opposite trunnion. Install a snap ring
upright in the bearing assembly (Fig. 27). A needle (Fig. 29).
roller lying at the bottom will prevent proper assem
bly. Be sure to remove any lube fittings that may
interfere with removal.
(5) Fit the center yoke on the remaining two trun-

Fig. 27 Install Bearing Assembly n i o n s a n d p r e s s b e a r i n g a s s e m b l i e s i n p l a c e , b o t h
(3) Press the bearing assembly in place and install sides (Fig. 30). Install a snap ring,
a snap ring (Fig. 28).
Fig. 28 Press In Bearing Assembly

BR DIFFERENTIAL AND DRIVELINE 3 -13
D I S A S S E M B L Y AND A S S E M B L Y (Continue
(6) Install the centering kit assembly inside the
center yoke making sure the spring is i n place (Fig.
31).
Fig. 33 Press in Bearing Assembly

J9316-14
Fig. 31 instail Centering Kit

(7) Place two bearing assemblies on the remaining
cross (opposite sides). Fit the open trunnions into the
center yoke holes and the bearing assemblies into the
centering kit (Fig. 32).
J9316-17
Fig. 84 Seat Snap Rings In Groove

J9316-15
SINGLE AND DOUBLE CARDAN JOINT
Fig. 32 instaii Remaining Cross (1) Clean all the universal joint yoke bores with
(8) Press the remaining two bearing assemblies cleaning solvent and a wire brush.
into place and install snap rings (Fig. 33). (2) Inspect the yokes for distortion, cracks and
(9) Tap the snap rings to allow them to seat into worn bearing assembly bores.
the grooves (Fig. 34).
(10) Check for proper assembly. Flex the CV joint
beyond center, it should snap over-center in both
directions when correctly assembled (Fig. 35).
(11) Install the propeller shaft.
3 -14 DIFFERENTIAL AND DRIVELINE — — • — — BR
washers. Replace the original bolts with the appropriate

increased length bolts.
J9316-18
Fig. 35 Check Assembly

ADJUSTMENTS
ADJUSTMENT AT AXLE WITH LEAF SPRINGS J9316-25
Adjust the pinion shaft angle at the springs with
Fig. 37 Angle Adjustment at Center Bearing
tapered shims (Fig. 36). Install tapered shims between
the springs and axle pad to correct the angle. Refer to SPECIFICATIONS
Rear Suspension for additional information.
TORQUE
DESCRIPTION TORQUE
FRONT SHAFT
Bolts, flange yoke 88 N-m (65 ft. lbs.)
Bolts, axle yoke ...... .19 N-m (14 ft. lbs.)
REAR SHAFT AXLE YOKE BOLTS
9 1/4 Axle . . . . . . . . . . . . . . .19 N-m (14 ft. lbs.)
Dana Axle. . 30 N-m (22 ft. lbs.)
CENTER BEARING BRACKET
Frame Bolts .68 N-m (50 ft. lbs.)
Bearing Bolts .68 N-m (50 ft. lbs.)
SPECIAL TOOLS
PROPELLER SHAFT
Fig. 36 Adjustment at Leaf Springs—Typical
CENTER BEARING ADJUSTMENT—TWO PIECE
SHAFT
Drive away shudder is the vibration that occurs at first
acceleration from a stop. Shudder vibration usually peaks
at the engines highest torque output. Shudder is a symp
tom associated on vehicles using a two-piece prop shaft.
To decreased shudder lowering the center bearing in 1/8
inch increments. Use shim stock or fabricated plates (Fig.
37). Plate stock must be used to maintain compression of
the rubber insulator around the bearing. Do not use Inclinometer—7663
BR STEERING 19-1
STEERING
C O N T E N T S
page page
GENERAL INFORMATION . 1 STEERING COLUMN . . 35

POWER STEERING PUMP 12 STEERING LINKAGE . . . . . . . . . . . .18
POWER STEERING SYSTEM DIAGNOSIS 3 TORQUE SPECIFICATIONS 40
RECIRCULATING BALL POWER STEERING
GEAR 20
G E N E R A L I N F O R M A T I O N
STEERING SYSTEM COMPONENTS wheel alignment. For additional wheel alignment in
Dodge Trucks use a power assisted recirculating- formation refer to Group 2, Front Suspension.
ball type steering gear (Fig. 1). The gear is used with
four wheel drive and two wheel drive vehicles. REGMCULATING-BALL POWER STEERING
. Power steering systems use: GEARS
• Steering gear The recirculating ball system acts as a rolling
• Steering linkage thread between the worm shaft and rack piston. The
• Pressure and return fluid hoses, fittings and some input and output shafts are supported by a thrust
times a power steering cooler bearing at the lower end and a bearing assembly at
• Hydraulic steering pump with fluid reservoir the upper end. When the worm shaft is turned the
rack piston moves. The rack piston teeth mesh with
the pitman (sector) shaft. Turning the worm shaft
turns the pitman shaft, which turns the steering
linkage.
Two different type steering gears are used, variable
ratio and fixed ratio. The fixed ratio is used on all
Dodge Ram Trucks 8,800 lbs. GVW to 11,000 lbs.
GVW. The variable ratio gear is used on 6,010 lbs.
GVW to 7,500 lbs. GVW trucks. The steering gears
can be adjusted and internally serviced.
An identification code HF on the upper adjustment
cover designates 16-13:1 variable ratio. The identifi
cation code BN designates 17.5:1 fixed ratio.
POWER STEERING PUMP '
The Saginaw P-Series pump (Fig. 1) is used on
Dodge Ram Truck vehicles.
On the gas engine hydraulic pressure is provided
by a belt driven power steering pump. The power
steering pump is a constant flow rate and displace
ment, vane-type pump. The internal parts that are
J9219-65 inside the housing operate submerged in fluid. The
flow control orifice is part of the pressure line union.
Fig. 1 Power Steering Systems The pressure relief valve inside the flow control valve
The 4X2 steering linkage consists of a pitman arm, limits the pump pressure.
idler arm, tie rods, steering damper and center link. The power steering pump is connected to the steer
The 4X4 steering linkage consists of pitman arm, ing gear via the pressure hose and the return hose.
drag link, steering damper and tie rods. Adjustment The pump shaft has a pressed-on pulley that is belt
sleeves are used on the tie rods for toe and steering driven by the crankshaft pulley.
Trailer tow option vehicles are equipped with a STEERING COLUMNS
power steering pump oil cooler. The oil cooler is Two steering columns are used on Dodge Ram
mounted to the front cross member in front of the Truck vehicles. A fixed or non-tilt column and a tilt
steering gear. column. Both types have anti-theft provisions. When
The power steering pump on the DODGE TURBO in the LOCK position, the ignition switch and steer
DIESEL engine is bolted onto the rear of the vac ing shaft cannot be operated. The lock mechanism
uum pump. The pump is driven by the accessory also prevents operation of the automatic transmis
drive through a common shaft. sion gear shift lever. Both columns are energy-ab
Dodge Ram Truck power steering pumps are sorbing (collapse from impact in the event of a front-
not interchangeable with pumps installed in end collision).
other vehicles.
BR STEERING 19 - 3
POWER STEERING SYSTEM DIAGNOSIS
PUMP PRESSURE TEST (7) Gauge should read below 862 kPa (125 psi). If
The following procedure is used to test the opera reading is above inspect hoses for restrictions and re
tion of the power steering system on the. vehicle. pair as necessary. The initial pressure should be in
(1) Check belt tension and adjust as necessary. the range of 345-552 kPa (50-80 psi).
THE AUTOMATIC TENSIONER. CAUTION: The following test procedure involves
(2) Disconnect high pressure hose at gear or pump. testing maximum pump pressure output and flow
Use a container for dripping fluid. control valve operation. Do not leave valve closed
(3) Connect Gauge 6815 to both hoses using for more than five seconds as the pump could be
adapter fitting (Fig. 1). Connect spare pressure hose damaged.
to gear or pump.
(8) Close valve fully three times and record highest
pressure indicated each time. All three readings
must be above specifications and within 345
kPa (50 psi) of each other.
o Pressures above specifications but not within 345
kPa (50 psi) of each other, replace pump.
• Pressures within 345 kPa (50 psi) of each other
but below specifications, replace pump.
CAUTION: Do not force the pump to operate against
the stops for more than 2 to 4 seconds at a time be
cause, pump damage will result.
(9) Open the test valve, turn steering wheel ex

9519-1 treme left and right positions against the stops.
Record the highest indicated pressure at each posi
Fig. 1 Pressure Test Gauge tion. Compare readings to specifications. If highest
(4) Open the test valve completely. output pressures are not the same against either
(5) Start engine and warm up to operating temper stop, the gear is leaking internally and must be re
ature. paired.
(6) Check fluid level, add fluid as necessary. PUMP OPERATING SPECIFICATIONS
RELIEF PRESSURE FLOW

ENGINE (PoS.I.) (G.P.M.)
3.9L 1425-1500 2 4-2.8

5.2L 1425-1500 2.4-2.8
5.9LGAS 1400-1500 2.7-3.1
8.0L , 1400-1500 2.7-3.1
5.9LDSL 1400-1500 2.7-3.1
J9519-62
19 - 4 STEERING BR
P O W E R STEERING SYSTEM DIAGNOSIS
STEERING NOISES
There is some noise in all power steering systems. One of the most common is a hissing sound evident at standstill
parking. Hiss is a high frequency noise similar to that experienced while slowly closing a water tap. The noise is •
present in every valve and results from high velocity fluid passing valve orifice edges. There is no relationship
between this noise and performance of the steering. Hiss may be expected when steering wheel is at end of travel or
when slowly turning at standstill.

OBJECTIONAL HISS OR 1. Damaged or mispositioned 1. Check for proper seal between steering
WHISTLE steering column coupler to dash column coupler and dash seal.
panel seal.
2. Noisy valve in power steering gear. 2. Replace steering gear.
RATTLE OR CLUNK 1. Gear loose on front crossmember. 1. Check gear-to-crossmember mounting

bolts. Tighten to specification.
2. Crossmember-to-frame bolts or 2. Torque bolts and studs to
studs loose. specifications.
3. Tie rod looseness (outer or inner). 3. Check tie rod pivot points for wear.
Replace if necessary.
4. Loose lower control arm to 4. Torque control arm bolts to
crossmember bolts. specifications.
5. Loose strut to body attaching bolts. 5. Check upper strut mount to body
attaching bolts to see if torqued to
specifications.
6. Pressure hose touching other 6. Adjust hose to proper position by
parts of body. loosening, repositioning and tightening
fitting. Do not bend tubing.
7. Noise internal to gear. 7. Replace gear.
8. Damaged front crossmember. 8. Replace front crossmember.
CHIRP OR SQUEAL (IN THE 1. Loose belt. 1. Adjust belt tension to specification.
AREA OF PUMP)
PARTICULARLYNOTICEABLE
AT FULL WHEEL TRAVEL
AND DURING STANDSTILL
PARKING
9519-25
BR STEERING 19-5
m^mmmG NOISES - Continued

There is some noise in all power steering systems. One of the most common is a hissing sound evident at
standstill parking. Hiss is a high frequency noise similar to that experienced while slowly closing a water tap. The
noise is present in every valve and results from high velocity fluid passing valve orifice edges. There is no
relationship between this noise and performance of the steering. Hiss may be expected when steering wheel is at
end of travel or when slowly turning at standstill.
Pump growl results from the development of high pressure fluid flow. Normally this noise should not be high enough
to be objectionable. Abnormal situations, such as a low oil level causing aeration or hoses touching the vehicle
body, can create a noise level that could bring complaints.
WHINE OR GROWL 1 Low fluid level. 1. Fill to proper level and perform leakage
(PUMP-NOISE) diagnosis. (Recheck after system is free
of aeration.)
2. Hose touching vehicle body 2. Reposition hose. Replace hose if tube
or frame. ends are bent.
3. Extreme wear of pump internal 3. Replace pump and flush system.
parts.
SUCKING AIR SOUND 1. Loose return line clamp. 1. Tighten or replace clamp.
2. Missing O-ring on hose 2. Inspect connection and replace O-ring
connection. as required.
3. Low fluid level. 3. Fill to proper level and perform leakage
diagnosis.
4. Air leak between reservoir and 4. Inspect and replace reservoir as
pump. required.
SQUEAK OR RUB 1. Sound from steering column. 1. Check for squeak in steering column.
SOUND Inspect for contact between shroud
intermediate shaft, column, and wheel.
(Realign if necessary.)
(a) Check for lack of grease on steering
column, dash to lower coupling seal.
2. Sound internal to steering gear. . 2. Replace gear.
SCRUBBING/KNOCKING 1. Incorrect tire size. 1. Verify tire size is the same as originally
supplied.
2. Check clearance between tires
and other vehicle components,
2. Correct as necessary.
through full travel.
3. Check for interference between
steering gear and other
3. Correct as necessary.
components.
4. Incorrect gear supplied.
4. Replace gear.
9219-45
19-6 STEERING
P O W E R S T E E R I N G SYSTEM DIAGNOSIS
BINDS STICKS SEIZED

CATCHES, STICKS IN 1. Low fluid level. 1. Fill to proper level and perform leakage
CERTAIN POSITIONS OR diagnosis.
DIFFICULT TO TURN 2. Tires not properly inflated. 2. Inflate tires to proper pressure.
3. Lack of lube in ball joints. 3. Lubricate where possible.
4. Lack of lube in outer tie rod ends. 4. Lubricate where possible.
5. Loose pump belt. 5. Tighten or replace belt.
6. Faulty pump flow control (Verify 6. Replace pump.
cause using Pump Test
Procedure).
7. Excessive friction in steering 7. Correct condition. (See Steering
column or intermediate shaft. Column Service Procedure.)
8. Steering column coupling binding. 8. Realign as necessary.
9. Binding upper strut bearing. 9. Correct binding condition.
10. Excessive friction in steering gear. 10. Replace steering gear.
SHAKE SHUDDER VIBRATION
CONDITION POSSIBLE CAUSES CORRECTION!
VIBRATION OF THE S T E E R 1. Air in the power steering system. 1. Steering shudder can be expected in
ING WHEEL AND/OR DASH new vehicles and vehicles with recent
DURING DRY PARK OR steering system repairs. Shudder should
LOW SPEED STEERING improve after the vehicle has been driven
MANEUVERS several weeks.
2. Tires not properly inflated. 2. Inflate tires to proper pressure.
3. Excessive engine vibration. 3. Make sure that engine is running
properly.
4. Loose tie rod end. 4. Check inner and outer tie rod and jam
nut for excessive free play.
5. Overcharged air conditioning 5. Check air conditioning pump head
system. pressure. (See Air Conditioning
Refrigerant System Diagnosis).
9519-26
BR STEERING 19-7
LOW ASSIST, NO ASSIST, OR HARD STEERING

STIFF, HARD TO TURN, 1. Tires not properly inflated. 1. Inflate tires to proper pressure.
SURGES, MOMENTARY 2. Add power steering fluid as required
2. Low fluid level.
INCREASE" IN EFFORT and perform leakage diagnosis.
WHEN TURNING
3. Loose belt. 3. Tighten or replace belt.
4. Lack of ball joint lubrication. 4. Lubricate or replace as required.

5. Low pressure pump (Verify using 5. Verify cause using Pump Test
Pump Test Procedure). Procedure. Replace pump if necessary.
6. High internal leak gear. 6. Check steering system using test
procedure. If steering gear is at fault,
replace steering gear.
POOR RETURN TO CENTER
STEERING WHEEL DOES 1. Tires not properly inflated. 1. Inflate tires to proper pressure.
NOT WANT TO RETURN
TO CENTER POSITION 2. Improper front wheel alignment. 2. Check and adjust as necessary.
3. Lack of lubrication in ball joint. 3. Replace as required or lubricate.
4. Steering column U-joints 4. Realign steering column U-joints.
misaligned.
5. Mispositioned dash cover. 5. Reposition dash cover.
To evaluate items 6 and 7, disconnect
the intermediate steering shaft. Turn
the steering wheel and listen for
internal rubbing in column.
6. Steering wheel rubbing. 6. Adjust covers.
7. Damaged, mis-positioned 7. Correct condition.
or un-lubricated steering column
coupler to dash seal.
8. Binding upper strut bearing. 8. Repair binding condition.
9. Tight steering shaft bearing. 9. Replace steering column.
10. Excessive friction in steering 10. Replace steering coupler!
coupler.
11. High friction in steering gear. 11. Replace steering gear.
12. Steering coupler mispositioned 12. Reposition coupling.
to steering gear (rubbing).
J9519-68
19-8 STEERING BR
LOOSE STEERING
EXCESSIVE WHEEL 1. Air in system. 1. Add fluid.

KICKBACK OR TOO MUCH
2. Gear loose on crossmember. 2. Check gear to crossmember mounting
S T E E R I N G W H E E L PLAY
bolts. Tighten to specification.
3. Free play in steering column. 3. Check and replace as required.
4. Loose ball joints. 4. Check and replace as required.
5. Pinch bolt loose on ball joint. 5. Check pinch bolts and tighten as
required to specified torque.
6. Front wheel bearings loose or 6. Tighten hub nut or replace with new
worn. parts as necessary.
7. Loose outer tie rod ends. 7. Check and replace as required.
8. Loose inner tie rod ends. 8. Replace gear.
9. Defective steering gear rotary 9. Replace gear.
valve.
VEHICLE LEADS TO THE SIDE

W H E E L D O E S NOT WANT 1. Radial tire lead. 1. Rotate tires as recommended in Tire
TO RETURN TO Service.
CENTER POSITION 2. Front end misaligned. 2. Align front end as recommended in
• Wheel Alignment Service Procedure.
3. Wheel braking. 3. Check for dragging brakes as directed
in Brake Service Procedure.
4. Unbalanced steering gear valve. 4. Replace steering gear.
(If this is the cause, the steering
efforts will be very light in
direction of lead and heavier in
the opposite direction).
S T E E R I N G W H E E L HAS 1. Steering wheel to steering column 1. Torque not to proper torque

FORE-AFT L O O S E N E S S shaft nut not securely tightened. specification.
2. Steering column lower bearing 2. Replace steering column.
spring retainer slipped on
steering column shaft.
J9519-37
BR STEERING 19 - 9
FLUID LEAK

LOW FLUID LEVEL WITH: 1. Overfilled reservoir. 1. Adjust fill level.
• NO VISIBLE SIGNS OF 2. Hose connections at pump 2. Check for loose fittings and tighten to
LEAKS ON THE STEERING or gear. specifications. If fittings are tight,
GEAR, PUMP, ON FLOOR, examine for damaged or missing O-ring
OR ANYWHERE ELSE and replace as required.
LOW FLUID LEVEL WITH: 3. Pump or gear leak. 3. Identify location of leak and repair or
• VISIBLE LEAK ON replace as indicated in Power Steering
STEERING GEAR, PUMP, Pump and/or Gear sections of this
FLOOR, OR ANYWHERE service manual.
ELSE
FOAMY OR MILKY FLUID

AERATION AND OVER 1. Air leaks. 1. Check for air leak as described under
FLOW OF FLUID sucking air and correct.
2. Low fluid level. 2. Extremely cold temperatures may
cause system aeration if the oil level is
low. Add fluid as required.
3. Cracked pump housing. 3. Remove pump from vehicle and
separate reservoir from housing. Check
expansion plug and housing for cracks.
Replace pump as required.
4. Water contamination. 4. Drain and refill fluid if there is evidence
of contamination.
9119-7
19 -10 STEERING BR
PUMP LEAKAGE DIAGNOSIS
J9419-33
BR — STEERING 19 -11
GEAR LEAKAGE DIAGNOSIS
1. SIDE COVER LEAK - TORQUE SIDE 3. PRESSURE LINE FITTING - TOR-

COVER BOLTS TO 60 N*m (45 FT. QUE THE HOSE FITTING NUT TO
LBS.). REPLACE THE SIDE COVER 27 N«m (20 FT. LBS.). IF LEAKAGE
SEAL IF THE LEAKAGE PERSISTS. PERSISTS, REPLACE' THE SEAL.
2. ADJUSTER PLUG SEAL - REPLACE 4. PITMAN SHAFT SEALS - REPLACE

THE ADJUSTER PLUG SEALS. THE SEALS.
5. TOP COVER SEAL - REPLACE THE
SEAL. J9219-29
19 -12 STEERING BR
POWER STEERING PUMP
page page
Power Steering Hose 12 Pump Replacement—Gasoline Engine 15

Power Steering Pump—Initial Operation 17 Pump Reservoir 16
Pump Pulley 16 Service Information 12
Pump Replacement—Diesel Engine 13
SERVICE INFORMATION REMOVAL

The power steering pump internal components are (1) Remove fasteners from hose retaining brackets
not serviced or adjusted. If a malfunction or internal at all locations.
fluid leak occurs, the complete unit must be replaced. (2) Disconnect pressure and return hose from the
steering gear. Drain the fluid from pump and reser
POWER STEERING HOSE voir (Fig. 2, 3).
Max. cool, vehicles are equipped with a power
steering auxiliary fin oil cooler.' The oil cooler is
mounted to the left front side of the radiator closure
panel (Fig. 1).
Fig. 2 Power Steering Hose Diesel Engine

(3) Disconnect pressure and return hose from the
pump. Remove hoses from vehicle (Fig. 2, 3).
Fig. 1 Power Steering Cooler INSTALLATION
Cap hose open ends and pump/steering gear fit (1) Wipe hose ends, pump and gear unions clean.
tings to prevent entry of foreign material. (2) Connect hose at steering gear and pump. Route
hose while avoiding extreme bends or kinks. The
WARNING: POWER STEERING FLUID (AND PUMP hose must be kept away from exhaust system
COMPONENTS) AND THE EXHAUST SYSTEM CAN components. Do not distort hose tube ends by bend
B E E X T R E M E L Y HOT IF THE ENGINE HAS B E E N ing, kinking or over tightening.
RECENTLY OPERATING. DO NOT START THE E N (3) When used, the protective foam sleeves must be
GINE WITH ANY LOOSE OR DISCONNECTED properly positioned on the hose to prevent chafing.
H O S E S . DO NOT A L L O W THE H O S E S TO TOUCH A
(4) Tighten fittings at pump and gear to 31 N-m
HOT EXHAUST MANIFOLD OR THE CATALYTIC
(5) Install clamps on return hose on gear and
CONVERTER*
pump.
BR STEERING 11 -13
PUMP LOWER PUMP

ENGINE BLOCK
ASSEMBLY BOLT
RETURN HOSE PRESSURE

HOSE
CLAMP
STEERING
GEAR J9519-72
Fig. 3 Power Steering Hose Gas Engine

(6) After installation, inspect and test for fluid BATTERY
leaks. GROUND
CABLE STEERING PUMP BRACKET
PUMP REPLACEMENT—DIESEL ENGINE ATTACHING NUT J9119-75
REMOVAL Fig. 5 Oii Feed Line Removal/lnstaliation
(1) Place a drain pan under the power steering (5) Remove the lower bolt that attaches the vacu
pump. um/steering pump assembly to the engine block. Re
(2) Disconnect and cap the vacuum and steering move the nut from the steering pump attaching
pump hoses. bracket (Fig. 5).
(3) Disconnect the electrical connector on the oil (6) Remove upper bolt from the pump assembly
pressure sender unit (Fig. 4). Remove sender unit (Fig. 6). Remove the assembly from the engine (Fig.
from engine block and plug hole in block. 7).
STEERING
PUMP ENGINE BLOCK
J9119-74
J9119-76
Fig. 4 Oii Pressure Sending Unit
(4) Disconnect and cap the oil feed line from the Fig. 6 Pump Assembly Upper Bolt
bottom of the vacuum pump (Fig. 5). (7) Remove the gasket from the mounting surfaces
on engine block and pump assembly.
(8) Drain the fluid from the steering pump.
11 -14 STEERING BR
PUMP SHAFT VACUUM

PUMP DRIVE
MOUNTING
PUMP BRACKET
J9119-77 SPACERS J9119-69
Fig. 9 Steering Pump Removai/instaiiation ,

Fig. 7 Pump Assembly Removal/Installation
(2) Rotate the drive gear until the steering pump
(9) Remove the steering pump to vacuum pump
and vacuum pump drive dogs align. Install the steer
bracket attaching nuts (Fig. 8).
ing pump onto the vacuum pump bracket. Use care
to avoid damaging the oil seal in the vacuum pump
during installation. The steering pump housing
and spacers must mate completely with the
vacuum pump bracket (Fig. 10).
VACUUM
OIL FEED PUMP
FITTING
VACUUM PUMP OIL FEED

BRACKET FITTING
PUMP
SPACERS
STEERING
PUMP
J9119-78
Fig. 8 Bracket Nut Removal/installation
(10) Slide the steering pump from the bracket. Use

care not to damage the internal oil seal in the vac J9119-71
uum pump (Fig. 9).
(11) Remove the two pump body spacers (Fig. 9), Fig. 10 Steering/Vacuum Pump Assembly
for pump installation.
(3) Install the three (3) vacuum pump bracket to
INSTALLATION steering pump nuts. Tighten to 24 N-m (18 ft. lbs.)
(1) Install the two pump body spacers (Fig. 9). torque.
BR STEERING 19 -15
(4) Position new gasket on vacuum pump assem

bly. Use sealer if necessary to-retain the gasket.
(5) Align and install the .pump assembly on the en
gine. Ensure the steering pump stud is inserted into
the block bracket. Tighten the pump-to-engine block
attaching bolts to 77 N-m (57 ft. lbs.) torque.
(6) Install the steering pump to attaching bracket
nut and tighten to 24 N-m (18 ft. lbs.) torque.
(7) Remove plug and install the oil pressure send
ing unit and electrical connector.
(8) Install the oil feed line to the vacuum pump.
Tighten the oil line connection to 7 N-m (60 in. lbs./ 5
ft. lbs.) torque.
(9) Install the fluid hoses to the power steering
pump. Tighten the pressure fitting at the pump to 31
(10) Install and clamp the hose on the vacuum
pump.
(11) Fill the reservoir with power steering fluid
only. If necessary, refer to Pump Initial Operation
for detailed instructions.
(12) Start and run the engine. Check the operation Fig. 11 Belt Removal 3.9L, 5.2L and 5.9L Light Duty
of the brakes, if necessary refer to Group 5, Brakes
(5) Remove the pump bracket (Fig. 12). On 8.0L
engine remove rear pump bracket (Fig. 13).
PUMP REPLACEMENT—GASOLINE ENGINE
REMOVAL
WARNING: DO NOT REMOVE THE WATER PUMP

COOLANT T U B E U N L E S S THE COOLANT S Y S T E M
HAS B E E N D E P R E S S U R I Z E D AND DRAINED.
WARNING: DO NOT ATTEMPT TO REMOVE THE

