Rta Merco
Rta Merco
Rta Merco
Introduction
2 Suspension
5 Brakes
7 Cooling
8A Audio/Video
8B Chime/Buzzer
8F Engine Systems
8G Heated Systems
8H Horn
8I Ignition Control
8J Instrument Cluster
8L Lamps
8N Power Systems
8O Restraints
8P Speed Control
8R Wipers/Washers
8W Wiring
9 Engine
11 Exhaust System
14 Fuel System
19 Steering
21 Transmission
22 Tires/Wheels
23 Body
25 Emissions Control
INTRODUCTION
TABLE OF CONTENTS
page page
DESCRIPTION
The SAE bolt strength grades range from grade 2
to grade 8. The higher the grade number, the greater
Refer to the Metric Conversion Chart to convert Also, use the chart to convert between millimeters
torque values listed in metric Newton- meters (N·m). (mm) and inches (in.) (Fig. 4).
6 INTRODUCTION VA
METRIC SYSTEM (Continued)
TORQUE REFERENCES tions Chart for torque references not listed in the
individual torque charts (Fig. 5).
DESCRIPTION
Individual Torque Charts appear within many or
the Groups. Refer to the Standard Torque Specifica-
page page
WARNING: Do not use alcohol or gasoline as a fuel CAUTION: Richer antifreeze mixtures cannot be
measured with normal field equipment and can
blending agent. They can be unstable under certain
cause problems associated with 100 percent ethyl-
conditions and hazardous or explosive when mixed
with diesel fuel. ene-glycol.
Use good quality diesel fuel from a reputable sup- The required ethylene-glycol (antifreeze) and water
mixture depends upon the climate and vehicle oper-
plier in your Dodge truck. For most year-round ser-
ating conditions. The recommended mixture of 50/50
vice, number 2 diesel fuel meeting ASTM
specification D-975 will provide good performance. If ethylene-glycol and water will provide protection
the vehicle is exposed to extreme cold (below 0°F/- against freezing to -37° C (-34° F). The antifreeze
18°C), or is required to operate at colder-than-normal concentration must always be a minimum of 44 per-
conditions for prolonged periods, use climatized No. 2 cent, year-round in all climates. If percentage is
lower than 44 percent, engine parts may be
diesel fuel or dilute the No. 2 diesel fuel with 50%
eroded by cavitation, and cooling system com-
No. 1 diesel fuel. This will provide better protection
from fuel gelling or wax-plugging of the fuel filters. ponents may be severely damaged by corrosion.
Maximum protection against freezing is provided
Diesel fuel is seldom completely free of water. To
prevent fuel system trouble, including fuel line freez- with a 68 percent antifreeze concentration, which
prevents freezing down to -67.7° C (-90° F). A higher
ing in winter, drain the accumulated water from the
percentage will freeze at a warmer temperature.
fuel/water separator using the fuel/water separator
drain provided. If you buy good-quality fuel and fol- Also, a higher percentage of antifreeze can cause the
0-2 LUBRICATION & MAINTENANCE VA
FLUID TYPES (Continued)
engine to overheat because the specific heat of anti- CAUTION: Use of Propylene-Glycol based coolants
freeze is lower than that of water. is not recommended, as they provide less freeze
Use of 100 percent ethylene-glycol will cause for- protection and less corrosion protection.
mation of additive deposits in the system, as the cor-
rosion inhibitive additives in ethylene-glycol require The cooling system is designed around the coolant.
the presence of water to dissolve. The deposits act as The coolant must accept heat from engine metal, in
insulation, causing temperatures to rise. The the cylinder head area near the exhaust valves and
increased temperature can result in engine detona- engine block. Then coolant carries the heat to the
tion. In addition, 100 percent ethylene-glycol freezes radiator where the tube/fin radiator can transfer the
at -22° C (-8° F ). heat to the air.
The use of aluminum cylinder blocks, cylinder
PROPYLENE-GLYCOL MIXTURES heads, and water pumps requires special corrosion
It’s overall effective temperature range is smaller protection. Mopart Antifreeze/Coolant, 5
than that of ethylene-glycol. The freeze point of 50/50 Year/100,000 Mile Formula (MS-9769), or the equiva-
propylene-glycol and water is -32° C (-26° F), 10° C lent ethylene-glycol base coolant with organic corro-
higher than ethylene-glycol’s freeze point. The boiling sion inhibitors (called HOAT, for Hybrid Organic
point (protection against summer boil-over) of propy- Additive Technology) is recommended. This coolant
lene-glycol is 125° C (257° F ) at 96.5 kPa (14 psi), offers the best engine cooling without corrosion when
compared to 128° C (263° F) for ethylene-glycol. Pro- mixed with 50% ethylene-glycol and 50% distilled
pylene glycol also has slightly poorer heat transfer water to obtain a freeze point of -37°C (-34°F). If it
characteristics than ethylene glycol. This can loses color or becomes contaminated, drain, flush,
increase cylinder head temperatures under certain and replace with fresh properly mixed coolant solu-
conditions. tion.
Propylene-glycol/ethylene-glycol mixtures can cause
the destabilization of various corrosion inhibitors, CAUTION: MoparT Antifreeze/Coolant, 5
causing damage to the various cooling system compo- Year/100,000 Mile Formula (MS-9769) may not be
nents. Also, once ethylene-glycol and propylene-glycol mixed with any other type of antifreeze. Mixing of
based coolants are mixed in the vehicle, conventional coolants other than specified (non-HOAT), may
methods of determining freeze point will not be accu- result in engine damage that may not be covered
rate. Both the refractive index and specific gravity under the new vehicle warranty, and decreased cor-
differ between ethylene glycol and propylene glycol. rosion protection.
REAR AXLE
• Synthetic Gear & Axle Lubricant SAE 75W-140
BRAKE FLUID
• DOT-4 or equivalent brake fluid.
PARTS & LUBRICANT position with jack stands at the front and rear ends
of the frame rails.
RECOMMENDATION
CAUTION: Do not lift vehicle with a floor jack posi-
STANDARD PROCEDURE - PARTS & tioned under:
LUBRICANT RECOMMENDATIONS • An axle tube.
Lubricating grease is rated for quality and usage • A body side sill.
by the NLGI. All approved products have the NLGI • A steering linkage component.
symbol (Fig. 1) on the label. At the bottom NLGI • A drive shaft.
symbol is the usage and quality identification letters. • The engine or transmission oil pan.
Wheel bearing lubricant is identified by the letter • The fuel tank.
“G”. Chassis lubricant is identified by the latter “L”. • A front suspension arm.
The letter following the usage letter indicates the
quality of the lubricant. The following symbols indi-
HOIST
cate the highest quality.
A vehicle can be lifted with:
• A single-post, frame-contact hoist.
• A twin-post, chassis hoist.
• A ramp-type, drive-on hoist.
HOISTING
STANDARD PROCEDURE - HOISTING
Refer to the Owner’s Manual for emergency vehicle
lifting procedures.
When the next maintenance service is due, this ENGINE OIL CHANGE AND FILTER REPLACEMENT
will be indicated in the multi-function display with At the minimum, change the engine oil and oil fil-
the wrench icon symbol displayed in km/miles or ter once a year – even if the vehicle mileage per year
days. is extremely low. For standard oil service schedules
• One wrench icon showing indicates Oil Service refer to the chapter oil service and maintenance ser-
is necessary. vice.
• Two wrench icons showing indicates Mainte- Once a Year
nance Service is necessary – displayed in km/miles or Select the viscosity of the engine oil (SAE classes)
days. according to the outside air temperature.
If the display shows the number of days, a clock Only use engine oil approved by DaimlerChrysler
symbol will also appear in the multi-function display. Corporation if following the ASSYST system guide-
You should have the maintenance performed lines.
within the stated period/distance. If the fuel used has a sulphur content exceeding
The service indicator should be reset after an oil 0.05% by weight, the service intervals should be split
service and/or maintenance service has been per- in half.
formed.
SCOPE OF WORK FOR MAINTENANCE SERVICE
REGULAR CHECK-UPS Oil Service
To maintain the safe operation of the vehicle, it is • Engine:
recommended that the following tasks be performed Oil change and filter replacement
on a regular basis (i.e. weekly or whenever the vehi- Check fluid levels of the following system,
cle is refueled). Check: refill as necessary.
• Engine oil level • If fluid is lost, trace and eliminate cause – as a
• Brake system, clutch mechanism – fluid level separate order.
• Battery – acid level • Power-assisted steering
• Windshield washer system and headlamp clean- Lubrication work:
ing system – fluid level • Trailer tow hitch (original equipment)
• Mechanical assemblies (e. g. engine, transmis- Maintenance
sion, etc.) – check for leaks • ASSYST maintenance computer reset
• Condition of tires and tires pressures Function check
• All exterior lights • Signalling system, warning and indicator lamps
• Headlamps, exterior lighting
SPECIAL MAINTENANCE REQUIREMENTS • Windshield wipers, windshield washer system
If bodies built by manufacturers other than Check for leaks and damage.
DaimlerChrysler Corporation are fitted to the vehi- • Check for abrasion points and ensure that lines
cle, the maintenance requirements and lubrication are correctly routed!
intervals specified by the body manufacturer must be • All lines and hoses, sensor cables
adhered to, in addition to all standard maintenance • Rubber boots on front axle drive shafts, rubber
requirements. boots on front axle suspension ball joints, shock
Brake Fluid absorbers
Only use brake fluids approved by the manufac- Check fluid levels for the following systems,
turer (DOT 4 plus). correct as necessary.
Coolant
Corrosion inhibitor/antifreeze concentration in the NOTE: Should there be a loss of fluid which cannot
coolant should be checked before the onset of winter be explained by regular use, trace and eliminate the
(once year in countries with high prevailing temper- cause.
atures).
VA LUBRICATION & MAINTENANCE 0-9
MAINTENANCE SCHEDULES (Continued)
• Engine cooling system. Check corrosion inhibi- ADDITIONAL MAINTENANCE WORK AFTER YEARS
tor/antifreeze, refill as necessary. Every 3 years
• Hydraulic brake system Air cleaner filter element renewal (note installa-
• Battery tion date)
• Windshield washer system Every 5 years or 100,000 miles
Engine Coolant renewal
• Fuel filter renewal Note coolant composition
• Air cleaner with maintenance indicator:
• Check degree of contamination.
• Air cleaner filter element renewed as necessary. INTERNATIONAL SYMBOLS
Chassis and body
• Trailer coupling: DESCRIPTION
Check operation, play and retaining fixtures DaimlerChrysler Corporation uses international
• Secondary rubber springs: symbols to identify engine compartment lubricant
Visual check and fluid inspection and fill locations (Fig. 3).
• Tire pressures:
Correct as necessary, including spare tire
• Check thickness of brake pads
• Brake test
• Check condition of steering mechanism
• Heating/ventilation dust filter renewal
SUSPENSION
TABLE OF CONTENTS
page page
FRONT
TABLE OF CONTENTS
page page
FRONT SPRING
SPECIFICATIONS - TORQUE CHART .........2 REMOVAL .............................8
SPECIAL TOOLS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
FRONT SUSPENSION . . . . . . . . . ..........3 SPRING CLAMP PLATES
BUSHINGS REMOVAL .............................9
REMOVAL ................... ..........4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLATION . . . . . . . . . . . . . . . . ..........4 SPRING STOP PLATES
HUB / BEARING REMOVAL .............................9
DIAGNOSIS AND TESTING - ..... ..........4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
REMOVAL ................... ..........5 STABILIZER BAR
INSTALLATION . . . . . . . . . . . . . . . . ..........5 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
KNUCKLE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
REMOVAL ................... ..........6 REMOVAL .............................9
INSTALLATION . . . . . . . . . . . . . . . . ..........6 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10
LOWER BALL JOINT STABILIZER LINK
REMOVAL ................... ..........6 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . ..........6 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10
LOWER CONTROL ARM STRUT
REMOVAL ................... ..........7 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . ..........7 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10
2-2 FRONT VA
FRONT
SPECIFICATIONS - TORQUE CHART
TORQUE SPECIFICATIONS
SPECIAL TOOLS
FRONT SUSPENSION
SPECIAL TOOL CROSS REFERENCE CHART
MB MILLER DESCRIPTION
TOOL # TOOL #
N/A 9288 LEAF SPRING WEDGE
BLOCK
N/A 9294 LOWER BALL JOINT
REMOVE/INSTALLER
N/A 9302 BUSHING REMOVER
BALL JOINT SEPARATOR - 9282
/INSTALLER
N/A C-3894-A PULLER TIE ROD
730 589 9282 BALL JOINT SEPARATOR
02 33 00
N/A C-4212F BALL JOINT PRESS
BUSHINGS
REMOVAL
(1) Remove the lower control arm (Refer to 2 -
SUSPENSION/FRONT/LOWER CONTROL ARM -
REMOVAL).
(2) Install the lower control arm in a vise.
(3) Install special tool C-4212F (Press) with special
tool 9302-1 (Driver) and 9302–3 (Receiver) (Fig. 1).
(5) Pull the wheel hub firmly back and forth and
read off the wheel bearing play on the dial gauge.
(Wheel bearing play should be 0.02 - 0.04 mm
Fig. 1 LCA BUSHING REMOVAL (0.000787 - 0.00158 in.).
1 - SPECIAL TOOL C-4212F (PRESS) (6) If necessary, loosen the locking screw and
2 - SPECIAL TOOL 9302-1 (DRIVER) adjust the wheel bearing play by loosing or tighten-
3 - LOWER CONTROL ARM ing the clamping nut.
4 - SPECIAL TOOL 9302-3 (RECEIVER CUP)
5 - BUSHING (7) Retighten the locking screw and recheck the
wheel bearing play.
(4) Press out the old control arm bushing.
INSTALLATION
(1) Install the new control arm bushing into the
control arm.
(2) Press the new bushing into the control arm
using special tool C-4212F and 9302-1 (Driver) with
9302-2 (Sizer cup) and 9302-4 (Receiver) (Fig. 2).
(3) Press the bushing in all the way until the lip is
seated properly into the control arm.
(4) Install the lower control arm to the vehicle
(Refer to 2 - SUSPENSION/FRONT/LOWER CON-
TROL ARM - INSTALLATION).
HUB / BEARING
Fig. 3 MEASURING & ADJUSTING WHEEL BEARING
DIAGNOSIS AND TESTING -
1 - WHEEL HUB
(1) Raise and support the vehicle. 2 - LOCKING SCREW
(2) Remove the grease cap. 3 - DIAL INDICATOR
(3) Position a dial indicator against the face of the
wheel hub (Fig. 3).
(4) Tighten the locking screw on the clamping nut
(Fig. 3).
VA FRONT 2-5
HUB / BEARING (Continued)
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the front wheels (Refer to 22 - TIRES/
WHEELS/WHEELS - REMOVAL).
(3) Remove the disc brake caliper adapter (Refer to
5 - BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPER ADAPTER - REMOVAL).
(4) Remove the wheel flange ring (if equipped with
dual rear wheels) (Fig. 5).
(5) Remove the disc brake rotor (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ROTORS -
REMOVAL).
(6) Remove the grease cap (Fig. 4).
(7) Loosen the bolt on the clamping nut and
remove the clamping nut (Fig. 4).
(8) Remove the thrust washer (Fig. 4).
(9) Remove the wheel hub and tapered roller bear- Fig. 5 FRONT WHEEL HUB WITH DUAL REAR
ing from the stub axle assembly (Fig. 4). WHEELS (DRW)
1 - ADAPTER BOLT
2 - DISC BRAKE CALIPER
3 - INNER BEARING RACE
4 - WHEEL HUB
5 - DISC BRAKE ROTOR
6 - LOCKING BOLT
7 - WHEEL FLANGE RING
8 - OUTER BEARING
9 - THRUST WASHER
10 - CLAMPING NUT
11 - GREASE CAP
12 - WHEEL FLANGE RING MOUNTING BOLT
13 - GREASE SEAL
14 - STEERING KNUCKLE
KNUCKLE (4) Install the outer tie rod end to the steering
knuckle (Fig. 6) and tighten the nut to 130 N·m (96
ft. lbs.).
REMOVAL
(5) Install the ABS sensor by pushing the sensor
(1) Raise and support the vehicle.
all the way into the knuckle and the sensor will self
(2) Remove the front wheels (Refer to 22 - TIRES/
adjust when the wheel is turned.
WHEELS/WHEELS - REMOVAL).
(6) Install the hub/bearing (Refer to 2 - SUSPEN-
(3) Remove the disc brake caliper adapter (Refer to
SION/FRONT/HUB / BEARING - INSTALLATION).
5 - BRAKES/HYDRAULIC/MECHANICAL/DISC
(7) Install the disc brake caliper adapter with the
BRAKE CALIPER ADAPTER - REMOVAL).
brake caliper (Refer to 5 - BRAKES/HYDRAULIC/
(4) Remove the hub/bearing (Refer to 2 - SUSPEN-
MECHANICAL/DISC BRAKE CALIPER ADAPTER -
SION/FRONT/HUB / BEARING - REMOVAL).
INSTALLATION).
(5) Separate the outer tie rod from the steering
(8) Install the front wheels (Refer to 22 - TIRES/
knuckle (Fig. 6) using special tool C-3894–A.
WHEELS/WHEELS - INSTALLATION).
(6) Raise the lower control arm approximately 10
(9) Lower the vehicle.
mm using a jack. In order to eliminate tensile
(10) Check and set toe if necessary (Refer to 2 -
force in the damper strut.
SUSPENSION/WHEEL ALIGNMENT - STANDARD
(7) Remove the ABS sensor from the knuckle by
PROCEDURE).
pulling straight out.
(8) Remove the strut at the knuckle (Fig. 6).
(9) Separate the lower ball joint from the steering LOWER BALL JOINT
knuckle using special tool 9282 (Fig. 6).
(10) Remove the steering knuckle from the vehicle
REMOVAL
(Fig. 6).
(1) Raise and support the vehicle.
(2) Remove the front tire and wheel assembly.
(3) Remove the front strut (Refer to 2 - SUSPEN-
SION/FRONT/STRUT - REMOVAL).
(4) Remove the steering knuckle (Refer to 2 - SUS-
PENSION/FRONT/KNUCKLE - REMOVAL).
(5) Remove the lower ball joint using special tool
9294-1 (Driver) with 9294-2 (Reciever) and C-4212–F.
(Fig. 7).
INSTALLATION
(1) Install the steering knuckle on the lower ball Fig. 7 LOWER BALL JOINT
joint stud (Fig. 6). 1 - LOWER CONTROL ARM
(2) Install the lower ball joint nut (Fig. 6). Tighten 2 - LOWER BALL JOINT
to 280 N·m (206 ft. lbs.)
(3) Install the strut to the steering knuckle (Fig. INSTALLATION
6). Tighten to 185 N·m (136 ft. lbs.). (1) Install the ball joint into the lower control arm
using special tool 9294-3 (Installer ring) inserted in
9294-2 (Reciever) and C-4212–F (Fig. 7).
VA FRONT 2-7
LOWER BALL JOINT (Continued)
(2) Install the front strut (Refer to 2 - SUSPEN-
SION/FRONT/STRUT - INSTALLATION).
(3) Install the steering knuckle (Refer to 2 - SUS-
PENSION/FRONT/KNUCKLE - INSTALLATION).
(4) Install the tire and wheel assembly (Refer to 22
- TIRES/WHEELS/WHEELS - INSTALLATION).
(5) Lower the vehicle.
(6) Check the front wheel alignment (Refer to 2 -
SUSPENSION/WHEEL ALIGNMENT - SPECIFICA-
TIONS).
SPRING
REMOVAL
(1) To do this next step the vehicle must be
on the ground. Remove the front and rear bolts on
the left and right spring clamp plates (Fig. 9).
(2) Raise and support the vehicle.
(3) Remove the front wheels.
(4) Remove the brake caliper adapter (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPER ADAPTER - REMOVAL).Do not
allow the caliper to hang by the hose, support
the caliper accordingly.
(5) Remove the ABS sensor from the mounting
bore in the steering knuckle (Fig. 9).
(6) Remove the outer tie rod retaining nut and
separate the tie rod from the knuckle (Fig. 9) using Fig. 9 FRONT SPRING
special tool C-3894–A. 1 - NUT
2 - STRUT
3 - STOP PLATE
NOTE: In order to remove tension from the strut, 4 - STOP PLATE BOLT
Raise the lower control arm approximately 10 mm 5 - CALIPER ADAPTER BOLT
with a jack. 6 - DISC BRAKE CALIPER
7 - OUTER TIE ROD END NUT
8 - ABS SENSOR
(7) Remove the strut bolts from the steering 9 - SPEED SENSOR
knuckle. 10 - LOWER CONTROL ARM RETAINING NUTS
(8) Remove both stop plate bolts and rotate the 11 - OUTER TIE ROD END
12 - RUBBER SPRING MOUNT
plates upwards with the stabilizer link attached. 13 - SHEAR BUSHING
(9) Lower the lower control arm. 14 - SPRING CLAMP PLATE BOLT
(10) Remove the lower ball joint nut from the 15 - SPRING CLAMP PLATE
16 - LOWER RUBBER SPRING MOUNT
steering knuckle. 17 - SPRING
(11) Separate the lower ball joint from the knuckle 18 - STRUT BOLTS
using special tool 9282. 19 - LOWER CONTROL ARM BOLTS
(12) Remove the lower control arm nuts and bolts
from the frame. INSTALLATION
(13) Remove the lower control arm from the frame
NOTE: To avoid damaging the transverse leaf
(Fig. 9).
spring, cushion the pad on the jack accordingly.
NOTE: To avoid damaging the transverse leaf
spring, cushion the pad on the jack accordingly. NOTE: Hand tighten all bolts until vehicle is on the
ground, unless the bushings may become distorted.
(14) Support the transverse leaf spring in the cen-
ter with a jack.
(15) Remove the left and right spring clamp plates NOTE: The height blocks between the engine cradle
(Refer to 2 - SUSPENSION/FRONT/SPRING CLAMP and the spring are color coded, Make sure not to
PLATES - REMOVAL) (Fig. 9). mix the blocks per sides. The blocks are different in
sizes to accommodate the weight of the vehicle and
NOTE: The upper spring blocks between the engine driver in order for the vehicle to sit level.
cradle and the spring are color coded, Make sure
not to mix the blocks per sides. The blocks are dif- (1) Install the transverse leaf spring in the center
ferent in sizes to accommodate the weight of the with a jack with all the rubber mounts attached.
vehicle and driver in order for the vehicle to sit (2) Install the lower control arm to the frame (Fig.
level. 9).
(3) Install the knuckle on the lower ball joint.
(16) Lower the jack and remove the transverse leaf (4) Raise the lower control arm approximately 10
spring towards the side. mm with a jack.
VA FRONT 2-9
SPRING (Continued)
(5) Install both stop plate bolts to the lower control SPRING STOP PLATES
arm
(6) Install the strut bolts to the steering knuckle.
REMOVAL
(7) Reinstall the tie rod to the steering knuckle
(1) Raise and support the vehicle.
(Fig. 9). Tighten to 150 N·m (110 ft. lbs.).
(2) Remove the tire and wheel assembly.
(8) Install the ABS sensor all the way into the
(3) Remove the lower end of the stabilizer link
steering knuckle, the sensor will adjust automatically
from the stop plate.
when the vehicle is moved (Fig. 9).
(4) Remove the three bolts retaining the spring
(9) Install the disc brake caliper adapter (Fig. 9).
stop plate from the lower control arm.
Tighten to 170 N·m (125 ft. lbs.).
(10) Install the front wheels.
(11) Lower the vehicle.
INSTALLATION
(1) Install the spring stop plate to the lower con-
(12) Install the spring clamp plates (Fig. 9).
trol arm. Tighten the bolts to 60 N·m (44 ft. lbs.).
Tighten (M-10 bolts) to 65 N·m (48 ft. lbs.) (M-12
(2) Install the stabilizer link to the spring stop
bolts) to 130 N·m (96 ft. lbs.).
plate.
(13) Roll the vehicle approximately 1 mm forwards
(3) Install the tire and wheel assembly.
and the backwards, and rock firmly.
(4) Lower the vehicle.
(14) Tighten the nuts on the lower control arm to
the frame to 150 N·m (110 ft. lbs.).
(15) Apply brake to actuate brake pressure. STABILIZER BAR
SPRING CLAMP PLATES DESCRIPTION
The bar extends across the front underside of the
REMOVAL chassis and connects to the frame crossmember. The
(1) Raise and support the vehicle. ends of the bar mount to the lower suspension arm.
(2) Install a jack under the lower ball joint and All mounting points of the stabilizer bar are isolated
lower the weight of the vehicle enough to allow a by bushings (Fig. 10).
wrench between the lower control arm and the
bracket tighten the nut.
(3) Remove the front and rear bolts to the spring
clamp plates.
(4) Remove the four inner retaining bolts and
nuts.
(5) Remove the spring clamp plate and rubber
block.
(6) Remove the shear bushings from the front and
rear bolts.
INSTALLATION
(1) Install a jack under the lower ball joint and
lower the weight of the vehicle enough to allow a
wrench between the lower control arm and the
bracket tighten the nut.
(2) Fit one spring clamp plate together with the Fig. 10 STABILIZER BAR
lower spring rubber block.
(3) Install the bolt with the shear bushing on the
OPERATION
The stabilizer bar is used to minimize vehicle front
rear mounting, Do not tighten yet.
sway during turns. The bar helps to maintain a flat
(4) Install the four retaining bolts for the spring
attitude to the road surface.
clamp plate. Tighten to 65 N·m (48 ft.lbs.).
(5) Align the holes for the front clamp plate joint
using a suitable drift (shear bushing not installed).
REMOVAL
(6) Remove the alignment drift. (1) Raise and support the vehicle.
(7) Insert the shear bushing and retaining bolt (2) Remove the stabilizer bar clamp bolts at the
into the hole and tighten to 130 N·m (96 ft.lbs.). front axle (Fig. 11).
(8) Remove the jack and lower the vehicle. (3) Press the rubber mount outwards out of the
brackets (Fig. 11).
2 - 10 FRONT VA
STABILIZER BAR (Continued)
(4) Remove the stabilizer links from the stabilizer STRUT
bar (Fig. 11).
REMOVAL
(1) On the drivers side remove the floor covering
off to the side.
(2) On the passengers side take off the cover for
the tools.
(3) Remove the cover for the upper strut mounting
(Fig. 12).
(4) Remove the nut on the upper strut mounting
(Fig. 12).
(5) Raise and support the vehicle.
(6) Remove the front wheels.
(7) Raise the lower control arm approximately 10
mm with a jack to remove the tension from the strut.
(8) Remove the strut from the steering knuckle
(Fig. 12).
INSTALLATION
(1) Install the stabilizer links to the stabilizer bar
(Fig. 11).
(2) Install the stabilizer to the front axle (Fig. 11).
(3) Install the stabilizer bar clamp and bolts (Fig.
11). Tighten the bolts to 30 N·m (22 ft. lbs.).
(4) Lower the vehicle.
Fig. 12 STRUT
STABILIZER LINK 1 - COVER
2 - NUT
3 - RUBBER MOUNT
REMOVAL 4 - STRUT
(1) Raise and support the vehicle. 5 - STRUT BOLT
(2) Insert a pry bar between the stabilizer link and 6 - LOCKING BOLT
something solid to pry on.
(3) Pry the stabilizer link off the stabilizer bar and INSTALLATION
the spring stop plate.
NOTE: Hand tighten the strut upper mounting nut
until the vehicle is on the ground, otherwise the
INSTALLATION
bushings may become distorted.
(1) Install a mild detergent soap the to rubber
bushings on the stabilizer link. (1) Install strut to the steering knuckle (Fig. 12).
(2) Install the stabilizer links onto the stabilizer Tighten to 185 N·m (136 ft. lbs.).
bar and spring stop plate by pushing on the link. (2) Raise the lower control to install the upper
(3) Lower the vehicle. part of the strut into the footwell. Tighten to 100
N·m (74 ft. lbs.).
(3) Install wheels (Refer to 22 - TIRES/WHEELS/
WHEELS - INSTALLATION).
(4) Lower the vehicle.
(5) Install the nut covers (Fig. 12).
(6) Refit the floor covering and the tool cover.
VA REAR 2 - 11
REAR
TABLE OF CONTENTS
page page
SHOCK
DIAGNOSIS AND TESTING - SHOCK
A knocking or rattling noise from a shock absorber
may be caused by movement between mounting
bushings and metal brackets or attaching compo-
nents. These noises can usually be stopped by tight-
ening the attaching nuts. If the noise persists,
inspect for damaged and worn bushings, and attach-
ing components. Repair as necessary if any of these
conditions exist.
A squeaking noise from the shock absorber may be
caused by the hydraulic valving and may be intermit-
tent. This condition is not repairable and the shock
absorber must be replaced.
The shock absorbers are not refillable or adjust-
able. If a malfunction occurs, the shock absorber Fig. 1 SHOCK ABSORBER (LEFT SIDE SHOWN)
must be replaced. To test a shock absorber, hold it in 1 - CLIP
2 - WASHER
an upright position and force the piston in and out of 3 - MOUNTING STUD/BOLT
the cylinder four or five times. The action throughout 4 - WASHER
each stroke should be smooth and even. 5 - NUT
6 - FRAME
The shock absorber bushings do not require any 7 - SHOCK ABSORBER
type of lubrication. Do not attempt to stop bushing 8 - BOLT
noise by lubricating them. Grease and mineral oil- 9 - NUT
10 - ALB LEVER
base lubricants will deteriorate the bushing.
bolt) or Tighten to 110 N·m (81 ft.lbs.) for (M14X1.5
REMOVAL bolt).
(1) Raise and support the vehicle. (6) Lower the vehicle.
(2) Remove the shock absorber bolt from the rear
axle (Fig. 1).
(3) Unsnap the clip for the ALB lever (left hand SPRING
side) (Fig. 1).
(4) Remove the ALB lever from the upper shock DESCRIPTION
bolt/stud (Fig. 1). The rear suspension system uses a multi-leaf
(5) Remove the shock absorber bolt from the frame springs and a solid drive axle. The forward end of the
side (Fig. 1). springs are mounted to the body rail hangers
(6) Remove the shock absorber (Fig. 1). through rubber bushings. The rearward end of the
springs are attached to the body by the use of shack-
INSTALLATION les. The spring and shackles use rubber bushings.
(1) Install the shock absorber (Fig. 1).
(2) Install the shock absorber bolt to the frame OPERATION
side (Fig. 1) Tighten to 80 N·m (59 ft.lbs.) for (SRW) The springs control ride quality and maintain vehi-
or Tighten to 140 N·m (103 ft.lbs.) for (DRW). cle ride height. The shackles allow the springs to
(3) Install the ALB lever to the upper shock bolt/ change their length as the vehicle moves over various
stud (left hand side only) (Fig. 1). road conditions.
(4) Snap the clip for the ALB lever (Fig. 1).
(5) Install the shock absorber bolt to the rear axle
(Fig. 1) Tighten to 70 N·m (52 ft.lbs.) for (M12X1.5
2 - 14 REAR VA
SPRING (Continued)
REMOVAL
REMOVAL - (SRW)
(1) Raise and support the vehicle.
(2) Support the rear axle.
(3) Remove the U-bolt and spring plate (Fig. 2).
(4) Remove the spring from the front spring
bracket (Fig. 2).
(5) Remove the rear spring with the spring shackle
from the spring bracket (Fig. 2).
(6) Lower the rear axle and remove the rear
spring.
(7) Remove the spring shackle from the spring (if
needed) (Fig. 2).
INSTALLATION
INSTALLATION - (SRW)
NOTE: Larger spring bushing goes toward the front.
SPRING SHACKLE
REMOVAL
(1) Raise and support the vehicle.
(2) Support the rear axle.
(3) Remove both the rear spring shackles from the
spring bracket.
(4) Lower the rear axle and remove the rear spring
shackle from the spring.
INSTALLATION
(1) Install the spring shackle to the spring.
Tighten to 90 N·m (66 ft. lbs.).
(2) Raise the rear axle while installing the spring
shackle to the spring bracket. Tighten to 85 N·m (63
ft. lbs.).
(3) Lower the vehicle. Fig. 4 SWAY BAR WITH SINGLE REAR WHEELS
(SRW)
1 - M12 NUT
STABILIZER BAR 2 - BUSHING
3 - SWAY BAR LINK
4 - M12 BOLT
REMOVAL 5 - SWAY BAR
6 - CLAMP
(1) Raise and support the vehicle. 7 - M8 BOLT
(2) Remove the stabilizer links at the bar (Fig. 4). 8 - BRACKET
(3) Remove the stabilizer bar clamp at the axle 9 - FOUR POINT NUT M8
10 - WASHER
(Fig. 4). 11 - M8 NUT
(4) Remove the bracket (Fig. 4) 12 - BUSHING
(5) Remove the stabilizer bar from the vehicle. 13 - MOUNT
INSTALLATION
(1) Install the stabilizer bar to the axle.
(2) Install the stabilizer bar clamps and bracket,
center the bar then tighten to 25 N·m (18ft. lbs.)
(SRW) (Fig. 4) or Tighten to 70 N·m (52 ft. lbs.) for
(DRW) (Fig. 5).
(3) Install the stabilizer bar to the stabilizer links
and tighten to 95 N·m (60 ft. lbs.) (Fig. 4) or (Fig. 5).
(4) Lower the vehicle.
STABILIZER LINK
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the stabilizer links at the bar (Fig. 4).
Fig. 5 SWAY BAR WITH DUAL REAR WHEELS
(3) Remove the stabilizer link at the frame.
(DRW)
1 - STABILIZER LINK
INSTALLATION 2 - SWAY BRA BOLT
(1) Install the stabilizer bar to the stabilizer links 3 - SWAY BAR NUT
and tighten to 95 N·m (60 ft. lbs.) (Fig. 4). 4 - SWAY BAR
5 - RUBBER MOUNT
(2) Lower the vehicle. 6 - SWAY BAR CLAMP
(3) Install the stabilizer link to the frame. Tighten 7 - CLAMP MOUNTING BOLTS
to 95 N·m (60 ft. lbs.).
2 - 16 WHEEL ALIGNMENT VA
WHEEL ALIGNMENT
TABLE OF CONTENTS
page page
WHEEL ALIGNMENT
DESCRIPTION
NOTE: Camber and Caster are not adjustable on
this vehicle. (TOE ONLY).
Wheel alignment involves the correct positioning of Fig. 1 Wheel Alignment Measurements
the wheels in relation to the vehicle. The positioning 1 - FRONT OF VEHICLE
is accomplished through suspension and steering 2 - STEERING AXIS INCLINATION
3 - PIVOT POINT
linkage adjustments. An alignment is considered 4 - TOE-IN
essential for efficient steering, good directional stabil-
ity and to minimize tire wear. The most important (1) Inspect tires for size, air pressure and tread
measurements of an alignment are caster, camber wear.
and toe (Fig. 1). (2) Inspect front wheel bearings for wear.
(3) Inspect front wheels for excessive radial or lat-
CAUTION: Never attempt to modify suspension or eral runout and balance.
steering components by heating or bending. (4) Inspect ball studs, linkage pivot points and
steering gear for looseness, roughness or binding.
(5) Inspect suspension components for wear and
DIAGNOSIS AND TESTING - PRE-ALIGNMENT noise.
INSPECTION (6) Road test the vehicle.
Before starting wheel alignment, the following
inspection and necessary corrections must be com-
pleted. Refer to Suspension and Steering System
Diagnosis Chart below for additional information.
VA WHEEL ALIGNMENT 2 - 17
WHEEL ALIGNMENT (Continued)
SUSPENSION AND STEERING SYSTEM DIAGNOSIS
FRONT END NOISE 1. Loose or worn wheel bearing. 1. Replace wheel bearing.
FRONT WHEELS SHIMMY 1. Loose or worn wheel bearing. 1. Replace wheel bearing.
STANDARD PROCEDURE - TOE ADJUSTMENT wheel with the front wheels in the straight-ahead
CAMBER AND CASTER ARE NOT ADJUSTABLE position.
(TOE ONLY).. (2) Loosen the tie rod jam nuts.
The wheel toe position adjustment is the final
NOTE: Each front wheel should be adjusted for
adjustment.
(1) Start the engine and turn wheels both ways one-half of the total toe position specification. This
will ensure the steering wheel will be centered
before straightening the wheels. Secure the steering
when the wheels are positioned straight-ahead.
2 - 18 WHEEL ALIGNMENT VA
WHEEL ALIGNMENT (Continued)
(3) Adjust the wheel toe position by turning the REAR SPECIFICATIONS
inner tie rod as necessary.
(4) Tighten the tie rod jam nut to 50 N·m (37 ft.
lbs.). DESCRIPTION REAR SPECIFICATION
(5) Verify the specifications Toe-In 0° (±0.25°)
(6) Turn off engine. Max
Camber 0° (-0.66°/+0.33°)
SPECIFICATIONS Max
FRONT SPECIFICATIONS
Inclination of Rear 0° (±0.25°)
Wheels (Individual Wheel
DESCRIPTION FRONT SPECIFICATION Toe)= Maximum
Toe-In 0° (±0.16°) Inclination of Rear Axle
Max
Camber 0° (±0.75°)
Camber 1.33°
Left to Right Difference
Max
Caster 0° (±0.5°)
Steering Knuckle 0° (±0.5°)
Inclination
Steering Knuckle 1°
Inclination
Left to Right Difference
Max
TORQUE SPECIFICATIONS
page page
PROPELLER SHAFT
TABLE OF CONTENTS
page page
PROPELLER SHAFT BALANCE (8) Mark and number propeller shaft six inches
from the pinion yoke end at four positions 90° apart.
NOTE: Removing and indexing the propeller shaft (9) Run and accelerate the vehicle until vibration
180° relative to the yoke may eliminate some vibra- occurs. Note intensity and speed the vibration
tions. occurred. Stop the engine.
(10) Install a screw clamp at position 1 (Fig. 1).
If propeller shaft is suspected of being out of bal- (11) Start engine and re-check for vibration. If lit-
ance, verify with the following procedure: tle or no change in vibration is evident, move clamp
(1) Place vehicle in netrual. to the next positions and repeat vibration test.
(2) Raise and support the vehicle by the axles as
level as possible. NOTE: If there is no difference in vibration at the
(3) Clean all foreign material from propeller shaft other positions, the vibration may not be propeller
and universal joints. shaft.
(4) Inspect propeller shaft for missing balance
weights, broken welds, and bent areas. (12) If vibration decreased, install a second clamp
(Fig. 2) and repeat vibration test.
NOTE: If propeller shaft is bent, it must be replaced. (13) If additional clamp causes additional vibra-
tion, separate clamps 1/2 inch above and below the
(5) Inspect universal joints for wear, properly mark. Repeat the vibration test (Fig. 3).
installed and correct alignment with the shaft. (14) Increase distance between clamps and repeat
(6) Check universal joint clamp screws torque. test until vibration is at the lowest level. Bend the
(7) Remove wheels and tires. Install wheel lug slack end of the clamps so the screws will not loosen.
nuts to retain the brake drums/rotors.
VA PROPELLER SHAFT 3-3
PROPELLER SHAFT (Continued)
(15) If vibration remains unacceptable, preform
the procedure to the front end of the propeller shaft.
(16) Install the wheel and tires. Lower the vehicle.
RUNOUT SPECIFICATIONS
STANDARD PROCEDURE
PROPELLER SHAFT ANGLE
This procedure applies the front and rear propeller
shafts.
(1) Place vehicle in netural.
(2) Raise and support vehicle at the axles as level
as possible.
(3) Remove universal joint snap rings if equipped,
so Inclinometer 7663 base sits flat.
(4) Rotate shaft until transmission case output
yoke bearing is facing downward.
SPECIFICATIONS
TORQUE SPECIFICATIONS
SPECIAL TOOLS
SPECIAL TOOL CROSS-REFERENCE CHART
MILLER TOOL
MB TOOL # DESCRIPTION
#
N/A 938 BRIGE
N/A 1130 SPLITTER
387 589 05 15
9275 INSTALLER
00
INCLINOMETER
N/A 7663
BRIDGE 938
3-6 PROPELLER SHAFT VA
PROPELLER SHAFT (Continued)
SPLITTER 1130
INCLINOMETER 7663
PROPELLER SHAFT
REMOVAL
(1) Secure vehicle to prevent it from rolling.
(2) Make installing reference marks on propeller
shaft (Fig. 6) and (Fig. 7).
(3) Remove retaining bracket bolts (Fig. 8) and
Fig. 7 ALIGNMENT MARKS 3 PIECE SHAFT
(Fig. 9).
1 - REFERNCE MARK
(4) Remove propeller shaft bolts from rear axle 2 - CENTER SHAFT
and transmission at the flange. 3 - REFERENCE MARK
(5) Remove propeller shaft intermediate bearing 4 - REAR SHAFT
nuts from retaining bracket and bracket for brake
cable. (2) Install propeller shaft intermediate bearing
support/supports to frame floor and tighten bolts to
NOTE: The brake cable bracket is only installed in 95 N·m (70 ft. lbs.).
vehicles with wheelbase 3550 mm (3) Install propeller shaft intermediate bearing
with retaining bracket and bracket for brake cable.
(6) Remove shaft from the vehicle.
NOTE: The bracket is only installed on vehicles
INSTALLATION with wheelbase 3550 mm.
(1) Install propeller shaft intermediate bearing/
bearings to support and tighten nuts to 105 N·m (77 (4) Install propeller shaft to rear axle and trans-
ft. lbs.). mission flange with installation marks are aligned.
Tighten bolts to 70 N·m (66 ft. lbs.).
(5) Install retaining bracket and tighten bolts to
100 N·m (74 ft. lbs.).
VA PROPELLER SHAFT 3-7
PROPELLER SHAFT (Continued)
CENTER BEARING
REMOVAL
(1) Remove propeller shaft.
(2) Mark shafts for installation alignment (Fig.
10).
Fig. 11 BOOT
1 - BOOT Fig. 13 CENTER BEARING REMOVAL
2 - CLAMP 1 - BRIDGE
3 - SHAFT 2 - PLUG
3 - BEARING SPLITTER
(4) Pull apart propeller shaft. 4 - CENTER BEARING
(5) Remove snap-ring (Fig. 12).
(6) Pull off center bearing with a Bearing Splitter
1130 and Bridge 938, with a plug on the end of the
shaft (Fig. 13).
VA PROPELLER SHAFT 3-9
CENTER BEARING (Continued)
REAR AXLE
TABLE OF CONTENTS
page page
VIBRATION
Vibration at the rear of the vehicle is usually
caused by a:
• Damaged drive shaft.
• Missing drive shaft balance weight(s).
• Worn or out-of-balance wheels.
• Loose wheel lug nuts.
• Worn U-joint(s).
• Loose/broken springs.
• Damaged axle shaft bearing(s).
• Loose pinion gear nut.