PUMP WITHOUT REMOVING THE BELT FIRST. THE
AUTOMATIC TENSIONER IS UNDER A HIGH
S P R I N G LOAD,
(1) Remove the serpentine drive belt. Rotate ten

sioner clock-wise and hold in place, and remove belt
(Fig. 11). On 5.9L H.D. and 8.0L engines rotate
tensioner counter clock-wise.
(2) Clamp the fluid return hose and disconnect the
hoses from the power steering pump. Cap the fit
tings.
(3) Remove battery ground cable and nut at stud. Fig. 12 Pump Mounting 3.9L, 5.2L and 5.9L
Unthread stud from cylinder head, do not remove INSTALLATION
from bracket. Loosen upper bracket bolt. Remove the (1) Install the bracket to pump (Fig. 12). Tighten
lower bracket to engine block bolts. Pivot the pump
bolts to 47 N-m (35 ft. lbs.). On 8.0L engine install
assembly past the coolant tube. Remove the upper
stud. Remove upper bolt from cylinder head. The rear pump bracket (Fig. 13). Tighten nut to 47 N-m
steering pump and mounting bracket will be removed (35 ft. lbs.). Tighten bolts to 24 N-m (18 ft. lbs.).
from engine as an assembly. (2) Install the pump pulley, refer to the procedure
(4) Remove the pump pulley, refer to the procedure below.
below. This will allow access to the pump attaching (3) Position the steering pump (with pulley) and
screws. mounting bracket on the engine block. Install the up-
19 -16 STEERING BR
FRONT BRACKET
PULLEY J9419-27
Fig. 13 Pump Mounting S.OL Fig. 14 Pulley Removal (Typical)
per stud and bolt in bracket. Pivot the pump down
past the coolant tube. Install the lower bolts in
bracket (Fig. 12).
(4) Install bracket and pump assembly to engine
block. Tighten the bolts and nut to 41 N-m (30 ft.
lbs.).
(5) Connect the fluid hoses to the pump.
(6) Install the serpentine drive belt. Rotate ten
sioner clock-wise and hold in place, slip the belt over
the pulleys. Refer to Group 7, Cooling for belt rout
ing. On 5.9L H.D. and 8.0L rotate tensioner
counter clock-wise.
CAUTION: Do not use automatic transmission fluid
to fill the reservoir.
(7) Fill the reservoir with power steering fluid only. Fig. 15 Pulley Installation (Typical)
If necessary, refer to Pump Initial Operation for
detailed instructions. With Serpentine Belts; Run engine until warm (5
min.) and note any belt chirp. If chirp exists, move
PUMP PULLEY pulley outward approximately 0.5 mm (0.020 in.). If
noise is increases, press on 1.0 mm (0.040 in.). Be
REMOVAL careful that pulley does not contact mounting
(1) Remove the pulley with Puller C-4333 (Fig. 14). bolts.
Do not hammer on pulley because this will
damage it and the pump. PUMP RESERVOIR
(2) Replace pulley if bent, cracked, or loose.
REMOVAL
INSTALLATION Discard all O-ring seals during disassembly,
(1) Install the pulley with Installer C-4063-B (Fig. they are not re-usable.
15). Do not use the tool adapters. (1) Remove the filler cap and drain the fluid from
(2) Ensure that the tool and the pulley remain reservoir before removing parts.
aligned with the pump shaft. Prevent the pulley from (2) Remove mounting studs and pressure fitting
being cocked on the shaft. (Fig. 16). Rock reservoir by hand or use a soft face
(3) Force pulley flush with the end of the shaft. mallet to remove.
STEERING 19 -17
CAP
EXPANSION PLUG - DO NOT REMOVE; RESERVOIR

IF DEFORMED OR DISLODGED,
REPLACE PUMP
PITTING
SEALS 75 N»m
(55 ft. IBS.)
J9419-32
Fig. 16 Pump and Reservoir

(3) Remove O-ring seals f r o m housing and reser (2) Install new O-ring seals i n housing (Fig. 17).
voir. Tighten mounting studs to 48 N-m (35 ft. lbs.) torque.
(4) Remove flow control valve and spring from (3) Install fitting i n flow control valve bore.
housing. Tighten the fitting to 75 N-m (55 ft. lbs.) torque.
INSTALLATION POWER STEERING PUMP—INITIAL OPERATION

Clean all parts before installation. Lubricate Follow this procedure to remove air from the sys
new O-ring seals with MOPAR® Power Steering tem.
Fluid or an equivalent product.
(1) I n s t a l l flow control valve and spring (Fig. 17). CAUTION: The fluid level should be checked with
engine off to prevent injury from moving compo
VALVE AND
nents. Use only MOPAR® Power Steering Fluid. Do
SPRING
not use automatic transmission fluid. Do not over
fill.
Wipe filler cap clean, t h e n check the fluid level.

The dipstick should indicate F U L L COLD when the
fluid is at normal temperature.
(1) Raise front wheels off the ground and t u r n
steering wheel f u l l left.
(2) F i l l the pump fluid reservoir to the F U L L
COLD level.
(3) W i t h engine off t u r n the steering wheel lock-to-
lock 20 times.
(4) Check fluid level and check for bubbles i n fluid.
I f bubbles are found check all connections and repeat
step 3.
(5) Lower front wheels and start the engine. Let
engine r u n for two minutes.
(6) T u r n the steering wheel slowly from lock-to-
lock several times.
J8919-101 (7) Stop the engine. Check the fluid level and refill
as required.
Fig. 17 Flow Control Valve/Spring Installation (8) I f fluid is foamy, allow vehicle to stand a few
minutes and repeat the above procedure.
19-18 STEERING BR
STEERING LINKAGE
SERVICE INFORMATION
The tie-rod end ball stud seals should be inspected
during all oil changes.
Check for ball stud wear, corrosion or damaged
seal. If these conditions exist, replace the tie-rod. Lu
bricate the tie-rod end with MOPAR® Multi-Mileage
Lubricant, or equivalent.
STEERING LINKAGE—IFS SUSPENSION
Heavy duty steering linkage will be use on 8,800
and 10,500 GVW vehicles. The 10,500 GVW steering
linkage will have a steering damper mounted from a LINK
frame bracket to the centerlink.

Torque specification are the same for standard or J9419-37
heavy duty linkage.
Use Puller C-3894-A for tie rod removal. Fail Fig. 2 Steering Linkage—IFS Vehicles
ure to use this tool could damage the tie rod
and seal (Fig. 1).
Fig. 1 Tse Rod Removal

REMOVAL
(1) Remove the cotter pin and nut from the tie-rod.
(2) Remove the tie-rod end ball studs from steering
Fig. 3 Pitman Arm Removal
knuckle arms (Fig. 1 and 2).
Use care to avoid damaging the seals. INSTALLATION
(3) Remove inner tie-rod ends from center link Replace all damaged or worn steering linkage com
(Fig. 2). ponents.
(4) If equipped remove steering damper from cen (1) Position idler arm on the frame side rail. In
ter link and frame bracket. stall stud plate and tighten nuts to 88 N-m (65 ft.
(5) Remove idler arm ball stud from center link. lbs.) torque.
Remove idler arm stud plate from frame side rail (2) Center steering gear to alignment marks and
(Fig. 2). install pitman arm.
(6) Remove pitman arm ball stud from center link. (3) Install the lock washer and retaining nut on
(7) Mark the pitman arm and shaft positions for the pitman shaft. Tighten the nut to 251 N-m (185 ft.
reference. Remove pitman arm with Puller C-4150-A lbs.) torque.
(Fig. 3). (4) Install center link to ball studs (Fig. 2). Install
and tighten retaining nuts to 88 N-m (65 ft. lbs.)
torque. Install new cotter pins.
STEERING 19 - 1 1
(5) Install tie-rod ends into center link (Fig. 2). (3) Mark the pitman arm and shaft positions for
Tighten the nuts to 88 N-m (65 ft. lbs.) torque. Install reference. Remove the nut and washer from the pit
new cotter pins. man arm. Remove the pitman arm with Puller
(6) Install steering damper to frame bracket and C-4150-A (Fig. 5).
center link if equipped. Tighten nuts to 68 N-m (50
ft. lbs.) torque. Install new cotter pins.
(7) Insert tie-rod ends into steering knuckle arm
(Fig. 2). Tighten the nuts to 88 N-m (65 ft. lbs.)
torque. Install new cotter pins.
(8) Remove the supports and lower the vehicle to
the surface. Center steering wheel and adjust toe (re
fer to the Alignment Specifications chart within
Group 2, Front Suspension).
Position the clamp on the sleeve so retaining
bolt is located, on the bottom side of the sleeve.
(9) After adjustment, tighten the tie-rod adjust
ment sleeve clamp bolt to 54 N-m (40 ft. lbs.) torque.
STEERING LINKAGE—LINK/COIL SUSPENSION

Use Puller C-4150-A to remove drag link steer
ing damper or pitman arm (Fig. 5). Use Puller
tool to remove tie rod ends (Fig. 1). Failure to
use these tools could cause damage to the seals.
EEMOVAL
(1) Remove tie rod and steering damper from drag
link. (4) Remove tie rod from steering knuckle.
(2) Remove drag link tie-rod end from steering INSTALLATION
knuckle and pitman arm (Fig. 4). Replace all damaged or worn steering linkage com
ponents.
(1) Center steering gear to alignment marks and
install pitman arm.
(2) Install the lock washer and retaining nut on
the pitman shaft. Tighten the nut to 251 N-m (185 ft.
lbs.) torque.
(3) Install drag-link ball studs to steering knuckle
and pitman arm. Install the retaining nuts and
tighten to 88 N-m (65 ft. lbs.) torque. Install new cot
ter pins.
(4) Install tie-rod on steering knuckle and drag-
link. Tighten the nuts to 88 N-m (65 ft. lbs.) torque.
Install new cotter pins.
TIE ROD TIE ROD (5) Install steering damper on drag-link and
END tighten to 68 N-m (50 ft. lbs.) torque.
J9419-24 (6) Remove the supports and lower the vehicle to
Fig. 4 Steering Linkage—Link/Coil
the surface. Center steering wheel and adjust toe (re
fer to the Alignment Specifications chart within
Use care to avoid damaging the seals. Group 2, Front Suspension).
Position the clamp on the sleeve so retaining
bolt is located on the bottom side of the sleeve.
(7) After adjustment tighten tie-rod adjustment
sleeve clamp bolts to 54 N-m (40 ft. lbs.) torque.
19-20 STEERING BR
RECIRCULATING B A L L POWER STEERING GEAR
INDEl
page page
Adjuster Plug Assembly Replacement . 27 Pitman Shaft Seals—In Car Replacement 20

Check Valve Replacement 33 Rack Piston and Worm Shaft Replacement ...... 30
Gear Disassembly Information .,24 Service Information 20
Housing End Plug 26 Steering Gear Adjustments 22
Pitman Shaft and Side Cover Replacement . . . . . . 26 Steering Gear Replacement 22
Pitman Shaft Seals and Bearing Replacement . . . . 32 Valve Replacement 29
SERflCE INFORMATION PITMAN NYLON

A recirculating-ball steering gear is used with the SHAFT WASHER
DUST SHIELD
power (assisted) steering system. The power steering SPECIAL TOOL
gear can be adjusted and internally serviced. C-4171
PITMAN SHAFT SEALS—IN CAR REPLACEMENT
REMOVAL
(1) Remove pitman arm from gear. Refer to Pitman SPECIAL TOOL
C-4178
Arm Removal in Steering Linkage.
(2) Clean exposed end of pitman shaft and hous
ing. Use a wire brash to clean the shaft splines.
(3) Remove retaining ring with snap ring pliers.
CAUTION: Use care not to score the housing bore
when prying out seals and washers.
(4) Remove backup washer and double lip seal PITMAN

SHAFT
with screwdriver. SEAL
• Start the engine and turn the steering wheel fully
to the LEFT to force out the seals and washers.
• Stop the engine. J9519-6
(5) Remove backup washer and single lip seal with
screwdriver. Fig. 1 Pitman Shaft Seal Installation
(6) Inspect the housing for burrs and remove if (3) Install the backup washer.
necessary. Inspect the pitman shaft seal surface for (4) Install the double lip seal.
roughness and pitting. If pitted replace shaft. (5) Install the backup washer.
(6) Install the retainer ring with snap ring pliers.
INSTALLATION (7) Center the steering gear.
(1) Coat seal with white petroleum grease. Install (8) Install the pitman arm. Refer to Pitman Arm
single lip seal with Installer special tool C-4178 or a Installation in Steering Linkage.
suitable size deep socket (Fig. 1). (9) Add power steering fluid. Refer to Power Steer
(2) Coat the double lip seal and washer with white
ing Initial Operation.
petroleum grease.
19 - 22 STEERING — — — — BR
STEERING GEAR REPLACEMENT INSTALLATION

(1) Position the steering gear on the frame rail and
REMOVAL install the bolts. Tighten mounting bolts to 190 N-m
(1) Place the front wheels in a straight-ahead posi (140 ft. lbs.) torque.
tion. (2) Align steering coupler on gear shaft. Install
(2) Disconnect and cap the fluid hoses from steer pinch bolt and tighten to 49 N-m (36 ft. lbs.) torque.
ing gear. (3) Align and install the pitman arm.
(3) Remove coupler pinch bolt at the steering gear (4) Install the washer and retaining nut on the pit
and slide .shaft off gear (Fig. 3). man shaft. Tighten the nut to 251 N-m (185 ft. lbs.)
torque. ^
(5) Connect fluid hoses to steering gear, tighten to
31 N-m (23 ft. lbs.). Add fluid, refer to Power Steering
Pump Initial Operation.
STEERING GEAR ADJUSTMENTS

SERVICE INFORMATION
CAUTION: Steering gear must be adjusted as out

lined. Failure to adhere to the procedure may result
in gear damage or improper steering response.
Remove the gear from the vehicle and mount in a

vise. Drain the power steering fluid and make the
J9419-20 following adjustments in this order:
® FIRST - worm thrust bearing preload
Fig. 3 Column Shaft Removal • SECOND - over-center preload adjustment
(4) Mark the pitman shaft and pitman arm for in
stallation reference. Remove the pitman arm from WORM THRUST BEARING PRELOAD
the shaft with Puller C-4150-A (Fig. 4). ADJUSTMENT
(1) Remove adjuster plug locknut (Fig. 5).

(5) Remove steering gear retaining bolts and nuts. Fig. 5 Loosening the Adjuster Plug Locknut
Remove the steering gear from the vehicle. (2) Turn the adjuster in with Spanner Wrench
C-4381. Tighten the plug and thrust bearing in the
housing until firmly bottomed in housing.
BR TEERING 19 - 23
(3) Place an index mark on the housing even with FIRST

one of the holes in adjuster plug (Fig. 6). MAiK
J9219-30
J8919-58 Fig. 8 Aligning To The Second Mark
Fig. 6 Alignment Marking On Housing OVER-CENTER ADJUSTMENT

(1) Rotate the stub shaft from stop to stop and
(4) Measure back (counterclockwise) 13 mm (0.50
count the number of turns.
in) and mark housing (Fig. 7).
(2) Starting at either stop turn the stub shaft back
1/2 the total number of turns. This is the center of
the gear travel (Fig. 9).
Fig. 7 Remarking The Housing

(5) Rotate adjustment plug back (counterclockwise)
with spanner wrench C-4381 until hole is aligned
with the second mark (Fig. 8).
Fig. 9 Steering Gear Centered
(6) Install and tighten locknut to 109 N-m (80 ft.
lbs.) torque. Be sure adjustment plug does not turn (3) Turn the pitman shaft adjuster screw back
while tightening the locknut. (COUNTERCLOCKWISE) until extended, then turn
back in (CLOCKWISE) one half turn.
19 - 24 STEERING
(4) Place the torque wrench in the vertical position (5) Turn the adjuster in until torque to turn stub
on the stub shaft. Rotate wrench 45 degrees each shaft is 0.6 to 1.2 N-m (6.0 to 10.0 in. lbs.) more than
side of center and record the highest rotational reading in Step 4.
torque on center (Fig. 10). (6) Prevent the adjuster screw from turning while
tightening adjuster lock nut. Tighten the adjuster
lock nut to 58 N-m (43 ft. lbs.).
GEAR DISASSEMBLY INFORMATION
CAUTION: Cleanliness is extremely important when

repairing a power steering gear. Keep the bench,
tools and components clean at all times. Thor
oughly clean the exterior of the gear with cleaning
solvent before disassembly. Drain as much of the
fluid as possible. Use protective vise jaws at all
times when clamping components. During assem
bly, lubricate all components with power steering
fluid except when instructed otherwise (Fig. 11).
Fig. 10 Checking Over-center Rotation Torque

n
30
47)
1 - HOUSING, STEERING GEAR 25 - BEARING ASSY., NEEDLE (PITMAN SHAFT)

2 - RACE, THRUST BEARING (WORM) 26 - SEAL, PITMAN SHAFT (SINGLE LIP)
3 - BEARING ASSY., ROLLER THRUST (WORM) 27 - WASHER, SEAL BACK-UP (PITMAN SHAFT)
4 - RACE, THRUST BEARING (WORM) 28 - SEAL, PITMAN SHAFT (DOUBLE LIP)
5 - WORM, STEERING 29 - WASHER, SEAL BACK-UP (PITMAN SHAFT)
6 - SEAL "O" RING (STUB SHAFT) 30 - RING, RETAINING (PITMAN SHAFT SEAL)
7 - SHAFT, STUB 31 - WASHER, PITMAN SHAFT LOCK
8 - SPOOL, VALVE 32 - NUT, PITMAN SHAFT
9 - SEAL, "O" RING (SPOOL) 33 - NUT, RACK PISTON
10 - BODY, VALVE 34 - BALL
11 - RING, VALVE BODY (3) 35 - GUIDE, BALL RETURN (2)
12 - SEAL, "O" RING (VALVE BODY) (3) 3 6 - CLAMP, BALL RETURN GUIDE
13 - RETAINER, BEARING (ADJUSTER) 37 - SCREW ASSY., LOCKWASHER & (2)
14 - SPACER, THRUST BEARING 38 - PLUG, RACK PISTON
15 - RACE, UPPER THRUST BEARING (SMALL) 39 - SEAL, "O" RING (RACK PISTON)
16 - BEARING, UPPER THRUST 40 - RING, RACK PISTON
17 - RACE, UPPER THRUST BEARING (LARGE) 41 - SEAL, "O" RING (HOUSING END PLUG)
18 - SEAL, "O" RING (ADJUSTER) 42 - PLUG, HOUSING END
19 - PLUG, ADJUSTER 43 - RING, RETAINING (HOUSING END PLUG) m
20- BEARING, NEEDLE 44 - GEAR ASSY., PITMAN SHAFT •H
21 - SEAL, STUB SHAFT 45 - SEAL ASSY., GASKET m
22 - SEAL, STUB SHAFT DUST 46 - COVER ASSY., HOUSING SIDE
m
23 - RING, RETAINING 47 - BOLT, HEX. HEAD (SIDE COVER) (4) 2
24 - NUT, ADJUSTER PLUG LOCK 48 - NUT, LASH ADJUSTER
o
J9519-10 -i
m
Fig. 11 Power Steering Gear
19-26 STEERING mm
PITMAN SHAFT AND SIDE COVER REPLACEMENT (3) Install gasket to side cover and bend tabs
around edges of side cover.
REMOVE (4) Install pitman shaft assembly and side cover to
(1) Remove steering gear from vehicle. Refer to housing.
Power Steering Gear Replacement in this section. (5) Install side cover bolts and tighten to 61 N-m
(2) Remove pitman arm from steering gear. Refer (45 ft. lbs.).
to Pitman Arm Removal in the Steering Linkage sec (6) Adjust pitman shaft, refer to Over-Center Ad
tion. justment.
(3) Rotate stub shaft back and forth to drain power
steering fluid. msmtL
(1) Install steering gear. Refer to Power Steering
mmsmmmLE Gear Replacement in this section.
• Clean exposed end of pitman shaft and housing. (2) Install pitman arm onto steering gear. Refer to
• Clean pitman shaft spline with a wire brush. Steering Linkage in this group.
(1) Remove preload adjuster nut.
(2) Rotate stub shaft with socket to center gear. HOUSING END PLUG
Remove side cover bolts.
(3) Remove side cover, gasket and pitman shaft as REMOVE
an assembly. (1) Remove steering gear from vehicle. Refer to
(4) Remove pitman shaft from the side cover (Fig. Power Steering Gear Replacement in this section.
12). (2) Remove pitman arm from steering gear. Refer
to Steering Linkage in this group.
SIDE COVER BOLTS
- TORQUE TO 60 N-m
(3) Rotate stub shaft back and forth to drain power
(40 FT. LBS.) steering fluid.
DISASSEMBLE
• Rotate stub shaft back and forth to drain fluid.
PRELOAD
ADJUSTER NUT (1) Rotate retaining ring until one end is under the
hole in the housing. Unseat and force ring from
SIDE COVER groove (Fig. 13).
GASKET SEAL
PITMAN SHAFT
GEAR
RETAINING
RING
HOUSING ASSEMBLY
J9319-31
Fig. 12 Side Cover and Pitman Shaft J8919-31
ASSEMBLE
Fig. 13 End Plug Retaining Ring
(1) Install pitman shaft to side cover by screwing
shaft in until it fully seats to side cover. (2) Rotate stub shaft slowly COUNTER-CLOCK
(2) Install preload adjuster nut. Do not tighten WISE to remove end plug out from housing (Fig. 14).
nut until after pitman shaft adjustment has
been made.
mm STEERING 13-27
CAUTION: Do not turn stub shaft any further than INSTALL

necessary. The recirculating balls will drop out of (1) Install steering gear. Refer to Power Steering
the rack piston circuit and fall inside the rack pis Gear Replacement in this section.
ton chamber. This will require complete disassem (2) Install pitman arm onto steering gear. Refer to
bly of the gear. Steering Linkage in this group.
(3) Remove O-ring seal (Fig. 14). ADJUSTER PLUG ASSEMBLY REPLACEMENT
REMOVE
(1) Remove steering gear from vehicle. Refer to
Power Steering Gear Replacement in this section.
DISASSEMBLE
(1) Remove adjuster plug lock nut from housing.
(2) Remove adjuster plug from housing with Span
ner Wrench C-4381 (Fig. 16).
SPECIAL TOOL
C-4381 OR J-7624
HOUSING END PLUG

O-RING SEAL
HOUSING END PLUG
RETAINING RING J9319-30
Fig. 14 End Plug Components

ASSEMBLE
© Lubricate O-ring seal with power steering fluid.
(1) Install O-ring into housing.
(2) Install plug, tap lightly with a plastic mallet to
seat it.
(3) Install retaining ring with open end 25 mm (1
inch) from access hole (Fig. 15).
Fig. 16 Remove/Install Adjustment Plug
(3) Remove thrust washer bearing retainer from
adjuster plug with screwdriver (Fig. 17).
(4) Remove bearing spacer, races and thrust bear
ing (Fig. 18).
(5) Remove O-ring seal.
(6) Remove retaining snap ring.
(7) Remove needle bearing, dust seal and lip seal
with handle C-4171 (Fig. 19).
ASSEMBLE
CAUTION: Needle bearing must be installed with

identification on bearing facing tool to prevent dam
age to bearing.
Fig. 15 Installing The Retaining Ring (1) Install needle bearing into adjuster plug with
tool C-4177 and handle C-4171.
11 - 28 STEERING BR
Fig. 18 Adjustment Piug Components

(2) Apply white petroleum grease on lip seal In J9219-10
stall lip seal into adjuster plug with tool C-4177 and
handle C-4171. Fig. 20 install Retainer
(3) Apply white petroleum grease to dust seal cav (9) Adjust bearing preload, refer to Thrust Bearing
ity and install dust seal into adjuster plug with tool Preload Adjustment.
C-4177 and handle C-4171. (10) Install adjuster plug lock nut, and using a
(4) Install retaining snap ring. punch (drift) in a notch, tighten securely (Fig. 21).
(5) Install O-ring seal to adjuster plug. Hold adjuster plug to maintain alignment of the
(6) Install large bearing race, thrust bearing, small
marks*
bearing race and bearing spacer to adjuster plug.
(7) Install thrust washer bearing retainer to ad (11) Adjust pitman shaft. Refer to Over-Center Ad
juster plug (Fig. 20). justment.
CAUTION: When installing adjuster plug, care INSTALL

should be taken NOT to cut the seals. (1) Install steering gear. Refer to Power Steering
Gear Replacement in this section.
(8) Install adjuster plug into housing with Spanner
Wrench C-4381.
BR STEERING 19 - 29
GEAR, MAKE SURE ANGLE OF

THRUST RACES ARE AS SHOWN. J9319-32
Fig. 22 Bearing, Worm and Valve Assembly
Fig. 21 Tighten Lock Nut

VALVE REPLACEMENT
REMOVE
DISASSEMBLE
(1) Remove adjuster plug, refer to Adjuster Plug
Assembly Replacement,
CAUTION; When removing valve, do not rotate
valve until it has separated from worm shaft tangs.
Rotation may cause recirculating balls to drop out
of the rack piston circuit. This will require complete
J9319-36
disassembly of the gear.
Fig. 23 Remove and Install Stub Shaft
(2) Remove stub shaft and valve assembly (Fig.
22). (2) Lubricate valve spool and O-ring seal with
(3) Remove stub shaft from valve assembly, if nec power steering fluid.
essary. (3) Install valve spool to valve body by pushing
• Tap stub shaft lightly on a block of wood to loosen and rotating. Hole in valve spool for stub pin must be
shaft cap. accessible from opposite end of valve body.
• Pull cap and valve body and disengage stub shaft (4) Assemble stub shaft to valve spool, if necessary
pin from hole in valve body (Fig. 23). and insert pin (Fig. 26).
(4) Remove valve assembly if necessary. • Notch in stub shaft cap MUST fully engage valve
« Remove valve spool by pulling and rotating from body pin and seat against valve body shoulder.
valve body (Fig. 24). (5) Install O-ring seals and teflon rings to valve
• Remove valve spool O-ring seal. body.
• Remove valve body teflon rings and O-ring seals (6) Lubricate O-ring seals and teflon rings with
(Fig. 25). power steering fluid.
(7) Install stub shaft and valve assembly to worm
ASSEMBLE shaft. Line up worm shaft to slot in the valve assem
(1) Install valve spool O-ring seal to valve spool. bly.
19-30 STEERING BR
SPOOL VALVE NOTCH IN CAP
VALVE BODY PIN

ROTATE
VALVE TO
REMOVE
VALVE BODY J93I9-37
Fig. 24 Remove and instaii Spool
J9319-38
Fig. 26 Stub Shaft Installation

DISASSEMBLE ..
(1) Remove pitman shaft and side cover. Refer to
Side Cover and Pitman Shaft Replacement in this
section.
(2) Remove housing plug end. Refer to Housing
End Plug Replacement in this section.
(3) Turn stub shaft COUNTERCLOCKWISE until
the rack piston begins to come out of the housing.
(4) Remove rack piston plug (Fig. 27).
EXTENSION . END PLUG
J8919-48
Fig. 25 Remove and Instaii Waive Seals

(8) Adjust Thrust Bearing Preload Adjustment and
Over-Center Adjustment. Refer to Steering Gear Ad
justments in this section.
INSTALL
(1) Install steering gear. Refer to Power Steering RATCHET
RACK PISTON AND WORM SHAFT REPLACEMENT
REMOVE
Power Steering Gear Replacement in this section. RACK 10910 0
PISTON J¥2i¥-V
Fig. 27 Remove and Install Rack Piston End Plug
STEERING 19-31
(5) Insert Arbor 0-4175 into bore of rack piston (2) Check for scores, nicks or burrs on the rack pis
(Fig. 28). Hold tool tightly against worm shaft while ton finished surface. Slight wear is normal on the
turning the stub shaft COUNTERCLOCKWISE. worm gear surfaces.
The rack piston will be forced onto the tool and
hold the rack piston balls in place. ASSEMBLE
(1) Install O-ring seal and teflon ring and lubricate
with power steering fluid.
(2) Install worm shaft to rack piston outside of
housing. Fully seat worm shaft to rack piston. Align
worm shaft spiral groove with rack piston ball guide
hole (Fig. 30).
INSTALL BALLS IN THIS HOLE
WHILE SLOWLY ROTATING
WORM COUNTERCLOCKWISE
Fig. 28 Remove and instaii Rack Piston

(6) Remove the rack piston, rack balls, and tool to
gether from housing.
(7) Remove valve. Refer to Valve Replacement in
this section. J9319-39
(8) Remove worm shaft.