• Excessive pinion yoke run out.
• Bent axle shaft(s). Fig. 1 FILL PLUG
Check for loose or damaged front-end components
1 - FILL PLUG
or engine/transmission mounts. These components 2 - DRAIN PLUG
can contribute to what appears to be a rearend vibra-
tion. Do not overlook engine accessories, brackets REMOVAL
and drive belts. (1) Raise and support the vehicle.
(2) Position a suitable lifting device under the axle
NOTE: All driveline components should be exam-
and secure axle to device.
ined before starting any repair.
(3) Remove wheels and tires.
(4) Unplug wear indicator cable (Fig. 2) and (Fig.
DRIVELINE SNAP 3).
A snap or clunk noise when the vehicle is shifted (5) Detach cable connector for brake pad wear
into gear (or the clutch engaged), can be caused by: indicator.
• High engine idle speed. (6) Remove ABS sensor and clamp bushing from
• Transmission shift operation. mounting bore.
• Loose engine/transmission/transfer case mounts.
NOTE: The right-hand ABS sensor cable is labeled
• Worn U-joints.
at the factory with a white tag.
• Loose spring mounts.
• Loose pinion gear nut and yoke. (7) Remove cable ties from the park brake cables.
• Excessive ring gear backlash. Release connection cable of brake pad wear indicator
• Excessive side gear to case clearance. and ABS sensor cable up to the relay unit of the
The source of a snap or a clunk noise can be deter- parking brake.
mined with the assistance of a helper. Raise the vehi- (8) Remove brake cables from adjuster.
cle on a hoist with the wheels free to rotate. Instruct (9) Remove brake calipers with adapters and lines.
the helper to shift the transmission into gear. Listen
3 - 12 REAR AXLE VA
REAR AXLE (Continued)
(10) Remove stablizer bar from axle brackets. NOTE: On installation of the propeller shaft, joint
(11) Remove shock absorber bolts from rear axle. arrows must be flush and must point towards the
(12) Remove ALB lever from rear axle bracket. frame floor. Tighten the propeller shaft in this posi-
(13) Pull off hold-down clips and remove brake tion.
hoses.
(14) Pull vent line of rear axle out of frame. (4) Install ALB lever to axle bracket and tighten
(15) Remove propeller shaft. new nut 34 N·m (46 ft. lbs.).
(16) Remove U-brackets and plates (Fig. 2) and (5) Install shock absorbers to rear axle and tighten
(Fig. 3). bolts to:
(17) Remove axle from the vehicle. • M12 x 1.5 Bolt - 70 N·m (52 ft. lbs.)
• M14 x 1.5 Bolt - 110 N·m (81 ft. lbs.)
INSTALLATION (6) Install stabilizer bar to axle and tighten bolts
(1) Raise axle into position. to:
(2) Install plates and U-brackets with new nuts. • SRW Axle - 25 N·m (18 ft. lbs.)
Tighten nuts to 170 N·m (125 ft. lbs.). • DRW Axle - 70 N·m (52 ft. lbs.)
(3) Install propeller shaft and tighten bolts to 70 (7) Install calipers with adapters and lines.
N·m (52 ft. lbs.). (8) Install brake hoses and hold-down clips.
(9) Install and adjust park brake cables.
(10) Install connection cable of brake pad wear (15) Install the wheels and tires.
indicator and ABS sensor cable up to the relay unit (16) Fill axle with appropriate lubricant.
of the parking brake. (17) Remove lifting device from under the axle.
(11) Install cable ties to the park brake cables. (18) Remove support and lower vehicle.
(12) Install ABS sensor and clamp bushing to
mounting bore. SPECIFICATIONS
AXLE SPECIFICATIONS
NOTE: The right-hand ABS sensor cable is labeled
at the factory with a white tag.
DESCRIPTION SPECIFICATION
(13) Attach connector cable for brake pad wear Axle Ratio 3.73, 4.11
indicator. Ring Gear Diameter 216 mm (8.5 in.)
(14) Plug in cable of brake pad wear indicator.
3 - 14 REAR AXLE VA
REAR AXLE (Continued)
TORQUE SPECIFICATIONS
SPECIAL TOOLS
SPECIAL TOOL CROSS-REFERENCE CHART
MILLER TOOL
MB TOOL # DESCRIPTION
#
460-589-15-15-
9276 INSTALLER
00
741 589 01 15
9278 INSTALLER
00
741 589 00 35 INSTALLER 9276
9277 PLATE
00
460 589 01 07
9279 WRENCH
00
FLANGE
N/A 8992
PULLER
309 589 01 07
9290 WRENCH
00
389 589 02 15
9291 INSTALLER
00
N/A C-3281 WRENCH INSTALLER 9278
PLATE 9277
VA REAR AXLE 3 - 15
REAR AXLE (Continued)
WRENCH C-3281
INSTALLER 9291
3 - 16 REAR AXLE VA
AXLE SHAFTS (Continued)
AXLE BEARINGS/SEALS (4) Remove bearing nut and locking ring from axle
shaft (Fig. 9).
REMOVAL
(1) Remove rear axle shaft.
(2) With a punch and hammer straighten locking
ring (Fig. 7).
(6) Pull hub off axle tube. Fig. 21 AXLE HUB BEARINGS
(7) Pry out ABS sensor and remove seal from hub 1 - REAR BEARING
(Fig. 20). 2 - HUB
3 - FRONT BEARING
(8) Remove hub bearings from hub (Fig. 21). 4 - ROTOR
(9) Remove inner and outer bearing cups from hub
with a hammer and drift. CAUTION: Do not coat seals rubberized sealing sur-
faces with sealant.
INSTALLATION
(1) Install hub bearing cups with Installer 9291 (5) Install seal into hub with an appropriate
and a hammer. installer.
(2) Clean and thoroughly grease bearings with
Multi-purpose grease. NOTE: Sealing ring should be flush with wheel hub
(3) Install inner wheel bearing. or max. 3mm (0.12 in.) deep.
(4) Coat outer circumference of new seal with
(6) Coat contact surface of ABS sensor ring with
Hylomar SQ 32 M sealant.
Hylomar SQ 32 M sealant.
VA REAR AXLE 3 - 21
AXLE HUB BEARINGS/SEALS (Continued)
(7) Drive ABS sensor ring ring in as far as the
stop with a plastic hammer.
(8) Install hub on axle tube.
(9) Install outer hub bearing (Fig. 22).
Fig. 23 THRUST WASHER (14) Install outer hub nut and tighten with
1 - HUB Wrench 9290 to 250 N·m (184 ft. lbs.).
2 - WASHER (15) Install axle shaft.
(16) Install brake caliper and support.
(11) Install inner hub nut (Fig. 24). (17) Adjust parking brakes.
(12) Tighten inner hub nut with Wrench 9290 to
300 N·m (221 ft. lbs.) while spinning the wheel hub
constantly. Turn back inner nut and then tighten
until it touches the thrust washer without play. Then
tighten 1/8 turn.
(13) Install locking plate (Fig. 25).
3 - 22 REAR AXLE VA
PINION SEAL
REMOVAL
(1) Remove wheels.
(2) Push back brake pads and release hand brake.
(7) Unlock collared nut. CAUTION: Do not coat partially rubberized seals
(8) Hold pinion flange with Flange Wrench C-3281 with sealant.
and remove nut.
(3) Drive new pinion radial seals into rear axle
(9) Remove pinion flange from pinion shaft with
housing as far as the stop using Installer 9276 (Fig.
Flange Puller 8992 (Fig. 27).
29).
(10) Check sealing surfaces of joint flange for score
(4) Fit coupling flange on drive pinion shaft.
marks and replace joint flange if necessary.
(11) Remove both pinion radial seals (Fig. 28). NOTE: The groove in the drive pinion and the
groove in the joint flange must be in alignment.
INSTALLATION
(1) Pack space between dust lip and sealing lip on (5) Hold pinion flange with Flange Wrench C-3281.
radial seal ring with multi-purpose grease. (6) Screw on the collared nut illustrated up to the
(2) On radial seal rings without rubberized exter- marking applied beforehand.
nal surface, coat outer circumference with sealant. (7) Detach retainer wrench from joint flange.
(8) With a torque wrench, measure torque to
rotate pinion and record measurement.
VA REAR AXLE 3 - 23
PINION SEAL (Continued)
(9) Unscrew the marked nut. (14) Connect propeller shaft to pinion flange.
(10) Reattach retainer wrench to joint flange. (15) Pour in oil up to bottom edge of oil filler hole
(11) Screw on new collared nut and tighten care- (Fig. 32).
fully in stages until the previously value of torque to
rotate is exceeded by 0.5 N·m. (4.4 in. lbs.).
BRAKES
TABLE OF CONTENTS
page page
BRAKES - BASE
TABLE OF CONTENTS
page page
BRAKES - BASE (3) Inspect brake fluid level and condition. Note
that the brake reservoir fluid level will decrease in
proportion to normal lining wear. Also note that
DIAGNOSIS AND TESTING - BASE BRAKE
brake fluid tends to darken over time. This is
SYSTEM normal and should not be mistaken for contam-
Base brake components consist of the brake pads, ination.
calipers, brake drum in hat rotor in the rear, rotors, (a) If fluid level is abnormally low, look for evi-
brake lines, master cylinder, booster, and parking dence of leaks at calipers, wheel cylinders, brake
brake components. lines, and master cylinder.
Brake diagnosis involves determining if the prob- (b) If fluid appears contaminated, drain out a
lem is related to a mechanical, hydraulic, or vacuum sample to examine. System will have to be flushed
operated component. if fluid is separated into layers, or contains a sub-
The first diagnosis step is the preliminary check. stance other than brake fluid. The system seals
and cups will also have to be replaced after flush-
PRELIMINARY BRAKE CHECK ing. Use clean brake fluid to flush the system.
(1) Check condition of tires and wheels. Damaged (4) Check parking brake operation. Verify free
wheels and worn, damaged, or underinflated tires movement and full release of cables and pedal. Also
can cause pull, shudder, vibration, and a condition note if vehicle was being operated with parking
similar to grab. brake partially applied.
(2) If complaint was based on noise when braking, (5) Check brake pedal operation. Verify that pedal
check suspension components. Jounce front and rear does not bind and has adequate free play. If pedal
of vehicle and listen for noise that might be caused lacks free play, check pedal and power booster for
by loose, worn or damaged suspension or steering being loose or for bind condition. Do not road test
components. until condition is corrected.
(6) Check booster vacuum check valve and hose.
(7) If components checked appear OK, road test
the vehicle.
VA BRAKES - BASE 5-3
BRAKES - BASE (Continued)
ROAD TESTING NOTE: Some pedal pulsation may be felt during
(1) If complaint involved low brake pedal, pump ABS activation.
pedal and note if it comes back up to normal height.
(2) Check brake pedal response with transmission
BRAKE DRAG
in Neutral and engine running. Pedal should remain
firm under constant foot pressure. Brake drag occurs when the lining is in constant
(3) During road test, make normal and firm brake contact with the rotor or drum. Drag can occur at one
stops in 25-40 mph range. Note faulty brake opera- wheel, all wheels, fronts only, or rears only.
tion such as low pedal, hard pedal, fade, pedal pulsa- Drag is a product of incomplete brake shoe release.
tion, pull, grab, drag, noise, etc. Drag can be minor or severe enough to overheat the
(4) Attempt to stop the vehicle with the parking linings, rotors and drums.
brake only and note grab, drag, noise, etc. Minor drag will usually cause slight surface char-
ring of the lining. It can also generate hard spots in
PEDAL FALLS AWAY rotors and drums from the overheat-cool down pro-
A brake pedal that falls away under steady foot cess. In most cases, the rotors, drums, wheels and
pressure is generally the result of a system leak. The tires are quite warm to the touch after the vehicle is
leak point could be at a brake line, fitting, hose, or stopped.
caliper/wheel cylinder. If leakage is severe, fluid will Severe drag can char the brake lining all the way
be evident at or around the leaking component. through. It can also distort and score rotors and
Internal leakage (seal by-pass) in the master cylin- drums to the point of replacement. The wheels, tires
der caused by worn or damaged piston cups, may and brake components will be extremely hot. In
also be the problem cause. severe cases, the lining may generate smoke as it
An internal leak in the ABS or RWAL system may chars from overheating.
also be the problem with no physical evidence. Common causes of brake drag are:
• Seized or improperly adjusted parking brake
LOW PEDAL cables.
If a low pedal is experienced, pump the pedal sev- • Loose/worn wheel bearing.
eral times. If the pedal comes back up worn linings, • Seized caliper or wheel cylinder piston.
rotors, drums, or rear brakes out of adjustment are • Caliper binding on corroded bushings or rusted
the most likely causes. The proper course of action is slide surfaces.
to inspect and replace all worn component and make • Loose caliper mounting.
the proper adjustments. • Drum brake shoes binding on worn/damaged
support plates.
SPONGY PEDAL • Mis-assembled components.
A spongy pedal is most often caused by air in the • Long booster output rod.
system. However, thin brake drums or substandard If brake drag occurs at all wheels, the problem
brake lines and hoses can also cause a spongy pedal. may be related to a blocked master cylinder return
The proper course of action is to bleed the system, port, or faulty power booster (binds-does not release).
and replace thin drums and substandard quality
brake hoses if suspected. BRAKE FADE
Brake fade is usually a product of overheating
HARD PEDAL OR HIGH PEDAL EFFORT caused by brake drag. However, brake overheating
A hard pedal or high pedal effort may be due to and resulting fade can also be caused by riding the
lining that is water soaked, contaminated, glazed, or brake pedal, making repeated high deceleration stops
badly worn. The power booster or check valve could in a short time span, or constant braking on steep
also be faulty. mountain roads. Refer to the Brake Drag information
in this section for causes.
PEDAL PULSATION
Pedal pulsation is caused by components that are BRAKE PULL
loose, or beyond tolerance limits. Front brake pull condition could result from:
The primary cause of pulsation are disc brake • Contaminated lining in one caliper
rotors with excessive lateral runout or thickness vari- • Seized caliper piston
ation, or out of round brake drums. Other causes are • Binding caliper
loose wheel bearings or calipers and worn, damaged • Loose caliper
tires. • Rusty caliper slide surfaces
• Improper brake pads
• Damaged rotor
5-4 BRAKES - BASE VA
BRAKES - BASE (Continued)
A worn, damaged wheel bearing or suspension BRAKE NOISES
component are further causes of pull. A damaged Some brake noise is common with rear drum
front tire (bruised, ply separation) can also cause brakes and on some disc brakes during the first few
pull. stops after a vehicle has been parked overnight or
A common and frequently misdiagnosed pull condi- stored. This is primarily due to the formation of trace
tion is where direction of pull changes after a few corrosion (light rust) on metal surfaces. This light
stops. The cause is a combination of brake drag fol- corrosion is typically cleared from the metal surfaces
lowed by fade at one of the brake units. after a few brake applications causing the noise to
As the dragging brake overheats, efficiency is so subside.
reduced that fade occurs. Since the opposite brake
unit is still functioning normally, its braking effect is BRAKE SQUEAK/SQUEAL
magnified. This causes pull to switch direction in Brake squeak or squeal may be due to linings that
favor of the normally functioning brake unit. are wet or contaminated with brake fluid, grease, or
An additional point when diagnosing a change in oil. Glazed linings and rotors with hard spots can
pull condition concerns brake cool down. Remember also contribute to squeak. Dirt and foreign material
that pull will return to the original direction, if the embedded in the brake lining will also cause squeak/
dragging brake unit is allowed to cool down (and is squeal.
not seriously damaged). A very loud squeak or squeal is frequently a sign of
severely worn brake lining. If the lining has worn
REAR BRAKE GRAB OR PULL through to the brake pads in spots, metal-to-metal
Rear grab or pull is usually caused by improperly contact occurs. If the condition is allowed to continue,
adjusted or seized parking brake cables, contami- rotors can become so scored that replacement is nec-
nated lining, bent or binding shoes and support essary.
plates, or improperly assembled components. This is
particularly true when only one rear wheel is BRAKE CHATTER
involved. However, when both rear wheels are Brake chatter is usually caused by loose or worn
affected, the master cylinder or proportioning valve components, or glazed/burnt lining. Rotors with hard
could be at fault. spots can also contribute to chatter. Additional causes
of chatter are out-of-tolerance rotors, brake lining not
BRAKES DO NOT HOLD AFTER DRIVING THROUGH DEEP securely attached to the shoes, loose wheel bearings
WATER PUDDLES
and contaminated brake lining.
This condition is generally caused by water soaked
lining. If the lining is only wet, it can be dried by THUMP/CLUNK NOISE
driving with the brakes very lightly applied for a Thumping or clunk noises during braking are fre-
mile or two. However, if the lining is both soaked and quently not caused by brake components. In many
dirt contaminated, cleaning and/or replacement will cases, such noises are caused by loose or damaged
be necessary. steering, suspension, or engine components. However,
calipers that bind on the slide surfaces can generate
BRAKE LINING CONTAMINATION
a thump or clunk noise.
Brake lining contamination is mostly a product of
leaking calipers or worn seals, driving through deep
water puddles, or lining that has become covered STANDARD PROCEDURE
with grease and grit during repair. Contaminated lin-
ing should be replaced to avoid further brake prob- STANDARD PROCEDURE - MANUAL BLEEDING
lems. Use Mopar brake fluid, or an equivalent quality
fluid meeting SAE and DOT 4 standards only. Use
WHEEL AND TIRE PROBLEMS fresh, clean fluid from a sealed container at all times.
Some conditions attributed to brake components (1) Remove reservoir filler caps and fill reservoir.
may actually be caused by a wheel or tire problem. (2) If calipers, or wheel cylinders were overhauled,
A damaged wheel can cause shudder, vibration and open all caliper and wheel cylinder bleed screws.
pull. A worn or damaged tire can also cause pull. Then close each bleed screw as fluid starts to drip
Severely worn tires with very little tread left can from it. Top off master cylinder reservoir once more
produce a grab-like condition as the tire loses and before proceeding.
recovers traction. Flat-spotted tires can cause vibra- (3) Attach one end of bleed hose to bleed screw
tion and generate shudder during brake operation. A and insert opposite end in glass container partially
tire with internal damage such as a severe bruise, filled with brake fluid (Fig. 1). Be sure end of bleed
cut, or ply separation can cause pull and vibration. hose is immersed in fluid.
VA BRAKES - BASE 5-5
BRAKES - BASE (Continued)
(4) Open up bleeder, then have a helper press
down the brake pedal. Once the pedal is down close
the bleeder. Repeat bleeding until fluid stream is
clear and free of bubbles. Then move to the next
wheel.
HYDRAULIC/MECHANICAL
SPECIFICATIONS
SPECIFICATIONS - TORQUE CHART
TORQUE SPECIFICATIONS
REMOVAL
REMOVAL - FRONT (SRW)
(1) Unscrew the cap from the brake fluid reservoir.
(2) Raise and support the vehicle.
(3) Remove the front wheels (Refer to 22 - TIRES/
WHEELS/WHEELS - REMOVAL).
(4) Remove the wear indicator cable and the wear
indicator (Fig. 4).
Fig. 4 FRONT BRAKE PADS (5) Remove the brake caliper guide pins (Fig. 6).
1 - DISC BRAKE CALIPER
(6) Remove the brake caliper from the caliper
2 - GUIDE BOLT adapter (Fig. 6).
3 - WEAR INDICATOR (7) Remove the retaining spring (Fig. 6).
4 - DISC BRAKE PADS
5 - CALIPER ADAPTER
(8) Remove the pads (Fig. 6).
NOTE: Seal off the line ends and connection NOTE: Seal off the line ends and connection
threads in the brake calipers with plugs. Also check threads in the brake calipers with plugs. Also check
brake hoses for signs of cracks. brake hoses for signs of cracks.
(5) Remove the brake caliper guide bolt (Fig. 5). (5) Remove the brake caliper guide pin (Fig. 7).
(6) Remove the brake caliper (Fig. 5).
5 - 10 BRAKES - BASE VA
BRAKE PADS/SHOES (Continued)
(3) Remove the rear wheels (Refer to 22 - TIRES/
WHEELS/WHEELS - INSTALLATION).
(4) Remove the wear indicator cable and the wear
indicator (Fig. 8).
INSTALLATION
INSTALLATION - FRONT (SRW)
(1) Install the brake pads (Fig. 4).
(2) Install the wear indicator cable and the wear
indicator (Fig. 4). Tighten to 10 N·m (89 in. lbs.).
Fig. 7 REAR DISC BRAKE PADS - 15( WHEELS NOTE: Do not install the brake hose twisted and
(SRW) ensure freedom of movement.
1 - CALIPER GUIDE PIN
2 - DISC BRAKE CALIPER (3) Install the brake caliper to the brake caliper
3 - CALIPER ADAPTER adapter (Fig. 4). Tighten the guide bolt to 25 N·m
4 - DISC BRAKE PADS
5 - RETAINING SPRING
(221 in. lbs.).
6 - WEAR INDICATOR (4) Bleed the brake system.
(5) Check the brake system for any leaks.
REMOVAL - REAR (DRW) (6) Install the front wheels.
(1) Unscrew the cap from the brake fluid reservoir. (7) Lower the vehicle.
(2) Raise and support the vehicle.
VA BRAKES - BASE 5 - 11
BRAKE PADS/SHOES (Continued)
INSTALLATION - FRONT (DRW) (3) Install the brake caliper to brake caliper
(1) Install the brake pads (Fig. 5). adapter (Fig. 8). Tighten the guide pins to 25 N·m
(2) Install the wear indicator cable and the wear (221 in. lbs.) for M8 bolt or 30 N·m (266 in. lbs.) for
indicator (Fig. 5). Tighten to 10 N·m (89 in. lbs.). M10 10.9 bolt.
(4) Install the retaining spring (Fig. 8).
NOTE: Do not install the brake hose twisted and (5) Install the rear wheels (Refer to 22 - TIRES/
ensure freedom of movement. WHEELS/WHEELS - INSTALLATION).
(6) Lower the vehicle.
(3) Install the brake caliper to the brake caliper
adapter (Fig. 5). Tighten the guide bolt to 25 N·m
(221 in. lbs.)(M8 bolt) or Tighten the guide bolt to 30 DISC BRAKE CALIPERS
N·m (265 in. lbs.)(M10 10.9 bolt).
(4) Bleed the brake system.
(5) Check the brake system for any leaks. REMOVAL
(6) Install the front wheels.
(7) Lower the vehicle. REMOVAL - FRONT (SRW)
(1) Unscrew the cap from the brake fluid reservoir.
INSTALLATION - REAR (16” WHEELS) (SRW) (2) Raise and support the vehicle.
(1) Install the brake pads (Fig. 6). (3) Remove the front wheels (Refer to 22 - TIRES/
(2) Install the wear indicator cable and the wear WHEELS/WHEELS - REMOVAL).
indicator (Fig. 6). Tighten to 10 N·m (89 in. lbs.). (4) Remove the wear indicator cable and the wear
indicator (Fig. 9).
NOTE: Do not install the brake hose twisted and
ensure freedom of movement. NOTE: Seal off the line ends and connection
threads in the brake calipers with plugs. Also check
(3) Install the brake caliper to brake caliper brake hoses for signs of cracks.
adapter (Fig. 6). Tighten the guide pins to 25 N·m
(221 in. lbs.) for M8 bolt or 30 N·m (266 in. lbs.) for (5) Remove the brake hose at the brake caliper
M10 bolt. (Fig. 9).
(4) Install the retaining spring (Fig. 6). (6) Remove the brake caliper guide bolt (Fig. 9).
(5) Install the rear wheels (Refer to 22 - TIRES/ (7) Remove the brake caliper (Fig. 9).
WHEELS/WHEELS - INSTALLATION).
(6) Lower the vehicle.
INSTALLATION - REAR
(1) Install the brake caliper adapter to the axle
mount. Tighten to 90 N·m (66 ft. lbs.) for M12X1.5
bolt or 170 N·m (125 ft. lbs.) for M14X1.5 bolt.
(2) Install the disc brake pads (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/BRAKE
PADS/SHOES - INSTALLATION).
Fig. 13 FLUID LEVEL TYPICAL
NOTE: Do not install the brake hose twisted and 1 - FLUID RESERVOIR
ensure freedom of movement. 2 - MAX LEVEL MARK
DIAGNOSIS AND TESTING - BRAKE FLUID CAUTION: Never use reclaimed brake fluid or fluid
CONTAMINATION from an container which has been left open. An
Indications of fluid contamination are swollen or open container of brake fluid will absorb moisture
deteriorated rubber parts. from the air and contaminate the fluid.
Swollen rubber parts indicate the presence of
petroleum in the brake fluid.
CAUTION: Never use any type of a petroleum-based
To test for contamination, put a small amount of
fluid in the brake hydraulic system. Use of such
drained brake fluid in clear glass jar. If fluid sepa-
type fluids will result in seal damage of the vehicle
rates into layers, there is mineral oil or other fluid
brake hydraulic system causing a failure of the
contamination of the brake fluid.
vehicle brake system. Petroleum based fluids would
If brake fluid is contaminated, drain and thor-
be items such as engine oil, transmission fluid,
oughly flush system. Replace master cylinder, ALB
power steering fluid, etc.
Controller, caliper seals, Antilock Brakes hydraulic
unit and all hydraulic fluid hoses.
VA BRAKES - BASE 5 - 15
FLUID RESERVOIR (3) Install the lever to the shock bolt and then
install the clip (Fig. 15).
(4) Check the side deflection of the ALB lever with
REMOVAL
a straight edge from Point-A to Point-B as the
(1) Using a suction gun remove as much brake
graphic shows. Max deflection play of the actuator
fluid from the reservoir as possible (Fig. 14).
rod should be no more than 15 mm (.60 in) (Fig. 15).
(2) Disconnect the electrical connector for the
(5) Lower the vehicle.
brake fluid level indicator (Fig. 14).
(3) Remove the fluid reservoir (Fig. 14). Seal off
the ends and bore holes with plugs.
ADJUSTMENTS
ADJUSTMENT
(1) Clean any debris away from the test ports caps
at the ALB controller.
(2) Connect brake adapters special tool 9297 to the
test ports at the ALB controller.
(3) Install a Pressure Gauge, Special Tool
C-4007-A, to the adapters.
(4) Tighten all tube nut fittings to 17 N·m (145 in.
lbs.) torque.
(5) Bleed any air out of the system. This includes
bleeding the air from the hose between the pressure
test fitting and pressure gauge, which is done at the
pressure gauge.
Fig. 16 ALB CONTROLLER ADJUSTER NUT
NOTE: Adjustment is determined for the automatic 1 - ALB ADJUSTER NUT
2 - SPRING
load-dependent brake power control system accord-
ing to the ALB plate. This is housed in the stowage
compartment under the front passenger’s door MASTER CYLINDER
panel. The part number of the rear spring is
stamped into the spring eye. This must correspond DIAGNOSIS AND TESTING - MASTER
to the part number of the rear spring on the ALB CYLINDER/POWER BOOSTER
plate. (1) Start engine and check booster vacuum hose
connections. A hissing noise indicates vacuum leak.
(6) To accurately adjust the rear axle load you Correct any vacuum leak before proceeding.
must first determine the rear axle load by weighing (2) Stop engine and shift transmission into Neu-
the vehicle at a local scale. tral.
(7) Install the brake pedal winch Special tool 9296 (3) Pump brake pedal until all vacuum reserve in
between the brake pedal and the driver seat and booster is depleted.
slowly turn the dial until the specified inlet brake (4) Press and hold brake pedal under light foot
pressure is indicated at the gauge. pressure. The pedal should hold firm, if the pedal
falls away master cylinder is faulty (internal leak-
NOTE: The pressure gauge, connected at the ALB
age).
controller must indicate the outlet pressure which
(5) Start engine and note pedal action. It should
is assigned on the ALB plate to the rear axle load
fall away slightly under light foot pressure then hold
determined.
firm. If no pedal action is discernible, power booster,
vacuum supply, or vacuum check valve is faulty. Pro-
NOTE: If the rear axle load determined is between ceed to the POWER BOOSTER VACUUM TEST.
two figures indicated on the ALB plate, the outlet (6) If the POWER BOOSTER VACUUM TEST
pressure should be determined accordingly. passes, rebuild booster vacuum reserve as follows:
Release brake pedal. Increase engine speed to 1500
(8) If the pressure measured differs from the spec- rpm, close the throttle and immediately turn off igni-
ification, adjust the ALB controller (Fig. 16). tion to stop engine.
(9) Loosen the brake pedal winch. (7) Wait a minimum of 90 seconds and try brake
(10) Adjust the outlet pressure by turning the action again. Booster should provide two or more vac-
adjusting nut (Fig. 16) To increase pressure - uum assisted pedal applications. If vacuum assist is
tighten the adjusting nut. To reduce pressure - not provided, booster is faulty.
loosen the adjusting nut.
VA BRAKES - BASE 5 - 17
MASTER CYLINDER (Continued)
POWER BOOSTER VACUUM TEST
(1) Connect vacuum gauge to booster check valve
with short length of hose and T-fitting (Fig. 17).
(2) Start and run engine at curb idle speed for one
minute.
(3) Observe the vacuum supply. If vacuum supply
is not adequate, repair vacuum supply.
(4) Clamp hose shut between vacuum source and
check valve.
(5) Stop engine and observe vacuum gauge.
(6) If vacuum drops more than one inch HG (33
millibars) within 15 seconds, booster diaphragm or
check valve is faulty.
REMOVAL
(1) Using a suction gun remove as much brake
fluid from the reservoir as possible (Fig. 20).
5 - 18 BRAKES - BASE VA
MASTER CYLINDER (Continued)
(2) Remove the fluid reservoir (Fig. 20) or (Fig. INSTALLATION
21)(Refer to 5 - BRAKES/HYDRAULIC/MECHANI- (1) Install the master cylinder to the brake booster
CAL/FLUID RESERVOIR - REMOVAL). (Fig. 20). Tighten to 28 N·m (248 in. lbs.).
(3) Remove the brake lines Seal off the ends and (2) Install the brake lines (Fig. 20). Tighten to 14
bore holes with plugs. (Fig. 20) or (Fig. 21) N·m (124 in. lbs.).
(4) Remove the master cylinder mounting nuts (3) Install the fluid reservoir (Fig. 20) (Refer to 5 -
(Fig. 20) or (Fig. 21). Check brake booster for BRAKES/HYDRAULIC/MECHANICAL/FLUID RES-
damage due to leaking master cylinder. It is not ERVOIR - INSTALLATION).
possible to repair the master cylinder. (4) Bleed the brake system.
(5) Check the brake system for any leaks.
PEDAL
REMOVAL
(1) Remove the master cylinder (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/MASTER
CYLINDER - REMOVAL).
(2) Remove the retainer and pin for the master
cylinder push rod (Fig. 22).
(3) Remove the retainer and pin for the brake
pedal pivot bolt (Fig. 22).
(4) Unhook the spring and remove the brake pedal
(Fig. 22).
(5) Disconnect the plug connector on the stop lamp
Fig. 20 MASTER CYLINDER switch (Fig. 22).
(6) Remove the bolts and remove the pedal bearing
1 - SUCTION GUN
2 - BRAKE FLUID CAP bracket (Fig. 22).
3 - BRAKE FLUID LEVEL INDICATOR
4 - O-RING
5 - NUT
6 - BRAKE LINE
7 - MASTER CYLINDER
8 - FLUID RESERVOIR
INSTALLATION
(1) Install the bolts for the pedal bearing bracket
(Fig. 22). Tighten to 23 N·m (204 in. lbs.)
(2) Reconnect the plug connector for the stop lamp
switch (Fig. 22).
(3) Install the brake pedal and hook the spring
(Fig. 22).
(4) Install the retainer and pin for the brake pedal
(Fig. 22).
(5) Install the retainer and pin for the master cyl-
inder push rod (Fig. 22).
(6) Install the master cylinder (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/MASTER
CYLINDER - INSTALLATION).
Fig. 24 FRONT DISC BRAKE ROTOR Fig. 25 REAR DISC BRAKE ROTOR
1 - CALIPER ADAPTER BOLT 1 - M8 BOLT
2 - CALIPER ADAPTER 2 - CALIPER ADAPTER
3 - GUIDE BOLT 3 - DISC BRAKE ROTOR
4 - WEAR INDICATOR 4 - LOCKING BOLT
5 - DISC BRAKE CALIPER 5 - DISC BRAKE PADS
6 - DISC BRAKE PADS 6 - RATTLE SPRING
7 - LOCKING BOLT 7 - DISC BRAKE CALIPER
8 - DISC BRAKE ROTOR 8 - GUIDE BOLT
9 - COVER
10 - WEAR INDICATOR
REMOVAL - REAR (SRW)
(1) Raise and support the vehicle.
(2) Remove the rear wheels.
(3) Remove the rear disc brake pads (Fig. 25).
(4) Remove the disc brake caliper adapter (Fig.
25).
(5) Apply the parking brake.
(6) Install two lug studs to secure the disc brake
rotor when the locking bolt is removed.
(7) Remove the locking bolt for the disc brake rotor
(Fig. 25).
(8) Remove the two lug nuts.
(9) Release the parking brake.
(10) loosen the park brake adjuster to allow clear-
ance for the rotor removal (Fig. 25).
(11) Remove the rear disc brake rotor.
REMOVAL - FRONT (DRW) Fig. 26 FRONT DISC BRAKE ROTOR WITH DUAL
(1) Raise and support the vehicle. REAR WHEELS
(2) Remove the front wheels. 1 - ADAPTER BOLT
(3) Remove the front brake pads (Fig. 26). 2 - ADAPTER
(4) Remove the caliper adapter (Fig. 26). 3 - GUIDE PIN/BOLT
4 - WEAR INDICATOR WIRE
(5) Remove the wheel flange ring (Fig. 26). 5 - DISC BRAKE CALIPER
(6) Install two lug studs to secure the disc brake 6 - DISC BRAKE PADS
rotor when the locking bolt is removed. 7 - WHEEL FLANGE RING MOUNTING BOLT
8 - WHEEL FLANGE RING
(7) Remove the locking bolt for the disc brake rotor 9 - LOCKING BOLT
(Fig. 26). 10 - DISC BRAKE ROTOR
(8) Remove the two lug nuts.
(9) Remove the disc brake rotor (Fig. 26). REMOVAL - REAR (DRW)
(1) Raise and support the vehicle.
(2) Remove the rear wheels.
(3) Remove the rear disc brake pads (Fig. 27).
VA BRAKES - BASE 5 - 21
ROTORS (Continued)
(4) Remove the disc brake caliper adapter (Fig. (6) Check fluid in reservoir and correct if neces-
27). sary.
(5) Apply the parking brake. (7) Install the front wheels (Refer to 22 - TIRES/
(6) Install two lug studs to secure the disc brake WHEELS/WHEELS - INSTALLATION).
rotor when the locking bolt is removed. (8) Lower the vehicle.
(7) Remove the wheel flange ring (Fig. 27).
(8) Remove the locking bolt for the disc brake rotor INSTALLATION - REAR (SRW)
(Fig. 27). (1) Install the disc brake rotor to the hub and
(9) Remove the two lug nuts. install two lug studs to hold rotor in place (Fig. 25).
(10) Release the parking brake. (2) Apply the parking brake.
(11) loosen the park brake adjuster to allow clear- (3) Install the locking bolt for the rotor (Fig. 25).
ance for the rotor removal (Fig. 27). Tighten to 23 N·m (204 in. lbs.).
(12) Remove the rear disc brake rotor. (4) Install the disc brake caliper adapter (Fig. 25).
Tighten to 90 N·m (66 ft. lbs.) (Refer to 5 - BRAKES/
HYDRAULIC/MECHANICAL/DISC BRAKE CALI-
PER ADAPTER - INSTALLATION).
(5) Install the brake pads (Refer to 5 - BRAKES/
HYDRAULIC/MECHANICAL/BRAKE PADS/SHOES
- INSTALLATION) (Fig. 25).
(6) Release the parking brake.
(7) Adjust the parking brake (Refer to 5 -
BRAKES/PARKING BRAKE/SHOES - ADJUST-
MENTS).
(8) Press and release the brake pedal several times
until pressure has built up.
(9) Check fluid in reservoir and correct if neces-
sary.
(10) Install the rear wheels.
(11) Lower the vehicle.
Fig. 27 REAR DISC BRAKE ROTOR WITH DUAL
REAR WHEELS INSTALLATION - FRONT (DRW)
1 - ADAPTER BOLT
(1) Install the disc brake rotor to the hub and
2 - ADAPTER install two lug studs to hold rotor in place.
3 - GUIDE PIN/BOLT (2) Install the locking bolt for the rotor (Fig. 26).
4 - WEAR INDICATOR
5 - DISC BRAKE CALIPER
Tighten to 23 N·m (204 in. lbs.).
6 - RETAINING SPRING (3) Install the disc brake caliper adapter (Fig. 26).
7 - DISC BRAKE PADS Tighten to 170 N·m (125 ft. lbs.) (Refer to 5 -
8 - WHEEL FLANGE RING MOUNITNG BOLT
9 - WHEEL FLANGE RING BRAKES/HYDRAULIC/MECHANICAL/DISC
10 - DISC BRAKE ROTOR BRAKE CALIPER ADAPTER - INSTALLATION).
(4) Install the wheel flange ring. Tighten to 180
INSTALLATION N·m (133 ft. lbs.)
(5) Install the brake pads (Refer to 5 - BRAKES/
INSTALLATION - FRONT (SRW) HYDRAULIC/MECHANICAL/BRAKE PADS/SHOES
(1) Install the disc brake rotor to the hub and - INSTALLATION) (Fig. 26).
install two lug studs to hold rotor in place. (6) Press and release the brake pedal several times
(2) Install the locking bolt for the rotor (Fig. 24). until pressure has built up.
Tighten to 23 N·m (204 in. lbs.). (7) Check fluid in reservoir and correct if neces-
(3) Install the disc brake caliper adapter (Fig. 24). sary.
Tighten to 170 N·m (125 ft. lbs.) (Refer to 5 - (8) Install the front wheels (Refer to 22 - TIRES/
BRAKES/HYDRAULIC/MECHANICAL/DISC WHEELS/WHEELS - INSTALLATION).
BRAKE CALIPER ADAPTER - INSTALLATION). (9) Lower the vehicle.
(4) Install the brake pads (Refer to 5 - BRAKES/
HYDRAULIC/MECHANICAL/BRAKE PADS/SHOES INSTALLATION - REAR (DRW)
- INSTALLATION) (Fig. 24). (1) Install the disc brake rotor to the hub and
(5) Press and release the brake pedal several times install two lug studs to hold rotor in place (Fig. 27).
until pressure has built up. (2) Apply the parking brake.
5 - 22 BRAKES - BASE VA
ROTORS (Continued)
(3) Install the locking bolt for the rotor (Fig. 27). (4) Remove the rear park brake shoes (Refer to 5 -
Tighten to 23 N·m (204 in. lbs.). BRAKES/PARKING BRAKE/SHOES - REMOVAL).
(4) Install the disc brake caliper adapter (Fig. 27). (5) Remove the park brake cable from he support
Tighten to 170 N·m (125 ft. lbs.) (Refer to 5 - plate.
BRAKES/HYDRAULIC/MECHANICAL/DISC (6) Remove the rear axle bearing (Refer to 3 - DIF-
BRAKE CALIPER ADAPTER - INSTALLATION). FERENTIAL & DRIVELINE/REAR AXLE/AXLE
(5) Install the wheel flange ring (Fig. 27) Tighten BEARINGS - REMOVAL).
to 200 N·m (148 ft. lbs.). (7) Remove brake support plate.
(6) Install the brake pads (Refer to 5 - BRAKES/
HYDRAULIC/MECHANICAL/BRAKE PADS/SHOES INSTALLATION - REAR
- INSTALLATION) (Fig. 27). (1) Press the brake support plate with the axle
(7) Release the parking brake. bearing onto the axle shaft (Refer to 3 - DIFFEREN-
(8) Adjust the parking brake (Refer to 5 - TIAL & DRIVELINE/REAR AXLE/AXLE BEARINGS
BRAKES/PARKING BRAKE/SHOES - ADJUST- - INSTALLATION).
MENTS). (2) Install the park brake cable to the support
(9) Press and release the brake pedal several times plate.
until pressure has built up. (3) Install the rear park brake shoes (Refer to 5 -
(10) Check fluid in reservoir and correct if neces- BRAKES/PARKING BRAKE/SHOES - INSTALLA-
sary. TION).
(11) Install the rear wheels. (4) Install the disc brake rotor (Refer to 5 -
(12) Lower the vehicle. BRAKES/HYDRAULIC/MECHANICAL/ROTORS -
INSTALLATION).
(5) Install the disc brake caliper adapter (Refer to
SUPPORT PLATE 5 - BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPER ADAPTER - INSTALLATION).
REMOVAL - REAR (6) Adjust the rear park brake shoes (Refer to 5 -
(1) Raise and support the vehicle. BRAKES/PARKING BRAKE/SHOES - ADJUST-
(2) Remove the disc brake caliper adapter (Refer to MENTS).
5 - BRAKES/HYDRAULIC/MECHANICAL/DISC (7) Install the rear wheels (Refer to 22 - TIRES/
BRAKE CALIPER ADAPTER - REMOVAL). WHEELS/WHEELS - INSTALLATION).
(3) Remove the disc brake rotor (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ROTORS -
REMOVAL).
PARKING BRAKE
SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
SPECIAL TOOLS
PARK BRAKE
SPECIAL TOOL CROSS REFERENCE CHART
MB MILLER DESCRIPTION
TOOL # TOOL #
116 589 9280 RETURN SPRING
01 62 00 PULLING HOOK
112 589 9281 RETAINING SPRING
09 61 00 TOOL
RETURN SPRING PULLING HOOK - 9280
901 589 9289 RETAINING CLIP
00 63 00 RELEASE TOOL CABLE TENSIONER
REMOVAL
NOTE: Observe the installation position of the
brake control cable lock, for a reference on instal-
lation.
INSTALLATION
(1) Push the brake control cable lock onto the
brake cable (Fig. 28).
(2) Insert the safety bolt and snap shut the brake
control cable lock.Observe the installation posi-
tion of the brake control cable lock (Fig. 28).
5 - 24 BRAKES - BASE VA
CABLES
REMOVAL
REMOVAL - FRONT
(1) Raise and support the vehicle.
(2) Disconnect the front park brake cable from the
pulley unit.
(3) Remove the front park brake cable from the
hand brake lever (Fig. 29).
ADJUSTMENTS
ADJUSTMENT - PARKING BRAKE CABLES
(1) Loosen the bolts of the mounting brackets (Fig.
33). Fig. 34 PARK BRAKE ADJUSTMENT
(2) Insert a drill bit or an allen wrench with a 6 1 - ECCENTRIC CLOCKWISE
mm diameter between the mounting bracket and 2 - CLAMP SCREW TIGHTENED
front lever (Fig. 33).
(3) Push the mounting bracket back until the front (9) Release the hand brake lever.
brake cable is free of play and without tension (Fig. (10) Check the wheel for free movement.
33).
(4) Tighten the bolts to the mounting bracket
Tighten to 25 N·m (221 in. lbs.) (Fig. 33).
5 - 26 BRAKES - BASE VA
LEVER SHOES
REMOVAL
(1) Disconnect the front brake cable from the pul- REMOVAL
ley unit.
(2) Remove the front brake cable from the hand REMOVAL - (SRW)
brake lever (Fig. 29). (1) Raise and support the vehicle.
(3) Remove the circle cover (Fig. 35). (2) Remove the rear wheels.
(4) Remove the bolts on the hand brake lever (Fig. (3) Remove the disc brake rotor.
35). (4) Disconnect the front park brake cable from the
(5) Pull the cover off the hand brake lever (Fig. pulley unit. Do not remove the rear park brake
35). cables.
(6) Disconnect the hand brake check switch and (5) Remove the retracting springs using special
wiring harness from the hand brake lever (Fig. 35). tool 9280 (Fig. 36).
(7) Remove the hand brake lever (Fig. 35). (6) Remove the adjuster (Fig. 36).
(7) Remove the pressure springs using special tool
9281 (Fig. 36).
(8) Remove the rear park brake shoes (Fig. 36).
Pull the park brake shoes apart at the bottom
and remove them together with the adjuster.
INSTALLATION - (DRW)
NOTE: Preassemble the retracting spring with the
short hook eye from the inside together with the
adjuster wheel at the bottom. Fit the preassembled
park brake shoes on the brake carrier.
Fig. 37 PARK BRAKE SHOES WITH DUAL REAR (1) Ensure that the cable lock moves easily
WHEELS before installing shoes.Install the park brake
1 - HOLD DOWN PIN shoes.
2 - PRESSURE SPRING
3 - ADJUSTER (2) Install the lower retracting spring.
4 - UPPER RETRACTING SPRING (3) Install the pressure hold down springs by
5 - LOWER RETRACTING SPRING depressing with your fingers and twisting to lock in
6 - CABLE LOCK
7 - LOCKING PIN place.
8 - BRAKE CABLE (4) Install the upper retracting spring.
9 - PARK BRAKE SHOE (5) Install the adjuster.
(6) Install the front park brake cable to the pulley
CLEANING - REAR DRUM IN HAT BRAKE unit.
Clean the individual brake components, including (7) Install the disc brake rotor.
the support plate exterior, with a water dampened (8) Install the rear wheel flange ring. Tighten to
cloth or with brake cleaner. Do not use any other 200 N·m (148 ft. lbs.).
cleaning agents. Remove light rust and scale from (9) Install the rear wheels.
the brake shoe contact pads on the support plate (10) Adjust the parking brakes.
with fine sandpaper. (11) Lower the vehicle.
(12) Pump the brake pedal several times to check
the operation of the brakes before moving vehicle.
INSTALLATION
INSTALLATION - (SRW) ADJUSTMENTS
NOTE: Preassemble the retracting spring with the ADJUSTMENT
short hook eye from the inside together with the (1) Raise and support the vehicle.
adjuster wheel at the bottom. Fit the preassembled (2) Remove the rear wheels.
park brake shoes on the brake carrier. (3) Turn the adjusting wheel through the hole of
the wheel lug bolt until it is no longer possible to
(1) Ensure that the cable lock moves easily
rotate the rear wheel (Fig. 38).
before installing shoes.Install the park brake
shoes.
5 - 28 BRAKES - BASE VA
SHOES (Continued)
(4) Loosen the adjusting wheel 3-4 teeth divisions (5) Inspect the clearance, or a slight drag when
(Fig. 38). rotating the wheel/rear disc brake rotor (Fig. 39).
Fig. 38 STAR WHEEL ADJUSTER Fig. 39 ADJUSTING REAR PARK BRAKE SHOES
1 - LEFT HAND PARK BRAKE SHOES APPLIED 1 - FRONT BRAKE CABLE
2 - RIGHT HAND PARK BRAKE SHOES RELEASED 2 - SHOE ADJUSTER
3 - FLAT BLADED TOOL 3 - REAR BRAKE CABLES
4 - PARK BRAKE CABLE ADJUSTER
BRAKES - ABS
TABLE OF CONTENTS
page page
BRAKES - ABS
SPECIFICATIONS - TORQUE CHART
TORQUE SPECIFICATIONS
INSTALLATION
(1) Connect separate wheel speed sensor cables
with shrink-fit sleeves and shrink-fit tubing (Fig.
2).Only due this step if replacing the sensor. Fig. 3 REAR WHEEL SPEED SENSORS
(2) Install the wheel speed sensor all the way into 1 - SHRINK-FIT SLEEVE
the front wheel hub the wheel speed sensor will self 2 - SPEED SENSOR
3 - CLAMPING BUSHING
adjust when the vehicle is moved (Fig. 2). 4 - SHRINK TUBE
(3) Install the front wheels.
VA BRAKES - ABS 5 - 31
REAR WHEEL SPEED SENSOR (Continued)
COOLING
TABLE OF CONTENTS
page page
COOLING SYSTEM
COOLING SYSTEM DIAGNOSIS - DIESEL ENGINE
TEMPERATUREGAUGE READS 1. Vehicle is equipped with a heavy 1. None. System operating normaly.
LOW duty cooling system.
2. Temperature gauge not 2. Connect gauge.
connected
3. Temperature gauge connected 3. Check gauge. Refer (Refer to 8 -
but not operating. ELECTRICAL/INSTRUMENT
CLUSTER - DIAGNOSIS AND
TESTING)
4. Coolant level low. 4. Fill cooling system. (Refer to 7 -
COOLING - STANDARD
PROCEDURE)
TEMPERATURE GAUGE READS 1. Vehicle overloaded, high ambient 1. Temporary condition, repair not
HIGH. COOLANT MAY OR MAY (outside) temperatures with A/C required. Notify customer of vehicle
NOT BE LEAKING FROM SYSTEM turned on, stop and go driving or operation instructions located in
prolonged operation at idle speeds. Owners Manual.
2. Temperature gauge not 2. Check gauge. (Refer to 8 -
functioning correctly. ELECTRICAL/INSTRUMENT
CLUSTER - DIAGNOSIS AND
TESTING)
3. Air traped in cooling 3. Drain cooling system (Refer to 7 -
COOLING - STANDARD
PROCEDURE) and refill (Refer to 7
- COOLING - STANDARD
PROCEDURE)
4. Radiator cap faulty. 4. Replace radiator cap.
5. Plugged A/C or radiator cooling 5. Clean all debre away from A/C
fins. and radiator cooling fins.
6. Coolant mixture incorrect. 6. Drain cooling system (Refer to 7 -
COOLING - STANDARD
PROCEDURE) refill with correct
mixture (Refer to 7 - COOLING -
STANDARD PROCEDURE).
7. Thermostat stuck shut. 7. Replace thermostat.
8. Bug screen or winter front being 8. Remove bug screen or winter
used. front.
9. Viscous fan drive not operating 9. Check viscous fan (Refer to 7 -
properly. COOLING/ENGINE/FAN DRIVE
VISCOUS CLUTCH - DIAGNOSIS
AND TESTING)
10. Cylinder head gasket leaking. 10. Check for leaking head gaskets
(Refer to 7 - COOLING -
DIAGNOSIS AND TESTING).
11. Heater core leaking. 11. Replace heater core.
12. cooling system hoses leaking. 12. Tighten clamps or Replace
hoses.
VA COOLING 7-3
COOLING (Continued)
TEMPERATURE GAUGE READING 1. Heavy duty cooling system, 1. None. System operating normaly.
INCONSISTENT ( ERRATIC, extream cold ambient (outside)
CYCLES OR FLUCTUATES) temperature or heater blower motor
in high position.
2. Temperature gauge or gauge 2. Check gauge. (Refer to 8 -
sensor defective. ELECTRICAL/INSTRUMENT
CLUSTER - DIAGNOSIS AND
TESTING)
3. Temporary heavy usage or load. 3. None. Normal condition.
4. Air traped in cooling system. 4. Fill cooling system (Refer to 7 -
COOLING - STANDARD
PROCEDURE).
5. Water pump 5. Replace water pump.
6. Air leak on suction side of water 6. Check for leak. (Refer to 7 -
pump. COOLING - DIAGNOSIS AND
TESTING)
RADIATOR CAP LEAKING STEAM 1. Radiator cap defective. 1. Replace radiator cap.
AND /OR COOLANT INTO
RESERVOIR BOTTLE.
(TEMPERATURE GAUGE MAY
READ HIGH)
2. Radiator neck surface damaged. 2. Replace radiator.
HOSE OR HOSES COLLAPSE 1. Vacuum created in cooling 1. Replace radiator cap, check vent
WHEN ENGINE IS COOLING. system on engine cool-down is not hose between radiator and reservoir
being relieved through coolant bottle for blockage also check
reservior/overflow system. reservoir bottle vent for blockage.
NOISY FAN 1. Fan blade(s) loose, damaged. 1. Replace fan blade assembly.
2. Thermal viscous fan drive. 2. None. Normal condition.
3. Fan blades striking surrounding 3. Locate contact point and repair
objects. as necessary.
4. Thermal viscous fan drive 4. Replace viscous fan drive
bearing. assembly.
INADEQUATE AIR CONDITIONER 1. Radiator and/or A/C condenser 1. Remove obstruction and/or clean.
PERFORMANCE (COOLING air flow obstructed.
SYSTEM SUSPECTED)
2. Thermal viscous fan drive not 2. Check fan drive. (Refer to 7 -
working. COOLING/ENGINE/FAN DRIVE
VISCOUS CLUTCH - DIAGNOSIS
AND TESTING)
3. Air seals around radiator 3. Inspect air seals, repair or
damaged or missing. replace as necessary.
INADEQUATE HEATER 1. Heavy duty cooling system, and 1. None. Normal condition.
PERFORMANCE. GUAGE MAY OR cooler ambient temperatures.
MAY NOT READ LOW.
2. Obstruction in heater hoses. 2. Remove hoses, remove
obstruction.
3. Water pump damaged. 3. Replace water pump.
ACCESSORY DRIVE
TABLE OF CONTENTS
page page
OPERATION
WARNING: The automatic belt tensioner assembly
is spring loaded. do not attempt to disassemble the
tensioner assembly.
DRIVE BELTS
DIAGNOSIS AND TESTING - ACCESSORY
DRIVE BELT
VISUAL DIAGNOSIS
When diagnosing serpentine accessory drive belts,
small cracks that run across the ribbed surface of the
belt from rib to rib (Fig. 2), are considered normal.
These are not a reason to replace the belt. However,
cracks running along a rib (not across) are not nor-
mal. Any belt with cracks running along a rib must
be replaced (Fig. 2). Also replace the belt if it has
excessive wear, frayed cords or severe glazing.
Refer to ACCESSORY DRIVE BELT DIAGNOSIS
CHART for further belt diagnosis.
NOISE DIAGNOSIS
Noises generated by the accessory drive belt are
most noticeable at idle. Before replacing a belt to
resolve a noise condition, inspect all of the accessory Fig. 2 Belt Wear Patterns
drive pulleys for contamination, alignment, glazing, 1 - NORMAL CRACKS BELT OK
or excessive end play. 2 - NOT NORMAL CRACKS REPLACE BELT
RIB CHUNKING (One or more ribs 1. Foreign objects imbedded in 1. Remove foreign objects from
has separated from belt body) pulley grooves. pulley grooves. Replace belt.
LONGITUDAL BELT CRACKING 1. Belt has mistracked from pulley 1. Replace belt
groove
REMOVAL INSTALLATION
REMOVAL INSTALLATION
CAUTION: Do not attempt to check belt tension with CAUTION: When installing the accessory drive belt,
a belt tension gauge on vehicles equipped with an the belt must be the correct length and routed cor-
automatic belt tensioner. rectly. If not, engine may overheat due to water
pump rotating in wrong direction.
NOTE: The belt routing schematics are published (1) Position drive belt over all pulleys except
from the latest information available at the time of water pump pulley (Fig. 4).
publication. If anything differs between these sche-
matics and the Belt Routing Label, use the sche-
matics on Belt Routing Label.This label is located in
the engine compartment.
ENGINE
TABLE OF CONTENTS
page page
COOLANT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
DIAGNOSIS AND TESTING ENGINE COOLANT THERMOSTAT
COOLING SYSTEM LEAKS . . . . . . . . . . . . . . 10 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
STANDARD PROCEDURE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
ADDING ADDITIONAL COOLANT . . . . . . . . . . 11 FAN DRIVE VISCOUS CLUTCH
DRAINING COOLING SYSTEM . . . . . . . . . . . 12 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
REFILLING COOLING SYSTEM . . . . . . . . . . . 12 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16
COOLANT LEVEL SENSOR RADIATOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17
RADIATOR FAN RADIATOR PRESSURE CAP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
ENGINE BLOCK HEATER DIAGNOSIS AND TESTING - RADIATOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 PRESSURE CAP . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14 WATER PUMP
ENGINE COOLANT TEMP SENSOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 14 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20
WARNING: WITH RADIATOR PRESSURE TESTER Start engine and accelerate rapidly three times, to
TOOL INSTALLED ON RADIATOR, DO NOT ALLOW approximately 3000 rpm while observing coolant. If
PRESSURE TO EXCEED 110 KPA (20 PSI). PRES- internal engine combustion gases are leaking into
SURE WILL BUILD UP QUICKLY IF A COMBUSTION cooling system, bubbles will appear in coolant. If bub-
LEAK IS PRESENT. TO RELEASE PRESSURE, bles do not appear, internal combustion gas leakage
ROCK TESTER FROM SIDE TO SIDE. WHEN is not present.
REMOVING TESTER, DO NOT TURN TESTER MORE
THAN 1/2 TURN IF SYSTEM IS UNDER PRESSURE. STANDARD PROCEDURE
Operate engine without pressure cap on coolant
container until thermostat opens. Attach a Pressure ADDING ADDITIONAL COOLANT
Tester to container. If pressure builds up quickly it The use of aluminum cylinder blocks, cylinder
indicates a combustion leak exists. This is usually heads and water pumps requires special corrosion
the result of a cylinder head gasket leak or crack in protection. Only Mopart Antifreeze/Coolant, 5
engine. Repair as necessary. Year/100,000 Mile Formula (glycol base coolant with
If there is not an immediate pressure increase, corrosion inhibitors called HOAT, for Hybrid Organic
pump the Pressure Tester. Do this until indicated Additive Technology) is recommended. This coolant
pressure is within system range of 110 kPa (16 psi). offers the best engine cooling without corrosion when
Fluctuation of gauge pointer indicates compression or mixed with 50% distilled water to obtain to obtain a
combustion leakage into cooling system. freeze point of -37°C (-35°F). If it loses color or
becomes contaminated, drain, flush, and replace with
fresh properly mixed coolant solution.
7 - 12 ENGINE VA
COOLANT (Continued)
CAUTION: Do not use coolant additives that are from radiator. This will empty the coolant recovery
claimed to improve engine cooling. pressure container first. The coolant does not have to
be removed from the container unless the system is
being refilled with a fresh mixture. When container
DRAINING COOLING SYSTEM is empty, remove cap and continue draining cooling
system.
WARNING: Do not remove the cylinder block drain To drain the engine of coolant, loosen the cylinder
plug or loosen the radiator drain plug with system block drain plug located on the side of cylinder block
hot and under pressure. Serious burns from coolant (Fig. 3).
can occur.
REFILLING COOLING SYSTEM
(1) DO NOT remove coolant recovery pressure con-
(1) Tighten the radiator drain and the cylinder
tainer cap first. With engine cold, raise vehicle on a
block drain plug(s) (if removed). Tighten the engine
hoist and locate radiator draincock.
drain plug to 30 N·m (22 lbs. ft.).
NOTE: Radiator draincock is located on the left/ (2) Fill system using a 50/50 mixture of ethylene-
lower side of radiator. glycol antifreeze and low mineral content water. Fill
radiator to top and add sufficient coolant to the cool-
(2) Attach one end of a hose to the draincock (Fig. ant recovery pressure container to raise level to
3). Put the other end into a clean and appropriately COLD MINIMUM mark.
marked container. Open draincock and drain coolant (3) With heater control unit in the HEAT position,
operate engine with container cap in place.
NOTE: Drain coolant from radiator drain plug only. RADIATOR FAN
(1) Drain coolant until the coolant reservoir is
emptied. REMOVAL
(2) Disconnect the wiring harness electrical con- (1) Disconnect the negative battery cable.
nector. (2) Detach coolant line from lower radiator shroud.
(3) Turn the level sensor 90 degrees clockwise, lift (3) The radiator fan assembly is attached
up and out of the container (Fig. 4). (threaded) to the water pump hub shaft (Fig. 5).
Remove the fan blade/viscous fan drive assembly
INSTALLATION from the water pump by turning the mounting nut
(1) Align coolant level sensor with coolant counterclockwise as viewed from the front. Threads
reservior access whole, press down while turning on the radiator fan drive are RIGHT-HAND. A 36
counterclockwise 90 degrees to seat sensor (Fig. 4). MM Fan Wrench should be used to prevent pulley
(2) Connect coolant level sensor electrical connec- from rotating (Fig. 5).
tor (Fig. 4). (4) Remove radiator fan shroud and radiator fan.
(3) Refill cooling system to proper level (Refer to 7 (Fig. 5).
- COOLING/ENGINE/COOLANT - STANDARD PRO-
NOTE: Store the viscous fan clutch in the upright
CEDURE).
position. DO NOT place down flat.
(4) Inspect for leaks.
INSTALLATION
(1) Install fan blade to viscous clutch. Tighten
bolts to 9 N·m (80 lbs. in.). (Fig. 5).
(2) Install fan and clutch along with fan shroud in
to engine bay area (Fig. 5).
(3) Install the center bolt of the viscous clutch.
Tighten bolt to 45 N·m (33 lbs. ft.). (Fig. 5)
(4) Attach coolant line to lower radiator shroud.
(5) Properly align and clip the fan shroud into
place.
7 - 14 ENGINE VA
RADIATOR FAN (Continued)
INSTALLATION
(1) For fan drive viscous clutch installation refer to
(Refer to 7 - COOLING/ENGINE/RADIATOR FAN -
INSTALLATION).
RADIATOR
REMOVAL
WARNING: RISK OF INJURY TO SKIN AND EYES
FROM SCALDING WITH HOT COOLANT. RISK OF
POISONING FROM SWALLOWING COOLANT. DO
NOT OPEN COOLING SYSTEM UNLESS COOLANT
TEMPERATURE IS BELOW 90°C (194°F). OPEN CAP
Fig. 8 THERMOSTAT HOUSING ASSEMBLY SLOWLY TO RELEASE PRESSURE. STORE COOL-
1 - O-RING ANT IN SUITABLE AND APPROPRIATELY MARKED
2 - CLAMP
3 - COOLANT TEMPERATURE SENSOR CONTAINER. WEAR PROTECTIVE GLOVES,
4 - FUEL LINE W/BRACKET CLOTHES AND EYE WEAR.
5 - THERMOSTAT HOUSING ASSEMBLY
6 - COOLANT HOSE
7 - CLAMP
8 - COOLANT HOSE NOTE: Capture all residual fluid spillage and store
9 - GASKET in suitably marked containers. Inspect condition of
all clamps and hoses, replace as necessary.
(6) Close coolant drain.
(7) Connect negative battery cable. (1) Drain coolant from radiator only(Refer to 7 -
(8) Fill coolant system to proper level with appro- COOLING/ENGINE/COOLANT - STANDARD PRO-
priate coolant mixture (Refer to 7 - COOLING/EN- CEDURE).
GINE/COOLANT - STANDARD PROCEDURE). (2) Remove headlamps.
(3) Remove front cross member together with front
WARNING: USE EXTREME CAUTION WHEN ENGINE grille.
IS OPERATING. DO NOT STAND IN DIRECT LINE (4) Remove front bumper.
WITH FAN. DO NOT PUT YOUR HANDS NEAR PUL- (5) Remove bolts holding air charge hose to sheet
LEYS, BELTS OR FAN. DO NOT WEAR LOOSE metal and intercooler.
CLOTHES. (6) Detach air intake pipe at the body (Fig. 9).
(7) Detach both coolant hoses at the coolant reser-
(9) Start engine and inspect for leaks. voir (Fig. 9).
VA ENGINE 7 - 17
RADIATOR (Continued)
(8) Unplug wiring connector at coolant level sensor (19) Detach coolant hose at radiator.
(Fig. 9). (20) Detach coolant pipe together with coolant
(9) Detach coolant hose at bottom right of radiator hose at the fan shroud.
(Fig. 9). (21) Remove radiator fan shroud (Fig. 10).
(10) Detach transmission cooler lines at radiator
(Fig. 9). INSTALLATION
(11) Remove the radiator trim from the left and (1) Install fan shroud to radiator (Fig. 10).
right (Fig. 9). (2) Attach coolant pipe with hoses to fan shroud
(12) Remove radiator fan (Refer to 7 - COOLING/ (Fig. 10).
ENGINE/RADIATOR FAN - REMOVAL). (3) Attach coolant hose at radiator (Fig. 10).
(13) Remove bolts securing intercooler to radiator. (4) Install bottom radiator trim (Fig. 10).
(14) Remove screws and upper radiator trim from (5) Install charge air cooler along with cooling loop
radiator. of the power steering, to radiator (Fig. 10).
(15) Move condenser/intercooler/power steering (6) Install radiator assembly into the rubber grom-
cooler assembly forward. mets (Fig. 9).
(16) Lift the radiator assembly up and out of the (7) Install both right and left side radiator trim
rubber grommets (Fig. 9). panels (Fig. 9).
(17) Take off charge air cooler together with cool- (8) Attach the transmission cooler lines (Fig. 9).
ing loop of the steering at the radiator (Fig. 10). (9) Attach coolant hose to the bottom right of the
(18) Remove bottom radiator trim (Fig. 10). radiator (Fig. 9).
7 - 18 ENGINE VA
RADIATOR (Continued)
OPERATION
A vent valve in the center of the cap will remain
shut as long as the cooling system is pressurized. As
the coolant cools, it contracts and creates a vacuum
VA ENGINE 7 - 19
RADIATOR PRESSURE CAP (Continued)
in cooling system. This causes the vacuum valve to CAUTION: Radiator pressure testing tools are very
open and coolant in reserve/overflow tank to be sensitive to small air leaks, which will not cause
drawn through connecting hose into radiator. If the cooling system problems. A pressure cap that does
vacuum valve is stuck shut, or overflow hose is not have a history of coolant loss should not be
kinked, radiator hoses will collapse on cool-down. replaced just because it leaks slowly when tested
with this tool. Add water to tool. Turn tool upside
DIAGNOSIS AND TESTING - RADIATOR down and recheck pressure cap to confirm that cap
PRESSURE CAP needs replacement.
Remove cap from radiator. Be sure that sealing
surfaces are clean. Moisten rubber gasket with water
and install the cap on pressure tester Tool 7700 or an WATER PUMP
equivalent (Fig. 12).
REMOVAL
WARNING: Risk of injury to skin and eyes from
scalding with hot coolant. Risk of poisoning from
swallowing coolant. Do not open cooling system
unless coolant temperature is below 90°C (194°F)).
Open cap slowly to release pressure. store coolant
in suitable and appropriately marked container.
Wear protective gloves, clothes and eye wear.
AUDIO/VIDEO
TABLE OF CONTENTS
page page
AUDIO
SPECIAL TOOLS
AUDIO
SPECIAL TOOL CROSS REFERENCE CHART
MB MILLER DESCRIPTION
TOOL # TOOL #
000 589 9241 RADIO EXTRACTION
88 63 00 TOOL
Fig. 3 RADIO
1 - SPECIAL TOOL 9241
2 - RADIO
3 - RETAINING TAB
Fig. 2 INSTRUMENT PANEL ANTENNA CABLE
INSTALLATION SPEAKER
(1) Insert new cable through glove box opening to
the radio opening in the instrument panel. REMOVAL
(2) Route cable up the A-pillar and connect to the (1) Disconnect and isolate the battery cable.
antenna body and cable. (2) Remove the A-pillar trim (Refer to 23 - BODY/
(3) Connect the antenna and electrical connections INTERIOR/A-PILLAR TRIM - REMOVAL).
near the windshield. (3) Remove speaker grill (Fig. 4).
(4) Attach antenna cable to instrument panel wire
harness.
(5) Install glove box (Refer to 23 - BODY/INSTRU-
MENT PANEL/GLOVE BOX - INSTALLATION).
(6) Install the headliner (Refer to 23 - BODY/IN-
TERIOR/HEADLINER - INSTALLATION).
(7) Install the A-pillar trim (Refer to 23 - BODY/
INTERIOR/A-PILLAR TRIM - INSTALLATION).
(8) Install the radio (Refer to 8 - ELECTRICAL/
AUDIO/RADIO - INSTALLATION).
(9) Connect the battery negative cable.
RADIO
REMOVAL
(1) Disconnect and isolate the battery negative Fig. 4 INSTRUMENT PANEL SPEAKER
cable. (4) Using a trim stick (C-4755 or equivalent), pry
(2) Using special tool 9241 or equivalent, insert up on the speaker.
one into each slot on the face of the radio (Fig. 3). (5) Disconnect electrical harness connector and
(3) Disconnect wire harness connector and antenna remove speaker.
from radio.
INSTALLATION
(1) Install wire harness connector.
INSTALLATION
(2) Place speaker into instrument panel.
(1) Connect wire harness connector and antenna to
(3) Install speaker grille.
radio.
(4) Install the A-pillar trim (Refer to 23 - BODY/
(2) Position radio to instrument panel and push
INTERIOR/A-PILLAR TRIM - INSTALLATION).
into place.
(5) Connect the battery negative cable.
(3) Connect battery negative cable.
VA CHIME/BUZZER 8B - 1
CHIME/BUZZER
TABLE OF CONTENTS
page page
page page
INSTALLATION
(1) Install CAB to the HCU.
(2) Install mounting bolts. Tighten to 2 N·m (16 in.
lbs.).
(3) Install the wiring harness connector to the
CAB and push down on the release to secure the con-
nector.
(4) Install negative battery cable to the battery.
Fig. 2 ECM
1 - MASS AIR FLOW SENSOR 8 - CHARGE AIR PRESSURE SENSOR
2 - TURBOCHARGER SERVO MOTOR 9 - CHARGE AIR TEMPERATURE SENSOR
3 - CAMSHAFT POSITION SENSOR 10 - COOLANT TEMPERATURE SENSOR
4 - ENGINE OIL SENSOR 11 - FUEL RAIL PRESSURE SENSOR
5 - CRANKSHAFT POSITION SENSOR 12 - FUEL TEMPERATURE SENSOR
6 - PRESSURE REGULATOR VALVE 13 - FUEL QUANTITY CONTROL VALVE
7 - EGR VALVE 14 - AIR INTAKE PRESSURE SENSOR
ECM Control Strategy The engine control module • The maximum vehicle speed is programmable
is involved with a variety of functions such as: (Fig. from 19–82 m.p.h. The standard is 82 m.p.h.
3) New software has been loaded to the ECM for EGR
• Individual injector activation control. This is due to the wider operating range and
• Engine idle speed control to ensure smooth larger volume of recirculated gas. There is a consid-
engine idling independent of engine load erable number of new, adapted, and optimized func-
• Ride comfort function such as anti jerk control: tions, particularly with regard to injection, EGR,
The CDI control module detects irregularities in boost control, sensing of the input parameters and
engine speed (resulting, for example, from load the signaling of the actuators (Fig. 3).
changes or gear shift) from the signal supplied by the • The rail pressure control achieved by signaling
crankshaft position sensor and reduces them by the quantity control valve in the high pressure pump
adjusting the quantity injected into each of the cylin- and the pressure regulator results in reduced power
ders consumption of high pressure pump and in lowering
• Constant RPM (high idle feature) for ambulance fuel pressures
vehicle bodies equipped with electrical appliances • Individual cylinder torque control for smooth
• Starter control, immobilizer, cruise control, kick engine running: using the crankshaft position sensor
down, air conditioner signals, the ECM detect non-uniform engine running
• Maintenance computer ASSYST (optional) results from uneven torque contributions of the indi-
• Glow plug for pre-heating, post heating and vidual cylinders and adjust the injection quantities of
intermittent heating the individual injectors so that all cylinders make the
• Error code memory/diagnostics, communication same torque contribution
interface for diagnosis and handling the fault codes • A relay is used for activating the electric in-tank
fuel pump
VA ELECTRONIC CONTROL MODULES 8E - 5
ENGINE CONTROL MODULE (Continued)
OPERATION
The transmission control module (TCM) deter-
mines the current operating conditions of the vehicle
and controls the shifting process for shift comfort and
driving situations. It receives this operating data
from sensors and broadcast messages from other
modules.
The TCM uses inputs from several sensors that are
Fig. 4 ECM directly hardwired to the controller and it uses sev-
1 - BRACKET eral indirect inputs that are used to control shifts.
2 - ECM This information is used to actuate the proper sole-
3 - BRACKET TENSIONING SPRINGS
noids in the valve body to achieve the desired gear.
The shift lever assembly (SLA) has several items
INSTALLATION that are monitored by the TCM to calculate shift
lever position. The reverse light switch, an integral
NOTE: THE ECM MUST BE PROGRAMMED TO SUP-
part of the SLA, controls the reverse light relay con-
PORT THE VEHICLE OPTIONS PACKAGE.
trol circuit. The Brake/Transmission Shift Interlock
(1) Position the ECM into the guide of the retain- (BTSI) solenoid and the park lockout solenoid (also
ing bracket (Fig. 4). part of the SLA) are controlled by the TCM.
VA ELECTRONIC CONTROL MODULES 8E - 7
TRANSMISSION CONTROL MODULE (Continued)
The ECM and ABS broadcast messages over the input signal for the TCM. The temperature of the
controller area network (CAN C) bus for use by the ATF has an influence on the shifttime and resulting
TCM. The TCM uses this information, with other shift quality. As the temperature rises, resistance
inputs, to determine the transmission operating con- rises, and therefore, the probing voltage is decreas-
ditions. ing. Because of its registration, the shifting process
The TCM: can be optimized in all temperature ranges.
• determines the momentary operating conditions The ATF temperature sensor is wired in series
of the vehicle. with the park/neutral contact. The temperature sig-
• controls all shift processes. nal is transmitted to the TCM only when the reed
• considers shift comfort and the driving situation. contact of the park/neutral contact is closed because
The TCM controls the solenoid valves for modulat- the TCM only reads ATF temperature while in any
ing shift pressures and gear changes. Relative to the forward gear, or REVERSE. When the transmission
torque being transmitted, the required pressures are is in PARK or NEUTRAL, the TCM will substitute
calculated from load conditions, engine rpm, vehicle the engine temperature for the ATF temperature.
speed, and ATF temperature.
The following functions are contained in the TCM: Starter Interlock
• Shift Program The TCM monitors a contact switch wired in series
• Downshift Safety with the transmission temperature sensor to deter-
• Torque Converter Lock-Up Clutch. mine PARK and NEUTRAL positions. The contact
• Adaptation. switch is open in PARK and NEUTRAL. The TCM
This transmission does not have a TCM relay. senses transmission temperature as high (switch
Power is supplied to the SLA and the TCM directly supply voltage), confirming switch status as open.
from the ignition. The TCM then broadcasts a message over CAN bus
The TCM continuously checks for electrical prob- to confirm switch status. The PCM receives this
lems, mechanical problems, and some hydraulic prob- information and allows operation of the starter cir-
lems. When a problem is sensed, the TCM stores a cuit.
diagnostic trouble code (DTC). Some of these codes
cause the transmission to go into 9Limp-In9 or N2 and N3 Speed Sensors
9default9 mode. Some DTCs cause permanent The N2 and N3 Input Speed Sensors are two Hall-
Limp-In and others cause temporary Limp-In. The effect speed sensors that are mounted internally in
NAG1 defaults in the current gear position if a DTC the transmission and are used by the TCM to calcu-
is detected, then after a key cycle the transmission late the transmission’s input speed. Since the input
will go into Limp-in, which is mechanical 2nd gear. speed cannot be measured directly, two of the drive
Some DTCs may allow the transmission to resume elements are measured. Two input speed sensors
normal operation (recover) if the detected problem were required because both drive elements are not
goes away. A permanent Limp-In DTC will recover active in all gears.
when the key is cycled, but if the same DTC is
detected for three key cycles the system will not CAN C Bus Indirect Input Signals
recover and the DTC must be cleared from the TCM A 2.5-volt bias (operating voltage) is present on the
with the DRBIIIt scan tool. CAN C bus any time the ignition switch is in the
RUN position. Both the TCM and the ABS apply this
TCM SIGNALS bias. On this vehicle, the CAN C bus is used for mod-
The TCM registers one part of the input signals by ule data exchange only. The indirect inputs used on
direct inputs, the other part by CAN C bus. In addi- the NAG1 electronic control system are:
tion to the direct control of the actuators, the TCM • Wheel Speed Sensors.
sends various output signals by CAN C bus to other • Brake Switch.
control modules. • Engine RPM.
• Engine Temperature.
Selector Lever Position • Cruise Control Status.
The TCM monitors the SLA for all shift lever posi- • Gear Limit Request.
tions via the CAN bus. • Throttle Position - 0% at idle, 100% at WOT. If
open, TCM assumes idle (0% throttle opening).
ATF Temperature Sensor • Odometer Mileage
The ATF temperature sensor is a positive temper- • Maximum Effective Torque.
ature co-efficient (PTC) thermistor. It measures the • Engine in Limp-In Mode/Mileage Where DTC
temperature of the transmission fluid and is a direct Was Set.
8E - 8 ELECTRONIC CONTROL MODULES VA
TRANSMISSION CONTROL MODULE (Continued)
BRAKE TRANSMISSION SHIFT INTERLOCK (BTSI) • Clutch Filling Pressure.
The BTSI solenoid prevents shifting out of the • Torque Converter Lock-Up Control.
PARK position until the ignition key is in the RUN Adaptation data may be stored permanently and to
position and the brake pedal is pressed. The TCM some extent, can be diagnosed.
controls the ground while the ignition switch supplies
power to the BTSI solenoid. The PCM monitors the Driving Style Adaptation
brake switch and broadcasts brake switch status The shift point is modified in steps based on the
messages over the CAN C bus. If the park brake is information from the inputs. The control module
depressed and there is power (Run/Start) to SLA, the looks at inputs such as:
BTSI solenoid deactivates. • vehicle acceleration and deceleration (calculated
by the TCM).
SHIFT SCHEDULES • rate of change as well as the position of the
The basic shift schedule includes up and down- throttle pedal (fuel injection information from the
shifts for all five gears. The TCM adapts the shift ECM).
program according to driving style, accelerator pedal • lateral acceleration (calculated by the TCM).
position and deviation of vehicle speed. Influencing • gear change frequency (how often the shift
factors are: occurs).
• Road Conditions. Based on how aggressive the driver is, the TCM
• Incline, Decline and Altitude. moves up the shift so that the present gear is held a
• Trailer Operation, Loading. little longer before the next upshift. If the driving
• Engine Coolant Temperature. style is still aggressive, the shift point is modified up
• Cruise Control Operation. to ten steps. If the driving returns to normal, then
• Sporty Driving Style. the shift point modification also returns to the base
• Low and High ATF Temperature. position.
This adaptation has no memory. The adaptation to
driving style is nothing more than a shift point mod-
Upshift 1-2 2-3 3-4 4-5
ification meant to assist an aggressive driver. The
To:
shift points are adjusted for the moment and return
Activated 1-2/4-5 2-3 3-4 1-2/4-5 to base position as soon as the inputs are controlled
By in a more rational manner.
Solenoid:
Shift 17.8 32.1 67.5 73.8 Shift Time Adaptation (Shift Overlap Adaptation, Working
Pressure)
Point (at km/h km/h km/h km/h
35.2% of (11.6 (19.95 (41.94 (45.86 Shift time adaptation is the ability of the TCM to
throttle) mph) mph) mph) mph) electronically alter the time it takes to go from one
gear to another. Shift time is defined as the time it
takes to disengage one shift member while another is
Downshift 5-4 4-3 3-2 2-1 being applied. Shift time adaptation is divided into
From: four categories:
Activated 1-2/4-5 3-4 2-3 1-2/4-5 1. Accelerating upshift, which is an upshift under
By a load. For shift time adaptation for the 1-2 upshift
Solenoid: to take place, the transmission must shift from 1st to
Shift 55.7 40.5 24.4 15.1 2nd in six different engine load ranges vs. transmis-
Point km/h km/h km/h km/h sion output speed ranges.
(34.61 (25.17 (15.16 (9.38 2. Decelerating upshift, which is an upshift under
mph) mph) mph) mph) no load. This shift is a rolling upshift and is accom-
plished by letting the vehicle roll into the next gear.
3. Accelerating downshift, which is a downshift
DOWNSHIFT SAFETY under load. This shift can be initiated by the throttle,
Selector lever downshifts are not performed if inad- with or without kickdown. The shift selector can also
missible high engine rpm is sensed. be used.
4. Decelerating downshift, which is accomplished
ADAPTATION by coasting down. As the speed of the vehicle
To equalize tolerances and wear, an automatic decreases, the transmission downshifts.
adaptation takes place for:
• Shift Time.
• Clutch Filling Time.
VA ELECTRONIC CONTROL MODULES 8E - 9
TRANSMISSION CONTROL MODULE (Continued)
Fill Pressure Adaptation (Apply Pressure Adaptation, Hardware Error Mode
Modulating Pressure) When the TCM detects a major internal error, the
Fill pressure adaptation is the ability of the TCM transmission is placed in the permanent Limp-In
to modify the pressure used to engage a shift mem- Mode and ceases all communication over the CAN
ber. The value of this pressure determines how firm bus. When the TCM has entered this mode normal
the shift will be. transmission operation does not resume until all
• If too much pressure is used, the shift will be DTCs are cleared from the TCM.
hard.
• If too little pressure is used, the transmission Loss of Drive
may slip. If the TCM detects a situation that has resulted or
The pressure adjustment is needed to compensate may result in a catastrophic engine or transmission
for the tolerances of the shift pressure solenoid valve. problem, the transmission is placed in the neutral
The amount the solenoid valve opens as well as how position. Improper Ratio, Input Sensor Overspeed or
quickly the valve can move, has an effect on the pres- Engine Overspeed DTCs cause the loss of drive.
sure. The return spring for the shift member pro-
vides a resistance that must be overcome by the Controlled Limp-in Mode
pressure in order for shift member to apply. These When a failure does not require the TCM to shut
return springs have slightly different values. This down the solenoid supply, but the failure is severe
also affects the application pressure and is compen- enough that the TCM places the transmission into a
sated for by fill pressure adaptation. predefined gear, there are several shift performance
concerns. For instance, if the transmission is slip-
Fill Time Adaptation (Engagement Time Adaptation) ping, the controller tries to place the transmission
Fill time is the time it takes to fill the piston cav- into 3rd gear and maintain 3rd gear for all forward
ity and take up any clearances for a friction element drive conditions.
(clutch or brake). Fill time adaptation is the ability of
the TCM to modify the time it takes to fill the shift STANDARD PROCEDURE - TCM ADAPTATION
member by applying a preload pressure. The adaptation procedure requires the use of the
appropriate scan tool. This program allows the elec-
CONTROLLER MODES OF OPERATION tronic transmission system to re-calibrate itself. This
will provide the proper baseline transmission opera-
Permanent Limp-In Mode tion. The adaptation procedure should be performed
When the TCM determines there is a non-recover- if any of the following procedures are performed:
able condition present that does not allow proper • Transmission Assembly Replacement
transmission operation, it places the transmission in • Transmission Control Module Replacement
permanent Limp-In Mode. When the condition occurs • Clutch Plate and/or Seal Replacement
the TCM turns off all solenoids as well as the sole- • Electrohydraulic Unit Replacement or Recondi-
noid supply output circuit. If this occurs while the tion
vehicle is moving, the transmission remains in the (1) With the scan tool, reset the Transmission
current gear position until the ignition is turned off adaptives. Resetting the adaptives will set the adap-
or the shifter is placed in the 9P9 position. When the tives to factory settings.
shifter has been placed in 9P,9 the transmission only
allows 2nd gear operation. If this occurs while the NOTE: Perform the Coast Down Adaptations first.
vehicle is not moving, the transmission only allows The Transmission Temperature must be greater
operation in 2nd gear. than 60°C (140°F) and less than 70°C (158°F). Fail-
ure to stay within these temperature ranges will
Temporary Limp-In Mode void the procedure.
This mode is the same as the permanent Limp-In
Mode except if the condition is no longer present, the (2) Drive the vehicle until the transmission tem-
system resumes normal operation. perature is in the specified range.
(3) Perform 4 to 5 coast downs from 5th to 4th
Under Voltage Limp-In Mode gear and then 4th to 3rd gear.
When the TCM detects that system voltage has
dropped below 8.5 volts, it disables voltage-depen- NOTE: For Upshift adaptation, the Transmission
dant diagnostics and places the transmission in the temperature must be greater than 60°C (140°F) and
temporary Limp-In Mode. When the TCM senses less than 100°C (212°F). Failure to stay within these
that the voltage has risen above 9.0 volts, normal temperature ranges will void this procedure.
transmission operation is resumed.
8E - 10 ELECTRONIC CONTROL MODULES VA
TRANSMISSION CONTROL MODULE (Continued)
(4) From a stop, moderately accelerate the vehicle (6) The TCM will store the adaptives every 10
and obtain all forward gear ranges while keeping the minutes. After completion of the adaptation proce-
Engine RPM below 1800 RPM. Repeat this procedure dure make sure the vehicle stays running for at least
4 to 5 times. 10 minutes.
(5) Obtaining 5th gear may be difficult at 1800 (7) It is possible to manually store the adaptives
RPM. Allow the transmission to shift into 5th gear at under the 10 minute time frame using the DRBIIIt
a higher RPM then lower the RPM to 1800 and per- Store Adaptives procedure.
form manual shifts between 4th and 5th gears using
the shift lever.
VA ENGINE SYSTEMS 8F - 1
ENGINE SYSTEMS
TABLE OF CONTENTS
page page
BATTERY SYSTEM
TABLE OF CONTENTS
page page
THE BATTERY SEEMS 1. The electrical system 1. Refer to the IGNITION-OFF DRAW TEST
WEAK OR DEAD WHEN ignition-off draw is excessive. Standard Procedure for the proper test
ATTEMPTING TO START procedures. Repair the excessive ignition-off
THE ENGINE. draw, as required.