(9) Remove thrust bearing and races. Fig. 30 Installing Balls in Rack Piston
(10) Remove arbor tool from rack piston. WARNING: MAKE S U R E A L L RACK PISTON B A L L S
(11) Remove rack piston balls. A R E REINSTALLED IN THE RACK PISTON. IM
(12) Remove screws, clamp and ball guide. P R O P E R INSTALLATION MAY RESULT IN P E R
(13) Remove teflon ring and O-ring seal (Fig. 29). SONAL INJURY.
There are 24 balls in the rack piston circuit,

12 are black and 12 are silver (Chrome). The
black rack piston balls are smaller than the sil
ver balls. THE BLACK AND SILVER BALLS
MUST BE INSTALLED ALTERNATELY INTO
THE RACK- PISTON AND BALL GUIDE.'This
procedure will maintain worm shaft preload.
(3) Lubricate and install rack piston balls through
return guide hole while turning worm shaft COUN
TERCLOCKWISE.
(4) Install remaining balls to guide using grease or
petroleum jelly at each end to hold in place (Fig. 31).
(5) Install guide onto rack piston and retain with
clamp and bolt. Tighten bolt to 58 N-m (43 in. lbs.)
torque.
(6) Insert Arbor C-4175 into bore of rack piston.
Hold tool tightly against worm shaft while turning
J9219-12 the stub shaft COUNTERCLOCKWISE.
The rack piston will be forced onto the tool and
Fig. 29 Remove and Install Seal on Rack Piston hold the rack piston balls in place.
CLEAN AND INSPECTION (7) Install the races and thrust bearing to worm
(1) Wash all components in clean solvent and dry shaft (Fig. 32).
with compressed air. (8) Install worm shaft to housing.
19-32 STEERING
GUIDE
WARNING: MAKE SURE A L L RACK PISTON BALLS
ARE REINSTALLED IN THE RACK PISTON. IM
PROPER INSTALLATION MAY RESULT IN PER
SONAL INJURY.
(11) Install rack piston plug and tighten to 149

(12) Install housing end plug. Refer to Housing
End Plug Replacement in this section.
(13) Install pitman shaft and side cover. Refer to
section.
(14) Adjust steering gear. Refer to Steering Gear
Adjustments in this section.
INSTALL
PITMAN SHAFT S E A L S AND BEARING

BALLS J9319-40
REPLACEMENT
Fig. 31 Balls In the Return Guide
REMOVE
WORM SHAFT THRUST RACES (1) Remove steering gear from vehicle. Refer to
DISASSEMBLE
(1) Remove pitman arm from gear. Refer to Pitman
Arm Removal in Steering Linkage.
(2) Clean exposed end of pitman shaft and hous
ing. Use a wire brush to clean the shaft splines.
(3) Remove retaining ring with snap ring pliers.
CAUTION: Use care not to score the housing bore
w h e n prying out seals and washers.
(4) Remove backup washer and double lip seal

with screwdriver.
(5) Remove backup washer and single lip seal with
screwdriver.
(6) Inspect the housing for burrs and remove if
MAKE SURE ANGLE OF THRUST necessary.
RACES ARE AS SHOWN (7) Remove needle bearing from side cover area of
housing (Fig. 33).
Fig.,32 Worm Shaft and Bearing ASSEMBLE
(9) Install valve. Refer to Valve Replacement in (1) Install needle bearing into housing (Fig. 35).
this section. (2) Install single lip seal with Installer or a suit
(10) Install rack piston to worm shaft from tool, able size socket (Fig. 36).
compress seals. (3) Coat the double lip seal and washers with
Hold Arbor tightly against worm shaft and turn grease.
stub shaft CLOCKWISE until rack piston is seated (4) Install double lip seal use special tool C-4178
on worm shaft. (5) Install the plastic backup washer.
(6) Install the steel backup washer.
(7) Install the retainer ring with snap ring pliers.
(8) Install the double lip dust seal.
mm STEERING 19-33
SPECIAL TOOL
REMOVER SIDE COVER
C-4171
AREA ,
DO NOT
BOTTOM BEARING
N HOUSING
WHEN TOOL
BOTTOMS O N
HOUSING, BEARING IS
FULLY INSTALLED
SPECIAL TOOL
C-4178
J9319-42 i J9119-41
Fig. 33 Needle Bearing Removal Fig. 35 Pitman Shaft Bearing Installation
NYLON
WASHER
SINGLE-LIP SEAL
SPECIAL TOOL
RETAINING RING C-4171
BACKUP WASHER
BACKUP WASHER
DOUBLE-UP SEAL, SPECIAL TOOL

C-4178
NEEDLE BEARING
PITMAN
SHAFT
SEAL
J9519-8 J9519-6
Fig. 34 Pitman Shaft Seals And Bearing Fig. 36 Pitman Shaft Seal Installation
(9) Install the pitman shaft and side cover. Refer to • CHECK VALVE REPLACEMENT
section. REMOVE
INSTALL Power Steering Gear Replacement in this section.
Gear Replacement in this section. DISASSEMBLE
CAUTION: Use care not to damage the threads of

the housing when prying out check valve.
19 - 3 4 STEERING
(1) Remove valve by prying from housing with a INSTALL

small screwdriver. (1) Install steering gear. Refer to Power Steering
ASSEMBLE
(1) Install the valve into the housing with a 3/8-
inch diameter piece of tubing 100 mm (4 inches) long.
POWER STEERING GEAR SPECIFICATIONS
Steering Gear Type ......Recirculating ball with Steering Gear Adjustments:

hydraulic assist. Wormshaft Bearing Preload Torque ....0.45-1.13 N-m
(TO to 15in.-lbs.)
Ration Code (Top and End of Gear)
RN ................17.5:1 Pitman Shaft Overcenter Drag Torque:
HF ....16-13:1 New Gear
(less than 400 miles/640 km) 0.45-0.90 N-m
Steering Gear Hydraulic Fluid Use Mopar Power (6 to 10 in.-lbs.) in addition to wormshaft
Steering Fluid, or equivalent. bearing preload but not to exceed
combined total of 2 N-m (1.5 in.-lbs.).
Steering Gear Lubricants Lubricate pitman shaft
seals, bearings races, and rack Used Gear
piston recirculating balls with (over 400 miles/640 km) 0.5-0.6 N-m (4 to 5 in.-lbs.)
petroleum jelly. Lubricate all other in addition to wormshaft bearing
parts with power steering fluid. preload but not to exceed
combined total of 2 N-m (25 in.-lbs.).
Caution: Gears must be adjusted exactly as outlined in Steering

Gear Adjustments-On Bench. Failure to adhere to the
recommended procedures may result in gear damage
or improper steering response.
J9519-69
STEERING 19-35
TEERI5". . -SKI.;. .'>'•
SERVICE INFORMATION nition locking link, shaft lock plate or shaft lock
The Acustar columns (Fig.l) have been designed to plate retainer (Fig. 2, 3). Damage will occur.
be serviced as an assembly; less wiring, switches,
shrouds, steering wheel, etc. Most steering column
components can be serviced without removing the
column from the vehicle. For additional information
refer to Group 8H, Electrical.
UPPEI
SHROUD
Fig. 2 Observe Cautions
LOWER
SHROUD J9419-17
Fig. 1 Aousiar Steering Column

WARNING: B E F O R E BEGINNING AMY AIRBAG SYS
TEM REMOVAL OR INSTALLATION P R O C E D U R E S ,
REMOVE AND ISOLATE THE BATTERY NEGATIVE
{-) C A B L E FROM THE VE-llOLE BATTERY. THIS IS
THE ONLY SURE WAY TO D I S A B L E THE AIRBAG Fig. 3 Observe Caution
SYSTEMS. FAILURE TO DO THIS S C O L D R E S U L T IN
ACCIDENTAL A I R B A G DEPLOYMENT AND POSSI STEERING WHEEL
BLE PERSONAL INJURY,
REMOVAL
When removing a deployed airbag module Refer to
WARNING: W H E N A S T E E R I N G COLUMN H A S AM Group 8M.
A I R B A G MODULE ATTACHED, N E V E R P L A C E THE (1) Make sure the front wheels are in the straight
COLUMN ON THE FLOOR OR OTHER S U R F A C E ahead position.
WITH THE S T E E R I N G W H E E L OR MODULE FACE (2) Disconnect battery negative cable and isolate.
DOWM (3) From underside of steering wheel, remove
speed control switch mounting screws if equipped
(Fig. 4).
CAUTION: Bumping, jolting and hammering on (4) Pull switches from wheel and unplug connector
steering column shaft and gear shift tube must be (Fig. 5).
avoided during service procedures. (5) Using a small screwdriver remove right rear
steering wheel cover (Fig. 6).
CAUTION: Do not attempt to remove pivot pins to (6) Remove 4 nuts attaching Airbag Module (Fig.
dissemble the tilting mechanism. Do not remove ig 7).
19-36 STEERING BR
Fig. 4 Speed Control Switch Removal
Fig. 6 Flight Rear Steering Wheel Cover
Fig. 5 Speed Control Switches

(7) Remove Airbag Module from steering wheel
and unplug squib connector from airbag module.
(8) Remove the steering wheel retaining nut.
Steering wheel and shaft are master splined for in
stallation reference/
(9) Remove the steering wheel with puller. Do not
hammer or jolt steering column or shaft during
removal of wheel.
INSTALLATION
(1) Pull speed control and airbag wires through the
lower hole in the steering wheel. Pull the horn wire Fig. 7 Airbag Module Removal
through the smaller hole at the top (Fig. 8). Ensure (5) Connect clockspring wiring connector to the
the wires are NOT pinched. module, by pressing straight in on the connector. The
(2) Install the steering wheel with the scored connector should latch securely beneath module lock
marks or master splines aligned. ing clip to assure positive connection.
(3) Install the retaining nut and tighten to 61 N-m (6) Mount airbag module, install 4 nuts and torque
(45 ft. lbs.) torque. Force the steering wheel down to 9 to 11 N-m (80 to 100 in. lbs.).
on the shaft with the retaining n u t only. Do not (7) Do not connect negative battery cable. Refer to
hammer or shock the column with sudden im Airbag System Check for proper procedure.
pact to install the wheel.
(4) Connect the wires to the horn buttons, speed
control switch and airbag module.
BR STEERING 19-37
(2) Depress the 2 locking tabs to disengage the

locking mechanism (Fig. 9).
CONNECTOR J9419-19
Fig. 8 Steering Wheel Installation

CLOCKSPRING
REMOVAL
(1) Place the front wheels in the straight ahead po
sition before starting the repair.
(3) Remove the steering wheel, refer to Steering Fig. 9 Clockspring (Auto-Locking)
Wheel Removal.
(4) Remove upper and lower steering column (3) Keeping mechanism disengaged, rotate clock-
shrouds to gain access to the clockspring wiring. spring rotor in CLOCKWISE DIRECTION to end of
(5) Release wire connector at clockspring. travel. Do not apply excessive torque.
(6) Pull clockspring assembly from column by lift (4) From the end of travel, rotate the rotor 2 1/2
ing locking fingers as necessary. The clockspring can full turns in the COUNTER CLOCKWISE direction.
not be repaired, and must be replaced if faulty. The horn wire should end up at the top and the
squib wire at the bottom (Fig. 9).
INSTALLATION (5) Install the steering wheel, refer to Steering
(1) Snap clockspring assembly onto column. If Wheel Installation.
clockspring is not properly positioned, follow the cen
tering procedures before installing steering wheel. COLUMN— REMOVAL/INSTALLATION
(2) Connect the wire connector to the clockspring.
WARNING: WHEN A STEERING COLUMN HAS AN
WARNING: ENSURE CLOCKSPRING WIRE CON AIRBAG MODULE ATTACHED, NEVER PLACE THE
NECTION IS COMPLETELY SEATED. THE LATCHING COLUMN ON THE FLOOR OR OTHER SURFACE
CLIP ARMS MUST BE PROPERLY ENGAGED ON WITH THE STEERING WHEEL OR MODULE FACE
THE-MODULE. DOWN.
(3) Install upper and lower steering column

CAUTION: Bumping, jolting and hammering on
shrouds. Be sure wiring is inside of shrouds and not
steering column shaft and gear shift tube must be
pinched.
avoided during service procedures.
(4) Install the steering wheel and airbag module,
refer to Steering Wheel Installation.
REMOVAL
CENTERING PROCEDURE (1) Make sure the front wheels are in the straight
If the rotating tape within the clockspring is not ahead position.
positioned properly, the clockspring may fail during (2) Disconnect the negative (ground) cable from the
use. The following procedures MUST BE USED to battery.
center the clockspring. (3) Remove steering wheel from column, refer to
(1) Place the front wheels in the straight ahead po Steering Wheel-Removal.
sition before starting the procedure.
19-38 STEERING 3R
(4) Vehicles equipped with column shift, disconnect STEERING

link rod in engine compartment. Pry rod out from COLUMN
ASSY.
grommet in the shift lever (Fig. 10).
(5) Paint installation alignment marks on the col
umn shaft-to-coupler. This will aid in column shaft to
wheel alignment. Remove the steering column shaft-
to-coupler bolt (Fig. 10).
STEERING
COLUMN
TURN SIGNAL
MULTI- SWITCH AND
* ® FUNCTION LEVER
SWITCH
J918J-1 CONNECTOR
Fig. 12 Multi-function Switch Wiring

(12) Remove electrical connections from Key-in
light, Ignition Switch, Horn and Clock Spring (Speed
Control) (Fig. 13).
SHIFT MULTI-FUNCTION
KEY-IN SWITCH &
LEVER J9419-21 SWITCH
HALO LIGHT
Fig. 10 Coupler Screw Removal

(6) Remove the dash panel cover under column.
(7) For column shift vehicles, make sure shift lever
is in P a r k position. Pull cable and twist to remove
from position arm. Push tab on bottom of cable re
tainer, then squeeze sides to remove retainer from
column. TURN SIGNAL
SWITCH & LEVER
PRNDL
CABLE
POSITION IGNITION SPEED
ARM SWITCH CONTROL J918J-2
Fig. 13 Steering Column Wiring

(13) Remove the wiring harness from the column
by prying out the plastic retainer buttons.
(14) Remove lower dash panel and toe plate fasten
ers (Fig. 1).
(15) Remove column from vehicle. Use care to
STEERING avoid damaging the paint or trim.
PUSH TAB COLUMN
UP
J948E-4 INSTALLATION
Fig. 11 PRNDL Drive Cable CAUTION: Bumping, jolting and hammering on

(8) Remove tilt lever (if equipped) from column. steering column shaft and gear shift tube must be
(9) Remove the upper and lower lock housing avoided during service procedures.
shroud (Fig. 1). Remove the lower fixed shroud.
(1) Column shift vehicles, install a new grommet.
(10) Remove the turn signal multi-function switch
Use MOPAR® Multipurpose Lubricant, or equivalent,
with a 7mm socket (Fig. 12).
to aid installation of the grommet. A new grommet
(11) Loosen the upper Support Bracket nuts to al
should be used when ever the rod is discon
low some slack. This will aid in removal of the upper
nected from the lever.
fixed shroud.
BR STEERING 19 - 31
(2) Install the ground clip on the left spacer slot

(Fig. 14).
J948E-66
Fig, 15 PRNDL Adjuster

(15) Install steering wheel on column, refer to
Steering Wheel-Installation.
(16) Column shift vehicles, connect the shift link
RN832 rod to the transmission shift lever. Use MOPAR®
Multipurpose Lubricant, or an equivalent product, to
Fig, 14 Ground Clip & Spacer Installation aid the installation.
(3) Remove the shipping lock pin (Fig. 1), if neces . (17) Check operation of the transmission shift link
sary. age and adjust as necessary.. Refer to Group 21,
Transmission for the shift linkage adjustment.
(4) Install column through floor pan.
(18) Connect the battery ground (negative) cable.
(5) Position the column bracket shear pins on the
attaching studs. Install, but loose assemble the two COLUMN COMPONENT SERVICE
upper bracket washers and nuts.
The Acustar tilt and standard columns (Fig. 1) have
(6) With the front wheels in the straight-ahead po been designed to be serviced as an assembly; less
sition. Align steering column shaft to the coupler. In wiring, switches, shrouds, steering wheel, etc. Most
stall pinch bolt and tighten to 49 N-m (36 .ft. lbs.) steering column components can be serviced without
torque. removing the column from the vehicle.-For additional
(7) Clip the wiring harness on the steering column. information, refer to Group 8H, Electrical.
Connect the multi-function switch wiring and tighten The gear shift lever (if equipped) can be serviced.
with 7mm socket. Use a drift and a suitable size socket to drive out pin
(8) Install the upper fixed shroud. (Fig. 16).
(9) Be sure both breakaway capsules are fully HAMMER
seated in the slots in the column support bracket.
Tighten the two upper bracket nuts to 12 N-m (105
in. lbs.) torque.
(10) Tighten the toe plate to floor pan attaching
nuts to 22.5 N-m (200 in. lbs.) torque.
(11) Install the wiring connections to the column.
Install the lower fixed shroud.
(12) Column shift vehicles, install the PRNDL
driver cable. Place shifter in Park position. If indica
tor needs adjusting turn recessed hex head screw un
derneath cable retainer (Fig. 15).
(13) Install the lock housing shrouds. Install the
tilt lever (if equipped).
(14) Install the lower dash panel column cover.
Fig. W Gear Shift Removal
19-40 STEERING BR
STEERING COLUMN STEERING LINKAGE
Description Torque DESCRIPTION TORQUE
Drag Link Ball Stud Nuts

Steering Wheel to Shaft
Link / Coil.. 88 N»m (65 ft. lbs.)
Retaining Nut 61 N»m (45 ft. lbs.) Idler Arm to Frame Bolts Heavy-Duty 271 N*m (200 ft. lbs.)
Coupler Bolt 49 N*m (36 ft. lbs.) Pitman Shaft Nut 251 N*m (185 ft. lbs.)
Upper Column Bracket Tie-Rod Nut 88 N*m (65 ft. lbs.)
Support Nuts 12 N»m (105 in. lbs.) Tie-Rod Adjuster Clamps
4X2 and 4X4 54 N*m (40ft.lbs.)
Toe Plate Attaching
Damper to Centerlink Nut. 68 N®m (50ft.lbs.)
Bolts/Nuts .... 23 N«m (200 in. lbs.) Damper to Frame Nut 68 N*m (50ft.lbs.)
J9519-71 J9519-70
STEERING GEAR STEERING PUMP
Description Torque Description Torque

Adjustment Plug Locknut... 108 N-m (80ft.lbs.) Flow Control Valve 75 N°m 55ft.lbs.)
Adjustment Screw Locknut 58 N-m (43ft.lbs.) High Pressure Fluid Line 31 N-m 23ft.lbs.
Gear to Frame Bolts 190 N-m (140ft.lbs.; Oil Cooler Bolt 20 N-m 15ft.lbs.
Intermediate Shaft Pinch Pump Bracket to Engine 41 N-m 30ft.lbs.
Bolts (Upper and Lower) . 49 N-m (36ft.lbs.) Pump to Brocket 47 N-m 35ft.lbs.
Pitman Shaft Nut 251 N-m (185ft.lbs.) Pump to Rear Bracket Nuts
High Pressure Fluid Line ... 31 N-m (23ft.lbs.) (8.0 L) 47 N-m (35ft.lbs.)
Return Pressure Fluid Line . 31 N-m (23ft.lbs.) Rear Bracket to Front Bracket
Rack-Piston Plug 149 N-m (110ft.lbs.) (8.0 L) 24 N-m (18ft.lbs.)
Side Cover Bolts 61 N-m (45ft.lbs.) Pump to Vacuum Pump Nuts
J9419-30 (Diesel Engine) 24 N-m (18ft.lbs.)
Pump Assembly to Engine
Block (Diesel Enginel\. 77 N-m (57ft.lbs.)
Pump to Support Bracket
Nut (Diesel Enaine) 24 N-m (18ft.lbs.)
Reservoir to Body Bolts 56 N-m (42ft.lbs.)
J9419-31
BR TRANSMISSION AND TRANSFER CASE 21 - 1
TRANSMISSION AND TRANSFER CASE
CONTENTS
page page
42RH/46RH/47RH AUTOMATIC TRANSMISSION . 97 NV4500 MANUAL TRANSMISSION ,. 47

NP231 HD/NP241/NP241 HD TRANSFER CASE . 278 TRANSMISSION/TRANSFER CASE
NV021 PTO ADAPTER 309 SPECIFICATIONS 328
NV3500 MANUAL TRANSMISSION 1
NV3500 MANUAL TRANSMISSION
INDEX
page page
Drain and Fill Plug Locations 3 Transmission Gear Ratios 3

General Information 1 Transmission Installation (2-Wheel Drive) 7
Transmission Assembly 24 Transmission Installation (4-Wheel Drive) 7
Transmission Changes 4 Transmission Lubricant . 3
Transmission Component Cleaning and Inspection . 20 Transmission Lubricant Level and Capacity 3
Transmission Diagnosis 4 Transmission Removal (2-Wheel Drive) . 4
Transmission Disassembly and Overhaul 8 Transmission Removal (4-Wheel Drive) . . . . . . . . . . 6
GENERAL INFORMATION Roller bearings are used to support the transmis

The NV3500 is a medium-duty, 5-speed, constant sion shafts in the two housings. The transmission
mesh, fully synchronized manual transmission. Fifth gears all rotate on caged type needle bearings.
gear is an overdrive range with a ratio of 0.0729:1. The NV3500 has a single shaft shift mechanism.
The NV3500 is used with 3.9L and 5.2L engines and The three shift forks are all mounted on a one shift
is available in two and four-wheel drive configura shaft. The shaft is supported in the front and rear
tions. housings by bushings and one bearing. Internal shift
The transmission gear case consists of two alumi components consist of the forks, shaft, shift lever
num housings (Fig. 1). The clutch housing is not a re socket, and detent components (Fig. 2).
movable component. It is an integral part of the
transmission front housing.
- 2 NV3500 MANUAL TRANSMISSION BR
Fig. 1 NV3500 Manual Transmission J9421-1

BR NV3500 MANUAL TRANSMISSION 21 - 3
PLUNGER
J9521-147
Fig. 2 NV3500 Shift Mechanism

TRANSMISSION LUBRICANT
Required lubricant for the NV3500 is Mopar Man-
ual Transmission Lubricant, P/N 4761526. This is the
only lubricant to be used in NV3500 transmissions.
No other lubricants are acceptable, or recommended.
TRANSMISSION LUBRICANT LEVEL AND

CAPACITY
The correct transmission lubricant level is to the
bottom edge of the fill plug hole.
The transmission must be level to obtain an accu-
rate lubricant level check. A drive-on type of hoist is
recommended for this purpose.
Lubricant capacity of the NV3500 is approximately
1.98 liters (4.2 pints). This represents the approxi-
mate quantity needed to refill the transmission after
a lubricant change or overhaul.
DRAIN AND FILL PLUG LOCATIONS

The NV3500 fill and drain plugs are both located
in the front housing. The fill plug is at the passenger
side of the housing. The drain plug is at the bottom Fig. 3 Drain and Fill Plug Locations
of the housing (Fig. 3). 4.01 first gear and 2.318 second gear. The new close
ratio NV3500 has a 3.49 first gear and 2.16 second
TRANSMISSION GEAR RATIOS gear. Gear ratios are:
Two versions of the NV3500 are now available. The
original wide ratio version introduced last year, has a
21 - 4 NV3500 MANUAL TRANSMISSION B R
Wile Ratio Version hoist to ensure this. Also allow the lubricant to
first = 4.016:1 settle for a minute or so before checking. These
second = 2.318:1 recommendations will ensure an accurate
third = 1.401:1 check and avoid an under-or-overfill condition.
fourth = 1 : 1
fifth = 0.729:1 HARD SHIFTING
reverse = 3.55:1 Hard shifting is usually caused by a low lubricant
level, improper or contaminated lubricants, transmis
Close Ratio Version sion component damage, clutch linkage malfunction,
first = 3.49:1 or by a damaged clutch pressure plate or disc.
second = 2.16:1 Substantial lubricant leaks can result in gear, shift
third = 1.401:1 component, synchro and bearing damage. If a leak
fourth = 1:1 goes undetected for an extended period, the first in
fifth = 0.729:1 dications of a problem are usually hard shifting and
reverse = 3.55:1 noise.
Incorrect or contaminated lubricants can also con
TRANSMISSION CHANGES tribute to hard shifting. The consequence of using
The shift lever assembly and shift mechanism are non-recommended lubricants is noise, excessive wear,
new for 1995. The new design self-biasing shift lever internal bind and hard shifting.
is mounted in a lightweight shift tower. The lever Improper clutch release is a frequent cause of hard
and tower are serviced as an assembly. shifting. Incorrect adjustment or a worn, damaged
The shift socket and shift shaft are basically un pressure plate or disc can cause incorrect release. If
changed. However, the bias spring, anti-rotation the clutch problem is advanced, gear clash during
bracket, and bracket rollers are no longer necessary shifts can result.
and have been eliminated. This is made possible by Worn or damaged synchro rings can cause gear
the new self-biasing shift lever assembly. clash when shifting into any forward gear. In some
A new remover tool for the shift socket roll pin, has new or rebuilt transmissions, new synchro rings may
been developed. The tool is available through the tend to stick slightly causing stiff and/or noisy shifts.
dealer tool program as Remover Tool 6858. Tool use In most cases, this condition will decline as the rings
is described in the overhaul section. wear-in.
TRANSMISSION DIAGNOSIS TRANSMISSION. NOISE . A
Most manual transmissions make some noise dur