THE BATTERY STATE OF 1. The battery has an 1. Refer to Battery System Specifications for the
CHARGE CANNOT BE incorrect size or rating for proper specifications. Replace an incorrect
MAINTAINED. this vehicle. battery, as required.
2. The battery terminal 2. Refer to Battery Cable for the proper cable
connections are loose or diagnosis and testing procedures. Clean and
corroded. tighten the battery terminal connections, as
required.
3. The electrical system 3. Refer to the IGNITION-OFF DRAW TEST
ignition-off draw is excessive. Standard Procedure for the proper test
procedures. Repair the faulty electrical system, as
required.
4. The battery is faulty. 4. Test the battery using the Micro 420 battery
tester. Refer to Standard Procedures for
additional test procedures. Replace the faulty
battery, as required.
5. The starting system is 5. Determine if the starting system is performing
faulty. to specifications. Refer to Starting System for the
proper starting system diagnosis and testing
procedures. Repair the faulty starting system, as
required.
6. The charging system is 6. Determine if the charging system is performing
faulty. to specifications. Refer to Charging System for
additional charging system diagnosis and testing
procedures. Repair the faulty charging system, as
required.
7. Electrical loads exceed the 7. Inspect the vehicle for aftermarket electrical
output of the charging equipment which might cause excessive electrical
system. loads.
8. Slow driving or prolonged 8. Advise the vehicle operator, as required.
idling with high-amperage
draw systems in use.
THE BATTERY WILL NOT 1. The battery is faulty. 1. Test the battery using the Micro 420 battery
ACCEPT A CHARGE. tester. Charge or replace the faulty battery, as
required.
REMOVAL
UNDER HOOD BATTERY REMOVAL
(1) Turn the ignition switch to the Off position. Be
certain that all electrical accessories are turned off.
(2) Loosen the battery negative cable terminal
clamp pinch-bolt hex nut.
(3) Disconnect the battery negative cable terminal
clamp from the battery negative terminal post. If
necessary, use a battery terminal puller to remove
the terminal clamp from the battery post.
(4) Loosen the battery positive cable terminal
clamp pinch-bolt hex nut.
(5) Disconnect the battery positive cable terminal
clamp from the battery positive terminal post. If nec-
essary, use a battery terminal puller to remove the
terminal clamp from the battery post.
(6) Remove the battery hold downs from the bat-
tery (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/
BATTERY HOLDDOWN - REMOVAL).
Fig. 7 Battery Cell Caps
1 - BATTERY CELL CAP
WARNING: WEAR A SUITABLE PAIR OF RUBBER
2 - BATTERY GLOVES (NOT THE HOUSEHOLD TYPE) WHEN
REMOVING A BATTERY BY HAND. SAFETY
(2) Look through the battery cap holes to deter- GLASSES SHOULD ALSO BE WORN. IF THE BAT-
mine the level of the electrolyte in the battery (Fig. TERY IS CRACKED OR LEAKING, THE ELECTRO-
8). The electrolyte should be approximately 1 centi- LYTE CAN BURN THE SKIN AND EYES.
meter above the battery plates or until the hook
inside the battery cap holes is covered. (7) Remove the battery from the battery tray.
(3) Add only distilled water until the electrolyte
level is approx. one centimeter above the plates.
VA BATTERY SYSTEM 8F - 13
BATTERY (Continued)
AUXILIARY BATTERY REMOVAL the terminal clamp pinch-bolt hex nut to 7.9 N·m (70
(1) Turn the ignition switch to the Off position. Be in. lbs.).
certain that all electrical accessories are turned off. (5) Apply a thin coating of petroleum jelly or chas-
(2) Remove the passenger front seat assembly. sis grease to the exposed surfaces of the battery cable
Refer to the Body section for procedure. terminal clamps and the battery terminal posts.
(3) Remove the top cover from the seat base
assembly. AUXILIARY BATTERY INSTALLATION
(4) Loosen the battery negative cable terminal (1) Position the battery onto the battery tray.
clamp pinch-bolt hex nut. Ensure that the battery positive and negative termi-
(5) Disconnect the battery negative cable terminal nal posts are correctly positioned. The battery cable
clamp from the battery negative terminal post. If terminal clamps must reach the correct battery ter-
necessary, use a battery terminal puller to remove minal post without stretching the cables.
the terminal clamp from the battery post. (2) Reinstall the battery hold downs onto the bat-
(6) Loosen the battery positive cable terminal tery (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/
clamp pinch-bolt hex nut. BATTERY HOLDDOWN - INSTALLATION).
(7) Disconnect the battery positive cable terminal
clamp from the battery positive terminal post. If nec- CAUTION: Be certain that the battery cable terminal
essary, use a battery terminal puller to remove the clamps are connected to the correct battery termi-
terminal clamp from the battery post. nal posts. Reverse battery polarity may damage
(8) Remove the battery hold downs from the bat- electrical components of the vehicle.
tery (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/
(3) Reconnect the battery positive cable terminal
BATTERY HOLDDOWN - REMOVAL).
clamp to the battery positive terminal post. Tighten
WARNING: WEAR A SUITABLE PAIR OF RUBBER the terminal clamp pinch-bolt hex nut to 11.8 N·m
GLOVES (NOT THE HOUSEHOLD TYPE) WHEN (105 in. lbs.).
REMOVING A BATTERY BY HAND. SAFETY (4) Reconnect the battery negative cable terminal
GLASSES SHOULD ALSO BE WORN. IF THE BAT- clamp to the battery negative terminal post. Tighten
TERY IS CRACKED OR LEAKING, THE ELECTRO- the terminal clamp pinch-bolt hex nut to 7.9 N·m (70
LYTE CAN BURN THE SKIN AND EYES. in. lbs.).
(5) Apply a thin coating of petroleum jelly or chas-
(9) Remove the battery from the battery tray. sis grease to the exposed surfaces of the battery cable
terminal clamps and the battery terminal posts.
(6) Install the top cover on the seat base assembly.
INSTALLATION (7) Install the passenger front seat assembly. Refer
to the Body section for procedure.
UNDER HOOD BATTERY INSTALLATION
(1) Position the battery onto the battery tray.
Ensure that the battery positive and negative termi- BATTERY HOLDDOWN
nal posts are correctly positioned. The battery cable
terminal clamps must reach the correct battery ter- DESCRIPTION
minal post without stretching the cables. The battery hold down hardware includes two hex
(2) Reinstall the battery hold downs onto the bat- nuts with washers and two hold down brackets. The
tery (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/ battery hold down brackets are formed of stamped
BATTERY HOLDDOWN - INSTALLATION). steel. The hold down assembly is coated for corrosion
protection.
CAUTION: Be certain that the battery cable terminal When installing a battery into the battery tray, be
clamps are connected to the correct battery termi- certain that the hold down hardware is properly
nal posts. Reverse battery polarity may damage installed and that the fasteners are tightened to the
electrical components of the vehicle. proper specifications. Improper hold down fastener
tightness, whether too loose or too tight, can result in
(3) Reconnect the battery positive cable terminal damage to the battery, the vehicle or both.
clamp to the battery positive terminal post. Tighten
the terminal clamp pinch-bolt hex nut to 11.8 N·m REMOVAL
(105 in. lbs.).
(1) Turn the ignition switch to the Off position. Be
(4) Reconnect the battery negative cable terminal certain that all electrical accessories are turned off.
clamp to the battery negative terminal post. Tighten (2) Remove the two nuts that secure the battery
hold down brackets to the battery tray.
8F - 14 BATTERY SYSTEM VA
BATTERY HOLDDOWN (Continued)
(3) Remove the battery hold down brackets. reliable connection of the battery to the vehicle elec-
trical system.
INSTALLATION
(1) Install the battery hold down brackets. DIAGNOSIS AND TESTING - BATTERY CABLES
(2) Install the two nuts that secure the battery A voltage drop test will determine if there is exces-
hold down brackets to the battery tray. Tighten to 70 sive resistance in the battery cable terminal connec-
in. lbs. tions or the battery cables. If excessive resistance is
found in the battery cable connections, the connec-
tion point should be disassembled, cleaned of all cor-
BATTERY CABLES rosion or foreign material, then reassembled.
Following reassembly, check the voltage drop for the
DESCRIPTION battery cable connection and the battery cable again
The battery cables are large gauge, stranded cop- to confirm repair.
per wires sheathed within a heavy plastic or syn- When performing the voltage drop test, it is impor-
thetic rubber insulating jacket. The wire used in the tant to remember that the voltage drop is giving an
battery cables combines excellent flexibility and reli- indication of the resistance between the two points at
ability with high electrical current carrying capacity. which the voltmeter probes are attached. EXAM-
The battery cables cannot be repaired and, if dam- PLE: When testing the resistance of the battery pos-
aged or faulty they must be replaced. Both the bat- itive cable, touch the voltmeter leads to the battery
tery positive and negative cables are available for positive cable terminal clamp and to the battery pos-
service replacement only as a unit with the battery itive cable eyelet terminal at the starter solenoid
positive cable wire harness or the battery negative B(+) terminal stud. If you probe the battery positive
cable wire harness, which may include portions of terminal post and the battery positive cable eyelet
the wiring circuits for the generator and other com- terminal at the starter solenoid B(+) terminal stud,
ponents on some models. you are reading the combined voltage drop in the
The battery cables feature a stamped brass clamp- battery positive cable terminal clamp-to-terminal
ing type female battery terminal crimped onto one post connection and the battery positive cable.
end of the battery cable wire and then solder-dipped.
A square headed pinch-bolt and hex nut are installed VOLTAGE DROP TEST
at the open end of the female battery terminal clamp.
The battery positive cable also includes a red molded WARNING: IF THE BATTERY SHOWS SIGNS OF
rubber protective cover for the female battery termi- FREEZING, LEAKING, LOOSE POSTS, OR LOW
nal clamp. Large eyelet type terminals are crimped ELECTROLYTE LEVEL, DO NOT TEST, ASSIST-
onto the opposite end of the battery cable wire and BOOST, OR CHARGE. THE BATTERY MAY ARC
then solder-dipped. The battery positive cable wires INTERNALLY AND EXPLODE. PERSONAL INJURY
have a red insulating jacket to provide visual identi- AND/OR VEHICLE DAMAGE MAY RESULT.
fication and feature a larger female battery terminal
clamp to allow connection to the larger battery posi-
WARNING: EXPLOSIVE HYDROGEN GAS FORMS IN
tive terminal post. The battery negative cable wires
AND AROUND THE BATTERY. DO NOT SMOKE,
have a black insulating jacket and a smaller female
USE FLAME, OR CREATE SPARKS NEAR THE BAT-
battery terminal clamp.
TERY. PERSONAL INJURY AND/OR VEHICLE DAM-
AGE MAY RESULT.
OPERATION
The battery cables connect the battery terminal
posts to the vehicle electrical system. These cables WARNING: THE BATTERY CONTAINS SULFURIC
also provide a return path for electrical current gen- ACID, WHICH IS POISONOUS AND CAUSTIC. AVOID
erated by the charging system for restoring the volt- CONTACT WITH THE SKIN, EYES, OR CLOTHING.
age potential of the battery. The female battery IN THE EVENT OF CONTACT, FLUSH WITH WATER
terminal clamps on the ends of the battery cable AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT
wires provide a strong and reliable connection of the OF THE REACH OF CHILDREN.
battery cable to the battery terminal posts. The ter-
minal pinch bolts allow the female terminal clamps
to be tightened around the male terminal posts on
the top of the battery. The eyelet terminals secured
to the ends of the battery cable wires opposite the
female battery terminal clamps provide secure and
VA BATTERY SYSTEM 8F - 15
BATTERY CABLES (Continued)
WARNING: IF THE BATTERY IS EQUIPPED WITH between the battery positive cable terminal clamp
REMOVABLE CELL CAPS, BE CERTAIN THAT EACH and the battery positive terminal post.
OF THE CELL CAPS IS IN PLACE AND TIGHT
BEFORE THE BATTERY IS RETURNED TO SER-
VICE. PERSONAL INJURY AND/OR VEHICLE DAM-
AGE MAY RESULT FROM LOOSE OR MISSING
CELL CAPS.
OPERATION
The battery tray provides a mounting location and
support for the vehicle battery. The battery tray sup-
port supports the battery tray and provides an
anchor point for the inboard battery hold down hard-
ware. The battery tray and the battery hold down
hardware combine to secure and stabilize the battery
in the engine compartment, which prevents battery
movement during vehicle operation. Unrestrained
battery movement during vehicle operation could
result in damage to the vehicle, the battery or both.
The battery tray drain tube directs spilled water or
electrolyte from a leaking battery to the ground
through another hole in the front extension of the
left front wheelhouse inner panel.
REMOVAL
Fig. 12 Test Ground Circuit Resistance - Typical (1) Remove the battery from the battery tray.
1 - VOLTMETER (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/BAT-
2 - BATTERY
3 - ENGINE GROUND
TERY - REMOVAL).
(2) Remove the battery temperature sensor from
REMOVAL the battery tray. (Refer to 8 - ELECTRICAL/CHARG-
ING/BATTERY TEMPERATURE SENSOR -
(1) Turn the ignition switch to the Off position. Be
REMOVAL).
certain that all electrical accessories are turned off.
(3) Remove the bolts that secure the battery tray
(2) Disconnect and isolate the remote battery neg-
to the battery tray support.
ative cable terminal.
(4) Remove the battery tray from the vehicle.
(3) One at a time, trace and disconnect the battery
cable retaining pushpins, fasteners and routing clips
until the cables are free from the vehicle. INSTALLATION
(4) Feed the battery cable assembly out of the (1) Clean and inspect the battery tray.(Refer to 8 -
vehicle. ELECTRICAL/BATTERY SYSTEM - CLEANING).
(2) Position the battery tray onto the battery tray
INSTALLATION support.
(3) Install and tighten the bolts that secure the
(1) Position the battery cable in the vehicle.
battery tray to the battery tray support. Tighten the
(2) One at a time, install the battery cable retain-
screws to 11.8 N·m (105 in. lbs.).
ing pushpins, fasteners and routing clips until the
(4) Install the battery temperature sensor onto the
cable is installed exactly in the factory installed loca-
battery tray. (Refer to 8 - ELECTRICAL/CHARGING/
tion in the vehicle. Refer to the Wiring Diagram sec-
BATTERY TEMPERATURE SENSOR - INSTALLA-
tion of the service manual for reference.
TION).
(3) Connect the battery negative cable terminal.
(5) Install the battery onto the battery tray. (Refer
to 8 - ELECTRICAL/BATTERY SYSTEM/BATTERY -
INSTALLATION).
VA CHARGING SYSTEM 8F - 17
CHARGING SYSTEM
TABLE OF CONTENTS
page page
CHARGING SYSTEM
SPECIFICATIONS
TORQUE – 2.7L DIESEL
REMOVAL
CAUTION: DISCONNECT NEGATIVE CABLE FROM
BATTERY BEFORE REMOVING BATTERY OUTPUT
WIRE FROM GENERATOR. FAILURE TO DO SO
CAN RESULT IN INJURY.
GENERATOR DECOUPLER
PULLEY
DESCRIPTION
The generator decoupler is used only with
certain engines. The decoupler is used in place of
the standard generator drive pulley (Fig. 2).
INSTALLATION
(1) Raise and support vehicle.
(2) Position generator to engine.
(3) Install 4 generator mounting bolts (Fig. 1).
Refer to Torque Specifications.
(4) Connect field terminal connector at rear of gen-
erator. Fig. 2 GENERATOR DECOUPLER PULLEY
(5) Install battery output cable and nut to B+ ter- OPERATION
minal at top of generator. Refer to Torque Specifica- The generator decoupler is used only with
tions. certain engines. The decoupler (Fig. 2) is a one-way
(6) Install protective plastic cover to B+ stud at clutch designed to help reduce belt tension fluctua-
top of generator. tion, vibration, reduce fatigue loads, improve belt life,
(7) Lower vehicle. reduce hubloads on components, and reduce noise.
Dry operation is used (no grease or lubricants). The
CAUTION: Never force a belt over a pulley rim
decoupler is not temperature sensitive and also has a
using a screwdriver. The synthetic fiber of the belt
low sensitivity to electrical load. The decoupler is a
can be damaged.
non-serviceable item and is to be replaced as an
assembly.
8F - 20 CHARGING SYSTEM VA
GENERATOR DECOUPLER PULLEY (Continued)
REMOVAL
The generator decoupler is used only with
certain engines.
Two different type generator decoupler pulleys are
used. One can be identified by the use of machined
splines (Fig. 3). The other can be identified by a hex
opening (Fig. 4) and will not use splines.
Different special tools are required to service each
different decoupler. Refer to following procedure.
INA Decoupler
(1) Disconnect negative battery cable.
(2) Remove generator and accessory drive belt.
Refer to Generator Removal.
(3) Position Special Tool #8823 (VM.1048) into
decoupler (Fig. 5).
Fig. 3 GENERATOR DECOUPLER PULLEY (INA) (4) Determine if end of generator shaft is hex
1 - GENERATOR shaped (Fig. 6) or is splined (Fig. 7). If hex is used,
2 - DECOUPLER (INA)
3 - MACHINED SPLINES insert a 10MM deep socket into tool #8823 (VM.1048)
(Fig. 8). If splined, insert a 5/16” 6-point hex driver,
or a 10MM 12-point triple square driver into tool
#8823 (VM.1048) (Fig. 9).
(5) The generator shaft uses conventional right-
hand threads to attach decoupler. To break decoupler
loose from generator threads, rotate end of tool clock-
wise (Fig. 8) or, (Fig. 9).
(6) After breaking loose with tool, unthread decou-
pler by hand from generator.
VA CHARGING SYSTEM 8F - 21
GENERATOR DECOUPLER PULLEY (Continued)
Litens Decoupler
(1) Disconnect negative battery cable.
(2) Remove generator and accessory drive belt.
Refer to Generator Removal.
(3) Position Special Tool #8433 (Fig. 10) into
decoupler. Align to hex end of generator shaft.
(4) The generator shaft uses conventional right-
hand threads to attach decoupler. To break decoupler
loose from generator threads, rotate end of tool clock-
wise (Fig. 11).
(5) After breaking loose with tool, unthread decou-
pler by hand from generator.
Fig. 11 DECOUPLER REMOVAL (LITENS)
INSTALLATION
INA Decoupler
(1) Thread decoupler pulley onto generator shaft
by hand (right-hand threads).
(2) Position Special Tool #8823 (VM.1048) into
decoupler (Fig. 5).
(3) Determine if end of generator shaft is hex
shaped (Fig. 6) or is splined (Fig. 7). If hex is used,
insert a 10MM deep socket into tool #8823 (VM.1048)
(Fig. 12). If splined, insert a 5/16” 6-point hex driver,
or a 10MM 12-point triple square driver into tool
#8823 (VM.1048) (Fig. 13).
VA CHARGING SYSTEM 8F - 23
GENERATOR DECOUPLER PULLEY (Continued)
(4) Do not use an adjustable, ratcheting “click
type” torque wrench. Most “click type”
wrenches will only allow torque to be applied
in a clockwise rotation. Use a dial-type or
beam-type wrench. Tighten in counter-clockwise
rotation (Fig. 12) or, (Fig. 13). Refer to torque speci-
fications.
(5) Install accessory drive belt, and generator.
Refer to Generator Installation.
(6) Connect negative battery cable.
Litens Decoupler
(1) Thread decoupler pulley onto generator shaft
by hand (right-hand threads).
(2) Position Special Tool 8433 (Fig. 10) into decou-
pler. Align tool to hex end of generator shaft.
(3) Do not use an adjustable, ratcheting “click
type” torque wrench. Most “click type”
wrenches will only allow torque to be applied
in a clockwise rotation. Use a dial-type or
beam-type wrench. Tighten in counter-clockwise
rotation (Fig. 14). Refer to torque specifications.
(4) Install accessory drive belt, and generator.
Refer to Generator Installation.
(5) Connect negative battery cable.
DESCRIPTION
The electronic voltage regulator is attached to the
back of the generator. It is not serviced as a separate
component. If replacement is necessary, the generator
must be replaced.
8F - 24 STARTING SYSTEM VA
STARTING SYSTEM
TABLE OF CONTENTS
page page
INSPECTION TESTING
For complete starter wiring circuit diagrams, refer
COLD CRANKING TEST
to 8, Wiring Diagrams. Before removing any unit
from starting system for repair or diagnosis, perform For complete starter wiring circuit diagrams, refer
the following inspections: to 8, Wiring Diagrams. The battery must be fully-
charged and load-tested before proceeding. Refer to
WARNING: ON VEHICLES EQUIPPED WITH AIR- Battery in 8, Battery.
BAGS, REFER TO 8, PASSIVE RESTRAINT SYS- (1) Connect volt-ampere tester to battery terminals
TEMS, BEFORE ATTEMPTING ANY STEERING (Fig. 1). See instructions provided by manufacturer of
WHEEL, STEERING COLUMN, OR INSTRUMENT volt-ampere tester being used.
PANEL COMPONENT DIAGNOSIS OR SERVICE.
FAILURE TO TAKE THE PROPER PRECAUTIONS
COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY-
MENT AND POSSIBLE PERSONAL INJURY.
NOTE: A cold engine will increase starter current Fig. 2 TEST NEGATIVE BATTERY CABLE
(amperage) draw reading, and reduce battery volt- CONNECTION RESISTANCE - TYPICAL
age reading. 1 - VOLTMETER
2 - BATTERY
SPECIFICATIONS
TORQUE - STARTER - DIESEL
ITEM SPECIFICATION
INSTALLATION
(1) Raise and support vehicle.
(2) Position starter motor to transmission housing.
(3) Install 2 mounting bolts. Refer to Torque Spec-
ifications.
Fig. 8 CONTINUITY BETWEEN SOLENOID (4) Lower vehicle.
TERMINAL AND CASE - TYPICAL (5) Connect battery cable and solenoid wiring to
1 - SOLENOID TERMINAL solenoid (2 nuts). Refer to Torque Specifications.
2 - OHMMETER
3 - SOLENOID (6) Position wiring harness trough and install
retaining bolt.
REMOVAL (7) Install new nylon tie-wraps to wiring trough.
The starter motor and solenoid assembly is located (8) Connect negative battery cable.
at the left/rear side of engine (Fig. 9).
(1) Disconnect and isolate negative battery cable. STARTER MOTOR RELAY
(2) Working from under vehicle hood, remove bolt
retaining wiring trough (Fig. 11) to transmission bell-
housing.
DESCRIPTION
(3) Working from under vehicle hood, cut neces- The starter relay is an electromechanical device
sary nylon; wiring trough tie-wraps near starter that switches battery current to the pull-in coil of the
motor. Temporarily position wiring harness trough starter solenoid when ignition switch is turned to
for access to starter. Start position. The starter relay is located in the
Fuse/Relay Block. The Fuse/Relay Block is located
VA STARTING SYSTEM 8F - 31
STARTER MOTOR RELAY (Continued)
REMOVAL
The starter relay is located in the Fuse/Relay
Block. The Fuse/Relay Block is located under, and to
the left side of the drivers seat. See Fuse/Relay Block
cover for relay identification and location, or refer to
(Fig. 12).
(1) Remove Fuse/Relay Block cover by pushing
down on two tabs located at top of cover (Fig. 13). Fig. 12 FUSE / RELAY BLOCK
(2) Remove relay from Fuse/Relay Block.
1 - STARTER RELAY LOCATION
(3) Check condition of relay terminals and Fuse/ 2 - FUSE / RELAY BLOCK
Relay Block connector terminals for damage or corro-
sion. Repair if necessary before installing relay.
(4) Check for pin height (pin height should be the
same for all terminals within the Fuse/Relay Block
connector). Repair if necessary before installing relay.
8F - 32 STARTING SYSTEM VA
STARTER MOTOR RELAY (Continued)
INSTALLATION
The starter relay is located in the Fuse/Relay
Block. The Fuse/Relay Block is located under, and to
the left side of the drivers seat. See Fuse/Relay Block
cover for relay identification and location, or refer to
(Fig. 12).
(1) Install relay into Fuse/Relay Block.
(2) Install cover to side of Fuse/Relay Block (snaps
on).
HEATED SYSTEMS
TABLE OF CONTENTS
page page
HEATED GLASS
TABLE OF CONTENTS
page page
HEATED GLASS
DESCRIPTION
CAUTION: Grid lines can be damaged or scraped
off with sharp instruments. Care should be taken in
cleaning glass or removing foreign materials,
decals or stickers. Normal glass cleaning solvents
or hot water used with rags or toweling is recom-
mended.
OPERATION
REAR WINDOW DEFOGGER The left and right rear window defogger (EBL)
RELAY relays are electromechanical switches that uses a low
current input from the rear window defogger module
DESCRIPTION to control the high current output to the rear window
The left and right rear window defogger (EBL) defogger grids. The movable common feed contact
relays are International Standards Organization point is held against the fixed normally closed con-
(ISO)-type relays (Fig. 3). Relays conforming to the tact point by spring pressure. When the relay coil is
ISO specifications have common physical dimensions, energized, an electromagnetic field is produced by the
current capacities, terminal functions and patterns. coil windings. This electromagnetic field draws the
The EBL relays are electromechanical devices that movable relay contact point away from the fixed nor-
switch battery current through fuse 10 (30 amp) mally closed contact point, and holds it against the
located in the fuse/relay block under the driver seat fixed normally open contact point. When the relay
to the rear window defogger grids and when coil is de-energized, spring pressure returns the mov-
equipped, switches battery current to the outside able contact point back against the fixed normally
mirror heating grids. The EBL relays are energized closed contact point. The resistor or diode is con-
when the relay coils are provided battery current by nected in parallel with the relay coil in the relay, and
the rear window defogger module. helps to dissipate voltage spikes and electromagnetic
The EBL relays are located in the fuse/relay block interference that can be generated as the electromag-
under the driver seat. Refer to the fuse and relay netic field of the relay coil collapses.
map located on the inner surface of the fuse/relay The EBL relay terminals are connected to the vehi-
block cover for the left and right rear window defog- cle electrical system through receptacles in the fuse/
ger (EBL) relay locations. relay block. The inputs and outputs of the EBL
The black, molded plastic case is the most visible relays include:
component of the two rear window defogger (EBL) • The common feed terminal (30) receives a bat-
relays. Five male spade-type terminals extend from tery current input from fuse 10 (30 amp) in the fuse/
the bottom of the base to connect each relay to the relay block through a fused B(+) circuit at all times.
vehicle electrical system, and the ISO designation for • The coil ground terminal (86) is hardwired to
each terminal is molded into the base adjacent to ground point G202.
each terminal. • The coil battery terminal (85) receives a battery
current input from the rear window defogger module
when the rear window defogger switch is energized.
8G - 4 HEATED GLASS VA
REAR WINDOW DEFOGGER RELAY (Continued)
• The normally open terminal (87) provides a bat- (1) Position the rear window defogger (EBL) relays
tery current output to the rear window defogger grid as required into their proper receptacles in the fuse/
lines through the relay output circuit only when the relay block.
rear window defogger relay coil is energized. (2) Align the EBL relay terminals with the termi-
• The normally closed terminal (87A) is not con- nal cavities in the fuse/relay block receptacles.
nected to any circuit in this application, but provides (3) Push down firmly on the EBL relays until the
a battery current output only when the rear window terminals are fully seated in the terminal cavities in
defogger relay coil is de-energized. the fuse/relay block receptacles.
The left and right EBL relays cannot be repaired (4) Install the cover onto the fuse/relay block.
and, if faulty or damaged, they must be replaced. (5) Reconnect the negative battery cable.
Refer to the appropriate wiring information for diag-
nosis and testing of the EBL relays and for complete
rear window defogger system wiring diagrams. REAR WINDOW DEFOGGER
SWITCH
REMOVAL
(1) Disconnect and isolate the negative battery DESCRIPTION
cable. The rear window defogger switch is mounted in the
(2) Remove the cover from the fuse/relay block instrument panel to the right of the steering wheel
(Fig. 4). (Fig. 5). The rear window defogger switch contains a
yellow indicator lamp that illuminates when the rear
NOTE: Refer to the fuse and relay map located on
window defogger (EBL) system is activated.
the inner surface of the fuse/relay block cover for
The rear window defogger switch and the defogger
the left and right rear window defogger (EBL) relay
switch indicator cannot be repaired and, if faulty or
locations.
damaged, the rear window defogger switch must be
(3) Remove the EBL relays from the fuse/relay replaced.
block as required.
REMOVAL
WARNING: To avoid personal injury or death, on
vehicles equipped with airbags, disable the supple-
mental restraint system before attempting any
steering wheel, steering column, airbag, seat belt
tensioner, or instrument panel component diagno-
sis or service. Disconnect and isolate the battery
negative (ground) cable, then wait two minutes for
the system capacitor to discharge before perform-
ing further diagnosis or service. This is the only
sure way to disable the supplemental restraint sys-
tem. Failure to take the proper precautions could
result in accidental airbag deployment.
STANDARD PROCEDURE
GRID LINE AND TERMINAL REPAIR
REAR WINDOW DEFOGGER GRID LINE REPAIR
Fig. 7 Cluster Bezel Remove/Install
1 - SCREWS (2) WARNING: The repair kit contains epoxy resin and
2 - CLUSTER BEZEL amine type hardener which may cause skin or eye
3 - REAR WINDOW DEFOGGER SWITCH
4 - DEFOGGER SWITCH CONNECTOR irritation and can be harmful if swallowed. Use with
5 - WIRE HARNESS CONNECTOR adequate ventilation. Do not use near fire or open
6 - WIRE HARNESS CONNECTOR flame the contents contain flammable solvents.
Keep out of reach of children.
(3) From the back of the cluster bezel, squeeze the
• DO NOT TAKE INTERNALLY, IF SWALLOWED
two latches on the rear window defogger switch body
INDUCE VOMITING AND CALL A PHYSICIAN IMME-
and push the switch out through the face of the bezel
DIATELY.
(Fig. 8).
• IF SKIN CONTACT OCCURS, WASH AFFECTED
(4) Remove the rear window defogger switch from
AREAS WITH SOAP AND WATER.
the cluster bezel.
• IF EYE CONTACT OCCURS, FLUSH WITH
PLENTY OF WATER.
INSTALLATION
(1) Position the rear window defogger switch to the The repair of the grid lines is possible using the
proper mounting hole on the face of the cluster bezel. Mopart Grid Line Repair Package or an equivalent.
VA HEATED GLASS 8G - 7
REAR WINDOW DEFOGGER GRID (Continued)
(1) Mask the repair area so the conductive epoxy remove the portion of the clip remaining in the wire
can be extended onto the grid line(s) or the bus bar harness connector(s).
(Fig. 9).
(2) Follow the instructions in the repair kit for CAUTION: To prevent the glass from fracturing, do
preparing the damaged area. not allow the glass surface to exceed 204° C (400°
(3) Remove the package separator clamp and mix F).
the conductive epoxy thoroughly. Fold in half and cut
the center corner to dispense the epoxy. (2) If the grid terminal(s) is broken and a portion
(4) Apply the conductive epoxy through the slit in of the terminal is still attached to the rear window
the masking tape. Overlap both ends of the break(s) defogger bus bar, apply heat with a solder gun to the
by 19 mm (3/4 inch). portion of the terminal on the glass until the solder
(5) Carefully remove the masking tape from the starts to flow. Remove the terminal and carefully
grid line(s). smooth the solder on the bus bar.
CAUTION: To prevent the glass from fracturing, do NOTE: Wait five minutes for the glass to cool after
not allow the glass surface to exceed 204° C (400° applying heat with a solder gun before proceeding.
F).
NOTE: Use care when cleaning the mating surfaces.
(6) Allow the epoxy to cure 24 hours at room tem-
Excessive abrasion may wear away the copper grid
perature or use a heat gun with a 260° to 371° C
surface causing grid continuity to be lost.
(500° to 700° F) range for 15 minutes. Hold the heat
gun approximately 254 mm (10 inches) from the (3) Clean the mating surfaces on the grid bus bar
repaired area. and the new terminal(s) with “000” Extra Fine Steel
(7) After the conductive epoxy is properly cured, Wool or an equivalent.
verify operation of the rear window defogger.
NOTE: The terminal attaching clip(s) must face out-
board. Failure to reorient the terminal(s) may result
in an additional failure.
HEATED MIRRORS
TABLE OF CONTENTS
page page
HEATED SEATS
TABLE OF CONTENTS
page page
HEATED SEATS heated seat sensors are integral to each of the heated
seat element assemblies. Refer to heated seat sensor
later in this section for additional information.
DESCRIPTION
• Heated Seat Switches - Two heated seat
Individually controlled, electrically heated front
switches are used per vehicle, one for each front seat.
seats are available factory-installed optional equip-
The switches are mounted in the instrument panel.
ment on this model. Vehicles with this option can be
Refer to heated seat switches later in this section for
visually identified by the two separate heated seat
additional information.
switches mounted in the instrument panel. The
Hard wired circuitry connects the heated seat sys-
heated seat system allows the front seat driver and
tem components to each other through the electrical
passenger to select from two different levels of sup-
system of the vehicle. Refer to Wiring for additional
plemental electrical seat heating, or no seat heating
information. The wiring information includes wiring
to suit their individual comfort requirements. The
diagrams, proper wire and connector repair proce-
heated seat system for this vehicle includes the fol-
dures, further details on wire harness routing and
lowing major components, which are described in fur-
retention, as well as pin-out and location views for
ther detail later in this section:
the various wire harness connectors, splices and
• Heated Seat Elements - Four heated seat ele-
grounds.
ments are used per vehicle, two for each front seat.
One heating element in the seat back and one in the
seat cushion. The heated seat sensor is integral to
OPERATION
The heated seat system is designed to provide indi-
the seat cushion heating element. The heated seat
vidually controlled, supplemental heat to the seat
elements are integral to the front seat and seat back
cushion and seat back surfaces of both front seats.
cushions. Refer to heated seat elements later in this
Because this system converts electrical current to
section for additional information.
heat, the heated seat system can provide a measure
• Heated Seat Relay - One heated seat relay is
of warm comfort almost immediately upon entering a
used per vehicle. The relay is located in the fuse
cold vehicle, rather than having to wait for the
block and is responsible for distributing the voltage
engine coolant to reach sufficient temperature to
(B+) to the heated seat elements.
deliver heat through the conventional heater system.
• Heated Seat Sensors - Two heated seat sen-
This system allows each front seat occupant to indi-
sors are used per vehicle, one for each front seat. The
8G - 10 HEATED SEATS VA
HEATED SEATS (Continued)
vidually select one of two comfort levels, Hi or Lo, or sensor is above the designed temperature set points
to turn the heater for their seat off. of the system.
The heated seat system components operate on
battery current received through a fuse in the Fuse DIAGNOSIS AND TESTING - HEATED SEATS
Block on a fused ignition switch output (run-acc) cir- Refer to Wiring for the appropriate wiring infor-
cuit so that the system will only operate when the mation. The wiring information includes wiring dia-
ignition switch is in the On or Accessory positions. grams, proper wire and connector repair procedures,
The heated seat system will be turned Off automati- further details on wire harness routing and reten-
cally whenever the ignition switch is turned to any tion, as well as pin-out and location views for the
position except On or Accessory. Also, the heated seat various wire harness connectors, splices and grounds.
system will not operate when the surface tempera-
ture of the seat cushion cover at either heated seat
NO HEATED SEAT SWITCH 1. Faulty fuse. 1. Check heated seat fuse in Fuse Block.
ILLUMINATION WITH Replace fuse, if required.
IGNITION ON 2. Wiring faulty. 2. Check fused ignition switch output (run-acc)
circuit from heated seat switch connector to
ignition switch. Repair, if required.
3. Ground faulty. 3. Check for ground at heated seat switch
connector. Repair, if required.
4. Faulty switch. 4. Refer to Heated Seat Switch for the proper
switch diagnosis and testing procedures.
DRIVER HEATED SEAT Both switches provide separate hard wire inputs to
the Heated Seat Relay to indicate the selected mode.
SWITCH The Heated Seat Relay responds to the heated seat
switch messages by controlling the output to the seat
DESCRIPTION heater elements of the selected seat.
The heated seat switches are located on the instru-
ment panel, in the accessory switch bezel. The two, DIAGNOSIS AND TESTING - DRIVER HEATED
momentary rocker type switches provide a signal to SEAT SWITCH
the Heated Seat Relay through separate hard wired For circuit description and diagrams, refer to Wir-
circuits. Each switch contains two light emitting ing.
diodes (LED), one for each High and Low setting to (1) Inspect the Heated Seat Switches for apparent
let the occupant know that the seat heater system is damage or sticking/binding and replace if required.
on. Refer to Heated Seat Switch Removal and Installa-
The heated seat switches and their LED’s cannot tion in this section.
be repaired. If either switch is faulty or damaged the (2) Replace the heated seat switch with a known
entire switch must be replaced. good unit and retest the heated seat system.
OPERATION REMOVAL
There are three modes that can be selected with (1) Disconnect and isolate the negative battery
each of the heated seat switches: Off, Low, and High.
cable.
When the top of the switch rocker is depressed, the
(2) Remove the gear selector bezel trim. Refer to
low mode is selected and the low mode LED indicator the Body section for the procedure.
illuminates. Depressing the top of the switch rocker a (3) Remove the storage bin. Refer to the Body sec-
second time will turn the heated seat to Off. This
tion for the procedure.
same process is repeated for High heat setting. The (4) Remove the switch bezel retaining screw and
heated seats will automatically return to the Off remove the switch bezel from the instrument panel.
mode anytime the vehicle ignition switch is turned
Refer to the Body section for the procedure.
Off.
(5) Disconnect electrical connections.
VA HEATED SEATS 8G - 11
DRIVER HEATED SEAT SWITCH (Continued)
(6) Working from the underside of the switch, gen- The seat heating elements are glued onto the seat
tly rock the switch back and forth out of its mounting and seat back cushions. The heated seat elements
location in the switch bezel. and the temperature sensor cannot be adjusted or
repaired and, if faulty or damaged a new seat assem-
INSTALLATION bly must be installed.
(1) Install the heated seat switch in its mounting
location in the switch bezel. OPERATION
(2) Connect electrical connections. The heated seat elements resist the flow of electri-
(3) Position the switch bezel and install the retain- cal current. When battery current is passed through
ing screw. Refer to the Body section for the proce- the elements, the energy lost by the resistance of the
dure. elements is released in the form of heat. The heated
(4) Install the storage bin. Refer to the Body sec- seat temperature sensor is a NTC thermistor. When
tion for the procedure. the temperature of the seat cushion cover rises, the
(5) Install the gear selector bezel trim. Refer to the resistance of the sensor decreases. The heated seat
Body section for the procedure. relay uses this temperature sensor input to monitor
(6) Connect the negative battery cable. the temperature of the seat, and regulates the cur-
rent flow to the seat heating elements accordingly.
HORN
TABLE OF CONTENTS
page page
IGNITION CONTROL
TABLE OF CONTENTS
page page
INSTRUMENT CLUSTER
TABLE OF CONTENTS
page page
INSTRUMENT CLUSTER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2 LOW FUEL INDICATOR
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 19
DIAGNOSIS AND TESTING - INSTRUMENT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 LOW OIL LEVEL INDICATOR
REMOVAL .............................7 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
ABS INDICATOR MAINTENANCE INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 20
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
ADR INDICATOR MALFUNCTION INDICATOR LAMP (MIL)
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 21
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
AIRBAG INDICATOR MULTI-FUNCTION INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 21
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
AMBIENT TEMPERATURE INDICATOR ODOMETER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 22
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
BRAKE INDICATOR PARK BRAKE INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 12 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 23
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
BRAKE WEAR INDICATOR SEATBELT INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 24
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
CHARGING INDICATOR SPEEDOMETER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 24
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
CLOCK TACHOMETER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 14 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 25
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
COOLANT LOW INDICATOR TRACTION CONTROL INDICATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 14 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 26
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
ENGINE TEMPERATURE GAUGE TRACTION CONTROL MALFUNCTION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 15 INDICATOR
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 26
ESP INDICATOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 16 TURN SIGNAL INDICATOR
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 27
FUEL FILTER CLOGGED INDICATOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 16 WAIT-TO-START INDICATOR
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 28
FUEL GAUGE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 17 WASHER FLUID INDICATOR
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 29
GEAR SELECTOR INDICATOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 18 WATER-IN-FUEL INDICATOR
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 29
HIGH BEAM INDICATOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 18
8J - 2 INSTRUMENT CLUSTER VA
INSTRUMENT CLUSTER
DESCRIPTION
• Washer Fluid Indicator LED units are not available for service replacement
• Wait-To-Start Indicator and, if damaged or faulty, the entire EMIC must be
• Water-In-Fuel Indicator replaced.
Except for the indications provided within the Hard wired circuitry connects the EMIC to the
multi-function indicator LCD unit, each indicator in electrical system of the vehicle. These hard wired cir-
the EMIC is illuminated by a dedicated LED that is cuits are integral to the vehicle wire harnesses,
soldered onto the EMIC electronic circuit board. which are routed throughout the vehicle and retained
Cluster illumination is accomplished by dimmable by many different methods. These circuits may be
LED back lighting, which illuminates the gauges for connected to each other, to the vehicle electrical sys-
visibility when the exterior lighting is turned on. The tem and to the EMIC through the use of a combina-
cluster general illumination LED units are also sol- tion of soldered splices, splice block connectors, and
dered onto the EMIC electronic circuit board. The many different types of wire harness terminal con-
VA INSTRUMENT CLUSTER 8J - 5
INSTRUMENT CLUSTER (Continued)
nectors and insulators. Refer to the appropriate wir- frequency. Each audible warning is provided to the
ing information. The wiring information includes vehicle operator to supplement a visual indication.
wiring diagrams, proper wire and connector repair The EMIC circuitry operates on battery current
procedures, further details on wire harness routing received through a non-switched fused B(+) circuit,
and retention, as well as pin-out and location views and on a fused ignition switch output circuit. The
for the various wire harness connectors, splices and EMIC circuitry is grounded through a ground circuit
grounds. and take out of the frame wire harness with an eye-
The EMIC modules for this model are serviced only let terminal connector that is secured to a stud by a
as complete units. The EMIC module cannot be nut at a ground location on the dash panel just for-
adjusted or repaired. If a gauge, an LED indicator, ward of the instrument cluster. Separate switched
the multi-fuction indicator LCD unit, an electronic ground inputs from the key-in ignition switch and
tone generator, the electronic circuit board, the cir- the front door jamb switches provide wake-up signals
cuit board hardware, the cluster overlay, the cluster to the EMIC circuitry. This arrangement allows the
housing, the cluster hood, the cluster lens, or the EMIC to provide some features regardless of the igni-
cluster rear cover are damaged or faulty, the entire tion switch position, while other features will operate
EMIC module must be replaced. only with the ignition switch in the On position.
Proper diagnosis and testing of the EMIC, the
OPERATION CAN data bus, the data bus electronic message
The ElectroMechanical Instrument Cluster (EMIC) inputs to and outputs from the EMIC, as well as the
is designed to allow the vehicle operator to monitor retrieval or erasure of a Diagnostic Trouble Code
the conditions of many of the vehicle components and (DTC) requires the use of a DRBIIIt scan tool. Refer
operating systems. The gauges, meters and indicators to the appropriate diagnostic information. See the
in the EMIC provide valuable information about the owner’s manual in the vehicle glove box for more
powertrain, fuel and emissions systems, cooling sys- information on the features, use and operation of the
tem, lighting systems, safety systems and many EMIC.
other convenience items. The EMIC is installed in
the instrument panel so that all of these monitors GAUGES
can be easily viewed by the vehicle operator when All gauges receive battery current through the
driving, while still allowing relative ease of access for EMIC circuitry only when the instrument cluster
service. The microprocessor-based EMIC hardware detects the ignition switch is in the On position. With
and software uses various inputs to control the the ignition switch in the Off position, battery cur-
gauges and indicators visible on the face of the clus- rent is not supplied to any gauges and the EMIC cir-
ter. Some of these inputs are hard wired, but many cuitry is programmed to move all of the gauge
are in the form of electronic messages that are trans- needles back to the low end of their respective scales.
mitted by other electronic modules over the Control- Therefore, the gauges do not accurately indicate any
ler Area Network (CAN) data bus network. (Refer to vehicle condition unless the ignition switch is in the
8 - ELECTRICAL/ELECTRONIC CONTROL MOD- On position.
ULES/COMMUNICATION - OPERATION). All of the EMIC gauges are air core magnetic
The EMIC microprocessor smooths the input data units. Two fixed electromagnetic coils are located
using algorithms to provide gauge readings that are within each gauge. These coils are wrapped at right
accurate, stable and responsive to operating condi- angles to each other around a movable permanent
tions. These algorithms are designed to provide magnet. The movable magnet is suspended within
gauge readings during normal operation that are con- the coils on one end of a pivot shaft, while the gauge
sistent with customer expectations. However, when needle is attached to the other end of the shaft. One
abnormal conditions exist such as high coolant tem- of the coils has a fixed current flowing through it to
perature, the algorithm can drive the gauge pointer maintain a constant magnetic field strength. Current
to an extreme position and the microprocessor can flow through the second coil changes, which causes
sound a chime through the on-board audible tone changes in its magnetic field strength. The current
generator to provide distinct visual and audible indi- flowing through the second coil is changed by the
cations of a problem to the vehicle operator. The EMIC circuitry in response to messages received over
instrument cluster circuitry also provides audible the CAN data bus. The gauge needle moves as the
turn signal and hazard warning support by emulat- movable permanent magnet aligns itself to the
ing the “ticking” sound associated with a conven- changing magnetic fields created around it by the
tional electro-mechanical flasher using a contactless electromagnets.
relay. The relay will also provide an indication of a Proper diagnosis and testing of the gauges, the
turn signal failure by sounding at double the usual CAN data bus and the electronic data bus message
8J - 6 INSTRUMENT CLUSTER VA
INSTRUMENT CLUSTER (Continued)
inputs to the EMIC that control each gauge require nation intensity of these lamps is adjusted by a dim-
the use of a DRBIIIt scan tool. Refer to the appro- ming level input received from the multi-function
priate diagnostic information. Specific operation indicator “+” (plus) and “–” (minus) switch push but-
details for each gauge may be found elsewhere in tons that extend through the lower edge of the clus-
this service information. ter lens below the right end of the multi-function
indicator. When the exterior lighting is turned Off,
INDICATORS the display is illuminated at maximum brightness.
Indicators are located in various positions within When the exterior lighting is turned On and the
the EMIC and are all connected to the EMIC elec- transmission gear selector is in the Park position,
tronic circuit board. The ambient temperature indica- depressing the plus switch push button brightens the
tor (optional), brake indicator, brake wear indicator, display lighting, and depressing the minus switch
charging indicator, coolant low indicator, high beam push button dims the display lighting. The EMIC
indicator, low fuel indicator, park brake indicator, also provides a Pulse-Width Modulated (PWM) panel
seatbelt indicator, turn signal indicators, and washer lamps dimmer output that can be used to synchro-
fluid indicator operate based upon hard wired inputs nize the illumination lighting levels of external illu-
to the EMIC. The airbag (SRS) indicator is normally mination lamps (up to about 23 to 30 watts) with
controlled by a hard wired input from the Airbag that of the EMIC.
Control Module (ACM); however, if the EMIC sees an The hard wired multi-function switch input and
abnormal or no input from the ACM, it will automat- the EMIC panel lamps dimmer output may be diag-
ically turn the airbag indicator On until the hard nosed using conventional diagnostic methods. How-
wired input from the ACM has been restored. The ever, proper testing of the PWM control of the EMIC
Malfunction Indicator Lamp (MIL) is normally con- and the electronic dimming level inputs from the
trolled by CAN data bus messages from the Engine multi-function indicator push buttons requires the
Control Module (ECM); however, if the EMIC loses use of a DRBIIIt scan tool. Refer to the appropriate
CAN data bus communication, the EMIC circuitry diagnostic information.
will automatically turn the MIL on until CAN data
bus communication is restored. The EMIC uses CAN INPUT AND OUTPUT CIRCUITS
data bus messages from the ECM, the ACM, and the
Controller Antilock Brake to control all of the HARD WIRED INPUTS
remaining indicators. The hard wired inputs to the EMIC include the fol-
The various EMIC indicators are controlled by dif- lowing:
ferent strategies; some receive battery feed from the
EMIC circuitry and have a switched ground, while NOTE: Final approved circuit names were not yet
others are grounded through the EMIC circuitry and available at the time this information was compiled.
have a switched battery feed. However, all indicators
are completely controlled by the EMIC microproces- • Airbag Indicator Driver
sor based upon various hard wired and electronic • Ambient Temperature Sensor Signal
message inputs. Except for the indications provided (Optional)
by the multi-function indicator Liquid Crystal Dis- • Brake Wear Indicator Sense
play (LCD) unit, all indicators are illuminated at a • Charging Indicator Driver
fixed intensity, which is not affected by the selected • Coolant Level Switch Sense
illumination intensity of the EMIC general illumina- • Front Door Jamb Switch Sense
tion lamps. • Fuel Level Sensor Signal
The hard wired indicator inputs may be diagnosed • Fused B(+)
using conventional diagnostic methods. However, • Fused Ignition Switch Output
proper testing of the EMIC circuitry and the CAN • High Beam Indicator Driver
bus message controlled indicators requires the use of • Key-In Ignition Switch Sense
a DRBIIIt scan tool. Refer to the appropriate diag- • Left Turn Signal
nostic information. Specific details of the operation • Park Brake Switch Sense
for each indicator may be found elsewhere in this • Right Turn Signal
service information. • Seat Belt Switch Sense
• Washer Fluid Switch Sense (Optional)
CLUSTER ILLUMINATION Refer to the appropriate wiring information for
The EMIC has several general illumination lamps additional details.
that are illuminated when the exterior lighting is
turned on with the multi-function switch. The illumi-
VA INSTRUMENT CLUSTER 8J - 7
INSTRUMENT CLUSTER (Continued)
HARD WIRED OUTPUTS and the electronic modules that provide inputs to or
The hard wired outputs of the EMIC include the receive outputs from the instrument cluster requires
following: the use of a DRBIIIt scan tool and the appropriate
• Engine Running Relay Control diagnostic information. The DRBIIIt scan tool can
• Panel Lamps Driver provide confirmation that the CAN data bus network
Refer to the appropriate wiring information for is functional, that all of the modules are sending and
additional details. receiving the proper electronic messages over the
CAN data bus, and that the instrument cluster is
GROUNDS receiving the proper hard wired inputs and respond-
The EMIC receives and supplies a ground path to ing with the proper hard wired outputs needed to
several switches and sensors through the following perform its many functions.
hard wired circuits:
• Ambient Temperature Sensor Return WARNING: To avoid personal injury or death, on
(Optional) vehicles equipped with airbags, disable the supple-
• Fuel Level Sensor Return mental restraint system before attempting any
• Ground steering wheel, steering column, airbag, seat belt
Refer to the appropriate wiring information for tensioner, or instrument panel component diagno-
additional details. sis or service. Disconnect and isolate the battery
negative (ground) cable, then wait two minutes for
COMMUNICATION the system capacitor to discharge before perform-
The EMIC has provisions for the following commu- ing further diagnosis or service. This is the only
nication circuits: sure way to disable the supplemental restraint sys-
• CAN Data Bus - High tem. Failure to take the proper precautions could
• CAN Data Bus - Low result in accidental airbag deployment.
• Diagnostic Serial Communication Interface
(SCI) Data Bus Line
Refer to the appropriate wiring information for REMOVAL
additional details.
WARNING: To avoid personal injury or death, on
vehicles equipped with airbags, disable the supple-
DIAGNOSIS AND TESTING - INSTRUMENT mental restraint system before attempting any
CLUSTER steering wheel, steering column, airbag, seat belt
The hard wired inputs to and outputs from the tensioner, or instrument panel component diagno-
instrument cluster may be diagnosed and tested sis or service. Disconnect and isolate the battery
using conventional diagnostic tools and procedures. negative (ground) cable, then wait two minutes for
Refer to the appropriate wiring information. The wir- the system capacitor to discharge before perform-
ing information includes wiring diagrams, proper ing further diagnosis or service. This is the only
wire and connector repair procedures, details of wire sure way to disable the supplemental restraint sys-
harness routing and retention, connector pin-out tem. Failure to take the proper precautions could
information and location views for the various wire result in accidental airbag deployment.
harness connectors, splices and grounds.
If the instrument cluster is completely inoperative, (1) Disconnect and isolate the battery negative
be certain to check the fused B(+) circuit fuses and cable.
wiring for the instrument cluster. If the cluster general (2) Remove the cluster bezel from the instrument
illumination is inoperative, be certain to check the panel. (Refer to 23 - BODY/INSTRUMENT PANEL/
instrument lighting fuse and the input circuit to the CLUSTER BEZEL - REMOVAL).
instrument cluster from the exterior lighting circuitry (3) Remove the cluster top cover from the instru-
of the multi-function switch on the steering column. ment panel. (Refer to 23 - BODY/INSTRUMENT
Conventional diagnostic methods may not prove PANEL/TOP COVER - CLUSTER - REMOVAL).
conclusive in the diagnosis of the instrument cluster. (4) Remove the two screws that secure the instru-
In order to obtain conclusive testing of the instru- ment cluster mounting ears to the instrument panel
ment cluster, the Controller Area Network (CAN) base structure (Fig. 4).
data bus network and all of the electronic modules (5) Roll the top of the instrument cluster rearward
that provide inputs to or receive outputs from the far enough to access and release the latch that
instrument cluster must also be checked. The most secures the RKE/immobilizer module to the back of
reliable, efficient, and accurate means to diagnose the instrument cluster rear cover and disengage the
the instrument cluster, the CAN data bus network, module from the cluster (Fig. 5).
8J - 8 INSTRUMENT CLUSTER VA
INSTRUMENT CLUSTER (Continued)
INSTALLATION
WARNING: To avoid personal injury or death, on
vehicles equipped with airbags, disable the supple-
mental restraint system before attempting any
steering wheel, steering column, airbag, seat belt
tensioner, or instrument panel component diagno-
sis or service. Disconnect and isolate the battery
negative (ground) cable, then wait two minutes for
the system capacitor to discharge before perform-
ing further diagnosis or service. This is the only
sure way to disable the supplemental restraint sys-
tem. Failure to take the proper precautions could
Fig. 5 RKE/Immobilizer Module result in accidental airbag deployment.
1 - RKE/IMMOBILIZER MODULE
2 - LATCH
3 - INSTRUMENT CLUSTER
(1) Position the instrument cluster to the instru-
ment panel.
(6) Depress the release (Arrow A) and lift the lever (2) Align the two molded plastic pivot loops inte-
arm (Arrow B) to disconnect each of the two frame gral to the base of the cluster hood between the two
wire harness connectors for the cluster from the con- pairs of molded plastic pivot hooks that are integral
nector receptacles on the back of the cluster housing to the top of instrument panel base structure, then
(Fig. 6). push downward on the top of the cluster until the
(7) Lift the instrument cluster upward far enough loops snap into engagement with the hooks (Fig. 6).
to disengage the two molded plastic pivot loops inte- (3) Roll the top of the instrument cluster rearward
gral to the base of the cluster hood from the two to access, reconnect, and latch the two frame wire
VA INSTRUMENT CLUSTER 8J - 9
INSTRUMENT CLUSTER (Continued)
harness connectors for the cluster to the connector circuit, and that logic will only allow this indicator to
receptacles on the back of the cluster housing. operate when the instrument cluster detects that the
(4) Engage and latch the RKE/immobilizer module ignition switch is in the On position. Therefore, the
to the back of the instrument cluster rear cover (Fig. LED will always be off when the ignition switch is in
5) any position except On. The LED only illuminates
(5) Roll the top of the instrument cluster forward when it is provided a path to ground by the instru-
to position the instrument cluster into the instru- ment cluster transistor. The instrument cluster will
ment panel. turn on the ABS indicator for the following reasons:
(6) Install and tighten the two screws that secure • Bulb Test - Each time the ignition switch is
the instrument cluster mounting ears to the instru- turned to the On position the ABS indicator is illu-
ment panel base structure (Fig. 4). Tighten the minated by the cluster for about two seconds as a
screws to 2 N·m (20 in. lbs.). bulb test.
(7) Reinstall the cluster top cover onto the instru- • ABS Lamp-On Message - Each time the clus-
ment panel. (Refer to 23 - BODY/INSTRUMENT ter receives a lamp-on message from the CAB, the
PANEL/TOP COVER - CLUSTER - INSTALLA- ABS indicator will be illuminated. The indicator
TION). remains illuminated until the cluster receives a
(8) Reinstall the cluster bezel onto the instrument lamp-off message from the CAB, or until the ignition
panel. (Refer to 23 - BODY/INSTRUMENT PANEL/ switch is turned to the Off position, whichever occurs
CLUSTER BEZEL - INSTALLATION). first.
(9) Reconnect the battery negative cable. The CAB continually monitors the ABS and EBV
circuits and sensors to decide whether the systems
are in good operating condition. The CAB then sends
ABS INDICATOR the proper lamp-on or lamp-off messages to the
instrument cluster. If the CAB sends a lamp-on mes-
DESCRIPTION sage after the bulb test, it indicates that the CAB
An Anti-lock Brake System (ABS) indicator is stan- has detected a system malfunction and/or that the
dard equipment on all instrument clusters. The ABS ABS or EBV systems have become inoperative. The
indicator is located near the lower edge of the instru- CAB will store a Diagnostic Trouble Code (DTC) for
ment cluster, to the right of the multi-function indi- any malfunction it detects. For proper diagnosis of
cator display. The ABS indicator consists of the the ABS and EBV systems, the CAB, the CAN data
International Control and Display Symbol icon for bus, the electronic message inputs to the instrument
“Failure of Anti-lock Braking System” imprinted cluster, or the instrument cluster circuitry that con-
within a rectangular cutout in the opaque layer of trols the ABS indicator, a DRBIIIt scan tool is
the instrument cluster overlay. The dark outer layer required. Refer to the appropriate diagnostic infor-
of the overlay prevents the indicator from being mation.
clearly visible when it is not illuminated. An amber
Light Emitting Diode (LED) behind the cutout in the
opaque layer of the overlay causes the icon to appear ADR INDICATOR
silhouetted against an amber field through the trans-
lucent outer layer of the overlay when the indicator DESCRIPTION
is illuminated from behind by the LED, which is sol- A constant engine speed (ADR) indicator is stan-
dered onto the instrument cluster electronic circuit dard equipment on all instrument clusters, but is
board. The ABS indicator is serviced as a unit with only functional on vehicles equipped with the
the instrument cluster. optional ADR switch. The ADR indicator is located
near the lower edge of the instrument cluster, to the
OPERATION right of the multi-function indicator display. The
The ABS indicator gives an indication to the vehi- ADR indicator consists of the text “ADR” imprinted
cle operator when the ABS or the electronic brake within a rectangular cutout in the opaque layer of
force distribution (EBV) systems are faulty or inoper- the instrument cluster overlay. The dark outer layer
ative. This indicator is controlled by a transistor on of the overlay prevents the indicator from being
the instrument cluster circuit board based upon clus- clearly visible when it is not illuminated. An amber
ter programming and electronic messages received by Light Emitting Diode (LED) behind the cutout in the
the cluster from the Controller Antilock Brake (CAB) opaque layer of the overlay causes the text to appear
over the Controller Area Network (CAN) data bus. silhouetted against an amber field through the trans-
The ABS indicator Light Emitting Diode (LED) is lucent outer layer of the overlay when the indicator
completely controlled by the instrument cluster logic is illuminated from behind by the LED, which is sol-
8J - 10 INSTRUMENT CLUSTER VA
ADR INDICATOR (Continued)
dered onto the instrument cluster electronic circuit tor, a DRBIIIt scan tool is required. Refer to the
board. The ADR indicator is serviced as a unit with appropriate diagnostic information.
the instrument cluster.
BRAKE WEAR INDICATOR circuitry through the brake wear sense circuit when-
ever the brake linings for that wheel have exceeded
their wear limits. The four normally open brake wear
DESCRIPTION
sensors are connected in parallel between ground and
A brake wear indicator is standard equipment on
instrument cluster. The brake wear sensors and their
all instrument clusters. The brake wear indicator is
input circuit to the instrument cluster can be diag-
located near the lower edge of the instrument cluster,
nosed using conventional diagnostic tools and meth-
to the left of the multi-function indicator display. The
ods. For proper diagnosis of the instrument cluster
brake wear indicator consists of the International
circuitry that controls the brake wear indicator, a
Control and Display Symbol icon for “Worn Brake
DRBIIIt scan tool is required. Refer to the appropri-
Linings” imprinted within a rectangular cutout in the
ate diagnostic information.
opaque layer of the instrument cluster overlay. The
dark outer layer of the overlay prevents the indicator
from being clearly visible when it is not illuminated. CHARGING INDICATOR
An amber Light Emitting Diode (LED) behind the
cutout in the opaque layer of the overlay causes the
DESCRIPTION
icon to appear silhouetted against an amber field
A charging indicator is standard equipment on all
through the translucent outer layer of the overlay
instrument clusters. The charging indicator is located
when the indicator is illuminated from behind by the
near the lower edge of the instrument cluster, to the
LED, which is soldered onto the instrument cluster
left of the multi-function indicator display. The
electronic circuit board. The brake wear indicator is
charging indicator consists of the International Con-
serviced as a unit with the instrument cluster.
trol and Display Symbol icon for “Battery Charging
Condition” imprinted within a rectangular cutout in
OPERATION the opaque layer of the instrument cluster overlay.
The brake wear indicator gives an indication to the
The dark outer layer of the overlay prevents the indi-
vehicle operator when the brake linings have reached
cator from being clearly visible when it is not illumi-
their wear limits. This indicator is controlled by a
nated. A red Light Emitting Diode (LED) behind the
transistor on the instrument cluster circuit board
cutout in the opaque layer of the overlay causes the
based upon cluster programming and a hard wired
icon to appear silhouetted against a red field through
input from the four brake wear sensors, one at each
the translucent outer layer of the overlay when the
wheel. The brake wear indicator Light Emitting
indicator is illuminated from behind by the LED,
Diode (LED) is completely controlled by the instru-
which is soldered onto the instrument cluster elec-
ment cluster logic circuit, and that logic will only
tronic circuit board. The charging indicator is ser-
allow this indicator to operate when the instrument
viced as a unit with the instrument cluster.
cluster detects that the ignition switch is in the On
position. Therefore, the LED will always be off when
OPERATION
the ignition switch is in any position except On. The
The charging indicator gives an indication to the
LED only illuminates when it is provided a path to
vehicle operator when the electrical system voltage is
ground by the instrument cluster transistor. The
too low. This indicator is controlled by a transistor on
instrument cluster will turn on the brake wear indi-
the instrument cluster circuit board based upon clus-
cator for the following reasons:
ter programming and a hard wired input from the
• Bulb Test - Each time the ignition switch is
generator. The charging indicator Light Emitting
turned to the On position the brake wear indicator is
Diode (LED) is completely controlled by the instru-
illuminated by the instrument cluster for about two
ment cluster logic circuit, and that logic will only
seconds as a bulb test.
allow this indicator to operate when the instrument
• Brake Wear Sensor Input - Each time the
cluster detects that the ignition switch is in the On
cluster detects ground on the brake wear sense cir-
position. Therefore, the LED will always be off when
cuit (brake wear sensor closed = brake lining wear
the ignition switch is in any position except On. The
limit exceeded) while the ignition switch is in the On
LED only illuminates when it is provided a path to
position, the brake wear indicator is illuminated. The
ground by the instrument cluster transistor. The
indicator remains illuminated until the brake wear
instrument cluster will turn on the charging indica-
sense input to the cluster is an open circuit (brake
tor for the following reasons:
wear sensor open = brake lining wear within limits),
• Bulb Test - Each time the ignition switch is
or until the ignition switch is turned to the Off posi-
turned to the On position with the engine not run-
tion, whichever occurs first.
ning the charging indicator is illuminated by the
A brake wear sensor located at each wheel provides
instrument cluster as a bulb test.
a hard wired ground input to the instrument cluster
8J - 14 INSTRUMENT CLUSTER VA
CHARGING INDICATOR (Continued)
• Generator Input - Each time the cluster clock remains functional regardless of the ignition
detects that the voltage of the generator input is 12.7 switch position.
volts or lower while the engine is running, the charg- The vehicle operator can choose to have the
ing indicator will be illuminated. The indicator optional ambient temperature indicator displayed
remains illuminated until the cluster detects that the instead of the clock information, but the clock and
voltage of the generator input is above 12.7 volts, or ambient temperature indicator cannot be displayed
until the ignition switch is turned to the Off position, at the same time. The clock or ambient temperature
whichever occurs first. indicator display option is selected using the multi-
The generator provides a hard wired input to the function indicator clock switch on the instrument
instrument cluster circuitry on the engine running cluster circuit board. This switch is actuated manu-
(D+) circuit. If the instrument cluster turns on the ally by depressing the clock switch push button that
indicator while the engine is running, it may indicate extends through the lower edge of the cluster lens
that the charging system requires service. The gener- below the left end of the multi-function indicator.
ator input circuit to the instrument cluster can be Actuating this switch momentarily will toggle the
diagnosed using conventional diagnostic tools and display between the clock and ambient temperature
methods. For proper diagnosis of the charging sys- indicator modes. Actuating this switch twice within
tem, or the instrument cluster circuitry that controls about one second will cause the display to toggle, but
the charging indicator, a DRBIIIt scan tool is then automatically revert to the originally selected
required. Refer to the appropriate diagnostic infor- mode after about twenty seconds.
mation. See the owner’s manual in the vehicle glove box for
more information on the features, use, operation and
setting procedures for the clock. For proper testing of
CLOCK the instrument cluster circuitry that controls the
clock functions, a DRBIIIt scan tool is required.
DESCRIPTION Refer to the appropriate diagnostic information.
An electronic digital clock is standard equipment
on all instrument clusters. In vehicles equipped with
the optional ambient temperature indicator, the clock COOLANT LOW INDICATOR
indication can be toggled with the ambient tempera-
ture indication on the right side of the multi-function DESCRIPTION
indicator Liquid Crystal Display (LCD) located near A coolant low indicator is standard equipment on
the lower edge of the instrument cluster, directly all instrument clusters. The coolant low indicator is
below the speedometer. The clock provides a 12 hour- located near the lower edge of the instrument cluster,
based, digital indication of the current hours and to the left of the multi-function indicator display. The
minutes. The indications of the clock are not visible coolant low indicator consists of the International
when the LCD is not illuminated. When illuminated Control and Display Symbol icon for “Low Engine
the indications appear as dark characters silhouetted Coolant” imprinted within a rectangular cutout in
against an amber field. When the exterior lighting is the opaque layer of the instrument cluster overlay.
turned Off, the display is illuminated at maximum The dark outer layer of the overlay prevents the indi-
brightness. When the exterior lighting is turned On cator from being clearly visible when it is not illumi-
the display illumination level can be adjusted in con- nated. A red Light Emitting Diode (LED) behind the
cert with the cluster general illumination lighting cutout in the opaque layer of the overlay causes the
using the “+” (plus) and “2” (minus) multi-function icon to appear silhouetted against a red field through
indicator push buttons. The clock is serviced as a the translucent outer layer of the overlay when the
unit with the instrument cluster. indicator is illuminated from behind by the LED,
which is soldered onto the instrument cluster elec-
OPERATION tronic circuit board. The coolant low indicator is ser-
The clock gives an indication to the vehicle opera- viced as a unit with the instrument cluster.
tor of the current time. The electronic digital clock is
controlled by the instrument cluster microprocessor OPERATION
based upon cluster programming. The clock display is The coolant low indicator gives an indication to the
completely controlled by the instrument cluster logic vehicle operator when the engine coolant level is low.
circuit, and that logic will only allow this indication This indicator is controlled by a transistor on the
to be viewed when the multi-function indicator Liq- instrument cluster circuit board based upon cluster
uid Crystal Display (LCD) is activated. However, the programming and a hard wired input received by the
cluster from the engine coolant level switch. The cool-
VA INSTRUMENT CLUSTER 8J - 15
COOLANT LOW INDICATOR (Continued)
ant low indicator Light Emitting Diode (LED) is com- vehicles, or from 250° F to 110° F for United States
pletely controlled by the instrument cluster logic vehicles. An International Control and Display Sym-
circuit, and that logic will only allow this indicator to bol icon for “Engine Coolant Temperature” is located
operate when the instrument cluster detects that the on the cluster overlay, directly below the high end of
ignition switch is in the On position. Therefore, the the scale. Just to the right of the icon, the nomencla-
LED will always be off when the ignition switch is in ture “°C” or “°F” confirms the unit of measure for the
any position except On. The LED only illuminates gauge readings.
when it is provided a path to ground by the instru- The engine coolant temperature gauge graphics are
ment cluster transistor. The instrument cluster will white against a black field, except for a single red
turn on the coolant low indicator for the following graduation at the far left (high) end of the gauge
reasons: scale, making them clearly visible within the instru-
• Bulb Test - Each time the ignition switch is ment cluster in daylight. When illuminated from
turned to the On position the coolant low indicator is behind by the panel lamps dimmer controlled cluster
illuminated for about two seconds as a bulb test. illumination lighting with the exterior lamps turned
• Engine Coolant Level Switch Input - Each On, the white graphics appear amber and the red
time the cluster detects an appropriate input on the graphics appear red. The orange gauge needle is
low coolant fluid level sense circuit (engine coolant internally illuminated. Gauge illumination is pro-
level switch resistance low = engine coolant level low) vided by Light Emitting Diode (LED) units soldered
while the ignition switch is in the On position, the onto the instrument cluster electronic circuit board.
coolant low indicator will be illuminated. The indica- The engine coolant temperature gauge is serviced as
tor remains illuminated until the low coolant fluid a unit with the instrument cluster.
level sense input to the cluster changes (engine cool-
ant level switch resistance high = engine coolant OPERATION
level full), or until the ignition switch is turned to The engine coolant temperature gauge gives an
the Off position, whichever occurs first. The engine indication to the vehicle operator of the engine cool-
coolant level switch also features a diagnostic resis- ant temperature. This gauge is controlled by the
tor connected in parallel between the switch input instrument cluster circuit board based upon cluster
and output to provide the cluster with verification programming and electronic messages received by
that the low coolant fluid level sense circuit is not the cluster from the Engine Control Module (ECM)
open or shorted. over the Controller Area Network (CAN) data bus.
The engine coolant level switch integral to the cool- The engine coolant temperature gauge is an air core
ant bottle provides a hard wired input to the instru- magnetic unit that receives battery current on the
ment cluster circuitry through the low coolant fluid instrument cluster electronic circuit board when the
level sense circuit. The engine coolant level switch instrument cluster detects that the ignition switch is
and the low coolant fluid level sense circuit to the in the On position. The cluster is programmed to
instrument cluster can be diagnosed using conven- move the gauge needle back to the low end of the
tional diagnostic tools and methods. For proper diag- scale after the ignition switch is turned to the Off
nosis of the instrument cluster circuitry that controls position. The instrument cluster circuitry controls
the coolant low indicator, a DRBIIIt scan tool is the gauge needle position and provides the following
required. Refer to the appropriate diagnostic infor- features:
mation. • Engine Temperature Normal Message - Each
time the cluster receives a message from the ECM
indicating the engine coolant temperature is within
ENGINE TEMPERATURE the normal operating range [up to about 120° C (250°
GAUGE F), the gauge needle is moved to the actual relative
temperature position on the gauge scale.
DESCRIPTION • Engine Temperature High Message - Each
An engine coolant temperature gauge is standard time the cluster receives a message from the ECM
equipment on all instrument clusters. The engine indicating the engine coolant temperature is high
coolant temperature gauge is located in the upper [above about 120° C (250° F) the gauge needle is
right corner of the instrument cluster, to the right of moved into the red warning zone on the gauge scale.
the speedometer. The engine coolant temperature The ECM continually monitors the engine coolant
gauge consists of a movable gauge needle or pointer temperature sensor to determine the engine operat-
controlled by the instrument cluster circuitry and a ing temperature. The ECM then sends the proper
fixed 45 degree scale on the cluster overlay that engine coolant temperature messages to the instru-
reads left-to-right from 120° C to 40° C for Canadian ment cluster. If the instrument cluster moves the
8J - 16 INSTRUMENT CLUSTER VA
ENGINE TEMPERATURE GAUGE (Continued)
engine coolant temperature gauge needle to red area • ESP Lamp-On Message - Each time the clus-
of the gauge scale, it may indicate that the engine or ter receives a lamp-on message from the CAB, the
the engine cooling system require service. For proper ESP indicator will be illuminated. The indicator
diagnosis of the engine coolant temperature sensor, remains illuminated until the cluster receives a
the ECM, the CAN data bus, the electronic message lamp-off message from the CAB, or until the ignition
inputs to the instrument cluster, or the instrument switch is turned to the Off position, whichever occurs
cluster circuitry that controls the engine coolant tem- first.
perature gauge, a DRBIIIt scan tool is required. The CAB continually monitors the ESP circuits
Refer to the appropriate diagnostic information. and sensors to decide whether the system is in good
operating condition. The CAB then sends the proper
lamp-on or lamp-off messages to the instrument clus-
ESP INDICATOR ter. If the CAB sends a lamp-on message after the
bulb test, it indicates that the CAB has detected a
DESCRIPTION system malfunction and/or that the ESP system has
An Electronic Stability Program (ESP) indicator is become inoperative. The CAB will store a Diagnostic
standard equipment on all instrument clusters, but is Trouble Code (DTC) for any malfunction it detects.
only functional on vehicles equipped with the For proper diagnosis of the ESP system, the CAB,
optional ESP system. The ESP indicator is located the CAN data bus, the electronic message inputs to
near the lower edge of the instrument cluster, to the the instrument cluster, or the instrument cluster cir-
right of the multi-function indicator display. The ESP cuitry that controls the ESP indicator, a DRBIIIt
indicator consists of a stencil-like cutout of the text scan tool is required. Refer to the appropriate diag-
“ESP” in the opaque layer of the instrument cluster nostic information.
overlay. The dark outer layer of the overlay prevents
the indicator from being clearly visible when it is not
illuminated. An amber Light Emitting Diode (LED) FUEL FILTER CLOGGED
behind the cutout in the opaque layer of the overlay INDICATOR
causes the text to appear in amber through the
translucent outer layer of the overlay when the indi- DESCRIPTION
cator is illuminated from behind by the LED, which A fuel filter clogged indicator is standard equip-
is soldered onto the instrument cluster electronic cir- ment on all instrument clusters. The fuel filter
cuit board. The ESP indicator is serviced as a unit clogged indicator is located near the left edge of the
with the instrument cluster. instrument cluster, next to the tachometer. The fuel
filter clogged indicator consists of the International
OPERATION Control and Display Symbol icon for “Fuel Filter”
The ESP indicator gives an indication to the vehi- imprinted within a rectangular cutout in the opaque
cle operator when the ESP system is faulty or inop- layer of the instrument cluster overlay. The dark
erative. This indicator is controlled by a transistor on outer layer of the overlay prevents the indicator from
the instrument cluster circuit board based upon clus- being clearly visible when it is not illuminated. An
ter programming and electronic messages received by amber Light Emitting Diode (LED) behind the cutout
the cluster from the Controller Antilock Brake (CAB) in the opaque layer of the overlay causes the icon to
over the Controller Area Network (CAN) data bus. appear silhouetted against an amber field through
The ESP indicator Light Emitting Diode (LED) is the translucent outer layer of the overlay when the
completely controlled by the instrument cluster logic indicator is illuminated from behind by the LED,
circuit, and that logic will only allow this indicator to which is soldered onto the instrument cluster elec-
operate when the instrument cluster detects that the tronic circuit board. The fuel filter clogged indicator
ignition switch is in the On position. Therefore, the is serviced as a unit with the instrument cluster.
LED will always be off when the ignition switch is in
any position except On. The LED only illuminates OPERATION
when it is provided a path to ground by the instru- The fuel filter clogged indicator gives an indication
ment cluster transistor. The instrument cluster will to the vehicle operator when the pressure in the fuel
turn on the ESP indicator for the following reasons: system is low, which could indicate that the fuel filter
• Bulb Test - Each time the ignition switch is is clogged. This indicator is controlled by a transistor
turned to the On position the ESP indicator is illu- on the instrument cluster circuit board based upon
minated by the cluster for about two seconds as a cluster programming and electronic messages
bulb test. received by the cluster from the Engine Control Mod-
ule (ECM) over the Controller Area Network (CAN)
VA INSTRUMENT CLUSTER 8J - 17
FUEL FILTER CLOGGED INDICATOR (Continued)
data bus. The fuel filter clogged indicator Light Emit- The fuel gauge graphics are white against a black
ting Diode (LED) is completely controlled by the field, making them clearly visible within the instru-
instrument cluster logic circuit, and that logic will ment cluster in daylight. When illuminated from
only allow this indicator to operate when the instru- behind by the panel lamps dimmer controlled cluster
ment cluster detects that the ignition switch is in the illumination lighting with the exterior lamps turned
On position. Therefore, the LED will always be off On, the white graphics appear amber. The orange
when the ignition switch is in any position except gauge needle is internally illuminated. Gauge illumi-
On. The LED only illuminates when it is provided a nation is provided by Light Emitting Diode (LED)
path to ground by the instrument cluster transistor. units soldered onto the instrument cluster electronic
The instrument cluster will turn on the fuel filter circuit board. The fuel gauge is serviced as a unit
clogged indicator for the following reasons: with the instrument cluster.
• Bulb Test - Each time the ignition switch is
turned to the On position the fuel filter clogged indi- OPERATION
cator is illuminated by the cluster for about two sec- The fuel gauge gives an indication to the vehicle
onds as a bulb test. operator of the level of fuel in the fuel tank. This
• Fuel Filter Clogged Lamp-On Message - gauge is controlled by the instrument cluster circuit
Each time the cluster receives a lamp-on message board based upon cluster programming and a hard
from the ECM, the fuel filter clogged indicator will wired input received by the cluster from the fuel
be illuminated. The indicator remains illuminated level sensor in the fuel tank. The fuel gauge is an air
until the cluster receives a lamp-off message from core magnetic unit that receives battery current on
the ECM, or until the ignition switch is turned to the the instrument cluster electronic circuit board when
Off position, whichever occurs first. the instrument cluster detects that the ignition
The ECM continually monitors the low fuel pres- switch is in the On position. The cluster is pro-
sure sensor located at the inlet of the high pressure grammed to move the gauge needle back to the low
fuel pump to decide whether the fuel system is in end of the scale after the ignition switch is turned to
good operating condition. The ECM then sends the the Off position. The instrument cluster circuitry
proper lamp-on or lamp-off messages to the instru- controls the gauge needle position and provides the
ment cluster. If the ECM sends a lamp-on message following features:
after the bulb test, it indicates that the ECM has • Fuel Level Sensor Input (At Ignition On) -
detected a low pressure condition in the fuel system, When the cluster detects the ignition switch has been
which could result from a clogged fuel filter or from turned to the On position, the cluster moves the
any other restrictions in the fuel delivery system. gauge needle to the proper relative position on the
The ECM will store a Diagnostic Trouble Code (DTC) gauge scale as signaled by the fuel level sensor with-
for any malfunction it detects. For proper diagnosis out any electronic damping.
of the low fuel pressure sensor, the ECM, the CAN • Fuel Level Sensor Input (After Ignition On)
data bus, the electronic message inputs to the instru- - After the ignition switch has been turned to the On
ment cluster, or the instrument cluster circuitry that position, the cluster applies an algorithm to the input
controls the fuel filter clogged indicator, a DRBIIIt from the fuel level sensor to electronically dampen
scan tool is required. Refer to the appropriate diag- gauge needle movement against the negative effect
nostic information. that fuel sloshing within the fuel tank can have on
accurate gauge readings.
• Fuel Level Sensor Input Open - If the fuel
FUEL GAUGE level sensor input to the instrument cluster is an
open circuit, the cluster will move the fuel gauge nee-
DESCRIPTION dle to the “E” (Empty) position on the gauge scale,
A fuel gauge is standard equipment on all instru- but the low fuel indicator will not be illuminated.
ment clusters. The fuel gauge is located in the lower The fuel level sensor in the fuel tank provides a
right corner of the instrument cluster, to the right of hard wired input to the instrument cluster circuitry
the speedometer. The fuel gauge consists of a mov- through the fuel level sense circuit. The fuel level
able gauge needle or pointer controlled by the instru- sensor is a potentiometer that changes resistance
ment cluster circuitry and a fixed 45 degree scale on according to the fuel level. The instrument cluster
the cluster overlay that reads left-to-right from “F” applies a fuel tank characteristic curve and fuel tank
(or Full) to “E” (or Empty). An International Control reserve valve setting to the fuel level sensor input,
and Display Symbol icon for “Fuel” is located on the which must be configured when the cluster is initial-
cluster overlay, directly to the left of the low end of ized. These characteristics determine the algorithm
the scale. the cluster uses to display the fuel level data on the
8J - 18 INSTRUMENT CLUSTER VA
FUEL GAUGE (Continued)
fuel gauge and the control for the low fuel warning gear selector indicator information to be displayed
indicator. As the fuel level decreases, the resistance when the instrument cluster detects that the ignition
through the fuel level sensor increases. The fuel level switch is in the On position. Therefore, the gear
sensor and the fuel level sense circuit to the instru- selector indicator will always be off when the ignition
ment cluster can be diagnosed using conventional switch is in any position except On.
diagnostic tools and methods. For proper diagnosis of The TCM continually monitors the transmission
the instrument cluster circuitry that controls the fuel range sensor, then sends the proper gear selector
gauge, a DRBIIIt scan tool is required. Refer to the indicator position messages to the instrument cluster.
appropriate diagnostic information. For proper diagnosis of the transmission range sen-
sor, the TCM, the CAN data bus, or the electronic
message inputs to the instrument cluster that control
GEAR SELECTOR INDICATOR the gear selector indicator, a DRBIIIt scan tool is
required. Refer to the appropriate diagnostic infor-
DESCRIPTION mation.
An electronic automatic transmission gear selector
indicator is standard equipment on all instrument
clusters. The gear selector indicator information is HIGH BEAM INDICATOR
displayed in the center of the multi-function indicator
Liquid Crystal Display (LCD) located near the lower DESCRIPTION
edge of the instrument cluster, directly below the A high beam indicator is standard equipment on
speedometer. The gear selector indicator displays the all instrument clusters. The high beam indicator is
following characters as they are selected: “P,” “R,” located near the lower edge of the instrument cluster,
“N,” “D,” “4,” “3,” “2,” and “1.” Respectively, these to the left of the multi-function indicator display. The
characters represent the currently selected park, high beam indicator consists of the International
reverse, neutral, drive, fourth gear, third gear, second Control and Display Symbol icon for “High Beam”
gear, and first gear positions of the transmission gear imprinted within a rectangular cutout in the opaque
selector lever on the instrument panel. layer of the instrument cluster overlay. The dark
The indications of the gear selector indicator are outer layer of the overlay prevents the indicator from
not visible unless the multi-function indicator LCD is being clearly visible when it is not illuminated. A
illuminated and the engine is running. When illumi- blue Light Emitting Diode (LED) behind the cutout
nated, each indication appears as a dark character in the opaque layer of the overlay causes the icon to
silhouetted against an amber field. When the exterior appear silhouetted against a blue field through the
lighting is turned Off, the display is illuminated at translucent outer layer of the overlay when the indi-
maximum brightness. When the exterior lighting is cator is illuminated from behind by the LED, which
turned On, the display illumination level can be is soldered onto the instrument cluster electronic cir-
adjusted in concert with the cluster general illumina- cuit board. The high beam indicator is serviced as a
tion lighting using the “+” (plus) and “2” (minus) unit with the instrument cluster.
multi-function indicator push buttons. The gear
selector indicator is serviced as a unit with the OPERATION
instrument cluster. The high beam indicator gives an indication to the
vehicle operator whenever the headlamp high beams
OPERATION are illuminated. This indicator is controlled by a
The electronic gear selector indicator gives an indi- transistor on the instrument cluster circuit board
cation to the vehicle operator of the transmission based upon cluster programming and a hard wired
gear that is currently selected with the automatic input from the multi-function switch. The high beam
transmission gear selector lever. This indicator is indicator Light Emitting Diode (LED) is completely
controlled by the instrument cluster circuit board controlled by the instrument cluster logic circuit, and
based upon cluster programming and electronic mes- that logic will allow this indicator to operate when-
sages received from the Transmission Control Module ever the instrument cluster receives battery current
(TCM) over the Controller Area Network (CAN) data on the fused B(+) circuit. Therefore, the LED can be
bus. The gear selector indicator information is dis- illuminated regardless of the ignition switch position.
played by the multi-function indicator Liquid Crystal The LED only illuminates when it is provided a path
Display (LCD) unit on the instrument cluster elec- to ground by the instrument cluster transistor. The
tronic circuit board. The multi-function indicator instrument cluster will turn on the high beam indi-
LCD is completely controlled by the instrument clus- cator for the following reasons:
ter logic circuit, and that logic will only allow the
VA INSTRUMENT CLUSTER 8J - 19
HIGH BEAM INDICATOR (Continued)
• Bulb Test - Each time the ignition switch is path to ground by the instrument cluster transistor.
turned to the On position the high beam indicator is The instrument cluster will turn on the low fuel indi-
illuminated by the cluster for about two seconds as a cator for the following reasons:
bulb test. • Bulb Test - Each time the ignition switch is
• High Beams On Input - Each time the cluster turned to the On position the low fuel indicator is
receives a high beam headlamps-on input from the illuminated for about two seconds as a bulb test.
multi-function switch, the high beam indicator will • Fuel Level Sensor Input - Each time the clus-
be illuminated. The indicator remains illuminated ter receives an input from the fuel level sensor indi-
until the cluster receives a high beam headlamps-off cating that the fuel level has reached about 12 liters
input from the multi-function switch. (3 gallons) or less, the low fuel indicator is illumi-
The instrument cluster continually monitors the nated. The indicator remains illuminated until the
multi-function switch input to determine whether the cluster receives an input from the fuel level sensor
high beam indicator should be illuminated or extin- indicating that the fuel level is above 12 liters (3 gal-
guished. The multi-function switch and the multi- lons), or until the ignition switch is turned to the Off
function switch input circuit to the instrument position, whichever occurs first.
cluster can be diagnosed using conventional diagnos- The fuel level sensor in the fuel tank provides a
tic tools and methods. For proper diagnosis of the hard wired input to the instrument cluster circuitry
instrument cluster circuitry that controls the high through the fuel level sense circuit. The fuel level
beam indicator, a DRBIIIt scan tool is required. sensor is a potentiometer that changes resistance
Refer to the appropriate diagnostic information. according to the fuel level. As the fuel level
decreases, the resistance through the fuel level sen-
sor increases. The instrument cluster applies a fuel
LOW FUEL INDICATOR tank characteristic curve and fuel tank reserve valve
setting to the fuel level sensor input, which must be
DESCRIPTION configured when the cluster is initialized. These
A low fuel indicator is standard equipment on all characteristics determine the algorithm the cluster
instrument clusters. The low fuel indicator is located uses to display the fuel level data on the fuel gauge
directly below the low end of the fuel gauge scale. and the control for the low fuel warning indicator.