LOW LUBRICANT LEVEL ing normal operation. Rotating gears can generate a
A low transmission lubricant level is generally the mild whine that may only be audible at extreme
result of a leak, inadequate lubricant fill, or an incor speeds.
rect lubricant level check. Severe, obviously audible transmission noise is
Leaks can occur at the mating surfaces of the hous generally the result of a lubricant problem. Insuffi
ings, or from the front/rear seals. A suspected leak cient, improper, or contaminated lubricant can pro
could also be the result of an overfill condition. mote rapid wear of gears, synchros, shift rails, forks
Leaks at component mating surfaces will probably and bearings. The overheating caused by a lubricant
be the result of inadequate sealer, gaps in the sealer, problem, can also lead to gear breakage.
incorrect bolt tightening, or use of a non-recom
mended sealer. TRANSMISSION REMOVAL (2-WHEEL DRIVE)
A leak at the front of the transmission will be from (1) Disconnect battery negative cable.
either a loose or damaged, front bearing retainer or (2) Shift transmission into Neutral.
retainer seal. Lubricant may also drip from the (3) Remove shift boot bezel screws and slide boot
transmission clutch housing after extended opera upward on shift lever extension.
tion. If the leak is severe, it will contaminate the (4) Remove bolts attaching shift tower and lever
clutch disc causing slip, grab and chatter. assembly to rear case. Then remove shift tower and
Transmissions filled from air or electrically pow shift lever extension as assembly (Fig. 4).
ered lubricant containers can be underfilled. This (5) If isolator and plate came off during shift tower
generally happens when the container delivery mech removal (Fig. 4), remove assembly from shift hous
anism is improperly calibrated. Always check the lu ing. Note that plate is one-way fit. Narrow side of
bricant level after filling to avoid an under fill plate goes toward driver side of transmission.
condition. (6) Raise vehicle on hoist.
A correct lubricant level check can only be (7) Remove crankshaft position sensor. Retain sen
made when the vehicle is level; use a drive-on sor attaching bolts.
BR — NV3500 MANUAL TRANSMISSION 21 - 5
(12) Disengage harness from clips on transmission

housing.
(13) Support engine with adjustable jack stand.
(14) Remove nuts attaching rear mount to cross-
member (Fig. 5). Then remove insulator from exten
sion housing if necessary.
(15) Remove bolts and nuts attaching crossmember
to frame rails. Rotate crossmember diagonally and
remove crossmember.
(16) Disconnect exhaust pipes at manifold and at
converter or muffler connections as needed. Then re
move Y-pipe, converter and tailpipe.
(17) Remove slave cylinder attaching nuts and re
move cylinder from clutch housing.
(18) Remove starter motor.
(19) Support transmission with transmission jack.
Fig. 4 Shift Tower Removal Secure transmission to jack with safety chains.
(8) Remove skid plate, if equipped. (20) Remove nuts/bolts attaching transmission
front housing to engine.
(9) Drain transmission lubricant if transmission (21) Move transmission rearward until clear of en
will be disassembled for service. gine. Then lower jack and remove transmission from
(10) Mark propeller shaft and U-joint for installa under vehicle.
tion reference. Then disconnect and remove propeller (22) Remove transmission from jack and position
shaft. transmission on workbench.
(11) Disconnect vehicle speed sensor wires. (23) If transmission will be overhauled, remove re
lease bearing and fork from front housing.
J9509-126
Fig. 5 Transmission Rear Support Brackets

21 - I i ¥ 3 l l l MA1UAL TRANSMISSION BR
(24) If shift lever extension is press-on style and Note that plate is one-way fit. Narrow side of plate
must be removed from shift lever, refer to following goes toward driver side of transmission.
procedure: (6) Remove crankshaft position sensor. Retain sen
(a) Obtain Remover/Installer Tool 6783. sor attaching bolts.
(b) Scribe mark position of extension on shank of (7) Raise vehicle on hoist.
shift lever. (8) Remove skid plate, if equipped.
(c) Position notched, lower end of tool just under (9) Drain transmission lubricant if transmission
square shank of shift lever (Fig. 6). will be disassembled for service.
(d) Position tool upper jaws u n d e r flange on (10) Mark propeller shafts and U-joints for instal
shift lever extension (Fig. 6). lation reference. Then disconnect and remove propel
(e) Tighten tool screw to pull extension off ler shafts.
square shank of shift lever. (11) Disconnect vehicle speed sensor wires.
(f) Remove lever extension and tool. (12) Disconnect transfer case shift linkage at
transfer case range lever.
(13) Remove bolts attaching shift linkage bracket
to transfer case and move linkage and bracket aside.
(14) Remove nuts attaching transfer case to trans
mission adapter housing.
(15) Remove transfer case with aid of helper. Sup
port transfer case with transmission jack. Move
transfer case rearward, tilt it away from fixed (weld
ed) rear crossmember and work it out from between
transmission and crossmember.
(16) Support engine with adjustable jack stand.
(17) Remove nuts and bolts attaching support
bracket and cushions to fixed crossmember.
(18) Remove nuts and bolts attaching removable
crossmember to frame rails. Rotate crossmember di
agonally to remove it.
' (19) Disconnect exhaust pipes at manifold and at
converter or muffler connections as needed. Then re
move Y-pipe, converter and tailpipe.
(20) Remove slave cylinder attaching nuts and re
move cylinder from clutch housing. Move cylinder
aside for working clearance.
(21) Remove clutch housing dust cover.
(22) On some models, it may be necessary to re
move front axle struts for access and removal clear
ance. Remove these components if necessary.
(23) Support transmission with transmission jack.
Secure transmission to jack with safety chains.
Fig. 6 Removing Shift Lever Extension With Tool
6783
(24) Remove bolts attaching transmission clutch
housing to engine block.
TRANSMISSION REMOVAL (4-WHEEL DRIVE) (25) Move' transmission rearward until transmis
(1) Disconnect battery negative cable. sion clutch housing is clear of engine. Then lower
(2) Shift transmission into Neutral. jack and remove transmission from under vehicle.
(3) Remove screws attaching shift boot bezel and (26) Remove transmission from jack and position
slide boot upward on shift lever extension. Then transmission on workbench.
loosen extension locknut and unscrew extension from (27) If transmission will be disassembled for ser
shift lever. vice, remove release bearing and fork.
(4) Remove bolts attaching shift tower and lever (28) If shift lever extension is press-on style and
assembly to rear case. Then remove shift tower and must be removed from shift lever, refer to following
lever along with shift lever extension as an assembly. procedure:
(5) If isolator and plate came off shift tower during (a) Obtain Remover/Installer Tool 6783.
removal, remove assembly from rear housing (Fig. 4). (b) Scribe mark position of extension on shank of
shift lever.
(c) Position notched, lower end of tool just under (23) Install isolator plate on shift tower, or rear
square shank of shift lever (Fig. 6). case. Then install shift tower and lever assembly.
(d) * Position tool upper. jaws under flange on Tighten shift tower bolts to 7-10 N-m (5-7 ft. lbs.)
shift lever extension (Fig. 6). torque. Note that isolator plate is one-way fit.
• (e) Tighten tool screw to pull extension off Narrow side goes toward driver side of trans
square shank of shift lever, mission.
(f) Remove lever extension and tool. (24) If shift lever extension was removed from shift
lever, reinstall with Tool 6783 as follows:
TRANSMISSION INSTALLATION (2-WHEEL DRIVE) (a) Reposition upper jaw of Remover/Installer
(1) Make sure transmission front housing mount Tool 6783 above flange on lever extension (Fig. 7).
ing surface is clean before installation. Tool will now be used to press extension back onto
(2) Lubricate release fork pivot ball, release fork, shift lever.
release bearing hub and transmission bearing re (b) Tighten tool screw to press extension back
tainer surface with Mopar high temperature grease. onto lever. Press extension to scribe . mark made
(3) Mount transmission on jack. Secure transmis during removal.
sion to jack with safety chains. (c) Remove special tool.
(4) Lubricate transmission input shaft pilot hub
and splines with light coat of Mopar high tempera
ture grease.
(5) Align transmission input shaft with release
bearing and clutch disc. Then. slide transmission into
place on engine block.
(6) Install and tighten transmission attaching bolts
to 54-61 N-m (40-45 ft. lbs.) torque. Be sure front
housing is fully seated before tightening bolts. Install
front dust cover after all bolts are tightened.
(7) Fill transmission with Mopar lubricant P/N
4761526. Correct fill level is to bottom edge of fill
plug hole.
(8) Connect backup light switch wires.
(9) Connect transmission harnesses to clips on
case.
(10) Install crossmember. Tighten crossmember-to-
frame bolts to 68 N-m (50 ft. lbs.) torque.
(11) Tighten crossmember-to-transmission insula
tor nuts to 68 N-m (50 ft. lbs.) torque.
(12) Install slave cylinder. Tighten cylinder nuts to
23 N-m (200 in. lbs.) torque.
(13) Remove jack used to support transmission.
(14) Install strut bolts/nuts, if removed.
(15) Connect vehicle speed sensor wires.
(16) Install and connect exhaust system. Align ex
haust components before tightening clamp and
bracket bolts and nuts. Be sure exhaust components
are clear of all chassis and driveline components. Fig. 7 Installing Shift Lever Extension With Tool
(17) Align and install propeller shaft. Tighten 6783
U-joint clamp bolts to 19 N-m (170 in. lbs.) torque. (25) Install shift boot and bezel.
(18) Verify that all linkage components, hoses and
electrical wires have been connected. TRANSMISSION INSTALLATION (4-WHEEL DRIVE)
(19) Remove any remaining support stands and (1) Make sure transmission front housing and en
lower vehicle. .- •' gine block contact surfaces are clean.
(20) Install crankshaft position sensor. (2) Lubricate release fork pivot ball, release fork,
(21) Connect battery negative cable. release bearing hub and transmission bearing re
(22) Apply Mopar Gasket Maker, or Loctite 518 to tainer surface with Mopar high temperature grease.
mounting surface of shift tower, isolator plate, and (3) Mount transmission on jack. Secure transmis
transmission case. sion to jack with safety chains.
21 • S l¥35ii MANUAL TRANSMISSION BR
(4) Lubricate transmission input shaft pilot hub (29) Apply Mopar Gasket Maker, or Loctite 518 to
and splines with light coat of Mopar high tempera mounting surfaces of shift tower, isolator plate, and
ture grease. lever mounting surface on transmission front hous
(5) Align transmission, input shaft with release ing.
bearing and clutch disc. Then slide transmission into (30) Install isolator plate on shift tower, or rear
place on engine block. case. Then install shift tower and lever assembly.
(6) Install and tighten transmission attaching bolts Tighten shift tower bolts to 7-10 N-m (5-7 ft. lbs.)
to 54-61 N-m (40-45 ft. lbs.) torque. Be sure housing torque. Note that isolator plate is one-way fit.
is fully seated before tightening bolts. If equipped, in Narrow side goes toward driver side of trans
stall dust cover after tightening housing bolts. mission.
(7) Fill transmission with Mopar lubricant, P/N (31) If shift lever extension was removed from shift
4761526. Correct fill level is to bottom edge of fill lever, reinstall with Tool 6783 as follows:
(a) Reposition upper jaw of Remover/Installer
plug hole.
Tool 6783 above flange on lever extension (Fig. 7).
(8) Connect backup light switch wires. Tool will now be used to press extension back onto
(9) Connect transmission harnesses and vent line shift lever.
to retainer clips on housing. (b) Tighten tool screw to press extension back
(10) Install center crossmember. Tighten cross- onto lever. Press extension to scribe mark made
member-to-frame bolts to 67 N-m (50 ft. lbs.) torque. during removal.
(11) Tighten crossmember-to-support bracket nuts (c) Remove special tool.
to 54-61 N-m (40-45 ft. lbs.) torque. (32) Install shift boot and bezel.
(12) Install slave cylinder in transmission clutch
housing. Tighten cylinder attaching nuts to 23 N-m TRANSMISSION DISASSEMBLY AND 0WERHAUL
(200 in. lbs.) torque. ;
(13) Remove jack used to support transmission. FRONT HOUSING REMOVAL
(14) Install strut bolts/nuts, if removed. (1) If necessary, temporarily reinstall isolator
(15) Install transfer case. Align and position trans plate and shift lever assembly. Then shift trans
fer case with transmission jack or aid of helper. Tilt mission into Neutral.
case upward and work into position on transmission (2) If lubricant was not drained out of transmis
mounting studs. sion during removal, remove drain plug and drain lu
(16) Install and tighten transfer case attaching bricant into container at this time.
nuts to 47 N-m (35 ft. lbs.) torque. (3) Remove backup light switch. Switch is located
(17) Install and connect transfer case shift linkage. on driver side of rear housing (Fig. 1).
(18) Connect vehicle speed sensor harness wire to
sensor.
(19) Align and connect exhaust system compo
nents. Be sure exhaust components are clear of all
chassis and driveline components.
(20) Align and install front and rear propeller
shafts. Tighten U-joint clamp bolts to 19 N-m (170 in.
lbs.) torque.
(21) Verify that all linkage components, hoses and
electrical wires have been connected.
(22) Check transfer case fluid level. Add Mopar
Dexron II, or ATF Plus if necessary. Correct level is
to edge of fill plug hole. Be sure transfer case is level Fig. 1 Backup Light Switch Location
before checking or adding fluid. (4) Remove shift tower bolts and remove tower and
(23) Check and adjust transfer case shift linkage if lever assembly (Fig. 2). Use 8 mm socket to tower re
necessary. move bolts.
(24) Install transfer case skid plate, if equipped.
(25) Fill transmission with Mopar lubricant, P/N
4761526. Correct fill level is to bottom edge of fill
plug hole.
(26) Install crankshaft position sensor.
(27) Remove any remaining support stands and
lower vehicle.
(28) Connect battery negative cable.
BR . _ NV3500 MANUAL TRANSMISSION 21 - 1
(5) If isolator and plate assembly came off shift

tower during removal, remove plate assembly from
rear housing (Fig. 2). Note that plate assembly is
one-way fit. Narrow side of plate goes toward driver
side of transmission and rubber coated side faces up
ward.
Fig. 4 Input Shaft Bearing Retainer Bolt Removal

(8) Remove input shaft bearing retainer. Use pry
tool to carefully lift retainer and break sealer bead
(Fig. 5).
Fig. 2 Shift Tower Removal

(6) Remove shift shaft lock bolt (Fig.. 3). Bolt is lo
cated at top of front housing just forward of shift
tower. Bolt is a hex head, shoulder bolt that secures
shift shaft bushing and lever. Use 13 mm socket to
remove bolt.
Fig. 5 Loosening Bearing Retainer Sealer Bead

(9) Remove bearing retainer from input shaft (Fig.
6). Note position of retainer lube channel for instal
lation reference.
Fig. 3 Shift Shaft Look Bolt Removal

(7) Remove bolts attaching input shaft bearing re Fig. 6 Input Shaft Bearing Retainer Removal
tainer in front housing (Fig. 4). Use 10 mm socket to
remove bolts.
21 - 1C NV3500 MANUAL TRANSMISSION
(10) Remove snap ring that secures input shaft in three bolts at this time. Leave at least one bolt
front bearing (Fig. 7). in place until rear case is ready to be removed.
DETAINER
iMPUf SHAF'
SNAP RSNO
\ x ( U S E H E A V Y DUTY
v
" PltER TCOL)
39m-m HOUSING
BOLT
Fig. 7 Input Shaft Snap Ring Removal LOCATIONS
(11) Remove shift shaft detent plug (Fig. 8). Use
crowfoot bar and hammer to lightly pry and tap plug RETAINER
BOLT
out of housing.
HAMMER
PRY
TOOL
HOUSING
BOLTS
J9421-13
Fig. 10 Housing And Bearing Retainer Bolt

Locations
(14) Separate front housing from rear housing (Fig.
11). Use plastic mallet to tap front housing off align
Fig. 8 Shift Shaft Detent Plug Removal ment dowels.
(12) Remove shift shaft detent plunger and spring REAR
(Fig. 9). Use pencil magnet to remove spring then HOUSING
plunger.
PLASTIC
MALLET J9421-14
Fig. 9 Detent Plunger And Spring Removal

Fig. 11 Front Housing Removal
(13) Remove bolts that attach front housing to rear
housing (Fig. 10). Three bolts at. extreme r e a r of
housing a r e actually for the output shaft bear
ing retainer. It is not necessary to remove all
NV3500 MANUAL TRANSMISSION 21 - 11
(15) Remove input shaft bearing and countershaft

front bearing from front case (Fig. 12). Use hammer
handle to tap input shaft bearing out of case. Coun
tershaft bearing can be removed by hand.
Fig. 14 Removing Shift Shaft Lever Detent Ball And

Spring
(a) Position Tool 6858 on shift socket. Then cen
ter tool over roll pin. Be sure tool legs are firmly
Fig. 12 Input Shaft And Countershaft Front Bearing seated on shift socket (Fig. 15).
Location (b) Tilt socket toward passenger side of case.
.(16) Note position of input shaft, shift shaft and This places roll pin at slight angle to avoid trap
forks, and geartrain components in housing (Fig. 13). ping pin between gear teeth.
SHIFT BUSHING REAR (c) Tighten tool punch to press roll pin downward
SHAFT I HOUSING and out of shift socket (Fig. 15). Roll pin does not
have to come completely out of shift shaft; it only
has to clear shift socket.
(d) If roll pin accidentally becomes jammed
between gear teeth locking socket and shaft
in place, proceed to alternate disassembly
method in step (3).
COUNTERSHAFT AND GEARS J942M5
Fig. 13 Geartrain And Shift Component

Identification
SHIFT SHAFT, SHIFT FORKS AMD REVERSE
Fig. 15 Unseating Shift Socket Roll Pin With Tool
IDLER SEGMENT REMOVAL
(1) Place shop towel over shaft lever and bushing 6858
to contain lever detent ball and spring. Then rotate (3) If shift socket roll pin becomes jammed,
lever and bushing upward out of shift forks and alternate disassembly method is as follows:
catch ball and spring as they exit shaft lever (Fig. (a) Remove rear bearing retainer bolts.
14). (b) Remove reverse idler segment (but leave gear
(2) Unseat roll pin that secures shift socket to shift in case).
shaft with Special Tool 6858 as follows:
21 -12 NV3500 MANUAL TRANSMISSION — B i t
(c) Remove input shaft, bearing, and 3-4 synchro (6) Remove shift socket from rear housing (Fig.
ring. 18).
(d) Remove 3-4 shift fork and 3-4 synchro sleeve
simultaneously. Use shop rag to catch struts, balls, SHAFT
and springs as sleeve comes off hub.
(e) Slide shift shaft bushing off shaft lever. Then
rotate lever out of shift fork arms and catch ball
and spring as lever clears notches.
(f) Push shift shaft rearward, tap out pin (if
needed) and pull shaft out of rear housing and shift
forks. Use plastic mallet to assist shaft removal.
(4) Drive out roll pin that secures shift bushing
and lever to shift shaft (Fig. 16).
Fig. 18 Shift Socket And Roil Pin
(7) Remove lever and bushing from shift shaft (Fig.
19).
Fig. 16 Removing Shift Shaft Lever And Bushing

Roil Pin
(5) Pull shift shaft out of rear housing, shift socket, Fig. 19 Removing Shift Shaft Lever And Bushing
fifth-reverse fork, and 1-2 fork (Fig. 17). Tap shift
socket rearward with mallet to help remove shaft. (8) Remove shift shaft (Fig. 20). Pull shaft straight
out of fork.
PLASTIC
MALLET
J9421-42
Fig. 17 Pulling Shift Shaft Out Of Housing, Shift
Fig. 20 Shift Shaft Removal
Socket, And Shift Forks
N¥3SI§ M A N U A L TRANSMISSION 13
(9) Remove 3-4 fork. Rotate fork around synchro

sleeve fork until it clears shift arms and other forks
(Fig. 21).
3-4 1-2 AND

5TH-REVERSE
FORK
FORK ARMS
INPUT SHAFT COUNTERSHAFT
3-4 SPECIAL
SYNCHRO TOOL
SLEEVE 6747
J9421-44
Fig. 21 Removing 3-4 Shift Fork 16

J9421-46
(10) Support geartrain and rear housing on Assem
bly Fixture Tool 6747 (with aid of helper) as follows: Fig. 23 Geartrain And Housing Mounted On Fixture
(a) Adjust height of reverse idler pedestal rod to Tooi
18.42 cm (7-1/4 in.) Then position Adapters 6747-1 (11) Remove bolts attaching reverse idler shaft and
and 6747-2 on Assembly Fixture 6747. shaft support segment to rear housing (Fig. 24).
(b) Slide fixture tool onto input shaft, counter
shaft and idler gear (Fig. 22). The pedestal rod
on the fixture tool is used to support the re
verse idler.
(c) Stand geartrain and rear housing upright on
fixture (Fig. 23). Have helper hold fixture tool in REVERSE
place while housing and geartrain is being rotated IDLER
SHAFT
into upright position. BOLT
(d) Position 5 x 10 cm (2 x 4 in.) wood blocks un LOCATIONS
der legs of fixture tool. Blocks are needed to raise
fixture high enough for input shaft to clear work
bench surface.
SPECIAL SPECIAL
TOOL TOOL
6747 6747-1 SPECIAL
TOOL
6747
J9421-47
Fig. 24 Removing/lnstaliing Reverse Idler Shaft

Bolts
REVERSE
IDLER
PEDESTAL J9421-45
Fig. 22 Installing Assembly Fixture On Geartrain

21 - 1 4 NV3500 MANUAL TRANSMISSION BR
(12) Remove reverse idler shaft support segment (2) Unseat output shaft bearing from bearing bore
by sliding it straight out of housing (Fig. 25). in rear housing. Use plastic or rawhide mallet to tap
rear housing upward and off output shaft bearing as
shown (Fig. 27).
Fig. 25 Reverse Idler Shaft Support Segment

Removal/installation
REAR HOUSING REMQWAL (2-WHEEL DRIVE
TRANSMISSION)
(1) On 2-wheel drive transmission, remove three bolts
that attach output shaft bearing retainer to rear case
(Fig. 26). Bolts are to rear of shift tower opening. Fig. 27 Unseating Rear Housing From Output Shaft
Bearing (2-Wheei Drive Transmission)
(3) Lift rear housing up and off geartrain (Fig. 28).
J9421-50
Fig. 26 Removing/Installing Output Shaft Bearing

Retainer Bolts (2-Wheel Drive Transmission)
Fig. 28 Rear Housing Removal (2-Wheel Drive Transmission)
g K _ _ _ _ ^ ^ ^ ^ ^ NV3500 MANUAL TRANSMISSION 21 - 15
(4) Remove countershaft rear bearing from rear (3) Locate dimples in face of rear seal (Fig. 31).
housing (Fig. 29). Fabricated seal remover tool will be threaded into
(5) Examine condition of oil tube, bearing bore and one of these dimples.
idler shaft notch in rear housing (Fig. 29). Replace
housing if any of these components are damaged. LOCATION
OF
mmE$
J942M97
Fig. 31 Location Of Dimples In Seal Face (4-Wheel

Drive Transmission)
(4) Thread fabricated seal remover tool into one of
the dimples in the seal face (Fig. 32).
REAR
HOUSING FABRICATED SLIDE HAMMER
J9421-52 SEAL
Fig. 29 Rear Housing Components (2-Wheel Drive REMOVER
TOOL
Transmission)
REAR ADAPTER MOUSING REMOVAL ( 4 -
WHEEL DRIVE
( D A tool is required to remove the rear seal from
the adapter housing. Use either a dent puller, or fab
ricate a remover tool from 5/16 x 1-1/2 in. long lag
screw and appropriate size hex nut. Use hex nut that
will fit on a slide hammer. Tack weld, braze or silver
solder nut to lag screw (Fig. 30).
(2) Install fabricated seal remover tool on slide
hammer shaft (Fig. 30). J9421-198
AfWOPfPfl Fig. 32 Remover Tool Threaded into Seal (4-Wheei

SIDE 5/\6 x 1 1/2 in. Drive Transmission)
mmm tAGSOtlW
wm (5) Remove rear seal with slide hammer. Seal
should only require 2-3 light bumps with slide ham
mer to remove it (Fig. 33).
(6) Remove rear bearing snap ring from output
shaft with heavy duty snap ring pliers (Fig. 34).
(7) Lift rear adapter or extension housing upward
and off geartrain (Fig. 35).
(8) Remove bearing retainer bolts and remove rear
WHD\MtA2 bearing retainer and rear bearing (Fig. 36). Use ham
NtJfTO mer handle to push or tap bearing out of housing if
needed.
J942M99 (9) Examine condition of bearing bore, counter
Fig. 30 Rear Seal Remover Tool (4-Wheel Drive
shaft rear bearing race and idler shaft notch in rear
Transmission)
housing. Replace housing if race, bore or notch are
worn or damaged.
21 -16 1W35II MANUAL TRANSMISSION BR
J9421-200
Fig. 33 Rear Seal Removal (4-Wheel Drive