The low fuel indicator consists of a small triangular The fuel level sensor and the fuel level sense circuit
cutout in the opaque layer of the instrument cluster to the instrument cluster can be diagnosed using con-
overlay. The dark outer layer of the overlay prevents ventional diagnostic tools and methods. For proper
the indicator from being clearly visible when it is not diagnosis of the instrument cluster circuitry that con-
illuminated. An amber Light Emitting Diode (LED) trols the fuel gauge, a DRBIIIt scan tool is required.
behind the cutout in the opaque layer of the overlay Refer to the appropriate diagnostic information.
causes the triangle to appear in amber through the
translucent outer layer of the overlay when the indi-
cator is illuminated from behind by the LED, which LOW OIL LEVEL INDICATOR
is soldered onto the instrument cluster electronic cir-
cuit board. The low fuel indicator is serviced as a DESCRIPTION
unit with the instrument cluster. A low oil level indicator is standard equipment on
all instrument clusters. The low oil level indicator is
OPERATION located near the lower edge of the instrument cluster,
The low fuel indicator gives an indication to the to the left of the multi-function indicator display. The
vehicle operator when the level of fuel in the fuel low oil level indicator consists of the International
tank becomes low. This indicator is controlled by a Control and Display Symbol icon for “Engine Oil”
transistor on the instrument cluster circuit board imprinted within a rectangular cutout in the opaque
based upon cluster programming and a hard wired layer of the instrument cluster overlay. The dark
input received by the cluster from the fuel level sen- outer layer of the overlay prevents the indicator from
sor in the fuel tank. The low fuel indicator Light being clearly visible when it is not illuminated. A red
Emitting Diode (LED) is completely controlled by the Light Emitting Diode (LED) behind the cutout in the
instrument cluster logic circuit, and that logic will opaque layer of the overlay causes the icon to appear
only allow this indicator to operate when the instru- silhouetted against a red field through the translu-
ment cluster detects that the ignition switch is in the cent outer layer of the overlay when the indicator is
On position. Therefore, the LED will always be off illuminated from behind by the LED, which is sol-
when the ignition switch is in any position except dered onto the instrument cluster electronic circuit
On. The LED only illuminates when it is provided a
8J - 20 INSTRUMENT CLUSTER VA
LOW OIL LEVEL INDICATOR (Continued)
board. The low oil level indicator is serviced as a unit to the instrument cluster that control the low oil
with the instrument cluster. level indicator, a DRBIIIt scan tool is required. Refer
to the appropriate diagnostic information.
OPERATION
The low oil level indicator gives an indication to
the vehicle operator when the engine oil level is low. MAINTENANCE INDICATOR
This indicator is controlled by a transistor on the
instrument cluster electronic circuit board based DESCRIPTION
upon cluster programming and electronic messages An Active Service SYSTem (ASSYST) engine oil
received by the cluster from the Engine Control Mod- maintenance indicator is optional equipment on all
ule (ECM) over the Controller Area Network (CAN) instrument clusters. In vehicles so equipped, a sec-
data bus. The low oil level indicator Light Emitting ond, dedicated ASSYST microprocessor is integral to
Diode (LED) is completely controlled by the instru- the cluster electronic circuit board. The ASSYST indi-
ment cluster logic circuit, and that logic will only cations are displayed and can be toggled with the
allow this indicator to operate when the instrument clock indication on the right side of the multi-func-
cluster detects that the ignition switch is in the On tion indicator Liquid Crystal Display (LCD) located
position. Therefore, the LED will always be off when near the lower edge of the instrument cluster,
the ignition switch is in any position except On. The directly below the speedometer. The ASSYST displays
LED only illuminates when it is provided a path to include numeric values combined with several icons
ground by the instrument cluster transistor. The to indicate actual engine oil level, and reminders in
instrument cluster will turn on the low oil level indi- time (days) or distance (miles or kilometers) until the
cator for the following reasons: next required engine oil maintenance is anticipated.
• Bulb Test - Each time the ignition switch is ASSYST also provides several audible indications
turned to the On position the low oil level indicator using the electronic tone generator on the instrument
is illuminated for about two seconds as a bulb test. cluster circuit board to supplement these visual dis-
• Engine Oil Level Low Message - Once the plays.
engine has been started, each time the cluster The indications of the ASSYST engine oil mainte-
receives a message from the ECM indicating that the nance indicator are not visible when the LCD is not
engine oil level is at or near the “Minimum” mark on illuminated. When illuminated, the ASSYST indica-
the dipstick, the low oil level indicator is illuminated. tions appear as dark characters and icons silhouetted
The indicator remains illuminated briefly at first, but against an amber field. When the exterior lighting is
will remain illuminated for longer periods as subse- turned Off, the display is illuminated at maximum
quent messages indicate that the oil level has brightness. When the exterior lighting is turned On,
dropped further. Eventually, the indicator will the display illumination level can be adjusted in con-
remain illuminated solid until the engine oil level is cert with the cluster general illumination lighting
corrected, or until the ignition switch is turned to the using the “+” (plus) and “2” (minus) multi-function
Off position, whichever occurs first. indicator push buttons. The ASSYST engine oil main-
The instrument cluster also supplements the oil tenance indicator is serviced as a unit with the
level indicator by displaying an engine oil icon along instrument cluster.
with alpha-numeric messages in the multi-function
indicator Liquid Crystal Display (LCD) advising the OPERATION
vehicle operator how much oil is required to correct The ASSYST engine oil maintenance indicator
the engine oil level, and when the “Maximum” engine microprocessor uses numerous criteria besides time
oil level has been exceeded. See the owner’s manual and mileage to evaluate vehicle maintenance require-
in the vehicle glove box for more information on this ments. Time data is taken from the electronic digital
feature. clock integral to the instrument cluster. Vehicle dis-
The ECM continually monitors the engine oil level tance data is obtained from the Controller Antilock
and temperature sensor to determine the engine oil Brake (CAB) over the Controller Area Network
level. The ECM then sends the proper engine oil (CAN) data bus. Coolant temperature, engine oil
level messages to the instrument cluster. If the temperature, engine oil level, engine oil quality,
instrument cluster turns on the indicator after the engine speed, and engine load data are obtained from
bulb test, even after the engine oil level is sufficient, the Engine Control Module (ECM) over the CAN
it may indicate that the engine or the engine oiling data bus. Using all of the available data and internal
system requires service. For proper diagnosis of the programming, the ASSYST microprocessor then cal-
engine oil level and temperature sensor, the ECM, culates the estimated time and distance to the next
the CAN data bus, or the electronic message inputs required engine oil maintenance interval. The
VA INSTRUMENT CLUSTER 8J - 21
MAINTENANCE INDICATOR (Continued)
ASSYST uses the multi-function indicator LCD to LED only illuminates when it is provided a path to
display that data and, when necessary, issues audible ground by the instrument cluster transistor. The
alerts to the vehicle operator through the electronic instrument cluster will turn on the MIL for the fol-
tone generator on the cluster circuit board. lowing reasons:
See the owner’s manual in the vehicle glove box for • Bulb Test - Each time the ignition switch is
more information on the features, use, operation and turned to the On position the MIL is illuminated as a
resetting procedures for the ASSYST maintenance bulb test. The indicator will remain illuminated until
computer. Proper diagnosis and testing of the the engine is started, or until the ignition switch is
ASSYST engine oil maintenance computer, the CAN turned to the Off position, whichever occurs first.
data bus and the electronic data bus message inputs • MIL Lamp-On Message - Each time the clus-
to the EMIC that are used by the ASSYST computer ter receives a MIL lamp-on message from the ECM,
for its calculations requires the use of a DRBIIIt the indicator will be illuminated. The indicator will
scan tool. Refer to the appropriate diagnostic infor- remain illuminated until the detected fault is
mation. repaired, or until the ignition switch is turned to the
Off position, whichever occurs first. For more infor-
mation on the ECM and the DTC set and reset
MALFUNCTION INDICATOR parameters, (Refer to 25 - EMISSIONS CONTROL -
LAMP (MIL) OPERATION).
• Communication Error - If the cluster receives
DESCRIPTION no lamp-on or lamp-off message from the ECM, the
MIL is illuminated by the instrument cluster. The
A Malfunction Indicator Lamp (MIL) is standard
indicator remains controlled and illuminated by the
equipment on all instrument clusters. The MIL is
cluster until a valid lamp-on or lamp-off message is
located near the lower edge of the instrument cluster,
received from the ECM.
to the right of the multi-function indicator display.
The ECM continually monitors the fuel and emis-
The MIL consists of the International Control and
sions system circuits and sensors to decide whether
Display Symbol icon for “Engine” imprinted within a
the system is in good operating condition. The ECM
rectangular cutout in the opaque layer of the instru-
then sends the proper lamp-on or lamp-off messages
ment cluster overlay. The dark outer layer of the
to the instrument cluster. If the instrument cluster
overlay prevents the indicator from being clearly vis-
turns on the MIL after the bulb test, it may indicate
ible when it is not illuminated. An amber Light
that a malfunction has occurred and that the fuel
Emitting Diode (LED) behind the cutout in the
and emissions systems may require service. For
opaque layer of the overlay causes the icon to appear
proper diagnosis of the fuel and emissions systems,
silhouetted against an amber field through the trans-
the ECM, the CAN data bus, or the electronic mes-
lucent outer layer of the overlay when the indicator
sage inputs to the instrument cluster that control the
is illuminated from behind by the LED, which is sol-
MIL, a DRBIIIt scan tool is required. Refer to the
dered onto the instrument cluster electronic circuit
appropriate diagnostic information.
board. The MIL is serviced as a unit with the instru-
ment cluster.
MULTI-FUNCTION INDICATOR
OPERATION
The Malfunction Indicator Lamp (MIL) gives an
DESCRIPTION
indication to the vehicle operator when the Engine
A multi-function indicator is standard equipment
Control Module (ECM) has recorded a Diagnostic
on all instrument clusters. The multi-function indica-
Trouble Code (DTC) for an On-Board Diagnostics II
tor is located near the lower edge of the instrument
(OBDII) emissions-related circuit or component mal-
cluster, directly below the speedometer. The multi-
function. The MIL is controlled by a transistor on the
function indicator consists of a Liquid Crystal Dis-
instrument cluster circuit board based upon cluster
play (LCD) unit and four push button-controlled
programming and electronic messages received by
switches that are soldered onto the instrument clus-
the cluster from the ECM over the Controller Area
ter electronic circuit board. The LCD is visible
Network (CAN) data bus. The MIL Light Emitting
through a large rectangular cutout in the instrument
Diode (LED) is completely controlled by the instru-
cluster overlay, while the four switch push buttons
ment cluster logic circuit, and that logic will only
extend through a black plastic switch bezel located
allow this indicator to operate when the instrument
on the cluster lens directly below the LCD. The four
cluster detects that the ignition switch is in the On
multi-function indicator push buttons allow the vehi-
position. Therefore, the LED will always be off when
cle operator to configure and adjust several of the
the ignition switch is in any position except On. The
8J - 22 INSTRUMENT CLUSTER VA
MULTI-FUNCTION INDICATOR (Continued)
display features. The buttons are labeled from left to dures for the various standard and optional multi-
right: “mi” (miles) or “km” (kilometers), an icon function indicator displays.
depicting an analog clock face (clock), “2” (minus), Proper testing of the multi-function indicator LCD
and “+” (plus). unit, the CAN data bus and the electronic data bus
The multi-function indicator LCD displays both message inputs to the instrument cluster that control
alpha-numeric characters and numerous icons to pro- some of the multi-function indicator functions
vide information to the vehicle operator. The indica- requires the use of a DRBIIIt scan tool. Refer to the
tions of the multi-function indicator are not visible appropriate diagnostic information. Additional details
when the LCD is not illuminated. When illuminated for the odometer/trip odometer, the clock, the gear
the indications appear as dark characters and icons selector indicator, the ambient temperature indicator
silhouetted against an amber field. When the exterior and the ASSYST warning and reminder functions of
lighting is turned Off, the display is illuminated at the multi-function indicator may be found elsewhere
maximum brightness. When the exterior lighting is in this service information.
turned On the display illumination level can be
adjusted in concert with the cluster general illumina-
tion lighting using the “+” (plus) and “2” (minus) ODOMETER
multi-function indicator push buttons. The multi-
function indicator LCD unit and push button DESCRIPTION
switches are serviced as a unit with the instrument An odometer and trip odometer are standard
cluster. equipment in all instrument clusters. The odometer
and trip odometer values are displayed on the left
OPERATION side of the multi-function indicator Liquid Crystal
The multi-function indicator has several display Display (LCD). The LCD is soldered onto the cluster
capabilities including odometer, trip odometer, clock, electronic circuit board and is visible through a win-
engine oil level data, gear selector indicator dow with a clear lens located near the lower edge of
(PRNDL), certain diagnostic information and, on the instrument cluster, directly below the speedome-
vehicles so equipped, an optional Active Service SYS- ter. However, the odometer and trip odometer infor-
Tem (ASSYST) engine oil maintenance indicator and mation are not displayed simultaneously. The “mi”
an optional outside ambient temperature indicator. (miles) or “km” (kilometers) switch on the instrument
The multi-function indicator is completely controlled cluster circuit board toggles the display between
by the instrument cluster logic circuit, and that logic odometer and trip odometer modes by depressing the
will allow this indication to be viewed whenever the switch push button that extends through the lower
multi-function indicator Liquid Crystal Display edge of the cluster lens, directly below the multi-
(LCD) is activated. Therefore, the indicator remains function indicator LCD.
functional regardless of the ignition switch position. The odometer and trip odometer information is
With the ignition switch in the Off or Accessory posi- stored in the instrument cluster memory. This infor-
tions and the key removed from the ignition lock cyl- mation can be increased when the proper inputs are
inder, the display is activated when the park lamps provided to the instrument cluster, but the informa-
are turned On or, for about thirty seconds after any tion cannot be decreased. The odometer can display
one of the multi-function indicator switch push but- values up to 999,999 kilometers (999,999 miles). The
tons is depressed. Otherwise, the display unit is odometer latches at these values, and will not roll
active for about thirty seconds after the key is over to zero. The trip odometer can display values up
inserted into the ignition lock cylinder, and inactive to 999.9 kilometers (999.9 miles) before it rolls over
about thirty seconds after the key is removed from to zero. The odometer display does not have a deci-
the ignition lock cylinder. mal point and will not show values less than a full
The multi-function indicator “mi” (miles) or unit (kilometer or mile), while the trip odometer dis-
“km”(kilometers) switch push button is used to con- play does have a decimal point and will show tenths
trol the odometer/trip odometer display modes. The of a unit (kilometer or mile). The unit of measure
multi-function indicator clock switch push button is (kilometers or miles) for the odometer and trip odom-
used to control the clock/outside temperature display eter display is imprinted on the cluster overlay below
modes. The multi-function indicator “+” (plus) and the left end of the LCD. The unit of measure for the
“2” (minus) switch push buttons are used to adjust instrument cluster odometer/trip odometer is selected
the cluster general illumination dimming level, the at the time that it is manufactured, and cannot be
clock, and other cluster settings. See the owner’s changed.
manual in the vehicle glove box for more information The indications of the odometer/trip odometer are
on the features, use, operation and setting proce- not visible when the LCD is not illuminated. When
VA INSTRUMENT CLUSTER 8J - 23
ODOMETER (Continued)
illuminated the indications appear as dark charac- wheel speed sensors, the CAB, the CAN data bus, or
ters silhouetted against an amber field. When the the electronic message inputs to the instrument clus-
exterior lighting is turned Off, the display is illumi- ter that control the odometer/trip odometer, a
nated at maximum brightness. When the exterior DRBIIIt scan tool is required. Refer to the appropri-
lighting is turned On the display illumination level ate diagnostic information.
can be adjusted in concert with the cluster general
illumination lighting using the plus and minus multi-
function indicator push buttons. The odometer has a PARK BRAKE INDICATOR
“Rental Car” mode, which will activate the multi-
function indicator LCD and illuminate the odometer DESCRIPTION
information for about thirty seconds after one of the A park brake indicator is standard equipment on
multi-function indicator push buttons is momentarily all instrument clusters. The park brake indicator is
depressed, or after the key is inserted into the igni- located near the lower edge of the instrument cluster,
tion switch lock cylinder with the ignition switch in to the left of the multi-function indicator display. The
the Off position. park brake indicator consists of stencil-like cutout of
The odometer/trip odometer and the miles/kilome- the word “PARK” in the opaque layer of the instru-
ters switch, and the miles/kilometers switch push ment cluster overlay. The dark outer layer of the
button are serviced as a unit with the instrument overlay prevents the indicator from being clearly vis-
cluster. ible when it is not illuminated. A red Light Emitting
Diode (LED) behind the cutout in the opaque layer of
OPERATION the overlay causes the “PARK” text to appear in red
The odometer and trip odometer give an indication through the translucent outer layer of the overlay
to the vehicle operator of the distance the vehicle has when the indicator is illuminated from behind by the
traveled. This indicator is controlled by the instru- LED, which is soldered onto the instrument cluster
ment cluster circuitry based upon cluster program- electronic circuit board. The park brake indicator is
ming and electronic messages received by the cluster serviced as a unit with the instrument cluster.
from the Controller Anti-lock Brake (CAB) over the
Controller Area Network (CAN) data bus. The odom- OPERATION
eter and trip odometer information is displayed by The park brake indicator gives an indication to the
the multi-function indicator Liquid Crystal Display vehicle operator when the parking brake is applied.
(LCD). The LCD will display the odometer informa- This indicator is controlled by a transistor on the
tion whenever it is activated, and will display the instrument cluster circuit board based upon a hard
last previously selected odometer or trip odometer wired input from the park brake switch. The park
information when the ignition switch is turned to the brake indicator Light Emitting Diode (LED) is com-
On position. The instrument cluster circuitry controls pletely controlled by the instrument cluster logic cir-
the LCD and provides the following features: cuit, and that logic will only allow this indicator to
• Odometer/Trip Odometer Display Toggling - operate when the instrument cluster detects that the
Actuating the multi-function indicator “mi” (miles) or ignition switch is in the On position. Therefore, the
“km” (kilometers) switch push button momentarily LED will always be off when the ignition switch is in
with the LCD illuminated will toggle the display any position except On. The LED only illuminates
between the odometer and trip odometer information. when it is provided a path to ground by the instru-
Each time the LCD is illuminated with the ignition ment cluster transistor. The instrument cluster will
switch in the On or Start positions, the display will turn on the park brake indicator for the following
automatically return to the last mode previously reasons:
selected (odometer or trip odometer). • Park Brake Switch Input - Each time the
• Trip Odometer Reset - When the multi-func- cluster detects ground on the park brake indicator
tion indicator “mi” (miles) or “km” (kilometers) switch signal circuit (park brake switch closed = park brake
push button is pressed and held for longer than applied or not fully released) while the ignition
about two seconds, the trip odometer will be reset to switch is in the On position, the brake indicator is
000.0 kilometers (miles). The LCD must be display- illuminated. The indicator remains illuminated until
ing the trip odometer information in order for the the brake signal indicator input to the cluster is an
trip odometer information to be reset. open circuit (park brake switch open = park brake
The CAB continually monitors the vehicle speed fully released), or until the ignition switch is turned
pulse information received from the four wheel speed to the Off position, whichever occurs first.
sensors, then sends the proper distance messages to The park brake switch on the park brake pedal
the instrument cluster. For proper diagnosis of the mechanism provides a hard wired ground input to
8J - 24 INSTRUMENT CLUSTER VA
PARK BRAKE INDICATOR (Continued)
the instrument cluster circuitry through the park be illuminated as a reminder for about six seconds,
brake indicator signal circuit whenever the park or until the ignition switch is turned to the Off posi-
brake is applied or not fully released. The two tion, whichever occurs first. This reminder function
switches are connected in series between ground and will occur regardless of the status of the input
the instrument cluster. The park brake switch and received by the cluster from the driver side front seat
the input circuit to the instrument cluster can be belt switch.
diagnosed using conventional diagnostic tools and • Driver Side Front Seat Belt Switch Input -
methods. For proper diagnosis of the instrument Following the seatbelt reminder function, each time
cluster circuitry that controls the park brake indica- the cluster detects ground on the seatbelt indicator
tor, a DRBIIIt scan tool is required. Refer to the driver circuit (seat belt switch closed = seatbelt
appropriate diagnostic information. unbuckled) with the ignition switch in the On posi-
tion, the seatbelt indicator will be illuminated. The
seatbelt indicator remains illuminated until the seat
SEATBELT INDICATOR belt switch input to the cluster is an open circuit
(seat belt switch open = seatbelt buckled), or until
DESCRIPTION the ignition switch is turned to the Off position,
A seatbelt indicator is standard equipment on all whichever occurs first.
instrument clusters. The seatbelt indicator is located • Airbag Indicator Malfunction - Following the
near the lower edge of the instrument cluster, to the seatbelt reminder function, each time the cluster
right of the multi-function indicator display. The detects a malfunction in the airbag (SRS) indicator or
seatbelt indicator consists of the International Con- the airbag indicator circuit, the cluster will flash the
trol and Display Symbol icon for “Seat Belt” seatbelt indicator on and off. The cluster will con-
imprinted within a rectangular cutout in the opaque tinue to flash the seatbelt indicator until the airbag
layer of the instrument cluster overlay. The dark indicator circuit fault is resolved, or until the ignition
outer layer of the overlay prevents the indicator from switch is turned to the Off position, whichever occurs
being clearly visible when it is not illuminated. A red first.
Light Emitting Diode (LED) behind the cutout in the The instrument cluster continually monitors the
opaque layer of the overlay causes the icon to appear status of the driver side front seat belt switch and
silhouetted against a red field through the translu- the airbag indicator circuit to determine the proper
cent outer layer of the overlay when the indicator is seatbelt indicator response. The seat belt switch is
illuminated from behind by the LED, which is sol- connected in series between the instrument cluster
dered onto the instrument cluster electronic circuit and ground. The seat belt switch and the seatbelt
board. The seatbelt indicator is serviced as a unit indicator driver circuit to the instrument cluster can
with the instrument cluster. be diagnosed using conventional diagnostic tools and
methods. For proper diagnosis of the ACM, the air-
OPERATION bag (SRS) indicator, or the instrument cluster cir-
The seatbelt indicator gives an indication to the cuitry that controls the seatbelt indicator, a DRBIIIt
vehicle operator of the status of the driver side front scan tool is required. Refer to the appropriate diag-
seat belt. This indicator is controlled by a transistor nostic information.
on the instrument cluster circuit board based upon
cluster programming and a hard wired input received
from the seat belt switch on the driver side front seat SPEEDOMETER
belt. The seatbelt indicator Light Emitting Diode
(LED) is completely controlled by the instrument DESCRIPTION
cluster logic circuit, and that logic will only allow A speedometer is standard equipment on all instru-
this indicator to operate when the instrument cluster ment clusters. The speedometer is located in the cen-
detects that the ignition switch is in the On position. ter of the instrument cluster. The speedometer
Therefore, the LED will always be off when the igni- consists of a movable gauge needle or pointer con-
tion switch is in any position except On. The LED trolled by the instrument cluster circuitry and a fixed
only illuminates when it is provided a path to ground 210 degree primary outer scale on the gauge dial face
by the instrument cluster transistor. The instrument that reads left-to-right either from “0” to “100” miles-
cluster will turn on the seatbelt indicator for the fol- per-hour, or from “0” to “180” kilometers-per-hour,
lowing reasons: depending upon the market for which the vehicle is
• Seatbelt Reminder Function - Each time the manufactured. Each version also has a secondary
cluster detects that the ignition switch has been inner scale on the gauge dial face that provides the
turned to the On position the seatbelt indicator will equivalent opposite units from the primary scale.
VA INSTRUMENT CLUSTER 8J - 25
SPEEDOMETER (Continued)
Text appearing on the cluster overlay near the left TACHOMETER
end of each scale abbreviates the unit of measure,
either “mph” or “km/h”.
DESCRIPTION
The speedometer graphics are white against a
A tachometer is standard equipment on all instru-
black field, making them clearly visible within the
ment clusters. The tachometer is located to the left of
instrument cluster in daylight. When illuminated
the speedometer, to the left of center in the instru-
from behind by the panel lamps dimmer controlled
ment cluster. The tachometer consists of a movable
cluster illumination lighting with the exterior lamps
gauge needle or pointer controlled by the instrument
turned On, the white graphics appear amber. The
cluster circuitry and a fixed 45 degree scale on the
orange gauge needle is internally illuminated. Gauge
gauge dial face that reads left-to-right from “0” to “7”.
illumination is provided by Light Emitting Diode
The text “rpm X 1000” imprinted on the cluster over-
(LED) units soldered onto the instrument cluster
lay near the left end of the gauge scale identifies that
electronic circuit board. The speedometer is serviced
each number on the tachometer scale is to be multi-
as a unit with the instrument cluster.
plied by 1000 rpm.
The tachometer graphics are white against a black
OPERATION field, making them clearly visible within the instru-
The speedometer gives an indication to the vehicle
ment cluster in daylight. When illuminated from
operator of the vehicle road speed. This gauge is con-
behind by the panel lamps dimmer controlled cluster
trolled by the instrument cluster circuit board based
illumination lighting with the exterior lamps turned
upon cluster programming and electronic messages
On, the white graphics appear amber. The orange
received by the cluster from the Controller Anti-lock
gauge needle is internally illuminated. Gauge illumi-
Brake (CAB) over the Controller Area Network
nation is provided by Light Emitting Diode (LED)
(CAN) data bus. The speedometer is an air core mag-
units soldered onto the instrument cluster electronic
netic unit that receives battery current on the instru-
circuit board. The tachometer is serviced as a unit
ment cluster electronic circuit board when the
with the instrument cluster.
instrument cluster detects that the ignition switch is
in the On position. The cluster is programmed to
OPERATION
move the gauge needle back to the low end of the
The tachometer gives an indication to the vehicle
scale after the ignition switch is turned to the Off
operator of the engine speed. This gauge is controlled
position. The instrument cluster circuitry controls
by the instrument cluster circuit board based upon
the gauge needle position and provides the following
cluster programming and electronic messages
features:
received by the cluster from the Engine Control Mod-
• Vehicle Speed Message - Each time the clus-
ule (ECM) over the Controller Area Network (CAN)
ter receives a vehicle speed message from the CAB it
data bus. The tachometer is an air core magnetic
will calculate the correct vehicle speed reading and
unit that receives battery current on the instrument
position the gauge needle at that relative speed posi-
cluster electronic circuit board when the instrument
tion on the gauge scale. The gauge needle will con-
cluster detects that the ignition switch is in the On
tinue to be positioned at the actual vehicle speed
position. The cluster is programmed to move the
position on the gauge scale until the ignition switch
gauge needle back to the low end of the scale after
is turned to the Off position.
the ignition switch is turned to the Off position. The
• Communication Error - If the cluster fails to
instrument cluster circuitry controls the gauge nee-
receive a speedometer message, it will hold the gauge
dle position and provides the following features:
needle at the last indication for about three seconds,
• Engine Speed Message - Each time the cluster
or until the ignition switch is turned to the Off posi-
receives an engine speed message from the ECM it
tion, whichever occurs first. After three seconds, the
will calculate the correct engine speed reading and
gauge needle will return to the left end of the gauge
position the gauge needle at that relative speed posi-
scale.
tion on the gauge scale. The gauge needle will con-
The CAB continually monitors the four wheel
tinually be repositioned at the relative engine speed
speed sensors to determine the vehicle road speed.
position on the gauge scale until the engine stops
The CAB then sends the proper vehicle speed mes-
running, or until the ignition switch is turned to the
sages to the instrument cluster. For proper diagnosis
Off position, whichever occurs first.
of the wheel speed sensors, the CAB, the CAN data
• Communication Error - If the cluster fails to
bus, or the electronic message inputs to the instru-
receive an engine speed message, it will hold the
ment cluster that control the speedometer, a DRBIIIt
gauge needle at the last indication for about three
scan tool is required. Refer to the appropriate diag-
seconds, or until the ignition switch is turned to the
nostic information.
Off position, whichever occurs first. After three sec-
8J - 26 INSTRUMENT CLUSTER VA
TACHOMETER (Continued)
onds, the gauge needle will return to the left end of • Bulb Test - Each time the ignition switch is
the gauge scale. turned to the On position the traction control indica-
The ECM continually monitors the crankshaft posi- tor is illuminated for about two seconds as a bulb
tion sensor to determine the engine speed. The ECM test.
then sends the proper engine speed messages to the • Traction Control (ASR) Indicator Lamp-On
instrument cluster. For proper diagnosis of the Message - Each time the cluster receives a traction
crankshaft position sensor, the ECM, the CAN data control indicator lamp-on message from the CAB, the
bus, or the electronic message inputs to the instru- indicator will be illuminated. This indicator can be
ment cluster that control the tachometer, a DRBIIIt flashed on and off, or illuminated solid, as dictated
scan tool is required. Refer to the appropriate diag- by the CAB message. The indicator is illuminated
nostic information. solid when the traction control system has been deac-
tivated; and is flashed when the traction control is
activated or when the driven wheels lose traction
TRACTION CONTROL with the traction control deactivated. The indicator
INDICATOR remains flashing or illuminated solid until the clus-
ter receives a lamp-off message from the CAB, or
DESCRIPTION until the ignition switch is turned to the Off position,
whichever occurs first.
A traction control (ASR) indicator is standard
The CAB continually monitors the traction control
equipment on all instrument clusters. The traction
(ASR) switch and the four wheel speed sensors to
control indicator is located near the center of the
determine the correct operating mode for the traction
speedometer in the instrument cluster. The traction
control system. The CAB then sends the proper
control indicator consists of an “!” (exclamation point)
lamp-on or lamp-off messages to the instrument clus-
imprinted within a triangular cutout in the opaque
ter. See the owner’s manual in the vehicle glove box
layer of the instrument cluster overlay. The dark
for more information on the features, use, activation
outer layer of the overlay prevents the indicator from
and deactivation of the traction control (ASR) system.
being clearly visible when it is not illuminated. An
For proper diagnosis of the traction control system,
amber Light Emitting Diode (LED) behind the cutout
the CAB, the CAN data bus, or the electronic mes-
in the opaque layer of the overlay causes the excla-
sage inputs to the instrument cluster that control the
mation point to appear silhouetted against an amber
traction control indicator, a DRBIIIt scan tool is
field through the translucent outer layer of the over-
required. Refer to the appropriate diagnostic infor-
lay when the indicator is illuminated from behind by
mation.
the LED, which is soldered onto the instrument clus-
ter electronic circuit board. The traction control indi-
cator is serviced as a unit with the instrument TRACTION CONTROL
cluster.
MALFUNCTION INDICATOR
OPERATION
The traction control (ASR) indicator gives several DESCRIPTION
indications to the vehicle operator concerning the A traction control (ASR) malfunction indicator is
operating status of the traction control (ASR) system. standard equipment on all instrument clusters. The
The traction control indicator is controlled by a tran- traction control malfunction indicator is located near
sistor on the instrument cluster circuit board based the lower edge of the instrument cluster, to the right
upon cluster programming and electronic messages of the multi-function indicator display. The traction
received by the cluster from the Controller Anti-lock control malfunction indicator consists of an icon that
Brake (CAB) over the Controller Area Network graphically depicts a tire and two skid marks
(CAN) data bus. The traction control indicator Light imprinted within a rectangular cutout in the opaque
Emitting Diode (LED) is completely controlled by the layer of the instrument cluster overlay. The dark
instrument cluster logic circuit, and that logic will outer layer of the overlay prevents the indicator from
only allow this indicator to operate when the instru- being clearly visible when it is not illuminated. An
ment cluster detects that the ignition switch is in the amber Light Emitting Diode (LED) behind the cutout
On position. Therefore, the LED will always be off in the opaque layer of the overlay causes the icon to
when the ignition switch is in any position except appear silhouetted against an amber field through
On. The LED only illuminates when it is provided a the translucent outer layer of the overlay when the
path to ground by the instrument cluster transistor. indicator is illuminated from behind by the LED,
The instrument cluster will turn on the traction con- which is soldered onto the instrument cluster elec-
trol indicator for the following reasons: tronic circuit board. The traction control malfunction
VA INSTRUMENT CLUSTER 8J - 27
TRACTION CONTROL MALFUNCTION INDICATOR (Continued)
indicator is serviced as a unit with the instrument scan tool is required. Refer to the appropriate diag-
cluster. nostic information.
OPERATION
The traction control (ASR) malfunction indicator TURN SIGNAL INDICATOR
gives the vehicle operator an indication when the
traction control system is faulty or inoperative. This DESCRIPTION
indicator is controlled by a transistor on the instru- Two turn signal indicators, one right and one left,
ment cluster circuit board based upon cluster pro- are standard equipment on all instrument clusters.
gramming and electronic messages received by the The turn signal indicators are located near the upper
cluster from the Controller Antilock Brake (CAB) edge of the instrument cluster, one to each side of the
over the Controller Area Network (CAN) data bus. speedometer. Each turn signal indicator consists of a
The traction control malfunction indicator Light arrow-shaped cutout of the International Control and
Emitting Diode (LED) is completely controlled by the Display Symbol icon for “Turn Warning” in the
instrument cluster logic circuit, and that logic will opaque layer of the instrument cluster overlay. The
only allow this indicator to operate when the instru- dark outer layer of the overlay prevents these icons
ment cluster detects that the ignition switch is in the from being clearly visible when they are not illumi-
On position. Therefore, the LED will always be off nated. A green Light Emitting Diode (LED) behind
when the ignition switch is in any position except each turn signal indicator cutout in the opaque layer
On. The LED only illuminates when it is provided a of the overlay causes the icon to appear in green
path to ground by the instrument cluster transistor. through the translucent outer layer of the overlay
The instrument cluster will turn on the traction con- when the indicator is illuminated from behind by the
trol malfunction indicator for the following reasons: LED, which is soldered onto the instrument cluster
• Bulb Test - Each time the ignition switch is electronic circuit board. The turn signal indicators
turned to the On position the traction control indica- are serviced as a unit with the instrument cluster.
tor is illuminated as a bulb test until the engine is
started. OPERATION
• Traction Control (ASR) Malfunction Indica- The turn signal indicators give an indication to the
tor Lamp-On Message - Each time the cluster vehicle operator that the turn signal (left or right
receives a traction control malfunction indicator indicator flashing) or hazard warning (both left and
lamp-on message from the CAB, the indicator will be right indicators flashing) have been selected and are
illuminated. The indicator remains illuminated until operating. These indicators are controlled by transis-
the cluster receives a lamp-off message from the tors on the instrument cluster electronic circuit board
CAB, or until the ignition switch is turned to the Off based upon the cluster programming and a hard
position, whichever occurs first. wired input received by the cluster from the turn sig-
The CAB continually monitors the traction control nal relay through the turn signal and hazard warn-
(ASR) system circuits and sensors to decide whether ing switch circuitry of the multi-function switch on
the system is in good operating condition. The CAB the left and right turn signal circuits. Each turn sig-
then sends the proper lamp-on or lamp-off messages nal indicator Light Emitting Diode (LED) is com-
to the instrument cluster. If the CAB sends a pletely controlled by the instrument cluster logic
lamp-on message after the bulb test, it indicates that circuit, and that logic will allow this indicator to
the CAB has detected a system malfunction and that operate whenever the instrument cluster receives a
the traction control (ASR) system has become inoper- battery current input on the fused B(+) circuit.
ative. The CAB will store a Diagnostic Trouble Code Therefore, each LED can be illuminated regardless of
(DTC) for any malfunction it detects. In addition, if the ignition switch position. The LED only illumi-
the traction control malfunction indicator is illumi- nates when it is provided a path to ground by the
nated, the CAB will deactivate an activated traction instrument cluster transistor. The instrument cluster
control system and engine power output may be will turn on the turn signal indicators for the follow-
reduced. See the owner’s manual in the vehicle glove ing reasons:
box for more information on the features, use, activa- • Turn Signal Input - Each time the cluster
tion and deactivation of the traction control (ASR) detects a turn signal input from the turn signal relay
system. For proper diagnosis of the traction control through the closed turn signal switch circuitry of the
system, the CAB, the CAN data bus, or the electronic multi-function switch on the hard wired left or right
message inputs to the instrument cluster that control turn signal circuit, the requested turn signal lamps
the traction control malfunction indicator, a DRBIIIt and turn signal indicator will be flashed on and off,
and a contactless relay soldered onto the cluster elec-
8J - 28 INSTRUMENT CLUSTER VA
TURN SIGNAL INDICATOR (Continued)
tronic circuit board will produce a clicking sound to through the translucent outer layer of the overlay
emulate a conventional turn signal flasher. The turn when the indicator is illuminated from behind by the
signals and the turn signal indicators continue to LED, which is soldered onto the instrument cluster
flash on and off until the turn signal switch circuitry electronic circuit board. The wait-to-start indicator is
of the multi-function switch is opened, or until the serviced as a unit with the instrument cluster.
ignition switch is turned to the Off position, which-
ever occurs first. OPERATION
• Hazard Warning Input - Each time the cluster The wait-to-start indicator gives an indication to the
detects a hazard warning input from the turn signal vehicle operator when the diesel engine glow plugs are
relay through the closed hazard warning switch cir- energized in their pre-heat operating mode. This indi-
cuitry of the multi-function switch on the hard wired cator is controlled by a transistor on the instrument
left and right turn signal circuits, all of the turn sig- cluster circuit board based upon cluster programming
nal lamps and both turn signal indicators will be and electronic messages received by the cluster from
flashed on and off, and a contactless relay soldered the Engine Control Module (ECM) over the Controller
onto the cluster electronic circuit board will produce Area Network (CAN) data bus. The wait-to-start indi-
a clicking sound to emulate a conventional hazard cator Light Emitting Diode (LED) is completely con-
warning flasher. The turn signals and the turn signal trolled by the instrument cluster logic circuit, and that
indicators continue to flash on and off until the haz- logic will only allow this indicator to operate when the
ard warning switch circuitry of the multi-function instrument cluster detects that the ignition switch is
switch is opened. in the On position. Therefore, the LED will always be
An electronic wipers, turn signals and engine start off when the ignition switch is in any position except
control module located within the fuse block beneath On. The LED only illuminates when it is provided a
the steering column monitors the turn signal circuits path to ground by the instrument cluster transistor.
and controls the flash rate of the turn signal relay. The instrument cluster will turn on the wait-to-start
The instrument cluster continually monitors the right indicator for the following reasons:
and left turn signal circuits to determine the proper • Bulb Test - Each time the ignition switch is
turn signal and hazard warning indicator operation, turned to the On position the wait-to-start indicator
then flashes the proper turn signal indicators and the is illuminated for about two seconds as a bulb test.
contactless relay on and off accordingly. The multi- • Wait-To-Start Lamp-On Message - Each time
function switch, the turn signal relay and the left and the cluster receives a wait-to-start lamp-on message
right turn signal circuits to the instrument cluster can from the ECM indicating that the diesel engine glow
be diagnosed using conventional diagnostic tools and plugs are energized in their pre-heat operating mode,
methods. For proper diagnosis of the wipers, turn sig- the wait-to-start indicator will be illuminated. The
nals and engine start control module within the fuse indicator remains illuminated until the cluster
block or the instrument cluster circuitry that controls receives a wait-to-start lamp-off message indicating
the turn signal indicators and the contactless relay, a that the pre-heat mode of the glow plugs has been
DRBIIIt scan tool is required. Refer to the appropri- completed, until the ECM detects that the engine is
ate diagnostic information. running, or until the ignition switch is turned to the
Off position, whichever occurs first.
The ECM continually monitors the engine coolant
WAIT-TO-START INDICATOR temperature sensor to determine when the glow
plugs need to be energized in their pre-heat operat-
DESCRIPTION ing mode. The ECM then sends the proper wait-to-
A wait-to-start indicator is standard equipment in start lamp-on and lamp-off messages to the
all instrument clusters. The wait-to-start indicator is instrument cluster. If the instrument cluster turns on
located near the lower edge of the instrument cluster, the indicator after the engine is started, it may indi-
to the right of the multi-function indicator display. cate that a malfunction has occurred and that the
The wait-to-start indicator consists of the Interna- engine glow control system requires service. The
tional Control and Display Symbol icon for “Diesel ECM will store a Diagnostic Trouble Code (DTC) for
Preheat” imprinted within a rectangular cutout in any malfunction it detects. For proper diagnosis of
the opaque layer of the instrument cluster overlay. the engine coolant temperature sensor, the engine
The dark outer layer of the overlay prevents the indi- glow control system and circuits, the ECM, the CAN
cator from being clearly visible when it is not illumi- data bus, or the electronic message inputs to the
nated. An amber Light Emitting Diode (LED) behind instrument cluster that control the wait-to-start indi-
the cutout in the opaque layer of the overlay causes cator, a DRBIIIt scan tool is required. Refer to the
the icon to appear silhouetted against an amber field appropriate diagnostic information.
VA INSTRUMENT CLUSTER 8J - 29
WASHER FLUID INDICATOR fluid level acceptable), or until the ignition switch is
turned to the Off position, whichever occurs first.
The instrument cluster continually monitors the
DESCRIPTION
washer fluid level switch to determine the level of the
A washer fluid indicator is standard equipment on
washer fluid. The instrument cluster logic applies a
all instrument clusters. However, this indicator is
delay strategy to this input to reduce the negative
only functional on vehicles equipped with an optional
effect that fluid sloshing within the reservoir can have
washer fluid level switch integral to the washer
on reliable indicator operation. The washer fluid level
pump/motor unit on the washer reservoir. The
switch and circuit can be diagnosed using conventional
washer fluid indicator is located near the lower edge
diagnostic tools and methods. For proper diagnosis of
of the instrument cluster, to the right of the multi-
the instrument cluster circuitry that controls the
function indicator display. The washer fluid indicator
washer fluid indicator, a DRBIIIt scan tool is required.
consists of the International Control and Display
Refer to the appropriate diagnostic information.
Symbol icon for “Windshield Washer Fluid” imprinted
within a rectangular cutout in the opaque layer of
the instrument cluster overlay. The dark outer layer WATER-IN-FUEL INDICATOR
of the overlay prevents the indicator from being
clearly visible when it is not illuminated. An amber
DESCRIPTION
Light Emitting Diode (LED) behind the cutout in the
A water-in-fuel indicator is standard equipment in
opaque layer of the overlay causes the icon to appear
all instrument clusters. The water-in-fuel indicator is
silhouetted against an amber field through the trans-
located near the lower edge of the instrument cluster,
lucent outer layer of the overlay when the indicator
to the left of the multi-function indicator display. The
is illuminated from behind by the LED, which is sol-
water-in-fuel indicator consists of the International
dered onto the instrument cluster electronic circuit
Control and Display Symbol icon for “Water In Fuel”
board. The washer fluid indicator is serviced as a
imprinted within a rectangular cutout in the opaque
unit with the instrument cluster.
layer of the instrument cluster overlay. The dark
outer layer of the overlay prevents the indicator from
OPERATION being clearly visible when it is not illuminated. An
The washer fluid indicator gives an indication to
amber Light Emitting Diode (LED) behind the cutout
the vehicle operator that the fluid level in the washer
in the opaque layer of the overlay causes the icon to
reservoir is low. This indicator is controlled by the
appear silhouetted against an amber field through
instrument cluster circuit board based upon cluster the translucent outer layer of the overlay when the
programming and a hard wired input from the indicator is illuminated from behind by the LED,
optional washer fluid level switch that is integral to
which is soldered onto the instrument cluster elec-
the washer pump/motor unit. The washer fluid indi- tronic circuit board. The water-in-fuel indicator is
cator is completely controlled by the instrument clus- serviced as a unit with the instrument cluster.
ter logic circuit, and that logic will only allow this
indicator to operate when the instrument cluster
OPERATION
detects that the ignition switch is in the On position.
The water-in-fuel indicator gives an indication to
Therefore, the indicator will always be off when the
the vehicle operator when there is excessive water
ignition switch is in any position except On. The indi-
detected in the fuel filter. This indicator is controlled
cator only illuminates when it is switched to ground
by a transistor on the instrument cluster circuit
by the instrument cluster circuitry. The instrument
board based upon the cluster programming and elec-
cluster will turn on the washer fluid indicator for the
tronic messages received by the cluster from the
following reasons:
Engine Control Module (ECM) over the Controller
• Bulb Test - Each time the ignition switch is
Area Network (CAN) data bus. The water-in-fuel
turned to the On position the brake wear indicator is
indicator Light Emitting Diode (LED) is completely
illuminated by the instrument cluster for about two
controlled by the instrument cluster logic circuit, and
seconds as a bulb test.
that logic will only allow this indicator to operate
• Washer Fluid Level Switch Input - Each time
when the instrument cluster detects that the ignition
the cluster detects ground on the washer fluid switch
switch is in the On position. Therefore, the LED will
sense circuit (washer fluid level switch closed =
always be off when the ignition switch is in any posi-
washer fluid level low) while the ignition switch is in
tion except On. The LED only illuminates when it is
the On position, the washer fluid indicator is illumi-
provided a path to ground by the instrument cluster
nated. The indicator remains illuminated until the
transistor. The instrument cluster will turn on the
washer fluid level switch input to the cluster is an
water-in-fuel indicator for the following reasons:
open circuit (washer fluid level switch open = washer
8J - 30 INSTRUMENT CLUSTER VA
WATER-IN-FUEL INDICATOR (Continued)
• Bulb Test - Each time the ignition switch is instrument cluster. If the water-in-fuel indicator
turned to the On position the water-in-fuel indicator remains illuminated with the engine running, excess
is illuminated for about seven seconds as a bulb test. water should be drained from the fuel filter. If the
• Water-In-Fuel Lamp-On Message - Each time indicator remains illuminated with the engine run-
the cluster receives a water-in-fuel lamp-on message ning after the water has been drained from the fuel
from the ECM indicating that there is excessive filter, it may indicate that a malfunction has
water in the fuel filter with the engine running, the occurred in the water-in-fuel sensor or circuits. The
water-in-fuel indicator will be illuminated. The indi- ECM will store a Diagnostic Trouble Code (DTC) for
cator remains illuminated until the cluster receives a any malfunction it detects. For proper diagnosis of
water-in-fuel lamp-off message, or until the ignition the water-in-fuel sensor and circuits, the ECM, the
switch is turned to the Off position, whichever occurs CAN data bus, or the electronic message inputs to
first. the instrument cluster that control the water-in-fuel
The ECM continually monitors the water-in-fuel indicator, a DRBIIIt scan tool is required. Refer to
sensor to determine whether there is excessive water the appropriate diagnostic information.
in the fuel filter. The ECM then sends the proper
water-in-fuel lamp-on and lamp-off messages to the
VA LAMPS 8L - 1
LAMPS
TABLE OF CONTENTS
page page
LAMPS/LIGHTING - EXTERIOR
TABLE OF CONTENTS
page page
LAMPS/LIGHTING - EXTERIOR front lamp units, the rear turn lamps that are inte-
gral to the tail lamp units, and a repeater lamp
mounted to each front fender just above the front
DESCRIPTION
wheel opening.
The exterior lighting system for this model
Other components of the exterior lighting system
includes the following exterior lamps:
for this model include:
• Backup Lamps - The backup (or reverse) lamps
• Brake Lamp Switch - A plunger-type brake
are integral to the tail lamp units mounted to the
lamp switch is located on the steering column sup-
back of the quarter panel on each side of the tailgate
port bracket under the instrument panel and actu-
at the rear of the vehicle.
ated by the brake pedal arm.
• Brake Lamps - The brake (or stop) lamps
• Daytime Running Lamp Relays - Vehicles
include a bulb and reflector that are integral to the
manufactured for sale in Canada have two Daytime
tail lamp units mounted to the back of the quarter
Running Lamps (DRL) relays. Dedicated right and
panel on each side of the tailgate opening, and the
left side relays illuminate the low beam headlamp
Center High Mounted Stop Lamp (CHMSL) that is
bulb installed in each front lamp unit whenever the
centered on the rear edge of the roof panel above the
engine is running. These relays are located in dedi-
tailgate opening.
cated vehicle wire harness connectors within the
• Daytime Running Lamps - Vehicles manufac-
driver side front seat riser.
tured for sale in Canada have a Daytime Running
• Fog Lamp Relay - Vehicles equipped with the
Lamps (DRL) relay that illuminates the low beam
optional fog lamps have a fog lamp relay located in a
headlamp bulbs whenever the engine is running.
dedicated vehicle wire harness connector within the
• Fog Lamps - Fog lamp bulbs and reflectors are
driver side front seat riser.
included in both front lamp units of vehicles
• Fog Lamp Switch - A fog lamp switch is
equipped with this option.
mounted in the instrument cluster bezel, below the
• Hazard Warning Lamps - The hazard warning
cluster and outboard of the steering column on vehi-
lamps include all of the right and left turn signal and
cles equipped with this option.
repeater lamps.
• Headlamp Leveling Motor - A headlamp lev-
• Headlamps - Separate low beam and high
eling actuator motor is located on the back of each
beam headlamp bulbs are installed in the front lamp
headlamp housing and adjusts both the low beam
unit on each side of the front grille opening. A head-
headlamp, high beam headlamp, and fog lamp (if
lamp leveling actuator motor is also integral to each
equipped) reflector frames in unison.
front lamp unit.
• Headlamp Leveling Switch - A thumbwheel
• Park Lamps - The park lamps include the front
actuated headlamp leveling switch is mounted in the
park/side marker lamps and front position lamps
instrument cluster bezel, below the cluster and out-
that are integral to the front lamp units mounted on
board of the steering column.
either side of the front grille opening, as well as the
• Multi-Function Switch - The multi-function
rear park lamps and rear side marker lamps that are
switch is located on the top of the steering column,
integral to the tail lamp units mounted to the back of
just below the steering wheel. The multi-function
the quarter panel on each side of the tailgate open-
switch is connected directly to the fuse block located
ing. Included in the park lamps circuit are two rear
below the steering column through an integral inter-
license plate lamp units mounted on the left rear
face connector. Only the left (lighting), right (wiper)
tailgate door. The park lamps may also include
control stalks and the hazard warning switch button
optional clearance lamps, which are located on each
for the multi-function switch are visible, the remain-
side of a vehicle that is so equipped.
der of the switch is concealed beneath the steering
• Turn Signal Lamps - The turn signal lamps
column shrouds. The multi-function switch includes a
include the front turn lamps that are integral to the
VA LAMPS/LIGHTING - EXTERIOR 8L - 3
LAMPS/LIGHTING - EXTERIOR (Continued)
left (lighting) control stalk and a right (wiper) control exterior lighting systems may be diagnosed and
stalk. The left control stalk is dedicated to providing tested using conventional diagnostic tools and proce-
almost all of the driver controls for the exterior light- dures. However, conventional diagnostic methods
ing system. may not prove conclusive in the diagnosis of the wip-
• Trailer Tow Connector - Vehicles equipped ers, turn signals and engine start control module
with a factory-approved, field-installed trailer towing located within the fuse block underneath the steering
electrical package have a heavy duty 7-way trailer column, the ElectroMechanical Instrument Cluster
tow connector installed in a bracket on the trailer (EMIC), the Engine Control Module (ECM), or the
hitch receiver. This package includes a 7-way to Controller Area Network (CAN) data bus network.
4-way connector adapter unit. The most reliable, efficient, and accurate means to
• Trailer Tow Control Module - Vehicles diagnose the electronic module within the fuse block,
equipped with a factory-approved, field-installed the EMIC, the ECM, and the CAN data bus network
trailer towing electrical package have a trailer tow inputs and outputs related to the various exterior
brake/turn control module located within the driver lighting systems requires the use of a DRBIIIt scan
side front seat riser that controls the brake lamp and tool. Refer to the appropriate diagnostic information.
turn signal lamp outputs to the trailer lighting cir-
cuits. BACKUP LAMPS
• Turn Signal Relay - A turn signal relay is The backup (or reverse) lamps have a path to
installed in the fuse block located on the underside of ground received at all times through the vehicle wire
the steering column behind a fuse access panel in the harness from a ground point located on the frame
steering column opening cover on the instrument near the left end of the tailgate sill. The backup
panel. The electronic circuitry of the wipers, turn sig- lamps receive battery current on the backup lamp
nals and engine start control module within the fuse supply circuit only when the backup lamp switch cir-
block controls the turn signal relay. cuit of the Transmission Range Sensor (TRS) integral
• Wipers, Turn Signals, Engine Start Control to the gear shifter assembly is closed by the gear
Module - The wipers, turn signals and engine start shifter mechanism.
control module is integral to the fuse block located on
the underside of the steering column behind a fuse BRAKE LAMPS
access panel in the steering column opening cover on The brake (or stop) lamps have a path to ground at
the instrument panel. This module includes active all times through the vehicle wire harness from a
electronic elements that control the operation of the ground point located on the frame near the left end
turn signal relay based upon inputs from the multi- of the tailgate sill. The Center High Mounted Stop
function switch and feedback from the turn signal Lamp (CHMSL) has a path to ground at all times
circuits. (Refer to 8 - ELECTRICAL/POWER DISTRI- through the vehicle wire harness from a ground point
BUTION/FUSE BLOCK - DESCRIPTION). on the left side of the dash panel. The brake lamps
Hard wired circuitry connects the exterior lighting and CHMSL receive battery current on the brake
system components to the electrical system of the lamp switch output circuit when the brake lamp
vehicle. These hard wired circuits are integral to sev- switch is closed by the brake pedal arm.
eral wire harnesses, which are routed throughout the
vehicle and retained by many different methods. DAYTIME RUNNING LAMPS
These circuits may be connected to each other, to the Vehicles manufactured for sale in Canada illumi-
vehicle electrical system and to the exterior lighting nate the low beam headlamp bulb when the engine is
system components through the use of a combination running and the exterior lamps are turned off. This
of soldered splices, splice block connectors, and many feature is enabled by the right and left Daytime Run-
different types of wire harness terminal connectors ning Lamps (DRL) relays. When the DRL relays are
and insulators. Refer to the appropriate wiring infor- de-energized, they provide fused battery current from
mation. The wiring information includes wiring dia- the circuit K26 relay to the headlamp low beams.
grams, proper wire and connector repair procedures, When the headlamps are turned On using the left
further details on wire harness routing and reten- (lighting) control stalk of the multi-function switch
tion, as well as pin-out and location views for the the DRL relays are energized, which returns control
various wire harness connectors, splices and grounds. of the headlamps to the headlamp switch circuitry of
the multi-function switch. The circuit K26 relay is
OPERATION energized by the Electro-Mechanical Instrument
Following are paragraphs that briefly describe the Cluster (EMIC) whenever it receives an electronic
operation of each of the major exterior lighting sys- message from the Engine Control Module (ECM) over
tems. The hard wired circuits and components of the the Controller Area Network (CAN) data bus indicat-
ing that the engine is running. The DRL and circuit
8L - 4 LAMPS/LIGHTING - EXTERIOR VA
LAMPS/LIGHTING - EXTERIOR (Continued)
K26 relays are installed in a relay bracket located
below the forward edge of the driver side front seat
cushion within the driver side front seat riser.
SPECIFICATIONS - LAMPS/LIGHTING -
EXTERIOR
BULB SPECIFICATIONS
LAMP BULB
Backup P21W - 12V 21W
Fig. 2 Tail Lamp Socket Plate Remove/Install
Brake & Rear Park P21/5W - 12V 21/5W
1 - SOCKET PLATE
Center High Mounted P21W - 12V 21W 2 - INNER REAR PILLAR
Stop 3 - LATCH TAB (2)
Clearance W3W - 12V 3W (4) Pull the socket plate away from the inner rear
Front Fog H1 - 12V 55W pillar far enough to access the backup lamp bulb
Front Position W5W - 12V 5W (Fig. 3).
(5) Remove the backup lamp bulb from the tail
Front Turn, Park & Side 3457 NA - 12V 28/7.5W
lamp socket plate.
Marker Amber Glass
Low Beam Headlamp H7 - 12V 55W INSTALLATION
High Beam Headlamp H1 - 12V 55W (1) Install the backup lamp bulb into the tail lamp
License Plate C5W - 12V 5W socket plate (Fig. 3).
(2) Align the socket plate with the mounting hole
Rear Side Marker R5W - 12V 5W
in the inner rear pillar.
Rear Turn P21W - 12V 21W (3) Using hand pressure, push the socket plate
Side Repeater W5W - 12V 3W gently and evenly into the inner rear pillar mounting
hole until both latch tabs are fully engaged (Fig. 2).
(4) If the vehicle is so equipped, reinstall the trim
onto the inside of the right or left rear corner pillar.
8L - 6 LAMPS/LIGHTING - EXTERIOR VA
BACKUP LAMP BULB (Continued)
ADJUSTMENTS
ADJUSTMENT
WARNING: To avoid personal injury or death, on
vehicles equipped with airbags, disable the supple-
mental restraint system before attempting any
steering wheel, steering column, airbag, seat belt
tensioner, or instrument panel component diagno-
sis or service. Disconnect and isolate the battery
negative (ground) cable, then wait two minutes for
the system capacitor to discharge before perform-
ing further diagnosis or service. This is the only
sure way to disable the supplemental restraint sys-
tem. Failure to take the proper precautions could
result in accidental airbag deployment. Fig. 6 Tail Lamp Socket Plate Remove/Install
1 - SOCKET PLATE
(1) Disconnect and isolate the battery negative 2 - INNER REAR PILLAR
cable. 3 - LATCH TAB (2)
(2) Depress and hold the brake pedal in the
depressed position until the brake lamp switch (4) Pull the socket plate away from the inner rear
adjustment is completed. pillar far enough to access the brake/park lamp bulb
(3) Pull the plunger of the brake lamp switch out- (Fig. 7).
ward from the switch body to its travel limit. (5) Remove the brake/park lamp bulb from the tail
lamp socket plate.
NOTE: Do not pull the brake pedal upwards as this
will adjust the switch plunger to an incorrect posi- INSTALLATION
tion. The switch is properly adjusted when the (1) Install the brake/park lamp bulb into the tail
switch plunger is just contacting (no gap) the brake lamp socket plate (Fig. 7).
pedal arm with the pedal in the relaxed (released) (2) Align the socket plate with the mounting hole
position. in the inner rear pillar.
8L - 8 LAMPS/LIGHTING - EXTERIOR VA
BRAKE/PARK LAMP BULB (Continued)
INSTALLATION
(1) Install the CHMSL bulb into the lamp socket
(Fig. 8).
(2) Position the lens onto the CHMSL lamp hous-
ing
(3) Install and tighten the two screws that secure
the CHMSL lamp to the vehicle.
(4) Reconnect the battery negative cable.
INSTALLATION
(1) Position the CHMSL unit close enough to the
vehicle to reconnect the lamp pigtail wire connector
to the vehicle wire harness.
(2) Position the CHMSL unit to the vehicle.
(3) Install and tighten the two screws that secure
the CHMSL unit to the vehicle (Fig. 9).
Fig. 8 CHMSL Bulb Remove/Install (4) Reconnect the battery negative cable.
1 - LAMP HOUSING
2 - BULB
INSTALLATION
(1) Position the clearance lamp unit close enough
to the vehicle to reconnect the vehicle wire harness
to the bulb holder connector receptacle (Fig. 11).
Fig. 10 Clearance Lamp Bulb Remove/Install
(2) Position the clearance lamp unit to the vehicle.
1 - LAMP HOUSING (3) Install and tighten the two screws that secure
2 - BULB HOLDER
3 - WIRE HARNESS the clearance lamp unit to the vehicle.
4 - BULB (4) Reconnect the battery negative cable.
INSTALLATION
Daytime Running Lamps (DRL) are only used in
vehicles manufactured for the Canadian market,
where this is required equipment. On vehicles
equipped with DRL, a right and a left DRL relay are
each located in a dedicated connector of the vehicle
wire harness. Each connector is snapped into an
opening in a stamped sheet metal bracket which is
secured with screws within the driver side front seat Fig. 13 Front Lamp Unit Bulbs Remove/Install
riser just beneath the seat riser cover panel. 1 - COVER RETAINER (2)
2 - BULB RETAINER (3)
3 - FOG LAMP BULB (OPTIONAL)
WARNING: To avoid personal injury or death, on 4 - COVER
vehicles equipped with airbags, disable the supple- 5 - LOW BEAM BULB
mental restraint system before attempting any 6 - POSITION BULB
7 - HIGH BEAM BULB
steering wheel, steering column, airbag, seat belt 8 - TURN/PARK/SIDE MARKER BULB
tensioner, or instrument panel component diagno- 9 - FRONT LAMP UNIT
sis or service. Disconnect and isolate the battery
negative (ground) cable, then wait two minutes for (3) Disconnect the front lamp unit wire harness
the system capacitor to discharge before perform- connector from the fog lamp bulb base (Fig. 14).
ing further diagnosis or service. This is the only (4) Disengage the two fog lamp bulb retainers by
sure way to disable the supplemental restraint sys- pushing them slightly toward the front lamp unit
tem. Failure to take the proper precautions could housing, outward to each side of the bulb base, then
result in accidental airbag deployment. pivot the retainers off of the bulb base.
(5) Remove the fog lamp bulb from the integral
(1) Position the DRL relay to the relay connector. bulb holder on the front lamp unit reflector.
VA LAMPS/LIGHTING - EXTERIOR 8L - 11
FOG LAMP BULB (Continued)
WARNING: To avoid personal injury or death, on
vehicles equipped with airbags, disable the supple-
mental restraint system before attempting any
steering wheel, steering column, airbag, seat belt
tensioner, or instrument panel component diagno-
sis or service. Disconnect and isolate the battery
negative (ground) cable, then wait two minutes for
the system capacitor to discharge before perform-
ing further diagnosis or service. This is the only
sure way to disable the supplemental restraint sys-
tem. Failure to take the proper precautions could
result in accidental airbag deployment.
INSTALLATION
(1) Position the fog lamp bulb into the integral
bulb holder on the front lamp unit reflector. Be cer-
tain that the lugs on the bulb base are engaged in
the recesses of the bulb holder (Fig. 14).
(2) Engage the two fog lamp bulb retainers by piv-
oting them over the bulb base, pressing them slightly
toward the front lamp unit housing, then inward on
each side of the bulb base.
(3) Reconnect the front lamp unit wire harness
connector to the fog lamp bulb base.
(4) Position the front lamp unit rear cover onto the
lamp housing and engage the retainers over each
side of the cover to secure it (Fig. 13). Fig. 15 Seat Riser Cover
(5) Reconnect the battery negative cable. 1 - DRIVER SEAT BACK
2 - COVER PANEL
3 - SCREW (2)
4 - SEAT RISER
FOG LAMP RELAY
(3) Remove the cover panel from the top of the
REMOVAL driver side seat riser.
Fog lamps are optional equipment on this model. (4) Remove the fog lamp relay by grasping it
On vehicles equipped with fog lamps, a fog lamp firmly and pulling it straight out of the relay connec-
relay is located in a dedicated connector of the vehi- tor.
cle wire harness. This connector is snapped into an
opening in a stamped sheet metal bracket which is INSTALLATION
secured with screws within the driver side front seat Fog lamps are optional equipment on this model.
riser just beneath the seat riser cover panel. On vehicles equipped with fog lamps, a fog lamp
relay is located in a dedicated connector of the vehi-
cle wire harness. This connector is snapped into an
opening in a stamped sheet metal bracket which is
secured with screws within the driver side front seat
riser just beneath the seat riser cover panel.
8L - 12 LAMPS/LIGHTING - EXTERIOR VA
FOG LAMP RELAY (Continued)
WARNING: To avoid personal injury or death, on (2) Remove the cluster bezel from the instrument
vehicles equipped with airbags, disable the supple- panel (Fig. 16). (Refer to 23 - BODY/INSTRUMENT
mental restraint system before attempting any PANEL/CLUSTER BEZEL - REMOVAL).
steering wheel, steering column, airbag, seat belt
tensioner, or instrument panel component diagno-
sis or service. Disconnect and isolate the battery
negative (ground) cable, then wait two minutes for
the system capacitor to discharge before perform-
ing further diagnosis or service. This is the only
sure way to disable the supplemental restraint sys-
tem. Failure to take the proper precautions could
result in accidental airbag deployment.
INSTALLATION (4) Remove the cover from the front lamp unit.
(5) From the engine compartment, disconnect the
WARNING: To avoid personal injury or death, on vehicle wire harness connector from the connector
vehicles equipped with airbags, disable the supple- receptacle for the front lamp unit.
mental restraint system before attempting any (6) Remove the four screws that secure the front
steering wheel, steering column, airbag, seat belt lamp unit to the front of the vehicle.
tensioner, or instrument panel component diagno- (7) Remove the front lamp unit from the front of
sis or service. Disconnect and isolate the battery the vehicle.
negative (ground) cable, then wait two minutes for
the system capacitor to discharge before perform- INSTALLATION
ing further diagnosis or service. This is the only (1) Position the front lamp unit to the front of the
sure way to disable the supplemental restraint sys- vehicle (Fig. 18).
tem. Failure to take the proper precautions could (2) Install and tighten the four screws that secure
result in accidental airbag deployment. the front lamp unit to the front of the vehicle.
(3) From the engine compartment, reconnect the
(1) Position the fog lamp switch to the proper vehicle wire harness connector to the connector
mounting hole on the face of the cluster bezel (Fig. receptacle for the front lamp unit.
16). (4) Position the cover to the front lamp unit.
(2) Using hand pressure, push the fog lamp switch (5) Install and tighten the two screws that secure
firmly and evenly into the switch mounting hole of the cover at the inboard side of the front lamp unit.
the cluster bezel until both of the latches on the (6) Reinstall the front grille onto the vehicle.
switch body are fully engaged. (Refer to 23 - BODY/EXTERIOR/GRILLE - INSTAL-
(3) Reinstall the cluster bezel onto the instrument LATION).
panel. (Refer to 23 - BODY/INSTRUMENT PANEL/ (7) Reconnect the battery negative cable.
CLUSTER BEZEL - INSTALLATION). (8) Check and adjust the front lamp alignment as
(4) Reconnect the battery negative cable. required. (Refer to 8 - ELECTRICAL/LAMPS/LIGHT-
ING - EXTERIOR/FRONT LAMP UNIT - ADJUST-
MENTS).
FRONT LAMP UNIT
REMOVAL ADJUSTMENTS
(1) Disconnect and isolate the battery negative
cable. ADJUSTMENT - FRONT LAMP UNIT
(2) Remove the front grille from the vehicle. (Refer
to 23 - BODY/EXTERIOR/GRILLE - REMOVAL). VEHICLE PREPARATION FOR FRONT LAMP UNIT
(3) Remove the two screws that secure the cover at ALIGNMENT
the inboard side of the front lamp unit (Fig. 18). (1) Verify headlamp dimmer (multi-function)
switch, fog lamp switch (if equipped), and high beam
indicator operation.
(2) Verify that the headlamp leveling switch is in
the “0” position.
(3) Repair or replace any faulty or damaged com-
ponents that could interfere with proper lamp align-
ment.
(4) Verify proper tire inflation.
(5) Clean front lamp unit lenses.
(6) Verify that the cargo compartment is not
heavily loaded. Vehicle should be at or near curb
weight.
(7) The fuel tank should be “Full.” Add 2.94 kilo-
Fig. 18 Front Lamp Unit Remove/Install grams (6.5 pounds) of weight over the fuel tank for
1 - SCREW (2)
each estimated gallon of missing fuel.
2 - COVER (8) Load the driver’s seat with 75 kilograms (165
3 - SCREW (4) pounds) of weight.
4 - LAMP UNIT
5 - WIRE HARNESS CONNECTOR
8L - 14 LAMPS/LIGHTING - EXTERIOR VA
FRONT LAMP UNIT (Continued)
FRONT LAMP UNIT ALIGNMENT
(1) Position the vehicle on a level surface.
(2) Turn On the headlamp low beams or the fog
lamps (if equipped).
(3) Open the hood.
(4) Set up the headlamp adjuster according to the
instructions provided by the manufacturer of the
unit.
(5) Adjust the front lamp unit reflector as required
by turning the adjustment screws in or out (Fig. 19).
Fig. 23 Position Lamp Bulb Remove/Install Fig. 24 Front Lamp Unit Bulbs Remove/Install
1 - BULB HOLDER 1 - COVER RETAINER (2)
2 - LAMP REFLECTOR 2 - BULB RETAINER (3)
3 - FOG LAMP BULB (OPTIONAL)
4 - COVER
INSTALLATION 5 - LOW BEAM BULB
(1) Install the position lamp bulb into the bulb 6 - POSITION BULB
7 - HIGH BEAM BULB
holder (Fig. 23). 8 - TURN/PARK/SIDE MARKER BULB
(2) Push the position lamp bulb holder straight 9 - FRONT LAMP UNIT
into the mounting hole in the front lamp unit reflec-
tor.
(3) Position the front lamp unit rear cover onto the
lamp housing and engage the retainers over each
side of the cover to secure it (Fig. 22).
(4) Reconnect the battery negative cable.
FRONT TURN/PARK/SIDE
MARKER LAMP BULB
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Locate the turn/park/side marker bulb holder
on the rear outboard side of the front lamp unit
housing (Fig. 24).
Fig. 25 Front Turn/Park/Side Marker Bulb Remove/
(3) Rotate the bulb holder counterclockwise about
Install
30 degrees and pull it straight out from the lamp
housing (Fig. 25). 1 - LAMP HOUSING
2 - BULB HOLDER
(4) Remove the bulb from the front turn/park/side
marker bulb holder.
INSTALLATION
(1) Install the bulb into the front turn/park/side
marker bulb holder.
(2) Insert the bulb holder straight into the front
lamp unit housing and rotate the bulb holder clock-
wise about 30 degrees to lock it into place (Fig. 25).
(3) Reconnect the battery negative cable.
8L - 16 LAMPS/LIGHTING - EXTERIOR VA
HEADLAMP LEVELING
SWITCH
REMOVAL
WARNING: To avoid personal injury or death, on
vehicles equipped with airbags, disable the supple-
mental restraint system before attempting any
steering wheel, steering column, airbag, seat belt
tensioner, or instrument panel component diagno-
sis or service. Disconnect and isolate the battery
negative (ground) cable, then wait two minutes for
the system capacitor to discharge before perform-
ing further diagnosis or service. This is the only
sure way to disable the supplemental restraint sys-
tem. Failure to take the proper precautions could Fig. 30 Headlamp Leveling Switch Remove/Install
result in accidental airbag deployment. 1 - FOG LAMP SWITCH
2 - LATCH (2)
(1) Disconnect and isolate the battery negative 3 - CLUSTER BEZEL
cable.
(2) Remove the cluster bezel from the instrument INSTALLATION
panel (Fig. 29). (Refer to 23 - BODY/INSTRUMENT
PANEL/CLUSTER BEZEL - REMOVAL). WARNING: To avoid personal injury or death, on
vehicles equipped with airbags, disable the supple-
mental restraint system before attempting any
steering wheel, steering column, airbag, seat belt
tensioner, or instrument panel component diagno-
sis or service. Disconnect and isolate the battery
negative (ground) cable, then wait two minutes for
the system capacitor to discharge before perform-
ing further diagnosis or service. This is the only
sure way to disable the supplemental restraint sys-
tem. Failure to take the proper precautions could
result in accidental airbag deployment.
INSTALLATION
(1) Position the high beam headlamp bulb into the
integral bulb holder on the front lamp unit reflector.
Be certain that the lugs on the bulb base are
engaged in the recesses of the bulb holder (Fig. 31).
(2) Engage the high beam headlamp bulb retainer
by pivoting it over the bulb base, pressing it slightly
outward from the bulb base and toward the front
lamp unit housing, then inward toward the side of
the bulb base.
(3) Reconnect the front lamp unit wire harness
connector to the high beam headlamp bulb base.
(4) Position the front lamp unit rear cover onto the
lamp housing and engage the retainers over each
side of the cover to secure it (Fig. 13).
(5) Reconnect the battery negative cable.
Fig. 31 Front Lamp Unit Bulbs Remove/Install
1 - COVER RETAINER (2)
2
3
-
-
BULB RETAINER (3)
FOG LAMP BULB (OPTIONAL)
LICENSE PLATE LAMP BULB
4 - COVER
5 - LOW BEAM BULB REMOVAL
6 - POSITION BULB
7 - HIGH BEAM BULB
(1) Disconnect and isolate the battery negative
8 - TURN/PARK/SIDE MARKER BULB cable.
9 - FRONT LAMP UNIT (2) Remove the license plate lamp unit from its
mounting location, but do not disconnect it from the
(3) Disconnect the front lamp unit wire harness vehicle wire harness. (Refer to 8 - ELECTRICAL/
connector from the high beam headlamp bulb base LAMPS/LIGHTING - EXTERIOR/LICENSE PLATE
(Fig. 32). LAMP UNIT - REMOVAL).
(3) Remove the cover from the back of the lamp
housing (Fig. 33).
(4) Disengage the high beam headlamp bulb Fig. 33 License Plate Lamp Bulb Remove/Install
retainer by pushing it slightly toward the front lamp 1 - COVER
unit housing and outward from the bulb base, then 2 - BULB
pivot the retainer off of the bulb base. 3 - BULB HOLDER (2)
4 - WIRE HARNESS CONNECTOR (1 or 2)
(5) Remove the high beam headlamp bulb from the
integral bulb holder on the front lamp unit reflector.
VA LAMPS/LIGHTING - EXTERIOR 8L - 19
LICENSE PLATE LAMP BULB (Continued)
(4) Grasp the lamp housing firmly in one hand, (3) Engage the left side of the license plate lamp
then disengage the bulb from between the bulb hold- unit into the left side of the mounting hole.
ers with the other hand. (4) Using hand pressure, press the right side of
the license plate lamp housing toward the left
INSTALLATION against the spring pressure of the retaining clip, then
(1) Grasp the license plate lamp housing firmly in push the right side of the lamp upward to engage it
one hand, then engage the bulb between the bulb into the right side of the mounting hole.
holders with the other hand (Fig. 33). (5) Reconnect the battery negative cable.
(2) Reinstall the cover onto the back of the lamp
housing.
(3) Reinstall the license plate lamp unit to its LOW BEAM HEADLAMP BULB
mounting location. (Refer to 8 - ELECTRICAL/
LAMPS/LIGHTING - EXTERIOR/LICENSE PLATE REMOVAL
LAMP UNIT - INSTALLATION). (1) Disconnect and isolate the battery negative
(4) Reconnect the battery negative cable. cable.
(2) Disengage and swing the retainers that secure
the front lamp unit rear cover to each side of the
LICENSE PLATE LAMP UNIT lamp housing and remove the cover (Fig. 35).
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Using hand pressure, press the right side of
the license plate lamp housing toward the left
against the spring pressure of the retaining clip, then
pull the right side of the lamp downward to disen-
gage it from the mounting hole (Fig. 34).
REMOVAL (6) Remove the upper shroud from the top of the
multi-function switch.
WARNING: To avoid personal injury or death, on
(7) Remove the two screws that secure the multi-
vehicles equipped with airbags, disable the supple-
function switch to the steering column.
mental restraint system before attempting any
(8) Remove the multi-function switch from the
steering wheel, steering column, airbag, seat belt
steering column.
tensioner, or instrument panel component diagno-
(9) Remove the speed control switch from the back
sis or service. Disconnect and isolate the battery
of the multi-function switch. (Refer to 8 - ELECTRI-
negative (ground) cable, then wait two minutes for
CAL/SPEED CONTROL/SWITCH - REMOVAL).
the system capacitor to discharge before perform-
ing further diagnosis or service. This is the only
sure way to disable the supplemental restraint sys-
tem. Failure to take the proper precautions could
result in accidental airbag deployment.
VA LAMPS/LIGHTING - EXTERIOR 8L - 21
MULTI-FUNCTION SWITCH (Continued)
INSTALLATION
WARNING: To avoid personal injury or death, on
vehicles equipped with airbags, disable the supple-
mental restraint system before attempting any
steering wheel, steering column, airbag, seat belt
tensioner, or instrument panel component diagno-
sis or service. Disconnect and isolate the battery
negative (ground) cable, then wait two minutes for
the system capacitor to discharge before perform-
ing further diagnosis or service. This is the only
sure way to disable the supplemental restraint sys-
tem. Failure to take the proper precautions could
result in accidental airbag deployment.
(4) Pull the socket plate away from the inner rear
Fig. 40 Tail Lamp Bulb Remove/Install pillar far enough to access the turn signal lamp bulb
1 - BRAKE/PARK LAMP BULB (Fig. 42).
2 - BACKUP LAMP BULB (5) Remove the turn signal lamp bulb from the tail
3 - TURN SIGNAL LAMP BULB lamp socket plate.
4 - SIDE MARKER LAMP BULB
5 - TAIL LAMP SOCKET PLATE
INSTALLATION
INSTALLATION (1) Install the turn signal lamp bulb into the tail
(1) Install the side marker lamp bulb into the tail lamp socket plate (Fig. 42).
lamp socket plate (Fig. 40). (2) Align the socket plate with the mounting hole
(2) Align the socket plate with the mounting hole in the inner rear pillar.
in the inner rear pillar. (3) Using hand pressure, push the socket plate
(3) Using hand pressure, push the socket plate gently and evenly into the inner rear pillar mounting
gently and evenly into the inner rear pillar mounting hole until both latch tabs are fully engaged (Fig. 41).
hole until both latch tabs are fully engaged (Fig. 39). (4) If the vehicle is so equipped, reinstall the trim
(4) If the vehicle is so equipped, reinstall the trim onto the inside of the right or left rear corner pillar.
onto the inside of the right or left rear corner pillar. (5) Reconnect the battery negative cable.
(5) Reconnect the battery negative cable.
VA LAMPS/LIGHTING - EXTERIOR 8L - 23
REAR TURN LAMP BULB (Continued)
Fig. 45 Small Repeater Lamp Unit Remove/Install Fig. 46 Large Repeater Lamp Unit Remove/Install
1 - LAMP HOUSING 1 - LAMP HOUSING
2 - BULB HOLDER 2 - BULB
3 - BULB 3 - LENS
4 - SCREW
(4) Disconnect the vehicle wire harness connector
from the connector receptacle of the bulb holder on clip, then push the rear edge of the lamp into the
the back of the repeater lamp unit. rear of the mounting hole.
(5) Remove the repeater lamp unit from the vehi- (5) Reconnect the battery negative cable.
cle.
LARGE
LARGE (1) Position the repeater lamp unit near the
(1) Disconnect and isolate the battery negative mounting hole on the fender panel (Fig. 46).
cable. (2) Reconnect the vehicle wire harness connector
(2) Remove the screw that secures the lens and to the connector receptacle on the back of the
the repeater lamp housing to the fender panel (Fig. repeater lamp unit.
46). (3) Position the repeater lamp lens and housing to
(3) Pull the repeater lamp lens and housing out- the mounting hole as a unit.
ward to disengage the unit from the mounting hole. (4) Install and tighten the screw that secures the
(4) Disconnect the vehicle wire harness connector lens and the repeater lamp housing to the fender
from the connector receptacle on the back of the panel.
repeater lamp unit. (5) Reconnect the battery negative cable.
(5) Remove the repeater lamp unit from the vehi-
cle.
TAIL LAMP UNIT
INSTALLATION
REMOVAL
SMALL (1) Disconnect and isolate the battery negative
(1) Position the repeater lamp unit to the mount- cable.
ing hole on the fender panel (Fig. 45). (2) If the vehicle is so equipped, remove the trim
(2) Reconnect the vehicle wire harness connector from the inside of the right or left rear corner pillar.
to the connector receptacle of the bulb holder on the (3) From inside the vehicle, use hand pressure to
back of the repeater lamp unit. push the two latch tabs toward the center of the tail
(3) Engage the front edge of the repeater lamp lamp unit socket plate and pull the socket plate
unit into the front edge of the mounting hole. straight out from the inner rear pillar (Fig. 47).
(4) Using hand pressure, press the rear edge of the (4) Pull the socket plate away from the inner rear
repeater lamp lens/housing toward the front of the pillar far enough to access the tail lamp unit mount-
vehicle against the spring pressure of the retaining ing nuts (Fig. 48).
VA LAMPS/LIGHTING - EXTERIOR 8L - 25
TAIL LAMP UNIT (Continued)
(2) From the inside of the vehicle, install and
tighten the four nuts that secure the tail lamp unit
housing to the vehicle.
(3) Align the socket plate with the mounting hole
in the inner rear pillar.
(4) Using hand pressure, push the socket plate
gently and evenly into the inner rear pillar mounting
hole until both latch tabs are fully engaged.
(5) If the vehicle is so equipped, reinstall the trim
onto the inside of the right or left rear corner pillar.
(6) Reconnect the battery negative cable.
LAMPS/LIGHTING - INTERIOR
TABLE OF CONTENTS
page page
ASH RECEIVER/CIGAR damaged, the entire ash receiver housing and cigar
lighter receptacle unit must be replaced. (Refer to 23
LIGHTER LAMP UNIT - BODY/INSTRUMENT PANEL/ASH RECEIVER -
INSTALLATION).
REMOVAL
CARGO/DOME LAMP BULB
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the cargo/dome lamp unit from its
mounting location, but do not disconnect the vehicle
wire harness from the lamp connector receptacle.
(Refer to 8 - ELECTRICAL/LAMPS/LIGHTING -
INTERIOR/CARGO/DOME LAMP UNIT -
REMOVAL).
(3) Grasp the lamp housing in one hand and care-
fully pull the bulb out of the bulb holder with the
other hand (Fig. 2).
INSTALLATION - BULKHEAD
(1) From the front of the switch bezel, align the
cargo lamp switch body with the opening in the bezel
and push the switch into the bezel until the two
latches on the outside of the switch body snap into Fig. 5 Dome/Reading Lamp Bulb Remove/Install
place. 1 - LAMP HOUSING
(2) Reconnect the vehicle wire harness connector 2 - CONNECTOR RECEPTACLE
3 - BULB (2)
for the cargo lamp switch to the receptacle on the
back of the switch.
(3) Using hand pressure, firmly and evenly press INSTALLATION
the cargo lamp switch and switch bezel into the (1) Grasp the dome/reading lamp housing in one
switch box on the back of the cargo compartment hand and carefully insert the bulb into the bulb
bulkhead panel. holder with the other hand (Fig. 5).
(4) Reconnect the battery negative cable. (2) Reinstall the dome/reading lamp unit into its
mounting location. (Refer to 8 - ELECTRICAL/
INSTALLATION - REAR PILLAR LAMPS/LIGHTING - INTERIOR/DOME/READING
(1) From the front of the switch bezel, align the LAMP UNIT - INSTALLATION).
cargo lamp switch body with the opening in the bezel (3) Reconnect the battery negative cable.
and push the switch into the bezel until the two
latches on the outside of the switch body snap into
place.
DOME/READING LAMP UNIT
(2) Reconnect the vehicle wire harness connector
for the cargo lamp switch to the receptacle on the
REMOVAL
back of the switch. (1) Disconnect and isolate the battery negative
(3) Using hand pressure, firmly and evenly press cable.
the cargo lamp switch and switch bezel into the (2) Insert the tip of a small flat-bladed screwdriver
switch mounting hole on the inside of the rear door into the notch on one edge of the dome/reading lamp
opening pillar. housing to depress the retainer clip and pull that
(4) Reconnect the battery negative cable. edge of the lamp away from its mounting location
(Fig. 6).
8L - 32 LAMPS/LIGHTING - INTERIOR VA
DOME/READING LAMP UNIT (Continued)
INSTALLATION
(1) Position the door jamb switch close enough to
the mounting hole in the hinge pillar of the door
opening to reconnect the vehicle wire harness connec-
tor to the back of the switch.
(2) Position the door jamb switch into the mount-
ing hole in the hinge pillar (Fig. 9).