Transmission)
Fig. 36 Rear Adapter/Extension Housing

Components
(4) Remove output shaft bearing retainer from rear
surface of fifth gear (retainer will drop onto gear af
ter bolts are removed).
(5) Lift and remove output shaft and gears off in
put shaft.
(6) Lift and remove input shaft, pilot bearing and
fourth gear synchro ring from assembly fixture tool.
OUTPUT SHAFT GEARTRAIN DISASSEMBLY
T h e synchronizer hubs and sleeves are differ
Fig. 34 Rear Bearing Snap Ring Removal (4-Wheei ent and must not be intermixed. It is recom
Drive Transmission) mended that each synchronizer unit be
removed as an assembly to avoid intermixing
parts. It is also recommended that each syn
chro hub and sleeve be marked with a scriber
or paint for correct assembly reference.
(1) Remove snap ring that secures 3-4 synchro hub
on output shaft.
(2) Remove 3-4 synchro assembly and third speed
synchro ring with shop press and Remover Tool 1130
(Fig. 37).
(a) If remover tool has fairly thick jaws, position
tool jaws behind third speed synchro ring. Inspect
synchro ring afterward as remover tool may dam
Fig. 35 Rear Adapter/Extension Housing Removal age ring during removal.
BEMOwum GEAmrmMim FROM FIXTURE TOOL (b) If remover tool has fairly thin jaws, position
B747 tool jaws behind third gear. Then remove synchro
(1) Slide reverse idler gear assembly off assembly assembly and gear simultaneously.
fixture pedestal. (3) Remove third gear and needle bearing (Fig. 38).
(2) Remove 1-2 and fifth-reverse forks from syn " (4) Remove retaining ring that secures two-piece
chro sleeves. thrust washer on shaft (Fig. 39). Use small pry tool
(3) Slide countershaft out of fixture tool. to remove retaining ring.
BR NV3500 MANUAL TRANSMISSION 21 -17
SECOND
GEAR
OUTPUT
SHAFT
THRUST
WASHER
(2-PIECE)
THIRD
SPEED
SYNCHRO
RING J9421-24
J9421-21
Fig. 37 Removing 3-4 Synchro Assembly Fig. 40 Two-Piece Thrust Washer Removal
SECOND
THIRD SECOND GEAR
GEAR GEAR NEEDLE
THIRD NEEDLE BEARING
GEAR BEARING
J9421-22 J9421-25
Fig. 38 Third Gear And Needle Bearing Removal Fig. 41 Second Gear And Needle Bearing Removal
(7) Remove second speed synchro ring. Then re
move 1-2 synchro hub snap ring (Fig. 42).
SYNCHRO
SECOND HUB
GEAR
SNAP
SYNCHRO
RING
RING
1-2
THRUST WASHER SYNCHRO
RETAINING HUB
RING AND
J9421-23 SLEEVE
Fig. 39 Thrust Washer Retaining Ring Removal J9421-26
(5) Remove two-piece thrust washer (Fig. 40). Note Fig. 42 Second Speed Synchro Ring And Synchro
position of washer locating lugs in shaft notches for Hub Snap Ring Removal
installation reference.
(6) Remove second gear and needle bearing (Fig.
41).
21 - 18 IW3III MANUAL TRANSMISSION BR
(8) Remove 1-2 synchro hub and sleeve from out (11) On 2-wheel drive models, remove output shaft
put shaft with shop press and Remover Tool 1130 bearing with Remover Tool 1130 and shop press (Fig.
(Fig. 43). 46).
PRESS
SPACER RAM
(AS REQUIRED)
1-2
SYNCHRO
HUB
AND
SLEEVE
SPECIAL
TOOL
1130
J9421-27
Fig. 43 Hub And Sleeve Removal (1-2 Synchro)

(9) Remove first gear and needle bearing (Fig. 44).
FIRST FIRST
GEAR GEAR
NEEDLE
BEARING
PRESS
PLATES J9421-30
Fig. 46 Output Shaft Bearing Removal (2-Wheel

Drive)
(12) Remove fifth gear (Fig. 47).
FIFTH
J9421-28 GEAR
AND
Fig. 44 First Gear And Needle Bearing Removal SYNCHRO
(10) Remove output shaft bearing snap ring (Fig. 45).
OUTPUT
SHAFT
BEARING
J9421-31
Fig. 47 Fifth Gear Removal
SNAP
RING
PLIERS BEARING
SNAP
RING
J9421-29
Fig. 45 Output Shaft Bearing Snap Ring Removal

NV3500 MANUAL TRANSMISSION 21 -19
(13) Remove fifth gear needle bearing. Spread (15) Remove fifth reverse synchro hub and sleeve
bearing apart just enough to clear shoulder on output with shop press and standard type remover tool (Fig.
shaft (Fig. 48). 50).
SPECIAL
FIFTH TOOL
GEAR 1130
NEEDLE
BEARING
(SPREAD
BEARING T O
CLEAR
SHOULDER
ON
SHAFT]
MARK HUB
J9421-32 FOR INSTALLATION REFERENCE J9421.34
Fig. 48 Fifth Gear Needle Bearing Removal Fig. 50 Fifth-Reverse Synchro Hub And Sleeve
Removal
(14) Remove fifth-reverse synchro hub snap ring
(Fig. 49). (16) Remove reverse gear and needle bearing (Fig.
51).
FIFTH-REVERSE
• SYNCHRO REVERSE GEAR
HUB AND SLEEVE AND NEEDLE
BEARING
SYNCHRO
HUB
SNAP J9421-35
SNAP RING
RING Fig. 51 Reverse Gear And Needle Bearing Removal
PLIERS
J9421-33
Fig. 49 Fifth-Reverse Synchro Hub Snap Ring

Removal
21 - 20 NV3500 MANUAL TRANSMISSION BR
REVERSE
IDLER
GEAR IDLER
SNAP PLAT WAVE THRUST GEAR IDLER THRUST SNAP
RING WASHER WASHER BEARING SHAFT WASHER RING
WASHER
I) j , "5
V
THRUST
WASHER
LOCK BALLS J9421-53
Fig. 52 Reverse er Components

n e v e n s e IDLEM DISASSEMBLY fF I G * S 2 j Shift Shaft And Forks
(1) Remove idler gear snap rings. Inspect the shift fork interlock arms and synchro
(2) Remove thrust washer, wave washer, thrust sleeve contact surfaces (Fig. 53). Replace any fork ex
plate and idler gear from shaft. hibiting wear or damage in these areas. Do not at
(3) Remove idler gear needle bearing from shaft. tempt to salvage shift forks.
Inspect the shift shaft bushings and front
TRANSMISSION COMPONENT CLEANING ANO bearing carefully. The bushings and bearing are
INSPECTION not serviceable items. The front or rear housing
will have to be replaced if these components
Repair Parts Ordering are damaged in any way.
Two versions of the NV3500 are now avail Check condition of the shift shaft detent plunger
able. The wide ratio version introduced last and spring. The plunger should be smooth and free of
year, has 4.01 first gear and a 2.318 second gear. nicks, or scores. The plunger spring should be
The new close ratio version has a 3.49 first gear straight and hot collapsed, or distorted. Minor
and 2.16 second gear. Since the two transmis scratches, or nicks on the plunger can be smoothed
sion versions are virtually identical in appear with 320/400 grit emery soaked in oil. Replace the
ance, it is very important that the transmission plunger and spring if in doubt about condition.
assembly part number be available when order Inspect the shift shaft, the shaft lever and the le
ing repair parts. The assembly number is on a ver bushing that fits over the lever. Replace the shaft
sticker, or plate attached to the gear case. if bent, cracked, or severely scored. Minor burrs,
nicks, or scratches can be smoothed off with 320/400
Component Cleaning grit emery cloth followed by polishing with crocus
Clean the gears, shafts, shift components and cloth.
transmission housings with a standard parts clean Replace the shaft lever and bushing if either part
ing solvent. Do not use acid or corrosive base sol is deformed, or worn. Do not attempt to salvage these
vents. Dry all parts except bearings with compressed parts as shift fork binding will occur. Replace the
air. small detent ball and spring that goes in the lever if
Clean the shaft bearings with a mild solvent such the ball is worn, or if the spring is bent or collapsed.
as Mopar degreasing solvent, Gunk, or similar sol Replace the roll pin that secures the lever to the
vents. Do not dry the bearings with compressed air. shaft.
Allow the bearings to either air dry, or wipe them dry
with clean shop towels. Front/Rear Housings And Bearing Retainers
Inspect the housings carefully. Look for cracks,
Shift Lever Assembly stripped threads, scored mating surfaces, damaged
The shift lever assembly is not serviceable. Replace bearing bores, or worn dowel pin holes. Minor nicks
the lever and shift tower as an assembly if the tower, on mating surfaces can be dressed off with a fine file,
lever, lever ball, or internal components are worn, or or emery cloth. Damaged threads can be renewed by
damaged. either re-tapping or installing Helicoil inserts.
BR — — — — — NV3500 MANUAL TRANSMISSION 21 - 21
!
SHIFT SHAFT
SHAFT LEVER
SHAFT
LEVER
BUSHING
FIFTH-REVERSE SHIFT 1-2 SHIFT 3-4 SHIFT

FORK FORK FORK
J9421-54
Fig. 53 Shift Forks And Shaft

Check condition of the oil tube in the rear housing. The bearing races are a permanent press fit
The tube must not be bent or loose. The housing will in the housings and are NOT serviceable. If a
have to be replaced if the tube is loose or damaged. bearing race becomes damaged, it will be nec
Pay particular attention to the bushings and essary to replace the front or rear housing as
bearings in the front and rear housings. The necessary. In addition, if a countershaft bearing
front housing contains the shift shaft front becomes damaged, it will be necessary to re
bearing and bushing, the countershaft front place not only the bearing but the applicable
bearing race and the detent plunger bushing. housing as well. A new countershaft bearing
The r e a r housing contains the shift shaft r e a r will be supplied with each new housing for ser
bushing and t h e countershaft rear bearing vice use.
race. Be advised that these components are The countershaft bearings can be installed back
NOT serviceable items. The front housing will wards if care is not exercised. The bearing roller cage
have to be replaced if the shift shaft bearing is - a different diameter on each side. Be sure the
and bushing, detent plunger bushing, or coun bearing is installed so the large diameter side
tershaft bearing race is loose, worn, or dam of the cage is facing the countershaft gear (Fig.
aged. The rear housing will have to be replaced 54). The small diameter side goes in the bearing
if the shift shaft rear bushing, or the counter race.
shaft rear bearing race is loose, worn, or dam
aged. Reverse Idler Components
Inspect the input shaft bearing retainer. Be sure Inspect the idler gear, bearing, shaft, thrust
the release bearing slide surface of the retainer is in washer, wave washer and thrust plate (Fig. 52). Re
good condition. Minor nicks on the surface can be place the bearing if any of the needle bearing rollers
smoothed off with 320/420 grit emery cloth and final are worn, chipped, cracked, flat-spotted, or brin-
polished with oil coated crocus cloth. Replace the re nelled. Also replace the bearing if the plastic bearing
tainer seal if necessary. cage is damaged or distorted.
Inspect the output shaft bearing retainer. Be sure Replace the thrust washer, wave washer, or thrust
the U-shaped retainer is flat and free of distortion. plate if cracked, chipped, or worn. Replace the idler
Replace the retainer if the threads are damaged, or if gear if the teeth are chipped, cracked or worn thin.
the retainer is bent, or cracked. Replace the shaft if worn, scored, or the bolt threads
Countershaft Bearings And Races are damaged beyond repair. Replace the support seg
The countershaft bearings and races are machine ment if cracked, or chipped and replace the idler at
lapped during manufacture to form matched sets. taching bolts if the threads are damaged.
The bearings and races should not be interchanged.
21 - 22 I f 3 S I I MANUAL TRANSMISSION BR
COUNTERSHAFT
damaged. Minor nicks in the shift lever ball seat in
the socket can be smoothed down with 400 grit em
ery or wet/dry paper. Replace the socket if the ball
seat is worn, or cracked. Do not reuse the original
shift socket roll pin. Install a new pin during reas
sembly. The socket roll pin is approximately is ap
proximately 33 mm (1-1/4 in.) long.
Output Shaft And Geartrain
Inspect all of the gears (Fig. 55) for worn, cracked,
chipped, or broken teeth. Also check condition of the
bearing bore in each gear. The bores should be
smooth and free of surface damage. Discoloration of
the gear bores is a normal occurrence and is not a
reason for replacement. Replace gears only when
tooth damage has occurred, or if the bores are brin-
nelled or severely scored.
Inspect the shaft splines and bearings surfaces. Mi
nor nicks on the bearing surfaces can be smoothed
J9421-55 with 320/420 grit emery and final polished with cro
cus cloth. Replace the shaft if the splines are dam
Fig. 54 Correct Countershaft Bearing installation aged or bearing surfaces are deeply scored, worn, or
brinnelled.
Shift Socket
Inspect the shift socket for wear or damage, replace
the socket if the roll pin, or shift shaft bores are
0 INPUT SHAFT ® FIRST SPEED SYNCHRO RING

© FOURTH SPEED SYNCHRO RING FIRST GEAR
© OUTPUT SHAFT PILOT BEARING
©
FIRST GEAR NEEDLE BEARING
© SNAP RING, 3-4 SYNCHRO HUB
© OUTPUT SHAFT
© SLEEVE, 3-4 SYNCHRO REVERSE GEAR NEEDLE BEARING
© HUB, 3-4 SYNCHRO REVERSE GEAR
© STRUT, SPRING, DETENT BALL (3 SETS), 3-4 SYNCHRO
© REVERSE SYNCHRO RING (SOLID BRASS)
© THIRD SPEED SYNCHRO RING
© FIFTH-REVERSE
© THIRD GEAR
© STRUT, SPRING,SYNCHRO HUB
DETENT BALL (3 SETS), FIFTH-REVERSE SYNCHRO
© THIRD GEAR NEEDLE BEARING
©
SLEEVE, FIFTH-REVERSE SYNCHRO
© RETAINING RING
© SNAP RING, FIFTH-REVERSE SYNCHRO HUB
@ THRUST WASHER (2-PIECE)
© FIFTH SPEED SYNCHRO RING
@ SECOND GEAR NEEDLE BEARING
© FIFTH GEAR NEEDLE BEARING
© SECOND GEAR
© FIFTH GEAR
©
© SECOND SPEED SYNCHRO RING BEARING RETAINER (IN HOUSING)
® SLEEVE, 1-2 SYNCHRO
© OUTPUT SHAFT BEARING
© SNAP RING, 1-2 SYNCHRO HUB
©
© STRUT, SPRING, DETENT BALL (3 SETS), 1-2 SYNCHRO
© SNAP RING, SHAFT BEARING
J9421-37
Fig. 55 Output Shaft And Geartrain

21 - 24 if3500 MANUAL TRANSMISSION — — — — — — — — — — tIR
TRANSMISSION ASSEMBLY stallation. However, if both hub sides are the same,
the hub can be installed in either direction.
Assembly Information The 3-4 synchro sleeve has grooves machined on
Gaskets are not used in the NV3500 transmission. one side. Be sure this side also faces the front of the
Sealers are used at all flange joints. Recommended output shaft.
sealers are Mopar Gasket Maker (or Loctite 518) for
all flange joints and Loctite Ultra, heavy body sili 1-2 Synchro Position
cone (black) sealer (or Mopar equivalent) for the in The 1-2 synchro hub has raised shoulders on one
put shaft bearing retainer. Apply these products as side of the spline bore. This side of the hub must face
indicated in the reassembly procedures. the rear of the output shaft after installation.
It is very important that the transmission The top surface of the 1-2 synchro sleeve is marked
shift components be in Neutral position during for correct installation (Fig. 56). One side of the
assembly. This is necessary to prevent damag sleeve is marked "first gear side". Be sure this side is
ing synchro and shift components when the facing the first gear after installation.
housings are installed.
Transmission gears, shafts, and synchro compo
nents should all be lubricated with recommended
gear lubricant during assembly operations. Petro
leum jelly can be used to prelubricate bearings and
to hold parts in place during assembly. Only petro
leum jelly should be used. Do not use chassis or
bearing grease. This type of heavy grease will
plug oil channels in the housings and gears re
sulting in failure.
The 3-4, 1-2 and fifth-reverse synchro hub snap
rings can be fitted selectively. New snap rings are
available in 0.05 mm (0.0019 in.) thickness incre CORRECT POSITION
ments. Use the thickest snap ring that will fit in IS MARKED ON
each snap ring groove. SLEEVE
Proper reassembly of the NV3500 requires some J9421-56
special service tools. Geartrain Assembly Fixture
6747 is especially important. The entire geartrain Fig. 56 Location Of Position Marks On 1 -2 Synchro
and shift mechanism must be assembled in this fix Sieeve
ture before either transmission housing can be prop Fifth-Reverse Synchro Position
erly installed. The tools are needed to avoid The fifth-reverse synchro hub has raised shoulders
damaging the gears, housing, or shift components. on one side of the spline bore. This side of the hub
CORRECT ASSEMBLY OF SYNCHRONIZER
must face the rear of the output shaft after installa
COMPONENTS
tion.
The synchronizer sleeves, hubs and struts are dif The fifth-reverse sleeve has a large taper on one
ferent and must be kept in sets. Only the synchro de side. Be sure the sleeve is installed so the taper faces
tent balls and springs are interchangeable. toward front of the output shaft.
The 3-4 and 1-2 synchro rings are all made of cast
Synchro Component Assembly
metal and are interchangeable. However, the reverse
gear synchro ring is made of solid brass and must The easiest method of assembling each synchro is
not be interchanged. to install the springs, struts and detent balls one at a
A total of three detent springs, struts and balls are time as follows:
used in all three synchro assemblies. The balls and (1) Slide the sleeve part way onto the hub. Leave
springs are interchangeable. enough room to install the spring in the hub and the
The synchro sleeves and hubs must also be cor strut in the hub groove.
rectly positioned on the shaft in order to operate (2) Install the first spring in the hub. Then install
properly. Assemble and install each synchro accord a strut over the spring. Be sure the spring is seated
ing to the following instructions. in the spring bore in the strut.
(3) Slide the sleeve onto the hub just far enough to
3-4 Synchro Position hold the first strut and spring in place.
Some 3-4 synchro hubs may have a raised shoulder (4) Place the detent ball in the top of the strut.
on one side of the spline bore. If so, this side of the Then carefully work the sleeve over the ball to hold
hub must face the front of the output shaft after in-
it in place. A small flat blade screwdriver can be used age to the bearing rollers or plastic bearing cage.
to press the ball into place while moving the sleeve Petroleum jelly can be used to prelubricate bearings
over it. if desired.
. (5) Eepeat the procedure for the remaining (5) Lubricate and install reverse gear needle bear
springs, struts and balls. Tape, or a rubber band can ing on shaft (Fig. 58). Slide bearing up against shoul
be used to temporarily secure each strut and ball as der on output shaft as shown.
they are installed.
(6) Verify synchro assembly. Be sure the three REVERSE
GEAR
springs, struts and detent balls are all in place (Fig. BEARING
57).
HUB
SLEEVE SHOULDER
SPRING (3)
STRUT (3) SHOULDER J9421-58
Fig. 58 Reverse Gear Bearing Installation

(6) Install reverse gear over needle bearing (Fig.
59).
REVERSE
GEAR
DETENT
BALL (3)
J9421-57
J9421-59
Fig. 57 Assembled View Of Synchro Components
OUTPUT SHAFT AND GEARTRAIN ASSEMBLY Fig. 59 Reverse Gear Installation
Because the synchro hubs and rear bearing must (7) Install solid brass synchro ring on reverse gear
be pressed onto the output shaft, it is easier (and (Fig. 60).
faster), to assemble the entire geartrain while
mounted in a shop press. This method of reassembly SYNCHRO
RING
is demonstrated in the following procedure. (SOLID BRASS)
Two versions of the NV3500 are used in 1995
models. If any gears have been replaced, com REVERSE
pare them to the new parts before installation GEAR
to ensure a proper match. The original and new
versions have different ratio first and second
gears.
(1) Lubricate shaft, gears and bearings (Fig. 56)
with recommended lubricant during assembly. Petro J9421-60
leum jelly can be used to hold parts in place.
(2) Check bearing surfaces of output shaft for nicks Fig. 60 Reverse Gear Synchro Ring Installation
or scratches. Smooth surfaces with 320/400 grit em
ery cloth if necessary. Apply oil to emery cloth and (8) Assemble fifth-reverse synchro hub, sleeve,
shaft surface before polishing. struts, springs and detent balls, if not previously
(3) Inspect and replace any synchro ring that ex done.
hibits wear or damage. Completely immerse each
synchro ring in lubricant before installation.
(4) Recheck needle bearings once again before as
sembly, replace any bearing exhibiting wear, or dam
21 - 26 JW3500 MANUAL TRANSMISSION BR
CAUTION: The fifth-reverse synchro hub and sleeve
can be installed backwards if care is not exercised.
One side ©f the hub has shoulders around the hub
bore. Hake sure this side of the hub is facing the
rear of the shaft. In addition, one side of the sleeve
is tapered. B e sure the sleeve is installed so the ta
pered side will be facing the front of the shaft.
(9) Start fifth-reverse synchro assembly on output

shaft splines by hand. Then seat synchro onto shaft'
with shop press and suitable size pipe tool (Fig. 61).
Fig. 62 Installing Fifth-Reverse Synchro Hub Snap

Ring
J9421-61
Fig. 61 Fifth-Reverse Synchro Assembly installation

(10) Install new fifth-reverse hub snap ring (Fig.
62) as follows: Fig. 63 Installing Fifth Speed Synchro Ring
(a) Snap rings are available in thicknesses from
2.00 mm to 2.20 mm (0.078 to 0.086 in.).
(b) Install thickest snap ring that will fit in shaft
groove.
(c) Verify that snap ring is completely seated in
groove before proceeding.
(11) Install fifth speed synchro ring in synchro hub
and sleeve (Fig. 63).
(12) Install fifth gear bearing. Spread bearing only
enough to clear shoulder on output shaft (Fig. 64). Be
sure bearing is properly seated after installation.
Fig. 64 Installing Fifth Gear Bearing

(13) Install fifth gear on shaft and onto bearing

(Fig. 65).
Fig. 67 Installing Output Shaft Bearing Snap Ring
Fig. 65 Fifth Gear installation

(14) Install output shaft bearing with shop press
n
and suitable size pipe tool (Fig. 66).
Fig. 68 First Gear Bearing Installation

(18) Install first gear on shaft and over bearing
(Fig. 69). Make sure bearing synchro cone is facing
up as shown.
(19) Install first speed synchro ring (Fig. 70).
Fig. 66 Output Shaft Bearing installation
(20) Assemble 1-2 synchro hub sleeve, springs,
(15) Install output shaft bearing snap ring (Fig. struts and detent balls.
67). Use heavy duty snap ring pliers and spread snap
ring only enough to install it. Be sure snap ring is CAUTION; The 1-2 synchro hub and sleeve can be
completely seated in shaft groove before proceeding. installed backwards if care is not exercised. One
(16) Turn output shaft over so it is supported on side of the hub has a small diameter shoulder
press blocks by output shaft bearing (Fig. 68). Re around the hub bore. Make sure this side of the hub
mainder of .geartrain can now be installed on shaft faces the forward end of the output shaft. In addi
while it is still mounted in shop press. tion, one side of the synchro sleeve is marked "first
(17) Install first gear bearing on output shaft (Fig. gear side" (Figs. 57 and 72). B e sure this side of the
68). Be sure bearing is seated on shaft shoulder and sleeve will face the first gear after installation.
is properly joined.
21 - 28 NV3500 MANUAL TRANSMISSION - — - - — BR
(22) Press 1-2 synchro onto output shaft using

suitable size pipe tool and shop press (Fig. 72).
CAUTION; Take time to align the synchro ring and
sleeve as hub the is being pressed onto the shaft.
The synchro ring can be cracked if it becomes mis
aligned.
Fig. 69 First Gear installation
Fig. 72 Pressing 1-2 Synchro Assembly Onto Output

Shaft •
(23) Install new 1-2 synchro hub snap ring (Fig.
73) as follows:
Fig. 70 First Speed Synchro Ring Installation (a) Snap rings are available in thicknesses from
(21) Start 1-2 synchro assembly on shaft by hand 1.80 mm to 2.00 mm (0.070 to 0.078 in.).
(Fig. 71). Be sure synchro sleeve is properly posi (b) Install thickest snap ring that will fit in shaft
tioned. Side marked "first gear" must be facing first groove.
gear. (c) Verify that snap ring is completely seated in
Fig. 71 Starting 1-2 Synchro On Shaft

Fig. 73 Installing 1-2 Synchro Hub Snap Ring
IW3I1I MANUAL TRANSMISSION 21 - 29
(24) Install second speed synchro ring in 1-2 syn

chro hub and sleeve (Fig. 74). Be sure synchro ring is
properly seated in sleeve.
Fig. 76 Second Gear Installation
Fig. 74 Second Speed Synchro Ring installation

(25) Install second gear needle bearing on shaft
(Fig. 75).
SECOND
GEAR
BEARING
J9421-75
Fig. 75 Second Gear Bearing installation

(26) Install second gear onto shaft and bearing
(Fig. 76).
(27) Install two-piece thrust washer (Fig. 77). Be
sure washer halves are seated in shaft groove and J9421-77
that washer lugs are seated in shaft lug bores.
(28) Start retaining ring around two-piece thrust Fig. 77 Installing Two-Piece Thrust Washer
washer (Fig. 78). CAUTION: The 3-4 synchro hub and sleeve can be
(29) Seat thrust washer retaining ring with plastic installed backwards if care is not exercised. One
mallet (Fig. 79). side of the hub has shoulders around the hub bore.
(30) Install third gear needle bearing on shaft (Fig. Make sure this side of the hub is facing the front of
80). the shaft. In addition, one side of the sleeve has
(31) Install third gear on shaft and bearing (Fig. grooves in it. B e sure this side of sleeve is also fac
81). ing the front of the shaft.
(32) Install third speed synchro ring on third gear
(Fig. 82). (34) Start 3-4 synchro hub on output shaft splines
(33) Assemble 3-4 synchro hub, sleeve, springs, by hand (Fig. 83).
struts and detent balls.
21 - 30 NV3500 MANUAL TRANSMISSION mm
Fig. 78 Starting Retaining Ring Over Two-Piece

Thrust Washer
Fig. 82 Third Speed Synchro Ring installation

Fig. 79 Seating Thrust Washer Retaining Ring
-80
Fig. 80 Third Gear Bearing Snstaiiation Fig. 88 Starting 3-4 Synchro Hub On Output Shaft
BR _ — NV3500 MANUAL TRANSMISSION 21 - 31
3-4
SYNCHRO
HUB
SNAP RING
PRESS
RAM
HEAVY
DUTY
SNAP
RING
PLIERS
J9421-85
Fig. 85 installing 3-4 Synchro Hub Snap Ring
(b) Install thickest snap ring that will fit in shaft
groove. Use heavy duty snap ring pliers to install
3-4
SYNCHRO new ring.
J9421-84 (c) Verify that snap ring is completely seated in
Fig. 84 Pressing 3-4 Synchro Assembly On Output Shaft
(37) Verify correct position of synchro sleeves be
(35) Press 3-4 synchro assembly onto output shaft fore proceeding with assembly operations (Fig. 86).
with shop press and suitable size pipe tool (Fig. 84). Grooved side of 3-4 sleeve should be facing forward.
(36) Install 3-4 synchro hub snap ring (Fig. 85) as First gear side of 1-2 sleeve should be facing first
follows: gear. Tapered side of fifth-reverse sleeve should be
(a) Snap rings are available in thicknesses from facing forward.
2.00 mm to 2.30 mm (0.078 to 0.090 in.).
GROOVED SIDE "FIRST GEAR TAPERED
FORWARD SIDE" FACING SIDE
GEAR FORWARD
3-4 1-2 5TH REV.

SYNCHRO SYNCHRO SYNCHRO
SLEEVE SLEEVE SLEEVE J9421-145
Fig. 86 Correct Synchro Sleeve Position
21 - 32 113501 MANUAL TRANSMISSION BR
REVERSE IDLER ASSEMBLY (FIG. 52)

(1) Lubricate idler components with gear lube. •REAR GEAR THRUST
OF SHAFT WASHER
(2) Slide idler gear bearing on shaft (Fig. 87). AND BALL
Bearing fits either way on shaft. WAVE WASHER
(3) Slide gear onto shaft. Side of gear with recess FLAT WASHER
goes to rear (Fig. 87).
(4) Place first lock ball in dimple at rear end of
idler shaft (Fig. 87). Petroleum jelly can be used to
hold ball in place if desired.
IDLER
GEAR
BEARING
FRONT
OF SHAFT
SNAP
LOCK RING
BALL
SNAP RING
J9421-90
Fig. 89 Idler Gear And Shaft Assembly

REAR OF
SHAFT J9421-87 GEARTRAIN BUILDUP (IN ASSEMBLY
FIXTURE TOOL)
Fig. 87 Idler Gear And Bearing Installation (1) Instaii Adapter 6747-1 on input shaft hub of
fixture tool (Fig. 90). Then install Adapter 6747-2 on
(5) Slide thrust rear thrust washer onto shaft and front bearing hub of countershaft. Adapter 6747-2
over lock ball (Fig. 88). has a raised shoulder on one side. Be sure the
(6) Install snap ring in groove at rear of shaft (Fig. shoulder is seated against the countershaft.
88).
SPECIAL
LOCK TOOL SPECIAL WOOD
BALL 6747-2 TOOL BLOCKS (3)
(INSTALL ON 6747-1
COUNTERSHAFT
FRONT HUB|
SPECIAL
TOOL
SNAP 6747
RING
GROOVE
THRUST
WASHER
J9421-89
Fig. 88 Idler Gear Rear Thrust Washer Installation

(7) Install lock ball in dimple at front of shaft.
Hold ball in place with petroleum jelly if desired.
(8) Install front thrust washer on shaft and slide J9421-147
washer up against gear and over lock ball (Fig. 89).
(9) Install wave washer, flat washer and remaining Fig. 90 Preparing Assembly Fixture For Geartrain
snap ring on idler shaft (Fig. 89). Be sure snap ring Buildup
is fully seated.
(2) Position wood block under each leg of assembly-

fixture (Fig. 91). Blocks are needed to provide clear
ance for input shaft and can be made from 2 x 4 lum
ber.
(3) Install input shaft in fixture tool (Fig. 91).
Make sure Adapter Tool 6747-1 is positioned under
shaft as shown.
Fig. 93 Installing Fourth Speed Synchro Ring On

Input Shaft
Fig. 91 Installing Input Shaft In Assembly Fixture

(4) Install pilot bearing in input shaft (Fig. 92).
Fig. 94 Idler Pedestal Basic Height Adjustment

(7) Install assembled output shaft and geartrain in
input shaft (Fig. 95). Carefully rotate output shaft
until fourth speed synchro ring seats in synchro hub
and sleeve.
(8) Install Adapter 6747-2 on front bearing
hub of countershaft, if not previously done. The
adapter h a s a shoulder on one side. The shoul
der goes toward t h e countershaft.
(9) Slide countershaft (and adapter) into fixture
slot. Verify that countershaft and output shaft gears
are fully meshed before proceeding (Fig. 96).
(10) Check alignment of countershaft and output
shaft gear teeth. Note that gears may not align per
Fig. 92 installing Pilot Bearing in input Shaft fectly. A difference in height of 1.57 to 3.18 mm (1/16
(5) Install fourth speed synchro ring on input shaft to 1/8 in.) will probably exist. This difference will not
interfere with assembly. However, if the difference is
(Fig. 93).
greater than this, the countershaft adapter tool is
(6) Adjust height of idler gear pedestal on assem
probably upside down. Remove countershaft, reverse
bly fixture (Fig. 94). Start with a basic height of adapter tool, reinstall countershaft and check align
18.4 cm (7-1/4 in.). Final adjustment can be ment again.
made after gear is positioned on pedestal. (11) Position reverse idler on pedestal of assembly
fixture (Fig. 97). Be sure idler gear is properly
21 - 34 NV3500 MANUAL TRANSMISSION
geartrain. Adjust pedestal up or down if necessary.

Also be sure that short end of idler shaft is facing up
as shown.
COUNTERSHAFT
REVERSE
IDLER
OUTPUT ASSEMBLY
SHAFT (ON PEDESTAL)
OUTPUT
AND SHAFT
GEARTRAIN AND
GEARTRAIN
SPECIAL
TOOL
6747
INPUT
SHAFT
TOOL
PEDESTAL
J9421-97
J9421-95 Fig. 97 Reverse Idler Assembly Positioned On

Assembly Fixture Pedestal
Fig. 95 Output Shaft And Geartrain installed In input (12) On 2-wheel drive transmission, thread one Pi
Shaft
lot Stud C-3288-B in center or passenger side hole of
output shaft bearing retainer. Then position retainer
on fifth gear as shown (Fig. 98). Cut a screwdriver
OUTPUT slot at the end of the pilot stud with a hacksaw if
SHAFT necessary (slot makes for easy stud removal after
AND housing is installed).
GEARTRAIN
COUNTERSHAFT
(SLIDE INTO SPECIAL
PLACE ON TOOL
FIXTURE TOOL) C-3288-B
OUTPUT
SHAFT
BEARING
RETAINER J9421-98
J9421-96
Fig. 98 Positioning Output Shaft Bearing Retainer
Fig. 96 Countershaft Installed On Fixture Tool For Rear Housing Installation
meshed and aligned with shaft gear teeth and (13) Assemble 1-2 and fifth reverse-shift forks (Fig.
that bolt holes are facing out and not toward 99). Arm of fifth-reverse fork goes through slot in 1-2
fork.
l ¥ 3 i i l MANUAL TRANSMISSION 21 - 35
a ^ INSERT ARM
Fig. 99 Assembling 1 -2 And Fifth-Reverse Shift

Forks
(14) Install assembled shift forks in synchro
sleeves (Fig. 100). Be sure forks are properly seated
in sleeves.
Fig. 101 Preparing Rear Housing Dowels For
Installation
bushing/bearing in rear housing (Fig. 103).
(6) Reach into countershaft rear bearing with fin
ger, and push each bearing roller outward against
race. Then apply extra petroleum jelly to hold rollers
in place. This avoids having rollers becoming dis
placed during housing installation. This will result in
misalignment between bearing and countershaft
bearing hub.
COUNTERSHAFT
REAR
BEARING
Fig. 100 Shift Forks installed In Synchro Sleeves

REAR HOUSING INSTALLATION (2-WHEEL
DRIVE TRANSMISSION)
(1) Drive adapter housing alignment dowels back
into housing until dowels are flush with mounting
surface (Fig. 101).
(2) Apply liberal quantity of petroleum jelly to
countershaft rear bearing and bearing race.
(3) Install countershaft rear bearing in bearing
race (Fig. 102).
CAUTION: The countershaft bearings can be In
stalled backwards if care is not exercised. B e sure
the large diameter side of the roller retainer faces PETROLEUM JELLY
the countershaft and the small diameter side faces (APPLY TO BEARING
the race and housing (Fig. 103). AND RACE) J942M03
(4) Apply extra petroleum jelly to hold counter Fig. 102 Lubricating Countershaft Rear Bearing
shaft rear bearing in place when housing is installed.
(5) Apply light coat of petroleum jelly to shift shaft
(8) Seat rear housing on output shaft rear bearing

and countershaft. Use plastic or rawhide mallet to
tap housing into place.
(9) Install three bolts that secure rear bearing re
tainer to rear housing as follows:
(a) Apply Mopar Gasket Maker, or Loctite 518 to
bolt threads, bolt shanks and under bolt heads
(Fig. 105).
Fig. 103 Countershaft Rear Bearing

Seated in Race
(7) Install rear housing onto geartrain (Fig. 104).
Be sure bearing retainer pilot stud is in correct
bolt hole in housing. Also be sure countershaft
and output shaft bearings are aligned in hous
ing and on countershaft.
Fig. 105 Applying Sealer To Retainer And Housing
Bolts
(b) Start first two bolts in retainer (Fig. 106). It
may be necessary to move retainer rearward (with
pilot stud) in order to start bolts in retainer.
(c) Remove pilot stud C-3288-B and install last
retainer bolt (Fig. 106). Use screwdriver to remove
pilot stud.
(d) Tighten all three retainer bolts to 30-35 N-m
(22-26 ft. lbs.) torque.
Fig. 104 Rear Housing instailation (2-Wheel Drive

Transmission Shown)
Fig. 106 Removing Pilot Stud Tool And Installing

Retainer Bolts (2-Wheel Drive Transmission)
REAR ADAPTER HOUSING INSTALLATION

(4-WHEEL DRIVE TRANSMISSION)
(1) Install rear bearing in adapter housing. Use wood
hammer handle or wood dowel to tap bearing into place.
(2) Position rear bearing retainer in adapter hous
ing (Fig. 107).
Fig. 108 Installing Rear Bearing Snap Ring (4-Wheel

Drive Transmission)
Fig. 107 Preparing Adapter Homing For installation

(4-Wheel Drive Transmission)
(3) Apply Mopar Gasket Maker, or Loctite 518 to
threads, bolt shanks and under hex heads of bearing
retainer bolts (Fig. 108).
(4) Apply liberal quantity of petroleum jelly to
Fig. 109 Rear Seal Installation (4-Wheel Drive
countershaft rear bearing and bearing race.
Transmission)
(5) Install countershaft rear bearing in bearing
race (Fig. 103). REVERSE IDLER SEGMENT INSTALLATION
(1) Apply Mopar Gasket Maker, - or Loctite 518
CAUTION: The countershaft bearings can be in sealer to underside of idler shaft bolt heads, bolt
stalled backwards if care is not exercised. B e sure shanks and bolt threads (Fig. 105).
the large diameter side of the roller retainer faces (2) Align idler shaft and rear housing bolt holes
the countershaft and the small diameter side faces with drift, pin punch, or phillips screwdriver.
the race and housing (Fig. 103). (3) Work segment upward into housing and onto
idler shaft (Fig. 110).
(6) Apply extra petroleum jelly to hold counter (4) Verify that idler shaft is seated in housing
shaft rear bearing in place when housing is installed. notch before proceeding. Segment and housing can be
(7) Apply light coat of petroleum jelly to shift shaft damaged if idler shaft is misaligned.
bushing/bearing in adapter housing (Fig. 103). (5) Insert idler shaft retaining bolts through hous
(8) Install adapter housing on geartrain. ing and segment and into shaft. Long bolt goes
(9) Install rear bearing snap ring on output shaft through segment and short bolt goes through housing
(Fig. 108). and directly into rear of shaft (Fig. 111). Start both
(10) Lubricate lip of new rear seal (Fig. 109) with bolts by hand to avoid cross threading.
Mopar Door Ease, or transmission fluid. (6) Tighten idler shaft bolts to 19-25 N-m (14-18 ft.
(11) Install new rear seal in adapter housing bore lbs.) torque.
with suitable size tool. Be sure seal is fully seated in
housing bore (Fig. 109).
21 - 38 i f 3511 MANUAL TRANSMISSION BR
CAUTION; Make sure the idler shaft and support CAUTION: The transmission synchros must all be
segment are properly seated and held firmly in in Neutral position for proper reassembly. Other
place while tightening the shaft bolts. The segment, wise, the housings, shift forks and gears can be
housing or shaft threads can be damaged if the damaged during installation of the two housings.
idler shaft is allowed to shift out of position in the
housing. (3) Install 3-4 shift fork in synchro sleeve (Fig.
112). Verify that groove in fork arm is aligned with
grooves in 1-2 and fifth-reverse fork arms as shown.
3-4 ALIGN
Fig. 112 Installing 3-4 Shift Fork

(4) Check surface of shift shaft before proceeding.
Small nicks or scratches can be smoothed off with oil
soaked 320-400 grit emery cloth if necessary.
Fig. 110 installing Reverse Idler Shaft Support
(5) Slide shift shaft through 3-4 shift fork (Fig.
Segment
113). Be sure shaft detent notches are to front.
J9421-42
Fig. 111 installing Reverse Idler Shaft Bolts Fig. 113 Shift Shaft Installation
SHIFT SHAFT, SHAFT LEVER AND BUSHING (6) Assemble shift shaft shift lever and bushing
AND SHIFT SOCKET INSTALLATION (Fig. 114). Be sure slot in bushing is facing up
(1) Remove geartrain and housing assembly from and roll pin hole for lever is aligned with hole
fixture with aid of helper. in shaft.
(2) Before proceeding, verify that all synchro (7) Install assembled lever and bushing on shift
sleeves are in Neutral position (centered on hub). shaft (Fig. 115).
Move sleeves into neutral if necessary. (8) Slide shift shaft through 1-2 fork and part way
into shift lever opening in rear housing (Fig. 116).
Bit NV3500 MANUAL TRANSMISSION 21 - 39
(10) Push shift shaft through fifth-reverse fork and

SHAFT
LEVER
J9421-88
Fig. 114 Assembling Shift Shaft Lever And Bushing J9521-153
SHAFT - Fig. 117 Shift Socket Installation

SHIFT LEVER
SHAFT AND
f
into bushing in rear housing. Use plastic mallet to
BUSHING ~ tap shaft into place if necessary.
(11) Rotate shift shaft so detent notches in shaft
are facing driver side of housing.
CAUTION: Correct positioning of the shift shaft de
tent notch is important. Both of the shaft roll pins
can be installed even when the shaft is 180° off. If
this occurs, the transmission will have to be disas
sembled again to correct shaft alignment.
3-4 (12) Select correct new roll pin for shift shaft lever
FORK (Fig. 118). Shaft lever roll pin is approximately 22
J9421-41:
mm (7/8 in.) long. Shift socket roll pin is approxi
Fig. 115 installing Shift Shaft Lever And Bushing mately 33 mm (1-1/4 in.) long.
SHAFT
LEVER
ROLL
PIN
SHIFT
-SOCKET
SHIFT ROLL
SHAFT PIN
J9421-86
Fig. 118 Roll Pin Identification (Shaft Lever And

Shift Socket)
J9521-152 (13) Align roll pin holes in shift shaft, lever and
bushing. Then start roll pin into shaft lever by hand
Fig. 116 Inserting Shaft Into Lever Opening In (Fig. 119).
Housing (14) Seat shaft lever roll pin with pin punch (Fig.
(9) Align shift socket with shaft and slide shaft 120).
through socket and part-way into housing (Fig. 117).
CAUTION: The shaft lever roll pin must be flush
with the surface of the lever. The lever bushing will
bind on the roll pin if the pin is not seated flush.
21 - 41 NV3500 MANUAL TRANSMISSION mm
(17) Seat roll pin in shift socket with pin punch.
SHAFT Roll pin must be flush with socket after installation
LEVER (Fig. 122).
ROLL
PIN
(7/8" LONG)
LEVER
AND
BUSHING
^0 J9421-113
Fig. 119 Starting Roll Pin in Shift Shaft Lever
(15) Before proceeding, verify that lock pin slot in
lever bushing is positioned as shown (Fig. 120).
J9521-155
Fig. 122 Seating Shift Socket Roll Pin

(18) Verify that notches in shift fork arms are
aligned (Fig. 123). Realign arms if necessary.
(19) Rotate shaft lever and bushing downward (out
of fork arms), to expose detent bore in lever (Fig.
123).
SHIFT
FORK
J9421-114 ARMS
Fig. 120 Correct Seating Of Shift Shaft Lever Roll Pin
(16) Align roll pin holes in shift socket and shift DETENT
shaft. Then start roll pin into shift shaft by hand (Fig. BORE
122). IN SHAFT
LEVER
ROLL
PIN
J9421-115
Fig. 123 Shaft Lever Positioned For Detent Ball and

Spring installation
p J9521-154
ft Socket
BR — — — — • — if3110 MANUAL TRAiSMISSIOi 21 - 41
(20) Insert detent spring in lever bore with pencil SHIFT FORK
magnet (Fig. 124). ARMS
LEVER
DETENT
BORE
AND
SPRING J9421-117
Fig. 126 Correct Seating Of Lever Detent Ball In
Shift Fork Arms
Fig. 124 installing Detent Spring In Shaft Lever front housing race (Fig. 127). Large diameter side
(21) Install detent ball on top of spring in lever of bearing cage goes toward countershaft (Fig.
bore (Fig. 125). Use pencil magnet to hold ball in 128). Small diameter side goes toward bearing
place. race in housing.
Fig. 125 Installing Detent Bali In Shaft Lever Fig. 127 Lubricating/Positioning Countershaft Front
Bearing
(22) Press and hold detent ball in lever with mag
net. Then carefully rotate lever upward into fork arm (3) Reach into countershaft front bearing with fin
notches. Be sure ball is seated in fork arms before ger, and push each bearing roller outward against
proceeding (Fig. 126). race. Then apply extra petroleum jelly to hold rollers
in place. This avoids having rollers becoming dis
FRONT HOUSING AND INPUT SHAFT placed during housing installation. This will result in
BEARING RETAINER INSTALLATION misalignment between bearing and countershaft
(1) Before proceeding, verify that all synchro are in bearing hub.
Neutral position (centered on hub). Move sleeves into (4) Install input shaft bearing in front housing
neutral if necessary. bore (Fig. 128). Use plastic mallet to seat bearing.
CAUTION: The transmission synchros must all be Bearing goes in from front side of housing only.
in Neutral position during reassembly. Otherwise, (5) Apply small amount of petroleum jelly to shift
the housings, shift forks and gears can be damaged shaft bushing in front housing (Fig. 129).
during housing installation. (6) Apply 1/8 in. wide bead of Mopar Gasket
Maker, or Loctite 518 to mating surfaces of front and
(2) Apply liberal quantity of petroleum jelly to rear housings (Fig. 129).
countershaft front bearing. Then insert bearing in
21 • 42 NV3500 MANUAL TRANSMISSION — BR
FRONT
HOUSING
COUNTERSHAFT
FRONT BEARING J942M22
Fig. 128 Input Shaft Bearing And Countershaft Front

Bearing Installation
HOUSING
FLANGE
SURFACE J9421-124
Fig. 130 Front Housing installation

dowels should be flush fit in each housing. Have
helper hold transmission upright while dowels are
tapped back into place.
FRONT
HOUSING
MOPAR
GASKET
MAKER
(OR LOCTITE 518) Jf421-123
Fig. 129 Applying Sealer To Front/Rear Housings

(7) Have helper hold rear housing and geartrain in
upright position. Then install front housing on rear
housing and geartrain (Fig. 130).
(8) Work front housing downward onto geartrain
REAR
until seated on rear housing. HOUSING
J942M25
CAUTION: If the front housing will not seat on the
rear housing, either the shift components are not in Fig. 131 Reseating Housing Alignment Dowels
Neutral, or one or more components are mis (10) Place transmission in horizontal position.
aligned. Do not force the front housing into place. (11) Apply Mopar Gasket Maker, or Loctite 518 to
This will only result in damaged components, housing attaching bolts. Apply sealer material sealer
(9) Tap rear housing alignment dowels back into to underside of bolt heads and to bolt shanks and
place with hammer and pin punch (Fig. 131). Both threads (Fig. 132).
mm l ¥ 3 i l i MANUAL TRANSMISSION 21 - 43
(12) Install and start housing attaching bolts by CAUTION; If the Jock,bolt cannot be fully installed,
hand (Fig. 132). Then tighten bolts to 30-35 N-m do not try to force it into place. Either the shift
(22-26 ft. lbs.) torque. shaft is not in Neutral, or the shaft bushing (or le
ver) is misaligned (Fig. 134).
LOCK FRONT
BOLT HOUSING
Fig. 132 installing Housing Attaching Bolts

(13) Install shift shaft bushing lock bolt (Fig. 133).
Apply Mopar Gasket Maker, or Loctite 518 to bolt
threads, shank and underside of bolt head before in
stallation.
J942M28
Fig. 134 Correct Alignment Of Lock Bolt And Shaft

Bushing
(14) Lubricate then install shift shaft detent
plunger in housing bore (Fig. 135). Lubricate plunger
with petroleum jelly or gear lubricant. Be sure
plunger is fully seated in detent notch in shift
shaft.
Fig. 133 Installing Shift Shaft Bushing Lock Bolt
Fig, 135 installing Shift Shaft Detent Plunger

21 - 44 NWSI1I MANUAL TRANSMISSION
(15) Install detent spring inside plunger (Fig. 136). (17) Install backup light switch (Fig. 138).
i—rrTPI J9421-133
Fig. 138 installing Backup Light Switch

(18) Install input shaft snap ring (Fig. 139).
INPUT
SHAFT
Fig. 136 installing Detent Plunger Spring SNAP
(16) Install detent plug (Fig. 137). Start plug in RING
bore by hand. Then seat plug with brass punch.
J942 M39
Fig. 139 installing input Shaft Snap Ring

(19) Install new oil seal in front bearing retainer
with Installer Tool 6448 (Fig. 140).
PLUG
FRONT
f\ \ PUNCH HI t" " v : J942M31
BEARING
RETAINER
Fig. 137 Detent Plug Installation
J942M46
Fig. 140 installing Oii Seal In Front Bearing Retainer

(20) Apply bead of Loctite Ultra (heavy body), (22) Install and tighten bearing retainer bolts to
black silicone sealer (or Mopar equivalent), to flange 7-10 N-m (5-7 ft. lbs.) torque (Fig. 143).
surface of front bearing retainer. Then apply bead of (23) Install transmission in vehicle. Then refer to
same sealer to retainer mounting surface of front shift lever installation procedure.
housing (Fig. 141).
Fig. 143 Installing Input Shaft Bearing Retainer

Fig. 141 Applying Sealer To Bearing Retainer And
Bolts
Housing
SHIFT TOWER AMD LEVER ASSEMBLY
(21) Align and install front bearing retainer over INSTALLATION
input shaft and onto housing mounting surface (Fig. (1) Apply 1/8 to 3/16 in. wide bead of Mopar Gas
142). Although retainer is one-way fit on hous ket Maker, or Loctite 518 to isolator and plate mat
ing, be sure bolt holes are aligned before seat ing surface of rear housing (Fig. 144).
ing retainer.
Fig. 144 Applying Sealer To Shift Tower Mounting

Fig. 142 Installing Input Shaft Bearing Retainer
Surface
(2) If isolator and plate separated from shift tower,

SHIFT TOWER
apply sealer to plate and position It on tower. Or, po AND LEVER
sition it on rear housing (Fig. 145). Plate assembly ASSEMBLY
is a one-way fit. Narrow side of plate goes to
ward driver side of housing as shown (Fig. 145).
(8) Apply petroleum jelly to ball end of shift lever
and interior of shift socket.
(4) Align and install shift tower and lever assem
bly (Fig. 145). If isolator and plate was installed be
fore tower, be sure tower and plate assembly are
securely fitted together. Also be sure shift ball is
seated in socket before installing tower bolts.
SHIFT TOWER ISOLATOR
AND LEVER AND PLATE
ASSEMBLY ASSEMBLY
Fig. 146 Shift Tower Bolt Installation
(8) Check transmission vent (Fig. 147). Be sure
vent is open and not restricted.
<y "VX TRANSMISSION
VENT
J952M82
Fig. 145 Shift Tower Installation

J942M44
(5) Install shift tower bolts (Fig. 146). Tighten
bolts to 7-10 N-m (5-7 ft. lbs.) torqi ""Mts require Fig. 147 Transmission Vent Location
an 8 mm socket.
(6) Fill transmission to bottom edge of fill plug
hole with Mopar Transmission Lubricant, P/N
4761526.
(7) Install and tighten fill plug to 19-27 N-m (14-20
ft. lbs.) torque.
HW4S0© M A N U A L TRANSMISSION
INDEX
page page
Gear Ratios 49 Transmission Assembly and Adjustment . . . . . . . . . 75

Genera! Information 47 Transmission Cleaning and Inspection . . . . . . . . . . 70
Manual Transmission Diagnosis . . . . . . . . . . . . . . . 49 Transmission Disassembly and Overhaul . . . . . . . . 53
Required Lubricant—Capacity—Fill Level . . . . . . . . 49 Transmission Identification . . . . . . . . . . . . . . . . . . 49
Shift Cover Replacement . . .. 96 Transmission Installation (2-Wheel Drive) . . . . . . . . 51
Shift Cover Service 92 Transmission Installation (4-Wheel Drive) . . . . . . . . 52
Shift Lever Replacement 94 Transmission Removal (2-Wheel Drive) . . . . . . . . . 50
Shift Pattern 49 Transmission Removal (4-Wheel Drive) 51
GENERAL INFORMATION the shift - forks and rails directly. The shift forks and
The NV4500 is a five-speed, constant mesh manual rails are all located within the aluminum cover
transmission (Fig. 1). All gear ranges including re which is bolted to the top of the gear case.
verse are synchronized. Fifth gear is an overdrive A reverse gear inhibitor mechanism prevents re
range with a ratio of 0.74:1. The transmission has a verse gear engagement when shifting into forward
cast iron gear case and aluminum shift cover. gear ranges. The inhibitor mechanism is located In
Two versions of the NV4500 are used. A standard the shift cover.
duty version is used for 5.2L and 5.9L applications Tapered roller bearings support the drive gear,
and a heavy duty version for VIO/Cummins diesel ap mainshaft and countershaft In the gear case. Pilot
plications. Main differences are the larger diameter roller bearings in the drive gear hub support the for
input shaft, output shaft, and mainshaft fifth gear in ward end of the mainshaft. The mainshaft gears are
the heavy duty model. The different size shafts and all supported on caged type roller bearings. Drive
gear do not affect service. Overhaul procedures for gear thrust reaction Is controlled by a needle type
the two (versions are the same. thrust bearing. The bearing is located at the forward
The NV4500 is a top loader style transmission. The end of the mainshaft.
shift lever Is located in the shift cover and operates
J9521-10
Fig. 1 NV4500 Manual Transmission

BR NV4500 MANUAL TRANSMISSION 21-49
TRANSMISSION IDENTIFICATION GEAR RATIOS

The NV4500 transmission identification tag is at NV4500 gear ratios are:
tached to the driver side PTO cover (Fig. 2). First gear = 5.61:1
The tag provides the transmission model number, Second gear = 3.04:1
build date and part number. Be sure to reinstall the Third gear = 1.67:1
I.D. tag if removed during service. The information Fourth gear = 1.00:1
on the tag is essential to correct parts ordering. Fifth gear = 0.74:1
PTO Reverse gear = 5.61:1
COVER
SHIFT PATTERN
The NV4500 shift pattern is in a modified H pat
tern (Fig. 4). Overdrive fifth and reverse gears are in
line and outboard of the first through fourth gear po
sitions.
© 0 8 J9221-13
Fig. 4 NV4500 Shift Pattern

MANUAL TRANSMISSION DIAGNOSIS
J9221-14
Fig. 2 NV4500 Identification Tag Location COMMON PROBLEM CAUSES

The majority of transmission malfunctions are a re
REQUIRED LUBRICANT—CAPACITY—FILL LEVEL sult of:
Required lubricant for the NV4500 is Mopar Man • insufficient lubricant
ual Transmission Lubricant, P/N 4637579. This is the • incorrect lubricant
only lubricant recommended for use. • misassembled or damaged internal components
Dry fill lubricant capacity is approximately 3.78 li • improper operation.
ters (8 pints).
Correct lubricant fill level is to the bottom edge of HARD SHIFTING
the fill plug hole (Fig. 3). Check fill level only when A low lubricant level, loose or worn shift lever, or
the transmission is level. loose, damaged shift housing components are com
The transmission lubricant is drained through the mon causes of hard shifting. If hard shifting is also
PTO cover bottom bolt hole (Fig. 3). It will be neces accompanied by gear clash, synchronizer clutch and
sary to apply sealer to the bolt threads before install stop rings, or mainshaft gear teeth may be worn or
ing it during a lubricant change. damaged.
Hard shifting may also be caused by a loose, or
misaligned shift cover, or alignment dowels. Worn, or
damaged shift cover components will also cause hard
shifting. Any of the foregoing faults will cause com
ponent bind and high shift efforts.
Misassembled synchro components will also cause
FILL shift problems. Incorrectly installed synchro sleeves,
PLUG PTO struts, or springs will all cause shift problems.
COVER
NOISY OPERATION
DRAIN Transmission noise is most often a result of worn
BOLT J9421-210 or damaged components. Chipped, broken gear or
synchronizer teeth and brinnelled, spalled bearings
Fig. 3 NV4500 Fill Plug And Drain Bolt all cause noise.
21 - 5 0 NV4500 MANUAL TRANSMISSION — BR
Abnormal wear and damage to internal compo

nents Is frequently the end result of insufficient lu
bricant, non-recommended lubricants, or Improper
operation.
SLIPS OUT QF GEAR
Transmission disengagement may be caused by
misaligned or damaged shift components, or worn
teeth on the mainshaft gears or synchro components.
Incorrect assembly will also contribute to gear disen
gagement.
LOW LUBRICANT LEVEL
Insufficient transmission lubricant is usually the
result of leaks, or inaccurate fluid level check or refill
method.
Leaks will be evident by the presence of gear oil
around the leak point. If leakage is not evident, the
condition is probably the result of an underfill condi
tion.
If air powered lubrication equipment is used to fill
a transmission, be sure the equipment is properly
calibrated. Equipment out of calibration can lead to
an underfill condition.
CLUTCH PROBLEMS
Worn, damaged, or misaligned clutch components
can cause difficult shifting, gear clash and noise.
A damaged pilot bearing will cause noise. If bear
Fig. 5 Removing Shift Lever Extension With Toot
ing damage is severe, drive gear misalignment and
hard shifting can also occur. 8783
A worn or damaged clutch disc, pressure plate, or (5) Raise and support vehicle.
release bearing can cause hard shifting and gear (6) Mark propeller shaft and axle yokes for align
clash. ment reference. Use paint, scriber, or chalk to mark
Damaged or worn clutch hydraulic components, or yokes.
leaks in the fluid lines or cylinders will cause hard (7) Remove U-joint clamp strap screws and remove
shifting and gear clash. Failure of one of the clutch clamps.
hydraulic cylinders can result in incomplete clutch (8) Remove propeller shaft.
release or engagement. (9) Disconnect and remove exhaust system Y-pipe.
Verify that clutch components are all in good con (10) Disconnect wires at speed sensor and backup
dition before removing the transmission for repair. light switch.
(11) Support engine with adjustable safety stand
TRANSMISSION REMOVAL (2-WHEEL DRIVE) and wood block.
(1) Disconnect battery negative cable. (12) If transmission is to be disassembled for re
(2) Shift transmission into Neutral. pair, remove drain bolt at bottom of PTO cover and
(3) Remove screws attaching shift boot to floorpan. drain lubricant from transmission.
Then slide boot upward on lever extension. (13) Remove bolts/nuts attaching transmission to
(4) Remove shift lever extension with Remover/In rear mount.
staller Tool 6783 as follows: (14) Support transmission with a transmission
(a) Scribe mark position of extension on shank of jack. Secure transmission to jack with safety chains.
shift lever. (15) Remove rear crossmember.
(b) Position notched, lower end of tool just under (16) Remove bolts attaching clutch slave cylinder
square shank of shift lever (Fig. 5). to clutch housing. Then move cylinder aside for work
(c) Position tool upper jaws under flange on ing clearance.
shift lever extension (Fig. 5). (17) Remove transmission harness wires from clips
(d) Tighten tool screw to pull extension off on transmission shift cover.
square shank of shift lever. (18) Remove bolts attaching transmission to clutch
(e) Remove lever extension and tool. housing.
(19) Slide transmission and jack rearward until (c) Remove special tool.
drive gear clears clutch housing.
(20) Lower transmission jack and remove trans
mission from under vehicle.
(21) If transmission will be overhauled, clean
transmission exterior with solvent or with steam
gun.
TRANSMISSION INSTALLATION (2-WHEEL DRIVE)

(1) Apply light coat of Mopar high temperature
bearing grease to contact surfaces of following com
ponents:
• drive gear splines and pilot bearing hub
• release bearing slide surface of front retainer
© pilot bearing
• release bearing bore
• release fork
• release fork ball stud
© propeller shaft slip yoke
(2) Apply sealer to threads of bottom PTO cover
bolt and install bolt in case.
(3) Mount transmission on jack and position trans
mission under vehicle.
(4) Raise transmission until drive gear is centered
in release bearing and clutch disc hub.
(5) Move transmission forward and start drive gear
in release bearing, clutch disc and pilot bushing.
(6) Work transmission forward until seated against
clutch housing. Do not allow transmission to remain
unsupported after drive gear has entered clutch disc. Fig. 6 Installing Shift Lever Extension With Tool
(7) Install and tighten transmission-to-clutch hous 8783
ing bolts to 108 N-m (80 ft. lbs.) torque. (18) Install shift boot and bezel.
(8) Install clutch slave cylinder. (19) Connect battery negative cable.
(9) Connect speed sensor and backup light switch
wires. TRANSMISSION REMOVAL (4-WHEEL DRIVE)
(10) Fill transmission with recommended lubri (1) Disconnect battery negative cable.
cant. Correct fill level is bottom edge of fill plug hole. (2) Shift transmission into Neutral.
(11) Position transmission harness wires in clips
(3) Remove shift lever boot and bezel.
on shift cover.
(12) Install transmission mount on transmission or (4) Remove shift lever extension with Remover/In
rear crossmember. staller Tool 6783 as follows:
(13) Install rear crossmember. (a) Scribe mark position of extension on shank of
(14) Remove transmission jack and engine support shift lever.
fixture. (b) Position notched, lower end of tool just under
(15) Align and connect propeller shaft. square shank of shift lever (Fig. 5).
(16) Lower vehicle. (c) Position tool upper jaws under flange on
(17) Install lever extension on shift lever with Tool shift lever extension (Fig. 5).
6783 as follows: (d) Tighten tool screw to pull extension off
(a) Reposition upper jaw of Remover/Installer square shank of shift lever.
Tool 6783 above flange on lever extension (Fig. 6). (e) Remove lever extension and tool.
Tool will now be used to press extension back onto (5) Raise vehicle.
shift lever. (6) Remove skid plate if equipped.
(b) Tighten tool screw to press extension back (7) If transmission will be disassembled for repair,
onto lever. Press extension to scribe mark made remove drain bolt at bottom of PTO cover and drain
during removal. A 3-5 mm (0.12 - 0.20 in.) space lubricant from transmission.
should exist between shift lever isolator and top (8) Mark propeller shafts and yokes for assembly
edge of stub shaft and tool lower jaw. reference.
21 • 12 if4111 MANUAL TRANSMISSION — B R
(9) Disconnect propeller shafts and remove propel ing transmission removal/Installation easier. Cylinder
ler shafts. does not have to be removed completely.
(10) Disconnect and remove exhaust system Y-pipe. (28) Remove bolts attaching transmission to clutch
Then disconnect and lower remaining exhaust pipes housing.
for clearance as necessary. (29) Move transmission rearward until drive pin
(11) Support engine with adjustable safety stand. ion clears clutch disc and release bearing.
(12) Disconnect speed sensor wires and disconnect (30) Lower transmission and remove it from under
speedometer cable, If equipped. vehicle.
(13) Disconnect backup light switch wires. (31) If transmission will be overhauled, thoroughly
(14) Disconnect 'transfer case shift linkage at clean transmission exterior with solvent or steam
transfer case range lever. Then remove transfer case gun.
shift mechanism from transmission (Fig. 7).
TRANSMISSION INSTALLATION (4-WHEEL DRIVE)
(1) Apply light coat of Mopar high temperature
bearing grease to contact surfaces of following com
ponents:
• drive gear splines and pilot bearing hub
• release bearing slide surface of front retainer
• pilot bearing
• release bearing bore
• release fork
• release fork ball stud
• propeller shaft slip yoke
(2) Apply sealer to threads of PTO cover bottom
drain bolt then install bolt in case.
(3) Mount transmission on jack and position trans
mission under vehicle. Secure transmission to jack
with safety chains.
(4) Raise transmission until drive gear is centered
* Fig, 7 Transfer Case Shift Mechanism in release bearing and clutch disc hub.
(15) Remove bolts/nuts attaching transmission to (5) Move transmission forward and start drive gear
rear support. in release bearing and clutch disc.
(16) Remove crossmember bolts/nuts and remove (6) Work transmission forward until seated against
crossmember. clutch housing. Do not allow transmission to remain
(17) Support transfer case with transmission jack. unsupported after drive gear has entered clutch disc.
Secure transfer case to jack with safety chains. (7) Install and tighten transmission-to-clutch hous
(18) Remove transfer case attaching nuts. ing bolts to 108 N-m (80 ft. lbs.) torque.
(19) Move transfer case rearward until input gear (8) Connect speed sensor and backup light switch
clears transmission mainshaft. wires.
(20) 'Lower transfer case assembly and move it (9) Position transmission harness wires in clips on
from under vehicle. shift cover.
(10) Tighten slave cylinder attaching nuts and in
(21) If transmission is being removed for repair, re
stall slave cylinder shield, if equipped.
move drain -bolt at bottom of PTO cover and drain lu
(11) Install transmission mount on transmission or
bricant from transmission. rear crossmember.
(22) Support transmission with transmission jack. (12) Install transfer case shift mechanism on
Secure transmission to jack with safety chains. transmission (Fig. 7).
(23) Remove transmission harness from retaining (13) Install rear crossmember.
clips on transmission shift cover. (14) Remove transmission jack and engine support
(24) Remove bolts/nuts attaching transmission fixture.
mount to rear crossmember. (15) Install transfer case on transmission jack. Se
(25) Remove rear crossmember. cure transfer case to jack with safety chains.
(26) Remove clutch slave cylinder splash shield, if (16) Install new gasket on transmission adapter, or
equipped. coat adapter sealing surface with Mopar Gasket
(27) Loosen clutch slave cylinder attaching nuts Maker, or silicone adhesive sealer.
until cylinder piston rod Is clear of release lever. This (17) Raise jack and align transfer case input gear
reduces pressure on lever and release bearing mak- with transmission mainshaft.
(18) Move transfer case forward and seat it on SHIFT

adapter. COVER
SLOT
(19) Install and tighten transfer case attaching
nuts. Tighten nuts to 41-47 N-m (30-35 ft. lbs.) If case
has 3/8 studs, or 30-41 N-m (22-30 ft. lbs.) If case has
5/16 studs.
(20) Connect transfer case shift lever to range le
ver on transfer case.
(21) Align and connect propeller shafts. Tighten U-
joint clamp strap bolts to 19 N-m (170 in. lbs.)
torque.
(22) Fill transmission with required lubricant.
Check lubricant level in transfer case as well and
add lubricant If necessary,
(23) Install transfer case skid plate and crossmem
ber. Tighten attaching bolts/nuts to 41 N-m (30 ft. Fig. 2 Loosening Shift Cover
lbs.) torque. (4) Raise front of shift cover and lift cover up and
(24) Install exhaust system components. off gear case (Fig. 3).
(25) Lower vehicle. (5) Set cover assembly aside for inspection. If cover
(26) Install lever extension on shift lever with Tool components are damaged, refer to shift cover service
6783 as follows: information.
(a) Reposition upper jaw of Remover/Installer
Tool 6783 above flange on lever extension (Fig. 6).
Tool will now be used to press extension back onto
shift lever.
(b) Tighten tool screw to press extension back
onto lever. Press extension to scribe mark made
during removal. A 3-5 mm (0.12 - 0.20 in.) space
should exist between shift lever isolator and top
edge of stub shaft and tool lower jaw.
(c) Remove special tool.
(27) Install shift lever boot and bezel.
(28) Connect battery negative cable.
TRANSMISSION DISASSEMBLY AND OVERHAUL
SHIFT COVER REMOVAL

(1) Remove shift cover bolts (Fig. 1). Fig. 3 Shift Cover Removal/Installation
EXTENSION/ADAPTER HOUSING REMOVAL
(1) Remove bolts attaching extension/adapter hous
ing to gear case (Fig. 4). Use 10 mm, 12 point socket
to remove housing bolts. Loosen bolts 4-5 threads
with socket and ratchet first. An air wrench can then
be used to complete removal but only after bolts are
loose.
C A U T I O N : Spline head bolts are used to attach the
extension or adapter housing to the gear case. The
bolt splines are easily damaged if the wrong tool is
Fig. 1 Shift Cover Bolt Removal/Installation used to loosen and remove them. Use a 10 mm, 12
point socket or box end wrench only.
(2) Loosen shift cover with pry tool. To avoid dam
aging cover seal surface, insert pry tool only in slots (2) Remove extension/adapter housing (Fig. 5). Tap
provided in cover (Fig. 2). housing with rubber mallet to loosen it. Then break
(3) Raise cover enough to disengage it from align sealer bead with putty knife and work housing off
ment dowels in gear case (Fig. 3).
21 - S4 NV4500 MANUAL TRANSMISSION BR
Fig. 6 Mainshaft Spline Seal
Fig. 4 Extension/Adapter Housing Bolts

alignment dowels with two pry tools. One alignment
dowel is In case. Other dowel is in housing. Fig, 7 Extension Housing And Seal (2-Wheel Drive
Models)
GEAR
CASE J9221-85
Fig, 5 Extension/Adapter Housing Removal/

installation Fig. 8 Adapter Housing (4-Wheel Drive Models)
(3) Remove spline seal from end of mainshaft (Fig. MAINSHAFT AND COUNTERSHAFT FIFTH
6). The seal can be reused or discarded as de GEAR REMOVAL
sired. The seal is not an essential p a r t and can The fifth gear components can be removed in
be reused or discarded as desired. The seal is dividually or as an assembly. If the fifth gear
mainly used to prevent lubricant loss during components are only being removed for access
shipping and does not have to be replaced if to another component, remove them as an as
damaged. sembly. However, if any of the fifth gear compo
(4) On 2-wheel drive models, remove extension nents require service, remove them
housing seal (Fig. 7). Seal can' be removed by collaps individually. Procedures for both removal
ing one side with punch then prying seal out with methods are provided below.
suitable tool.
(5) Note that 4-wheel drive adapter housing
does not have a seal (Fig. 8).
mm — — NW4500 MANUAL TRANSMISSION 21 - 55
Removing Countershaft Fifth Gear Components As Assembly SYNCHRO SLEEVE

(1) Remove snap ring that secures fifth speed
clutch gear on countershaft (Fig. 9).
CLUTCH
GEAR J9221-89
Fig. 9 Removing Countershaft Fifth Speed Clutch

Gear Snap Ring J9221-90 GEAR
(2) Remove roll pins that secure countershaft fifth Fig. 11 Removing Countershaft Fifth Gear Synchro
gear shift fork to shift rail with pin punch (Fig. 10). Components
Roll pins are driven out from bottom of fork (a) Install nut wrench on fifth gear nut (Fig. 12).
and not from top* Use Nut Wrench 6443 on standard duty models
and Wrench 6743 on heavy duty models.
(b) Note that wrench only fits one way on nut.
Be sure wrench is fully engaged in nut slots and is
not cocked.
SPECIAL STRIKE
FIFTH GEAR
SHIFT FORK J9221-94
Fig. 10 Removing Fifth Gear Shift Fork Roll Pins

(3) Remove shift fork and fifth gear components as
assembly. Rotate mainshaft as needed to allow coun J9421-207
tershaft fifth gear to clear mainshaft fifth gear.
Fig. 12 installing Nut Wrench On Mainshaft Fifth
Removing Countershaft Fifth Gear Components Individually Gear
(1) Remove snap ring that secures fifth speed
clutch gear on countershaft (Fig. 9). (c) On 2-wheel drive models, install Socket
Wrench 6441 on mainshaft splines. On 4-wheel
(2) Remove countershaft fifth speed clutch gear,
drive models, install Socket Wrench 6442 on main-
stop ring and bearing spacer (Fig. 11).
shaft splines. Then install breaker bar in socket
(3) Remove three struts and strut springs from
wrench (Fig. 13). Wedge breaker bar handle
countershaft fifth gear hub and sleeve (Fig. 11).
against workbench. Purpose of socket wrench and
(4) Remove mainshaft fifth gear nut and washer as
breaker bar is to prevent mainshaft from turning
follows:
while nut is loosened.
SPECIAL FIFTH
(5) Remove roll pins that secure countershaft fifth
TOOL GEAR gear shift fork to shift rail with pin punch (Fig. 10).
6443
OR 6743
NUT Roll pins are driven out from bottom of fork
and not from top.
(6) Remove fifth gear shift fork and sleeve as as
SPECIAL
sembly (Fig. 15). Remove fork by tapping it off rail
TOOL with plastic mallet. Leave sleeve engaged in fork
6441 or note position of sleeve for assembly refer
OR
6442 ence.
PLASTIC FIFTH
MALLET GEAR
SHIFT
FORK
BREAKER
BAR
RATCHET
WRENCH J9421-208
Fig. 13 Removing Mainshaft Fifth Gear Nut From SYNCHRO

Shaft Threads SLEEVE J9221-95
(d) Position small end of Nut Wrench 6443 at ap

Fig. 15 Fifth Gear Shift Fork And Sleeve Removal
proximately 10 o'clock position (Fig, 12).
(e) Strike small end of nut wrench with heavy (7) Remove countershaft fifth gear and hub assem
copper hammer to break nut loose. Nut is secured bly (Fig. 16).
by interference fit thread plus Loctite adhesive and
FIFTH
will require several firm blows to loosen it (nut GEAR
torque is In 300 ft. lb. range). SYNCHRO
(f) Once nut is loose, it can be removed by hold HUB
ing nut wrench with breaker bar and rotating out

put shaft with socket wrench and ratchet.
(g) Remove fifth gear nut and coned washer from
shaft (Fig. 14). Note position of washer for assem
bly reference (coned side of washer faces rear).
FIFTH NUT
GEAR WASHER
" (CONED)
COUNTERSHAFT
FIFTH
FIFTH GEAR
GEAR
NUT
J9221-96
Fig. 16 Removing Countershaft Fifth Gear And

Synchro Hub Assembly
J9221-93
Fig. 14 Mainshaft Fifth Gear Nut And Washer

Removal
B R N¥451§ MANUAL TRANSMISSION 21 - 57
(8) Remove countershaft fifth gear needle bearing

assemblies (Fig. 17).
(9) Remove cone shaped rear bearing t h r u s t
washer from end of countershaft (Fig. 18). Note posi
tion of washer for assembly reference. Also note t h a t
washer bore has notch for locating p i n .
(10) Remove and retain thrust washer locating p i n
from countershaft (Fig. 19).
MAINSHAFT J9521-184
Fig. 19 Installing First Puller Jaw On Mainshaft Fifth

(Overdrive) Gear
COUNTERSHAFT SPECIAL TOOLS
6444-3 (3 REQD.)
NEEDLE
BEARING
ASSEMBLIES J9221-97
Fig. 17 Countershai I Fifth Gear Needle Bearing

Removal
J952M85
Fig. 20 Seating Puller Flange In First Puller Jaw

(d) Position second puller j a w (6459 or 6820) on
gear and i n notch of puller flange (Fig. 21).
(e) Slide Retaining Collar 6444-8 over puller
THRUST THRUST jaws to hold t h e m i n place (Fig. 21).
WASHER WASHER
PIN (CONE SHAPED) J9221-98 SPECIAL TOOLS SPECIAL TOOL
6459 OR 6820 6444-8
Fig. 18 Countershaft Rear Bearing Thrust Washer
Removal
(11) Remove mainshaft overdrive f i f t h gear w i t h
Puller Tool Set 6444. Note that puller set can be
used on both standard and heavy duty trans
missions. Gear removal procedure is as follows:
(a) Position first puller j a w on gear (Fig. 19).
Use Puller Jaws 6459 on. standard duty mod
els and Puller Jaws 6820 on heavy duty mod
els.
(b) Assemble Puller Flange 6444-1 and Puller
Rods 6444-3 (Fig. 20).
J9521-186
(c) Slide assembled puller flange and rods onto
output shaft. Then seat flange i n notch of puller
Fig. 21 ins\ detaining Collar Over Puller Jaws
j a w (Fig. 20).
21 - 58 N¥45§§ MANUAL TRANSMISSION —
(f) Install Puller and Bolt 6444 on puller rods.

Then secure puller to rods with retaining nuts (Fig.
22).
(g) Tighten puller bolt to remove gear from shaft
splines (Fig. 22).
SPECIAL TOOL
6444-8
Fig. 24 Removing Front Bearing Retainer Bolts

rock retainer back and forth by hand to work it out
of gear case. Note that retainer flange extends into
and is fairly snug fit in case bore.
(3) Remove seal from front retainer (Fig. 25). Use
small chisel to collapse one side of seal then pry it
out with suitable tool.
WRENCH J952M87
Fig. 22 Removing Fifth Gear From Mainshaft

•Splines
(12) Remove bolts attaching mainshaft rear bear
ing plate to gear case and remove fifth gear, plate,
end play shims and bearing cup (Fig. 23).
Fig. 25 Removing Bearing Retainer Seal

(4) Remove bearing cup from front retainer as fol
lows:
(a) Assemble Puller Flange 6444-1 and Puller
Rods 6444-6 (Fig. 26).
(b) Insert Puller Jaws 6453-1 in puller flange
(Fig. 26). Narrow Hp of puller jaws will go under
Fig. 23 Removing Mainshaft Fifth Gear, Bearing bearing cup.
Plate, Bearing Shims And Rear Bearing Cup (c) Install assembled tools in front retainer (Fig.
27). Be sure puller jaws are seated under bearing
mmw RETAINER REMOVAL Mmm cup.
&ISA&SEPIBLY (d) Place Insert Tool 6453-2 in center of puller
(1) Remove front retainer bolts (Fig. 24). Discard jaws (Fig. 27). Insert tool is used to hold puller
retainer boits. They should not be reused. jaws in place.
(2) Remove front retainer by lightly tapping It (e) Instaii Puller 6444 on puller rods (Fig. 28).
back and forth with plastic mallet to loosen It. Then Then install retaining nuts on puller rods.
N¥4500 MANUAL TRANSMISSION 21 - 59
SPECIAL (f) Tighten puller bolt to draw bearing cup out of

TOOL retainer (Fig. 28). Use holding wrench on puller
6444-6 and turn puller bolt with adjustable wrench.
DRIVE GEAR REMOVAL AND DISASSEMBLY
(1) Remove drive gear. Tilt gear downward and out
of case (Fig. 29).
SPECIAL
TOOL
6444-1
SPECIAL
TOOL
6453-1 ^ ^ ^ ^ ^ J9221-178
Fig. 26 Assembling Puller Rods, Flange And Jaws
SPECIAL SPECIAL
TOOL TOOL
6453-1 6453-2
J9221-105
Fig. 29 Drive Gear Removal

(2) Remove pilot bearing from drive gear (Fig. 30).
FRONT
RETAINER J9221-179
Fig. 27 Installing Puller Tools In Front Retainer

TIGHTENING HOLDING DRIVE GEAR
WRENCH WRENCH
MAINSHAFT
PILOT BEARING
J9221-106
Fig. 30 Pilot Bearing Removal/Installation

SPECIAL
TOOL
6453-2
FRONT
RETAINER | J9221-180
Fig. 28 Removing Bearing Cup From Front Retainer

(3) Remove bearing from drive gear as follows:

(a) Note that puller tool assembly and setup is
similar to that used for removing fifth gear from
mainshaft (Figs. 19-23).
(b) Assemble Puller Flange 6444-1 and Puller
Rods 6444-4. Then position first Puller Jaw 6447
on gear (Fig. 31).
(c) Slide assembled puller flange and rod tools
onto output shaft. Then seat flange in notch of
puller jaw (Fig. 31).
(d) Position second Puller Jaw 6447 on gear and
in notch of puller flange (Fig. 31).
jaws to hold them in place (Fig. 31).
(f) Install Puller 6444 on puller rods. Then se
cure puller to rods with retaining nuts (Fig. 31).
(g) Tighten puller bolt to remove bearing cone Fig. 32 Removing Countershaft Rear Bearing Plate
from drive gear (Fig. 31).
Fig. 33 Countershaft End Play Shim And Rear

Bearing Cup Removal
Fig. 31 Removing Front Bearing From Drive Gear

MAINSHAFT AND GEARTRAIN REMOVAL
(1) Remove countershaft rear bearing plate (Fig.
32).
(2) Remove countershaft end play shim and rear
bearing cup (Fig. 33). Fig. 34 Removing Reverse Idler Shaft
(3) Remove reverse idler shaft. Thread a shift
cover bolt into shaft and withdraw shaft from case
(Fig. 34).
(4) Move 1-2 and 3-4 synchro sleeves into Neutral,
if necessary.
(5) Remove drive gear thrust bearing from forward

end of mainshaft (Fig. 35).
Fig. 35 Drive Gear Thrust Bearing Removal

(6) Remove fourth speed clutch gear and synchro
stop ring from mainshaft (Fig. 36).
Fig. 36 Fourth Speed Clutch Gear Stop Ring

Removal
(7) Roll gear case onto left side (Fig. 37).
(8) Reach into gear case and push reverse idler
gear away from mainshaft gears.
(9) Remove mainshaft assembly as follows (Fig.
37):
(a) Lift front end of mainshaft slightly.
(b) Grasp mainshaft rear splines. Then turn
spline end of mainshaft in counterclockwise direc
tion to rotate shaft and geartrain out of case.
(c) Once mainshaft gears roll clear of counter
shaft gears, shaft and gear assembly can be tilted
outward and removed from gear case (Fig. 37).
(10) Refer to mainshaft disassembly procedures if
any gears or synchro components must be replaced.
REVERSE IDLER GEAR AND COUNTERSHAFT
REMOVAL/DISASSEMBLY
(1) Rotate countershaft outward and push reverse
J9221-114
idler gear away from countershaft and toward front
of case (Fig. 38). Fig. 39 Reverse Idler Gear Removal
(2) Remove idler gear through drive gear bore at
front of case (Fig. 39).
21 -12 NV4500 MANUAL TRANSMISSION — ™ ^ — _ E$R
(3) Keep reverse idler gear bearings and spacer to (6) Remove bearing puller tools.
gether for cleaning and inspection (Fig. 40). Insert idler (7) Rotate countershaft out of gear case (Fig. 42).
shaft through gear and bearings to keep them in place.
REVERSE
BEARINGS IDLER
Fig. 40 Reverse idler Gear Components

(4) Remove idler gear thrust washers from gear
case. Install washers on idler shaft to keep them to
gether for cleaning and inspection. Fig. 42 Removing Countershaft From Gear Case
(5) Remove countershaft r e a r bearing. Shaft can (8) Remove countershaft front bearing as follows:
not be removed from case until rear bearing has been (a) Assemble Puller Flange 6444-1 and Puller
removed. Bearing removal procedure is as follows: Bolts 6444-6 (Fig. 43).
(a) Assemble Puller Flange 8444-1 and Puller (b) Position first Puller Jaw 6451 on bearing.
Rods 6444-6 (Fig. 41). (c) Seat puller flange in notch of puller jaw.
(b) Position 'first Puller Jaw 6449 on bearing (d) Install second Puller Jaw 6451 on bearing
cone (Fig. 41). and in notch of puller flange.
(c) Seat puller flange in notch of puller jaw just (e) Slide Retaining Collar 6444-8 over puller
Installed on bearing cone (Fig. 41). jaws to hold them in place (Fig. 43). Note that re
(d) Install second Puller Jaw 6449 on bearing taining collar has small lip on one end and only fits
and in notch of puller flange (Fig. 41).
one way over jaws.
jaws to hold them in place (Fig. 41). Note that re (f) Install Puller Bridge And Bolt Assembly 6444
taining collar has small Hp on one end and only fits on puller bolts. Then secure bridge to bolts with re
one way over jaws. taining nuts (Fig. 43).
(f) Install Puller 6444 on puller rods. Then se (g) Tighten puller bolt to remove bearing from shaft
cure puller to rods with retaining nuts (Fig. 41). (Fig. 43). If bearing is exceptionally tight, tap end of
(g) Tighten puller bolt to remove bearing from puller bolt with mallet to help loosen bearing.
shaft (Fig. 41). If bearing is exceptionally tight, tap (9) Remove bearing puller tools.
end of puller bolt with copper mallet to help loosen (10) Set countershaft and idler gear aside for
bearing. cleaning and inspection.
J922M59 6444-6
Fig. 41 Removing Countershaft Rear Bearing Fig. 43 Removing Countershaft Front Bearing
BR 1W4III MANUAL TRANSMISSION 21 -13
GEAR CASE DISASSEMBLY

(1) Remove countershaft front bearing cap. Use
mallet or hammer to remove cap from * inside case
(Fig. 44).
HAMMER MODIFIED
PIN
PUNCH
BEARING
CAP
J9221-144
Fig. 44 Countershaft Front Bearing Cap Removal

(2) Remove countershaft front bearing cup with
Remover Tool 6454 and Tool Handle C-4171 (Fig. 45).
(3) Remove roll pin that secures shift lug on shift
SPECIAL
TOOL
6454 Fig. 46 Removing Shift Lug Roll Pin
. SHIFT ^ ^
SPECIAL
TOOL
C-4171 J9221-145
Fig. 45 Countershaft Front Bearing Cup Removal

rail in case (Fig. 46). A small pin punch can be mod J9221-147
ified by putting a slight bend in it to drive pin com
pletely out of shift rail (Fig. 46). Fig. 47 Removing Shift Lug Rail
(4) Remove shift lug rail by tapping it out of case
and shift lug with tapered punch (Fig. 47). Note po
sition of rail and lug for assembly reference.
(5) Remove lug rail bushings from gear case with
Special Tool 6456 (Fig. 48).
SPECIAL
TOOL
6456 J9221-148
Fig. 48 Removing Shift Lug Rail Bushings

21 - 64 NV4500 MANUAL TRANSMISSION
(6) Unclip and remove magnet from bottom of gear

case (Fig. 49).
Fig. 49 Gear Case Magnet Location

MAINSHAFT DISASSEMBLY
Fig. 51 Removing 3-4 Sleeve From Hub
Not all of the mainshaft gear a n d synchro
components are a one-way fit. Some gear and Then complete hub removal by tapping it off shaft
synchro components c a n he installed back with plastic mallet. Tap hub at 6-8 different points to
wards. To avoid reassembly problems, mark the remove hub evenly.
speed gears, clutch gears, synchro hubs, and (5) Remove 3-4 synchro hub, third gear stop ring
sleeves for reference during teardown. Use and third gear (Fig. 52).
paint or a scriber for marking purposes. Then
stack the geartrain parts in order of removal.
This practice will help avoid incorrect assem
bly and lost time.
(1) Remove drive gear thrust bearing from end of
mainshaft, if not previously removed.
(2) Remove fourth gear synchro struts and springs
from 3-4 hub and sleeve (Fig. 50). Three struts and
springs are used. Keep springs and struts together
for inspection and cleaning. Store parts in a paper
cup to avoid losing them.
J9221-120
Fig. 50 3-4 Synchro Strut And Spring Removal Fig. 52 Third Gear, Stop Ring And 3-4 Hub Removal
(3) Remove 3-4 sleeve from 3-4 synchro hub (Fig.
51).
(4) Remove 3-4 synchro hub from mainshaft
splines with suitable size bearing splitter, or with
two tapered drifts. Position splitter or drifts between
third gear stop ring to start moving hub off shaft.
(6) Remove third gear bearing assemblies from SECOND

mainshaft (Fig. 53). GEAR
THRUST
WASHER
THIRD
GEAR
NEEDLE SECOND
BEARING GEAR
ASSEMBLIES BEARING J922M23
Fig. 55 Second Gear Thrust Washer Removal
SECOND
GEAR
J922M21
Fig. 53 Third Gear Needle Bearing Removal

(7) Remove third gear bearing spacer (Fig. 54).
(8) Remove snap ring that retains second gear
thrust washer on mainshaft (Fig. 54).
SECOND
GEAR THRUST
WASHER
J922M24
THRUST Fig. 56 Second Gear Removal

WASHER
SNAP RING SECOND
GEAR NEEDLE
BEARING
ASSEMBLY
THIRD GEAR
BEARING
SPACER
J922M22
Fig. 54 Bearing Spacer And Snap Ring Location

(9) Remove second gear thrust' washer (Fig. 55).
Note that washer is notched for locating pin.
(10) Remove second gear (Fig. 56).
(11) Remove second gear bearing assembly (Fig. J922M25
57).
Fig. 57 Second Gear Bearing Removal
21 - §e NV4500 MANUAL TRANSMISSION
(12) Remove thrust washer locating pin (Fig. 58). 1-2

Use needle nose pliers to grip and remove pin. SLEEVE
AND
* w
" SECOND HUB SYNCHRO
GEAR STOP
THRUST RING
. WASHER
LOCATING CLUTCH
^ ^ P ! N (REMOVE RING
WITH NEEDLE
NOSE PLIERS)
SECOND
SPEED
CLUTCH
GEAR
J922M28
Fig. 60 Second Speed Clutch Gear, Clutch Ring And

J922M26
Stop Ring Removal
Fig. 58 Thrust Washer Locating Pin Removal
(13) Remove snap ring that retains second speed
clutch gear (Fig. 59). Snap ring is seated in main-
shaft synchro hub groove.
SNAP
RING
SECOND
SPEED
CLUTCH
GEAR
SLEEVE
AND
HUB J9221-129
Fig. 61 Removing 1-2 Sleeve And Hub Snap Ring

1-2
SLEEVE
J922M27 AND HUB
(AAARK
Fig. 59 Removing Second Speed Clutch Gear Snap POSITION FOR
ASSEMBLY
Ring REFERENCE)
(14) Remove second speed clutch gear, synchro
clutch ring and synchro stop ring (Fig. 60).
(15) Remove 1-2 synchro hub snap ring (Fig. 61).
(16) Mark position of 1-2 synchro sleeve and hub
for assembly reference. Side of hub with flat hub
spring goes toward front (Fig.. 62). Note that tapered
side of sleeve also goes toward front.
(17) Remove 1-2 synchro sleeve, hub, struts and
springs as an assembly (Fig. 62). It is not necessary HUB SPRING J9221-130
to disassemble synchro components unless worn, or
damaged. Fig. 62 Removing 1-2 Synchro Sleeve And Hub
mm 114111 MANUAL TRANSMISSION 21 - 87
(18) Remove first gear synchro stop ring and clutch (20) Remove first speed clutch gear (Fig. 65).
ring (Fig. 63). (21) Remove first speed clutch gear rear snap ring
FIRST GEAR
from mainshaft hub (Fig. 65). It is not really neces
CLUTCH RING sary to remove this snap ring unless it, or the main-
shaft is to be replaced.
CLUTCH GEAR
:
^ < S ^ ^ S N A P RING (REAR)
FIRST GEAR
STOP RING J9221-131
FIRST
Fig. 63 First Gear Stop And dutch Ring Removal SPEED
CLUTCH
(19) Remove first speed clutch gear front snap ring GEAR J922M33
from mainshaft hub (Fig. 64).
Fig. 65 First Speed Clutch Gear Removal
FIRST
SPEED (22) Remove mainshaft rear bearing as follows:
CLUTCH
GEAR
(a) Assemble Puller Flange 6444-1 and Puller
Rods 6444-3 (Fig. 66).
(b) Position first Puller Jaw 6445 on bearing
cone (Fig. 66).
(c) Seat Puller Flange 6444-1 In notch of first
puller jaw (Fig. 66).
CLUTCH (d) Install second Puller Jaw 6445 on bearing
GEAR
SNAP cone and on puller flange (Fig. 66).
RING (e) Slide Retaining Collar 6444-8 over puller
(FRONT) jaws to hold them in place (Fig. 67). Note that re
taining collar has small lip on one end and only fits
one way over jaws.
J9221-132 (f) Install Puller 6444 on puller rods. Then se
cure puller to rods with retaining nuts (Fig. 67).
Fig. 64 First Speed Clutch Gear Front Snap Ring (g) Place holding wrench on hex ât top of puller
Removal (Fig. 67). Then tighten puller bolt with adjustable
wrench to remove bearing from shaft (Fig. 67). If
bearing proves difficult to remove, tap end of puller
bolt with copper hammer after each turn of bolt.
This will help loosen bearing on shaft and ease re
moval.
(23) Remove bearing puller tools.
(24) Remove reverse gear thrust washer (Fig. 68).
Fig. 67 Removing Mainshaft Rear Bearing
(25) Remove reverse gear thrust washer locating (30) Remove first gear snap ring (Fig. 71). Tension
pin (Fig. 69). of this snap ring is considerable. Heavy duty snap
REVERSE
ring pliers will be required to spread the ring far
S GEAR enough to remove it.
FIRST
GEAR
NEEDLENOSE SNAP
PLIERS RING
THRUST
WASHER
LOCATING REVERSE
PIN J922M36 GEAR
BEARING
SPACER J9221-150
Fig. 69 Removing Thrust Washer Locating Pin
(26) Remove reverse gear and synchro components
Fig. 71 Reverse Gear Bearing Spacer And First Gear
as assembly (Fig. 70). I t is not necessary to re
Snap Ring Removal
move or disassemble synchro components u n
less they are damaged a n d need to be replaced. (31) Remove reverse clutch gear (Fig. 72).
If synchro sleeve or struts require service, FIRST
mark position of sleeve o n hub before removal. SPEED
CLUTCH
C o r r e c t sleeve position is i m p o r t a n t as sleeve GEAR
c a n be installed b a c k w a r d s c a u s i n g shift prob
lems,
(27) Remove reverse gear bearing assembly from
mainshaft (Fig. 70).
(28) Remove reverse gear synchro stop ring and
clutch gear (Fig. 70).
FIRST REVERSE
GEAR GEAR
ASSEMBLY
J9221-151
Fig. 72 Removing Reverse Clutch Gear
STOP
RING BEARING
ASSEMBLY J922M37
Fig. 70 Reverse Gear, Bearing And Stop Ring

Removal
(29) Remove reverse gear bearing spacer from
mainshaft (Fig. 71).
21 - 70 NV4500 MANUAL TRANSMISSION - — — — — — — — BR
(32) Remove first gear from bearing and mainshaft FRONT IDLER BEARINGS REAR
(Fig. 73).
FIRST
GEAR
J922M52
Fig. 73 Removing First Gear
(33) Remove first gear bearing from mainshaft SPACER SHAFT J922M83
(Fig. 74).
Fig. 75 Reverse Idler Components
MAINSHAFT FIRST
MAINSHAFT FRONT
PILOT BEARING
BEARING
J922H53
Fig. 74 Removing First Gear Bearing
TRANSMISSION CLEANING AND INSPECTION

Clean the gears, bearings shafts, extension/adapter DRIVE
housing and gear case with solvent. Dry all parts ex GEAR J9221-181
cept the bearings with compressed air. Allow the
bearings to either air dry or wipe them dry with Fig. 76 Drive Gear Components
clean shop towels. nicks, or pitting can be smoothed with 400 grit emery
Inspect the reverse idler gear, bearings, shaft and and polished out with crocus cloth. Wet the abrasive
thrust washers (Fig. 75). Replace the bearings if the paper and crocus cloth with oil when smoothing/pol
rollers are worn, chipped, cracked, flat-spotted, or ishing. Replace the retainer if worn or damaged in
brinnelled. Or if the bearing cage is damaged or dis any way. Do not reuse the original retainer
torted. Replace the thrust washers if cracked, bolts. Install new bolts during assembly.
chipped, or worn. Replace the gear if the teeth are
chipped, cracked or worn thin. Inspect the countershaft and bearings (Fig. 78). Re
Inspect the drive gear and bearings (Fig. 76). Mi place the bearings if worn, rough, flat spotted, or
nor scratches and burrs on the gear surfaces can be heat checked. Check the countershaft gear teeth
reduced with an oil stone and 400 grit paper wetted carefully. Small nicks, scratches, or burrs can be re
with oil. Replace either bearing if worn, or damaged. moved with an oil stone and 400 grit paper wetted
Replace the gear if any teeth, splines, or bearing sur with oil. However, replace the shaft as an assembly if
faces are also worn or damaged. the forward gear is loose, or any of the teeth are
Inspect the front bearing retainer and bearing cup worn, cracked, broken, or severely chipped.
(Fig. 77). Replace the bearing cup if scored, cracked, Be sure to check condition of the countershaft bear
brinnelled, or rough. Check the release bearing slide ing cups. Replace either bearings cup if worn, or
surface of the retainer carefully. Minor corrosion, damaged.
BEARING FRONT BEARING BEARING HUB BEARING NUT SPEEDOMETER

CUP SURFACES SURFACES THREADS TEETH
RETAINER
SPLINES
J922M82 SPLINES SPLINES J9221-185
Fig. 77 Front Bearing Retainer Components Fig. 79 Mainshaft Bearing And Spline Surfaces
FRONT
Replace the gear case or housing/adapter if cracked
REAR COUNTERSHAFT
BEARING BEARING or broken. Do not attempt to repair this type of dam
age by welding or brazing.
GEAR EXTENSION
CASE HOUSING
(2-WHEEL DRIVE)
J9221-184
Fig. 78 Countershaft And Bearings
Check condition of the mainshaft. Inspect all the

bearing surfaces, splines and threads. Also check con
dition of the snap ring grooves in the hub area and
the speedometer drive gear teeth (Fig. 79). Minor
ADAPTER
scratches or burrs can be removed with an oil stone HOUSING
and polished with crocus cloth. However, replace the (4-WHEEL
shaft if any surfaces exhibit considerable wear or DRIVE) J9221-186
damage.
Check condition of the gear case and extension or Fig. 80 Gear Case And Extension/Adapter Housings
adapter housing (Fig. 80). Be sure the alignment

dowels in the case top surface and in the housing/
adapter are tight and in good condition.
Run a tap through the gear case bolt holes if the
threads need minor cleanup. Helicoil inserts can be
used to repair seriously damaged threaded holes if
necessary.
Be sure all case and housing/adapter sealing and
mating surfaces are free of burrs and nicks. This is
especially important as gaskets are not used in the
NV4500. Minor nicks and scratches on the sealing
surfaces can be dressed off with a fine tooth file or oil
stone.
21 - 72 NV4500 MANUAL TRANSMISSION ^ ^ ^ BR
Fig. 81 Countershaft th Gear Components

Check condition of the countershaft fifth gear com fork to be sure the two parts fit and work smoothly.
ponents (Fig. 81). This includes the shift lug and rail Replace the fork if the roll pin holes are worn over
located in the gear case and the rail bushings. size or damaged. Do not attempt to salvage a worn
Inspect the gear and hub assembly. Minor burrs fork. It will cause shift problems later on. Replace
can be cleaned up with an oil stone. However, the the shift fork roll pins if necessary, or if doubt exists
gear and hub assembly should be replaced if the about their condition.
teeth or splines are excessively worn, or damaged. The bearings should be examined carefully for
The synchro sleeve should also be replaced If worn or wear, roughness, flat spots, pitting, or other damage.
damaged in any way. Do not reuse synchro struts Replace the bearings if necessary.
that are worn, or springs that are collapsed or se Inspect the stop ring and clutch gear, replace either
verely distorted. Replace worn distorted synchro
part if worn or damaged in any way. Also be sure re
parts to avoid shift problems after assembly and In
stallation. placement parts fit properly before proceeding with
assembly.
The shift fork should be inspected for evidence of
wear and distortion. Check fit of the sleeve in the
BR NV4500 MANUAL TRANSMISSION 21 -73
RETAINER 1-2 1-2

HUB
SPRING SYNCHRO SYNCHRO
WEIGHTS (4)
(ROUND) HUB SLEEVE
STRUTS
RETAINER
SPRING J9221-205
(FLAT) SPRINGS
Fig, 82 1-2 Synchro Components
Inspect the 1-2 synchro components (Fig. 82). The stop rings and clutch rings. The teeth must be in
hub weights and retainer springs are reusable if in good condition and not worn, cracked, or chipped. Re
good condition. However, replace the springs if dis place any component that exhibits wear or damage.
torted, or broken and replace the weights if worn or Examine the synchro stop rings, clutch rings and
damaged. clutch gears. Replace any part that exhibits wear,
Examine the hub and sleeve for wear or damage. distortion, or damage. Replace the clutch rings if the
Replace the sleeve and hub if the splines are worn, friction material is burned, flaking off, or worn.
chipped or damaged. Inspect all of the thrust washers and locating pins.
Replace the synchro struts if worn, or chipped. Also Replace the pins if bent, or worn. Replace the wash
replace the springs if collapsed, distorted, or broken. ers if worn, or the locating pin notches are distorted.
Inspect the mainshaft geartrain components (Fig. Check condition of the synchro struts and springs.
83). Check the teeth on all gears, hubs, clutch gears, Replace these parts if worn, cracked, or distorted.
BR NW451I MANUAL TRANSMISSION 21 - 71
LEGEND FOR MAINSHAFT GEARTRAIN
1. MAINSHAFT 25. SYNCHRO HUB SNAP RING

2. FIRST GEAR BEARING 26. FIRST GEAR SYNCHRO STOP RING
3. FIRST GEAR 27. 1-2 SYNCHRO SLEEVE
4. CLUTCH GEAR 28. SYNCHRO STRUTS AND SPRINGS (4 EACH)
5. SYNCHRO STOP RING 29. 1 -2 SYNCHRO HUB (INC. RETAINER SPRINGS AND WEIGHTS)
6. FIRST GEAR SNAP RING 30. SYNCHRO HUB SNAP RING
7. REVERSE GEAR BEARING SPACER 31. SECOND GEAR SYNCHRO STOP RING
8. REVERSE GEAR BEARING 32. SECOND SPEED CLUTCH GEAR
9. REVERSE SYNCHRO SLEEVE 33. SECOND GEAR SYNCHRO CLUTCH RING
10. SYNCHRO STRUTS AND SPRINGS (3 EACH) 34. CLUTCH GEAR SNAP RING
11. REVERSE GEARLINES 35. SECOND GEAR BEARING
12. THRUST WASHER 36. SECOND GEAR
13. THRUST WASHER LOCATING PIN 37. THRUST WASHER AND LOCATING PIN
14. MAINSHAFT REAR BEARING 38. THRUST WASHER SNAP RING
15. MAINSHAFT REAR BEARING CUP 39. THIRD GEAR BEARING SPACER
16. MAINSHAFT END PLAY SHIMS 40. THIRD GEAR
17. MAINSHAFT REAR BEARING PLATE 41. THIRD GEAR BEARING ASSEMBLIES (2)
18. MAINSHAFT FIFTH GEAR 42. THIRD GEAR SYNCHRO STOP RING
19. THRUST WASHER 43. 3-4 SYNCHRO SLEEVE
20. FIFTH GEAR NUT 44. SYNCHRO STRUTS AND SPRINGS (3 EACH)
21. MAINSHAFT SPLINE SEAL 45. 3-4 SYNCHRO HUB
22. CLUTCH GEAR SNAP RING 46. FOURTH GEAR SYNCHRO STOP RING
23.

1995 Dodge Ram Service Manual

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1995 Dodge Ram Service Manual

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19 9 5

To order the special service tools used and

NO PAET OF THIS PUBLICATION MAY BE

Chrysler Corporation reserves the right to make changes in design or to

Litho in U.S.A. Copyright © 1994 Chrysler Corporation 20M0694

0 Lubrication and Maintenance

2 Front Suspension and Axle

3 Rear Suspension and Axles

11 Exhaust System and Intake Manifold

13 Frame and Bumpers

21 Transmissions and Transfer Cases

22 Wheels and Tires

24 Heating and Air Conditioning ., f..- '• 7;.^'

25 Emission Control Systems

Service Manual Comment Forms (Rear of Manual)

DESIiNATIONS, LA1ELS/PLATE8/DECALS, l E I S U i E i E N T AND TOFtQUE

DESIGNATIONS, LABELS/PLATES/DECALS, CODES AND DIMENSIONS/WEIGHTS

Body Code Plate 2 Trailer Towing Specifications 19

BODY CODE PLATE

PROCEDURE (2) X X X xxxx xxxx xxxx X X X

Fig. 2 Vehicle Identification Number (VIN) Location AAARKET

Vehicle Type Line Engine Sequential

BODY CODE DECODING

Line # 2 Digit 1-3 Paint Procedure

• The optional and special equipment installed on VEHICLE DIMENSIONS

INTERNATIONAL VEHICLE CONTROL AND DISPLAY SYMBOLS

VEHICLE INTERIOR DIMENSIONS—STD CAB

A Head Room 40.2

VEHICLE INTERIOR DIMENSIONS—CLUB CAB

VEHICLE EXTERIOR DIMENSIONS—STD CAB

1500/ 2500/ 3500/

—At Front Wheel Lip

VEHICLE EXTERIOR DIMENSIONS—CLUB CAB

1500/ 2500/ 3500/

(1) 93.8 at cargo box with dual-rear wheels.

VEHICLE EXTERIOR DIMENSIONS—CHASSIS CAB

4x2 Models 4x4 Models

VEHICLE WEIGHTS • Payload.

G R O S S VEHICLE WEIGHT RATING—2WD STD CAB

—Front 3,300 3,300 3,300 4,000 4,000

—Total 4,010 4,035 —

GROSS VEHICLE WEIGHT RATING—4WD STD CAB

G R O S S VEHICLE WEIGHT RATING—2WD CLUB CAB

GROSS VEHICLE WEIGHT RATING—4WD CLUB CAB

(Z6A) (Z71) (Z8A|

G R O S S VEHICLE WEIGHT RATING—STD CAB 8.0L OR DIESEL

8 . 0 L ¥10 A N D DIESEL ENGINE MODELS

G R O S S VEHICLE WEIGHT RATING—CLUB CAB 8.0L OR DIESEL

8.0L V I 0 AND DIESEL ENGINE MODELS J

GVWR 8,800 10,500 DiW 8,800 11,000 DRW

G R O S S VEHICLE WEIGHT RATING—2WD CHASSIS GAB 5.9L

8,800 11,000 D R W 11,000 D R W

—Rear 6,200 8,000 7,500

—Front 4,500 4,500 4,500

G R O S S VEHICLE WEIGHT RATING—2WD CHASSIS CAB 8 . 0 L OR DIESEL

8.0L ¥1© AND 5.9L DIESEL — 4x2

G R O S S VEHICLE WEIGHT RATING—4WD CHASSIS CAB 8.0L OR DIESEL

8.0L ¥10 A N D 5.9L DIESEL — 4 x 4

TRAILER TOWING SPECIFICATIONS • Maximum trailer tongue weight rating.

TRAILER TOWING—STD CAB

SPECIFICATION NOTATIONS Torque Specifications chart to determine torque val

It is necessary to schedule maintenance as a time in ENGINE WINDSHIELD

W H E N USING A HIGH OUTPUT BOOSTING DE

(1) Raise hood on disabled vehicle and visually in

(2) Hoist and support vehicle on safety stands. Re