(3) Install and tighten the screw that secures the
door jamb switch to the hinge pillar.
Fig. 8 Dome Lamp/Intrusion Sensor Unit Remove/ (4) Reconnect the battery negative cable.
Install
1 - NOTCH
2
3
-
-
SENSOR (3)
HOUSING
ENTRY/EXIT LAMP BULB
4 - SWITCH (2)
REMOVAL
(3) Position the edge of the dome lamp/intrusion (1) Disconnect and isolate the battery negative
sensor unit housing opposite from the retainer clip cable.
into the mounting hole. (2) Remove the entry/exit lamp unit from its
(4) Push firmly and evenly on the notched edge of mounting location. (Refer to 8 - ELECTRICAL/
the dome lamp/intrusion sensor unit housing until LAMPS/LIGHTING - INTERIOR/ENTRY/EXIT
the retainer clip latches into place. LAMP UNIT - REMOVAL).
(5) Reconnect the battery negative cable. (3) Grasp the lamp housing firmly in one hand,
then rotate the bulb holder counterclockwise and pull
it straight out from the housing with the other hand
DOOR JAMB SWITCH (Fig. 10).
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Open the door and remove the screw that
secures the door jamb switch to the hinge pillar of
the door opening (Fig. 9).
INSTALLATION
(1) Insert the bulb into the entry/exit lamp bulb
holder (Fig. 10).
(2) Grasp the entry/exit lamp housing firmly in
one hand, then insert the bulb holder into the hous-
ing and rotate it clockwise to lock it in place with the
Fig. 9 Door Jamb Switch Remove/Install
other hand.
1 - DOOR JAMB SWITCH
2 - PLUNGER (3) Reinstall the entry/exit lamp unit into its
3 - PILLAR mounting location. (Refer to 8 - ELECTRICAL/
4 - SCREW LAMPS/LIGHTING - INTERIOR/ENTRY/EXIT
LAMP UNIT - INSTALLATION).
(3) Pull the door jamb switch away from the (4) Reconnect the battery negative cable.
mounting hole in the pillar far enough to access and
disconnect the vehicle wire harness connector from
the back of the switch.
8L - 34 LAMPS/LIGHTING - INTERIOR VA
INSTALLATION
(1) Position the entry/exit lamp unit to its mount-
ing location.
(2) Reconnect the vehicle wire harness connector
to the entry/exit lamp connector receptacle (Fig. 11).
(3) Position the edge of the entry/exit lamp hous-
ing opposite from the retainer clip into the mounting
hole.
(4) Push firmly and evenly on the notched edge of
the entry/exit lamp housing until the retainer clip
latches into place. Fig. 12 Seat Riser Cover
(5) Reconnect the battery negative cable. 1 - DRIVER SEAT BACK
2 - COVER PANEL
3 - SCREW (2)
4 - SEAT RISER
INSTALLATION (3) Push firmly and evenly on the top of the time
delay relay until the terminals are fully seated in the
WARNING: To avoid personal injury or death, on terminal cavities in the vehicle wire harness connec-
vehicles equipped with airbags, disable the supple- tor.
mental restraint system before attempting any (4) Position the cover panel onto the top of the
steering wheel, steering column, airbag, seat belt driver side seat riser (Fig. 12).
tensioner, or instrument panel component diagno- (5) Install and tighten the two screws that secure
sis or service. Disconnect and isolate the battery the cover panel to the top of the seat riser under the
negative (ground) cable, then wait two minutes for driver side front seat. Tighten the screws to 2 N·m
the system capacitor to discharge before perform- (18 in. lbs.).
ing further diagnosis or service. This is the only (6) Move the driver side front seat back to its driv-
sure way to disable the supplemental restraint sys- ing position.
tem. Failure to take the proper precautions could (7) Reconnect the battery negative cable.
result in accidental airbag deployment.
POWER SYSTEMS
TABLE OF CONTENTS
page page
POWER LOCKS
TABLE OF CONTENTS
page page
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the instrument panel center bezel
(Refer to 23 - BODY/INSTRUMENT PANEL/IN-
STRUMENT PANEL CENTER BEZEL - REMOVAL).
POWER MIRRORS
TABLE OF CONTENTS
page page
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the door handle trim.
(3) Remove the mirror switch/power window
switch trim (Fig. 2).
(4) Disconnect the electrical wire harness and
remove switch.
POWER WINDOWS
TABLE OF CONTENTS
page page
OPERATION
WINDOW SWITCH
The power window switches control the battery
and ground feeds to the power window motors. The
passenger door power window switches receive their
battery and ground feeds through the circuitry of the
drivers window switch.
WINDOW MOTOR
Window motors use permanent type magnets. The
B+ and ground applied at the motor terminal pins
will cause the motor to rotate in one direction.
Reversing current through the motor terminals will
Fig. 1 POWER WINDOW SWITCH
cause the motor to rotate in the opposite direction.
Refer to the appropriate wiring information. The
wiring information includes wiring diagrams, proper POWER WINDOW SWITCH CONTINUITY
wire and connector repair procedures, details of wire CHART
harness routing and retention, connector pin-out
information and location views for the various wire SWITCH POSITION CONTINUITY BETWEEN
harness connectors, splices and grounds.
UP PIN 1 AND 3
PIN 2 AND 4
WINDOW MOTOR DOWN PIN 1 AND 4
PIN 2 AND 5
REMOVAL
The window motor is serviced with the window NEUTRAL (OFF) PIN 1AND 3
regulator. PIN 2 AND 5
8N - 6 POWER WINDOWS VA
POWER WINDOW SWITCH (Continued)
REMOVAL INSTALLATION
(1) Disconnect and isolate the battery negative (1) Install switch to trim.
cable. (2) Connect wire harness connectors to switches.
(2) Remove door handle cover. (3) Install power window switch trim to door trim
(3) Remove power window switch trim from door panel.
trim panel. (4) Install door handle cover.
(4) disconnect wire harness connectors from (5) Connect battery negative cable.
switches.
(5) Remove power window switch from trim.
VA RESTRAINTS 8O - 1
RESTRAINTS
TABLE OF CONTENTS
page page
RESTRAINTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 22
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1 PASSENGER AIRBAG
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 22
WARNING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
WARNINGS - RESTRAINT SYSTEM . . . . . . . . 5 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
DIAGNOSIS AND TESTING - SUPPLEMENTAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24
RESTRAINT SYSTEM . . . . . . . . . . . . . . . . . . . 5 PASSENGER AIRBAG BRACKET
STANDARD PROCEDURE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
STANDARD PROCEDURE - HANDLING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 26
NON-DEPLOYED SUPPLEMENTAL REAR SEAT BELT & RETRACTOR
RESTRAINTS . . . . . . . . . . . . . . . . . . . . . . . . . 6 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
STANDARD PROCEDURE - SERVICE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 28
AFTER A SUPPLEMENTAL RESTRAINT REAR SEAT BELT BUCKLE
DEPLOYMENT. . . . . . . . . . . . . . . . . . . . . . . . . 6 REMOVAL
STANDARD PROCEDURE - VERIFICATION REMOVAL - INBOARD . . . . . . . . . . . . . . . . . . 28
TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 REMOVAL - OUTBOARD . . . . . . . . . . . . . . . . 29
AIRBAG CONTROL MODULE INSTALLATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8 INSTALLATION - INBOARD . . . . . . . . . . . . . . 29
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 INSTALLATION - OUTBOARD . . . . . . . . . . . . 30
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 SEAT BELT SWITCH
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 30
CLOCKSPRING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 12 SEAT BELT TENSIONER
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 30
STANDARD PROCEDURE - CLOCKSPRING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
CENTERING . . . . . . . . . . . . . . . . . . . . . . . . . 13 SEAT BELT TURNING LOOP ADJUSTER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 33
DRIVER AIRBAG SIDE CURTAIN AIRBAG
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 16 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 33
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 36
FRONT SEAT BELT & RETRACTOR SIDE IMPACT SENSOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 37
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
FRONT SEAT BELT BUCKLE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 38
ACTIVE RESTRAINTS switch that detects whether its seat belt has been
The active restraints for this model include: fastened.
• Front Seat Belts - Both outboard front seating • Rear Seat Belts - All rear seating positions are
positions are equipped with three-point seat belt sys- equipped with three-point seat belt systems. Each
tems employing a lower B-pillar mounted inertia rear seating position belt employs an integral seat
latch-type retractors, height-adjustable upper B-pil- cushion frame mounted inertia latch-type retractor, a
lar mounted turning loops, travelling lower seat belt fixed position upper seat back frame mounted turn-
anchors secured to the outboard seat tracks, and ing loop, and a fixed lower seat belt anchor secured
travelling end-release seat belt buckles secured to to the seat cushion frame. All rear seat belts have
the inboard seat track. The driver side front seat belt fixed end-release seat belt buckles that are also
buckle of all models includes an integral seat belt secured to the seat cushion frame.
VA RESTRAINTS 8O - 3
RESTRAINTS (Continued)
PASSIVE RESTRAINTS • Driver Knee Blocker - The structure of the
A Next Generation driver airbag is standard facto- lower instrument panel serves as a knee blocker for
ry-installed safety equipment on this model, while a the driver.
passenger side front airbag and side curtain airbags • Passenger Airbag - The optional passenger air-
are optional. This airbag system is a passive, inflat- bag is located within the instrument panel, behind
able, Supplemental Restraint System (SRS) and vehi- the passenger airbag door on the instrument panel
cles with this equipment can be readily identified by above the glove box on the passenger side of the vehi-
the “SRS - AIRBAG” logo molded into the driver air- cle.
bag trim cover in the center of the steering wheel • Passenger Knee Blocker - The structure of
and, if the vehicle is so equipped, also into the pas- the glove box door and the lower instrument panel
senger airbag door on the instrument panel above serve as a knee blocker for the front seat passenger.
the glove box (Fig. 2). Vehicles with the airbag sys- • Seat Belt Tensioner - A seat belt tensioner is
tem can also be identified by the airbag indicator, integral to the driver side front seat belt retractor
which will illuminate in the instrument cluster for unit, and to the passenger side front seat belt retrac-
about six seconds as a bulb test each time the igni- tor unit on vehicles equipped with an optional pas-
tion switch is turned to the On position. A pyrotech- senger airbag.
nic-type seat belt tensioner is integral to the front • Side Curtain Airbags - Optional side curtain
seat belt retractor mounted on the lower B-pillar on airbags are available for this model when it is also
the driver side, and to the passenger side retractor of equipped with dual front airbags. In vehicles
vehicles equipped with the optional passenger side equipped with this option, a side curtain airbag is
airbag. located on the inside of the roof side rail within a
garnish molding that extends from the A-pillar to the
B-pillar above each front door opening within the
passenger compartment of the vehicle.
• Side Impact Sensor - Two side impact sensors
are used on vehicles equipped with the optional side
curtain airbags, one on each side of the vehicle. One
sensor is located near the front of each front door
step well, concealed behind the step well trim.
The ACM contains a central processing unit and
programming that allows it to communicate on a
serial data bus diagnostic circuit connected to the
16-way Data Link Connector (DLC) located below the
left end of the instrument panel. This method of com-
munication is used for initialization of the ACM and
for diagnosis of the SRS circuits and components
using a DRBIIIt scan tool.
Hard wired circuitry connects the supplemental
Fig. 2 SRS Logo restraint system components to each other through
The supplemental restraint system includes the the electrical system of the vehicle. These hard wired
following major components, which are described in circuits are integral to several wire harnesses, which
further detail elsewhere in this service information: are routed throughout the vehicle and retained by
• Airbag Control Module - The Airbag Control many different methods. These circuits may be con-
Module (ACM) is located on a mount on the floor nected to each other, to the vehicle electrical system,
panel within the driver side seat riser, beneath the and to the supplemental restraint system compo-
driver seat in the passenger compartment. nents through the use of a combination of soldered
• Airbag (SRS) Indicator - The airbag indicator splices, splice block connectors, and many different
is integral to the ElectroMechanical Instrument Clus- types of wire harness terminal connectors and insu-
ter (EMIC), which is located on the instrument panel lators. Refer to the appropriate wiring information.
in front of the driver. The wiring information includes wiring diagrams,
• Clockspring - The clockspring is located near proper wire and connector repair procedures, further
the top of the steering column, directly beneath the details on wire harness routing and retention, as well
steering wheel. as pin-out and location views for the various wire
• Driver Airbag - The driver airbag is located in harness connectors, splices and grounds.
the center of the steering wheel, beneath the driver
airbag trim cover.
8O - 4 RESTRAINTS VA
RESTRAINTS (Continued)
STANDARD PROCEDURE ger airbags and must also be replaced if either front
airbag has been deployed. These components are not
STANDARD PROCEDURE - HANDLING intended for reuse and will be damaged or weakened
as a result of a supplemental restraint deployment,
NON-DEPLOYED SUPPLEMENTAL RESTRAINTS which may or may not be obvious during a visual
At no time should any source of electricity be per- inspection.
mitted near the inflator on the back of a non-de- It is also critical that the mounting surfaces and/or
ployed airbag or seat belt tensioner. When carrying a mounting brackets for the Airbag Control Module
non-deployed airbag, the trim cover or airbag cushion (ACM) and the side impact sensors be closely
side of the unit should be pointed away from the inspected and restored to their original conditions fol-
body to minimize injury in the event of an accidental lowing any vehicle impact damage. Because the ACM
deployment. If the airbag unit is placed on a bench or and each impact sensor are used by the supplemental
any other surface, the trim cover or airbag cushion restraint system to monitor or confirm the direction
side of the unit should be face up to minimize move- and severity of a vehicle impact, improper orientation
ment in the event of an accidental deployment. When or insecure fastening of these components may cause
handling a non-deployed seat belt tensioner, take airbags not to deploy when required, or to deploy
proper care to keep fingers out from under the when not required.
retractor cover and away from the seat belt webbing All other vehicle components should be closely
where it exits from the retractor cover. In addition, inspected following any supplemental restraint
the supplemental restraint system should be dis- deployment, but are to be replaced only as required
armed whenever any steering wheel, steering col- by the extent of the visible damage incurred.
umn, seat belt tensioner, airbag, impact sensor, or
instrument panel components require diagnosis or CLEANUP PROCEDURE
service. Failure to observe this warning could result Following a supplemental restraint deployment,
in accidental deployment and possible personal the vehicle interior will contain a powdery residue.
injury. This residue consists primarily of harmless particu-
All damaged, faulty or non-deployed airbags and late by-products of the small pyrotechnic charge that
seat belt tensioners which are replaced on vehicles initiates the propellant used to deploy a supplemen-
are to be handled and disposed of properly. If an air- tal restraint. However, this residue may also contain
bag or seat belt tensioner unit is faulty or damaged traces of sodium hydroxide powder, a chemical
and non-deployed, refer to the Hazardous Substance by-product of the propellant material that is used to
Control System for proper disposal. Dispose of all generate the inert gas that inflates the airbag. Since
non-deployed and deployed airbags and seat belt ten- sodium hydroxide powder can irritate the skin, eyes,
sioners in a manner consistent with state, provincial, nose, or throat, be certain to wear safety glasses,
local and federal regulations. rubber gloves, and a long-sleeved shirt during
cleanup (Fig. 3).
SUPPLEMENTAL RESTRAINT STORAGE
Airbags and seat belt tensioners must be stored in
their original, special container until they are used
for service. Also, they must be stored in a clean, dry
environment; away from sources of extreme heat,
sparks, and high electrical energy. Always place or
store any airbag on a surface with its trim cover or
airbag cushion side facing up, to minimize movement
in case of an accidental deployment.
REMOVAL
WARNING: To avoid personal injury or death, on Fig. 8 Airbag Control Module Location
vehicles equipped with airbags, disable the supple- 1 - DRIVER SEAT
mental restraint system before attempting any 2 - AIRBAG CONTROL MODULE
steering wheel, steering column, airbag, seat belt 3 - SEAT RISER
tensioner, impact sensor, or instrument panel com-
ponent diagnosis or service. Disconnect and isolate
the battery negative (ground) cable, then wait two
minutes for the system capacitor to discharge
before performing further diagnosis or service. This
is the only sure way to disable the supplemental
restraint system. Failure to take the proper precau-
tions could result in accidental airbag deployment.
(1) Disconnect and isolate the battery negative (4) Remove the cover panel from the top of the
cable. Wait two minutes for the system capacitor to driver side seat riser.
discharge before further service. (5) Remove the two screws that secure the control
(2) Move the driver side front seat to its most for- module bracket to the top of the seat riser under the
ward position for easiest access to the seat riser driver side front seat (Fig. 10).
cover panel (Fig. 8). (6) Remove the control module bracket from the
(3) Remove the two screws that secure the cover top of the driver side seat riser.
panel to the top of the seat riser under the driver
side front seat (Fig. 9).
VA RESTRAINTS 8O - 11
AIRBAG CONTROL MODULE (Continued)
CLOCKSPRING
DESCRIPTION
Fig. 13 ACM Cover Base Plate
1 - BASE PLATE
2 - SEAT RISER
3 - GROUND EYELET TERMINAL
4 - ACM CONNECTOR
5 - FLOOR PANEL
OPERATION
Fig. 18 Driver Airbag Trim Cover The driver airbag is deployed by electrical signals
1 - STEERING WHEEL generated by the Airbag Control Module (ACM)
2 - TRIM COVER
through the driver airbag squib circuit to the initia-
The color-keyed, injection molded, thermoplastic tor in the airbag inflator (Fig. 20). When the ACM
driver airbag protective trim cover is the most visible sends the proper electrical signal to the initiator the
part of the driver airbag (Fig. 18). The driver airbag electrical energy generates enough heat to initiate a
is located in the center of the steering wheel, where small pyrotechnic charge which, in turn, ignites
it is secured with two screws to the armature of the chemical pellets within the inflator. Once ignited,
horn switch within the hub cavity of the four-spoke these chemical pellets burn rapidly and produce a
steering wheel. Concealed beneath the driver airbag large quantity of inert gas. The inflator is sealed to
trim cover are the folded airbag cushion, the airbag the back of the airbag housing and a diffuser in the
cushion retainer, the airbag housing, the airbag infla- inflator directs all of the inert gas into the airbag
cushion, causing the cushion to inflate. As the cush-
VA RESTRAINTS 8O - 17
DRIVER AIRBAG (Continued)
REMOVAL
The following procedure is for replacement of a
faulty or damaged driver airbag. If the airbag is
faulty or damaged, but not deployed, review the rec-
ommended procedures for handling non-deployed
supplemental restraints. (Refer to 8 - ELECTRICAL/
RESTRAINTS - STANDARD PROCEDURE - HAN-
DLING NON-DEPLOYED SUPPLEMENTAL
RESTRAINTS). If the driver airbag has been
deployed, review the recommended procedures for
service after a supplemental restraint deployment
before removing the airbag from the vehicle. (Refer to
8 - ELECTRICAL/RESTRAINTS - STANDARD PRO-
CEDURE - SERVICE AFTER A SUPPLEMENTAL
RESTRAINT DEPLOYMENT).
(4) The clockspring driver airbag pigtail wire con- tensioner, impact sensor, or instrument panel com-
nector is a tight snap-fit into the airbag inflator con- ponent diagnosis or service. Disconnect and isolate
nector receptacle, which is located on the back of the the battery negative (ground) cable, then wait two
driver airbag housing. Firmly grasp and pull or gen- minutes for the system capacitor to discharge
tly pry on the connector insulator and pull the con- before performing further diagnosis or service. This
nector straight out from the airbag inflator to is the only sure way to disable the supplemental
disconnect it from the connector receptacle. restraint system. Failure to take the proper precau-
(5) Remove the driver airbag from the steering tions could result in accidental airbag deployment.
wheel.
(6) If the driver airbag has been deployed, the WARNING: To avoid personal injury or death, use
clockspring and the steering wheel must also be extreme care to prevent any foreign material from
replaced. (Refer to 8 - ELECTRICAL/RESTRAINTS/ entering the driver airbag, or becoming entrapped
CLOCKSPRING - REMOVAL) and (Refer to 19 - between the driver airbag cushion and the driver
STEERING/COLUMN/STEERING WHEEL - airbag trim cover. Failure to observe this warning
REMOVAL). could result in occupant injuries upon airbag
deployment.
INSTALLATION
The following procedure is for replacement of a WARNING: To avoid personal injury or death, the
faulty or damaged driver airbag. If the airbag is driver airbag trim cover must never be painted.
faulty or damaged, but not deployed, review the rec- Replacement airbags are serviced with trim covers
ommended procedures for handling non-deployed in the original colors. Paint may change the way in
supplemental restraints. (Refer to 8 - ELECTRICAL/ which the material of the trim cover responds to an
RESTRAINTS - STANDARD PROCEDURE - HAN- airbag deployment. Failure to observe this warning
DLING NON-DEPLOYED SUPPLEMENTAL could result in occupant injuries upon airbag
RESTRAINTS). If the driver airbag has been deployment.
deployed, review the recommended procedures for
service after a supplemental restraint deployment (1) Position the driver airbag close enough to the
before removing the airbag from the vehicle. (Refer to steering wheel to reconnect the clockspring driver
8 - ELECTRICAL/RESTRAINTS - STANDARD PRO- airbag pigtail wire connector at the back of the air-
CEDURE - SERVICE AFTER A SUPPLEMENTAL bag housing.
RESTRAINT DEPLOYMENT). (2) When installing the driver airbag, reconnect
the clockspring driver airbag pigtail wire connector
WARNING: To avoid personal injury or death, on to the airbag inflator connector receptacle by press-
vehicles equipped with airbags, disable the supple- ing straight in on the connector (Fig. 21). You can be
mental restraint system before attempting any certain that the connector is fully engaged by listen-
steering wheel, steering column, airbag, seat belt
VA RESTRAINTS 8O - 19
DRIVER AIRBAG (Continued)
ing carefully for a distinct, audible click as the con- restraint system. Failure to take the proper precau-
nector snaps into place. tions could result in accidental airbag deployment.
(3) Carefully position the driver airbag in the
steering wheel. Be certain that the clockspring pig- WARNING: To avoid personal injury or death, during
tail wire and horn switch wires in the steering wheel and following any seat belt service, carefully
hub area are not pinched between the driver airbag inspect all seat belts, buckles, mounting hardware,
and the horn switch armature. retractors, and anchors for proper installation, oper-
(4) From the underside of the steering wheel, ation, or damage. Replace any belt that is cut,
install and tighten the two screws that secure the frayed, or torn. Straighten any belt that is twisted.
driver airbag to the horn switch armature within the Tighten any loose fasteners. Replace any belt that
hub cavity of the steering wheel. Tighten the screws has a damaged or inoperative buckle or retractor.
to 6 N·m (53 in. lbs.). Replace any belt that has a bent or damaged latch
(5) Do not reconnect the battery negative cable at plate or anchor plate. Never attempt to repair a seat
this time. The supplemental restraint system verifi- belt component. Always replace damaged or faulty
cation test procedure should be performed following seat belt components with the correct, new and
service of any supplemental restraint system compo- unused replacement parts listed in the
nent. (Refer to 8 - ELECTRICAL/RESTRAINTS - DaimlerChrysler Mopar Parts Catalog.
STANDARD PROCEDURE - VERIFICATION TEST).
(1) Move the front seat to its most forward position
for easiest access to the B-pillar trim.
FRONT SEAT BELT & (2) Disconnect and isolate the battery negative
cable. Wait two minutes for the system capacitor to
RETRACTOR discharge before further service.
(3) If the vehicle is so equipped, unsnap and
REMOVAL remove the plastic cover from the screw that secures
The following procedure is for replacement of a the front seat belt lower anchor to the outboard side
faulty or damaged front seat belt and retractor unit, of the seat frame (Fig. 22).
which includes a seat belt tensioner for the driver
side as standard equipment. Vehicles equipped with
an optional passenger airbag also have a seat belt
tensioner for the passenger side. (Refer to 8 - ELEC-
TRICAL/RESTRAINTS/SEAT BELT TENSIONER -
DESCRIPTION). If the seat belt or retractor is faulty
or damaged, but the seat belt tensioner is not
deployed, review the recommended procedures for
handling non-deployed supplemental restraints.
(Refer to 8 - ELECTRICAL/RESTRAINTS - STAN-
DARD PROCEDURE - HANDLING NON-DE-
PLOYED SUPPLEMENTAL RESTRAINTS). If the
seat belt tensioner has been deployed, review the rec-
ommended procedures for service after a supplemen-
tal restraint deployment before removing the front
seat belt and retractor from the vehicle. (Refer to 8 -
ELECTRICAL/RESTRAINTS - STANDARD PROCE-
DURE - SERVICE AFTER A SUPPLEMENTAL Fig. 22 Front Seat Belt Lower Anchor
RESTRAINT DEPLOYMENT). 1 - FRONT SEAT BELT
2 - COVER AND/OR SCREW
WARNING: To avoid personal injury or death, on
(4) Remove the screw that secures the front seat
vehicles equipped with airbags, disable the supple-
belt lower anchor to the outboard side of the seat
mental restraint system before attempting any
frame.
steering wheel, steering column, airbag, seat belt
(5) Remove the front seat belt lower anchor from
tensioner, impact sensor, or instrument panel com-
the outboard side of the seat frame.
ponent diagnosis or service. Disconnect and isolate
(6) Remove the trim panel from the inside of the
the battery negative (ground) cable, then wait two
B-pillar. (Refer to 23 - BODY/INTERIOR/B-PILLAR
minutes for the system capacitor to discharge
TRIM - REMOVAL).
before performing further diagnosis or service. This
is the only sure way to disable the supplemental
8O - 20 RESTRAINTS VA
FRONT SEAT BELT & RETRACTOR (Continued)
(7) Pull the height adjuster trim away from the
upper B-pillar to disengage the driver from the lug of
the height adjuster (Fig. 23).
INSTALLATION (1) Position the front seat belt and retractor to the
The following procedure is for replacement of a lower inner (Fig. 25). Be certain to engage the guide
faulty or damaged front seat belt and retractor unit, on the retractor into the locating notch on the B-pil-
which includes a seat belt tensioner for the driver lar.
side as standard equipment. Vehicles equipped with (2) Install and tighten the screw that secures the
an optional passenger airbag also have a seat belt front seat belt retractor to the lower inner B-pillar.
tensioner for the passenger side. (Refer to 8 - ELEC- Tighten the screw to 35 N·m (26 ft. lbs.).
TRICAL/RESTRAINTS/SEAT BELT TENSIONER - (3) If so equipped, reconnect the vehicle wire har-
DESCRIPTION). If the seat belt or retractor is faulty ness connector for the seat belt tensioner to the ini-
or damaged, but the seat belt tensioner is not tiator receptacle of the retractor located on the lower
deployed, review the recommended procedures for inner B-pillar. The connector is a tight snap-fit into
handling non-deployed supplemental restraints. the initiator receptacle. Reconnect the connector by
(Refer to 8 - ELECTRICAL/RESTRAINTS - STAN- pressing the connector insulator straight into the ini-
DARD PROCEDURE - HANDLING NON-DE- tiator receptacle. You can be certain that the connec-
PLOYED SUPPLEMENTAL RESTRAINTS). If the tor is fully engaged by listening carefully for a
seat belt tensioner has been deployed, review the rec- distinct, audible click as the connector snaps into
ommended procedures for service after a supplemen- place.
tal restraint deployment before removing the front (4) Position the front seat belt turning loop onto
seat belt and retractor from the vehicle. (Refer to 8 - the height adjuster on the upper B-pillar (Fig. 24).
ELECTRICAL/RESTRAINTS - STANDARD PROCE- (5) Install and tighten the nut that secures the
DURE - SERVICE AFTER A SUPPLEMENTAL front seat belt turning loop to the height adjuster.
RESTRAINT DEPLOYMENT). Tighten the nut to 35 N·m (26 ft. lbs.).
(6) Route the front seat belt and lower anchor
WARNING: To avoid personal injury or death, on through the back of the height adjuster trim (Fig.
vehicles equipped with airbags, disable the supple- 23).
mental restraint system before attempting any (7) Position the height adjuster trim to the upper
steering wheel, steering column, airbag, seat belt B-pillar so that the driver on the back of the trim
tensioner, impact sensor, or instrument panel com- engages the lug of the height adjuster.
ponent diagnosis or service. Disconnect and isolate (8) Reinstall the trim panel onto the inside of the
the battery negative (ground) cable, then wait two B-pillar. (Refer to 23 - BODY/INTERIOR/B-PILLAR
minutes for the system capacitor to discharge TRIM - INSTALLATION).
before performing further diagnosis or service. This (9) Position the front seat belt lower anchor to the
is the only sure way to disable the supplemental outboard side of the seat frame (Fig. 22).
restraint system. Failure to take the proper precau- (10) Install and tighten the screw that secures the
tions could result in accidental airbag deployment. front seat belt lower anchor to the outboard side of
the seat frame. Tighten the screw to 35 N·m (26 ft.
lbs.).
WARNING: To avoid personal injury or death, during (11) If the vehicle is so equipped, snap the plastic
and following any seat belt service, carefully cover over the screw that secures the front seat belt
inspect all seat belts, buckles, mounting hardware, lower anchor to the outboard side of the seat frame.
retractors, and anchors for proper installation, oper- (12) Do not reconnect the battery negative cable at
ation, or damage. Replace any belt that is cut, this time. The supplemental restraint system verifi-
frayed, or torn. Straighten any belt that is twisted. cation test procedure should be performed following
Tighten any loose fasteners. Replace any belt that service of any supplemental restraint system compo-
has a damaged or inoperative buckle or retractor. nent. (Refer to 8 - ELECTRICAL/RESTRAINTS -
Replace any belt that has a bent or damaged latch STANDARD PROCEDURE - VERIFICATION TEST).
plate or anchor plate. Never attempt to repair a seat
belt component. Always replace damaged or faulty
seat belt components with the correct, new and
unused replacement parts listed in the
DaimlerChrysler Mopar Parts Catalog.
8O - 22 RESTRAINTS VA
FRONT SEAT BELT BUCKLE (5) Remove the screw that secures the front seat
belt buckle lower anchor to the inboard side of the
seat frame.
REMOVAL
(6) Remove the front seat belt buckle from the
WARNING: To avoid personal injury or death, during inboard side of the front seat frame.
and following any seat belt service, carefully
inspect all seat belts, buckles, mounting hardware, INSTALLATION
retractors, and anchors for proper installation, oper-
WARNING: To avoid personal injury or death, during
ation, or damage. Replace any belt that is cut,
and following any seat belt service, carefully
frayed, or torn. Straighten any belt that is twisted.
inspect all seat belts, buckles, mounting hardware,
Tighten any loose fasteners. Replace any belt that
retractors, and anchors for proper installation, oper-
has a damaged or inoperative buckle or retractor.
ation, or damage. Replace any belt that is cut,
Replace any belt that has a bent or damaged latch
frayed, or torn. Straighten any belt that is twisted.
plate or anchor plate. Never attempt to repair a seat
Tighten any loose fasteners. Replace any belt that
belt component. Always replace damaged or faulty
has a damaged or inoperative buckle or retractor.
seat belt components with the correct, new and
Replace any belt that has a bent or damaged latch
unused replacement parts listed in the
plate or anchor plate. Never attempt to repair a seat
DaimlerChrysler Mopar Parts Catalog.
belt component. Always replace damaged or faulty
(1) On the driver side only, move the seat to its seat belt components with the correct, new and
most forward position for easiest access to the seat unused replacement parts listed in the
belt switch pigtail wire and connector. DaimlerChrysler Mopar Parts Catalog.
(2) On the driver side only, remove the wire ties
(1) Position the front seat belt buckle to the
that secure the seat belt switch pigtail wire to the
inboard side of the front seat frame (Fig. 26).
seat frame (Fig. 26).
(2) Install and tighten the screw that secures the
front seat belt buckle lower anchor to the inboard
side of the front seat frame. Tighten the screw to 35
N·m (26 ft. lbs.).
(3) If the vehicle is so equipped, snap the plastic
cover over the screw that secures the front seat belt
buckle lower anchor to the inboard side of the seat
frame.
(4) On the driver side only, reconnect the seat belt
switch pigtail wire to the vehicle wire harness and
push the joined connectors through the clearance
hole in the seat riser cover.
(5) On the driver side only, route and secure the
seat belt switch pigtail wire to the seat frame with
wire ties.
WARNING: To avoid personal injury or death, the inflator connector receptacle by pressing straight in
passenger airbag door must never be painted. on the connector. You can be certain that the connec-
Replacement passenger airbags are serviced with tor is fully engaged by listening carefully for a dis-
doors in the original colors. Paint may change the tinct, audible click as the connector snaps into place.
way in which the material of the airbag door (3) Push the passenger airbag unit forward far
responds to an airbag deployment. Failure to enough to engage the lower edge of the airbag door
observe this warning could result in occupant inju- with the two lower clips in the instrument panel.
ries upon airbag deployment. (4) Install and tighten the two screws that secure
the flange of the passenger airbag housing to the
(1) Carefully position the passenger airbag and bracket on the instrument panel structural support.
airbag door unit to the instrument panel (Fig. 29). Tighten the screws to 10 N·m (89 in. lbs.).
(2) When installing the passenger airbag, recon- (5) Install and tighten the two screws that secure
nect the vehicle wire harness connector to the airbag the passenger airbag door upper clips to the instru-
8O - 26 RESTRAINTS VA
PASSENGER AIRBAG (Continued)
ment panel base trim. Tighten the screws to 2 N·m
(18 in. lbs.).
(6) Reinstall the instrument panel top cover tray
onto the instrument panel. (Refer to 23 - BODY/IN-
STRUMENT PANEL/INSTRUMENT PANEL TOP
COVER - TRAY - INSTALLATION).
(7) Do not reconnect the battery negative cable at
this time. The supplemental restraint system verifi-
cation test procedure should be performed following
service of any supplemental restraint system compo-
nent. (Refer to 8 - ELECTRICAL/RESTRAINTS -
STANDARD PROCEDURE - VERIFICATION TEST).
PASSENGER AIRBAG
BRACKET
Fig. 30 Passenger Airbag Bracket Remove/Install
REMOVAL 1 - BRACKET
2 - STRUCTURAL SUPPORT
3 - SCREW (4)
WARNING: To avoid personal injury or death, on
vehicles equipped with airbags, disable the supple- (1) Position the passenger airbag bracket onto the
mental restraint system before attempting any instrument panel structural support (Fig. 30).
steering wheel, steering column, airbag, seat belt (2) Install and tighten the four screws that secure
tensioner, impact sensor, or instrument panel com- the passenger airbag bracket to the instrument panel
ponent diagnosis or service. Disconnect and isolate structural support. Tighten the screws to 10 N·m (89
the battery negative (ground) cable, then wait two in. lbs.).
minutes for the system capacitor to discharge (3) Reinstall the passenger airbag into the instru-
before performing further diagnosis or service. This ment panel. (Refer to 8 - ELECTRICAL/RE-
is the only sure way to disable the supplemental STRAINTS/PASSENGER AIRBAG -
restraint system. Failure to take the proper precau- INSTALLATION).
tions could result in accidental airbag deployment.
(1) Remove the passenger airbag from the instru- REAR SEAT BELT &
ment panel. (Refer to 8 - ELECTRICAL/RE-
STRAINTS/PASSENGER AIRBAG - REMOVAL). RETRACTOR
(2) Remove the four screws that secure the passen-
ger airbag bracket to the instrument panel structural REMOVAL
support (Fig. 30).
(3) Remove the passenger airbag bracket from the WARNING: To avoid personal injury or death, during
instrument panel structural support. and following any seat belt service, carefully
inspect all seat belts, buckles, mounting hardware,
INSTALLATION retractors, and anchors for proper installation, oper-
ation, or damage. Replace any belt that is cut,
WARNING: To avoid personal injury or death, on frayed, or torn. Straighten any belt that is twisted.
vehicles equipped with airbags, disable the supple- Tighten any loose fasteners. Replace any belt that
mental restraint system before attempting any has a damaged or inoperative buckle or retractor.
steering wheel, steering column, airbag, seat belt Replace any belt that has a bent or damaged latch
tensioner, impact sensor, or instrument panel com- plate or anchor plate. Never attempt to repair a seat
ponent diagnosis or service. Disconnect and isolate belt component. Always replace damaged or faulty
the battery negative (ground) cable, then wait two seat belt components with the correct, new and
minutes for the system capacitor to discharge unused replacement parts listed in the
before performing further diagnosis or service. This DaimlerChrysler Mopar Parts Catalog.
is the only sure way to disable the supplemental
(1) Remove the rear bench seat containing the rear
restraint system. Failure to take the proper precau-
seat belt and retractor unit to be serviced from the
tions could result in accidental airbag deployment.
vehicle.
VA RESTRAINTS 8O - 27
REAR SEAT BELT & RETRACTOR (Continued)
(2) Lift the seat belt webbing to access and remove (6) For a left outboard seating position only,
the plastic push pin fastener that secures the rear unsnap and remove the plastic cover from the screw
seat belt turning loop trim cover to the turning loop that secures the rear seat belt lower anchor to the
bracket at the top of the seat back (Fig. 31). left outboard side of the seat frame (Fig. 33).
Fig. 31 Turning Loop Trim Cover Fig. 33 Left Outboard Rear Seat Belt Lower Anchor
1 - TRIM COVER 1 - REAR SEAT CUSHION TRIM
2 - SEAT BELT 2 - REAR SEAT BACK TRIM
3 - RETAINER 3 - SCREW AND COVER
4 - REAR SEAT BACK 4 - REAR SEAT BELT LOWER ANCHOR
(3) Remove the turning loop trim cover from the (7) Remove the plastic shield from the back of the
turning loop bracket. rear seat. (Refer to 23 - BODY/SEATS/REAR SEAT
(4) Remove the push nut at the back of the turn- BACK SHIELD - REMOVAL).
ing loop bracket that secures the pin on which the (8) Remove the screw that secures the rear seat
two turning loops pivot (Fig. 32). belt lower anchor to the rear seat cushion frame (Fig.
33) or (Fig. 34).
(5) Remove the pin and the two turning loops from (9) Pull the rear seat belt and lower anchor
the turning loop bracket. through the turning loop trim cover and the turning
loop bracket.
8O - 28 RESTRAINTS VA
REAR SEAT BELT & RETRACTOR (Continued)
(10) Remove the screw that secures the rear seat (5) Install and tighten the screw that secures the
belt retractor to the bracket on the rear seat cushion rear seat belt lower anchor to the rear seat cushion
frame (Fig. 35). frame. Tighten the screw to 35 N·m (26 ft. lbs.).
(6) For a left outboard seating position only, rein-
stall the plastic cover onto the screw that secures the
rear seat belt lower anchor to the left outboard side
of the seat frame.
(7) Position the two seat belt turning loops to the
turning loop bracket so that one turning loop is
located behind the bracket and one is located in front
of the bracket (Fig. 32).
(8) From the front of the turning loop bracket,
insert the pin through both turning loops and the
bracket, then secure it from behind the bracket with
a new push nut.
(9) Position the turning loop trim cover over the
turning loop bracket.
(10) Lift the seat belt webbing to access and install
the plastic push pin fastener that secures the rear
Fig. 35 Rear Seat Belt Retractor seat belt turning loop trim cover to the turning loop
bracket at the top of the seat back (Fig. 31).
1 - RETRACTOR
2 - REAR SEAT CUSHION FRAME (11) Reinstall the plastic shield onto the back of
3 - SCREW the rear seat. (Refer to 23 - BODY/SEATS/REAR
SEAT BACK SHIELD - INSTALLATION).
(11) Remove the rear seat belt and retractor unit (12) Reinstall the rear bench seat into the vehicle.
from the bracket on the rear seat cushion frame.
INSTALLATION - OUTBOARD belt buckle latch the switch leaf contact is released,
closing the circuit to ground.
WARNING: To avoid personal injury or death, during The seat belt switch is connected is series between
and following any seat belt service, carefully ground and the seat belt switch sense input of the
inspect all seat belts, buckles, mounting hardware, instrument cluster. The seat belt switch receives
retractors, and anchors for proper installation, oper- ground at all times through its pigtail wire connec-
ation, or damage. Replace any belt that is cut, tion to the vehicle wire harness from another take
frayed, or torn. Straighten any belt that is twisted. out of the vehicle wire harness. An eyelet terminal
Tighten any loose fasteners. Replace any belt that connector on the vehicle wire harness ground take
has a damaged or inoperative buckle or retractor. out is secured under a nut to a ground stud located
Replace any belt that has a bent or damaged latch on the floor panel within the driver side front seat
plate or anchor plate. Never attempt to repair a seat riser. The seat belt switch may de diagnosed using
belt component. Always replace damaged or faulty conventional diagnostic tools and methods.
seat belt components with the correct, new and
unused replacement parts listed in the
DaimlerChrysler Mopar Parts Catalog. SEAT BELT TENSIONER
(1) Position the rear seat belt buckle to the right DESCRIPTION
outboard side of the rear seat cushion frame (Fig.
37).
(2) Install and tighten the screw that secures the
outboard rear seat belt buckle to the rear seat cush-
ion frame. Tighten the screw to 35 N·m (26 ft. lbs.).
(3) Reinstall the plastic cover onto the screw that
secures the rear seat belt buckle to the right out-
board side of the rear seat cushion frame.
OPERATION
The seat belt tensioners are deployed in conjunc-
tion with the airbags by a signal generated by the
Airbag Control Module (ACM) through the driver and
passenger seat belt tensioner line 1 and line 2 (or
squib) circuits (Fig. 39). When the ACM sends the Fig. 39 Seat Belt Tensioner Operation
proper electrical signal to the tensioners, the electri- 1 - TUBE
cal energy generates enough heat to initiate a small 2 - PISTON
3 - CABLE
pyrotechnic gas generator. The gas generator is 4 - CYLINDER
installed so that it directs its expelled gas at the
underside of the piston in the cylinder. The piston is The ACM monitors the condition of the seat belt
connected to a cable that is wound around a pulley tensioners through circuit resistance. The ACM will
on one end of the retractor spool. As the gas expands, illuminate the airbag indicator in the ElectroMe-
it propels the piston through the tube, which pulls chanical Instrument Cluster (EMIC) and store a
the cable and rotates the retractor spool to take up Diagnostic Trouble Code (DTC) for any fault that is
slack in the seat belt webbing. detected. For proper diagnosis of the seat belt ten-
Once a seat belt tensioning sequence has been sioners, a DRBIIIt scan tool is required. Refer to the
completed, the forward momentum of the occupant appropriate diagnostic information.
results in deformation of the torsion bar. Removing
excess slack from the front seat belts not only keeps
the occupants properly positioned for an airbag
deployment following a frontal impact of the vehicle,
but also helps to reduce injuries that the occupant
might otherwise experience in a frontal impact event
as a result of harmful contact with the steering
wheel, steering column, instrument panel and/or
windshield. The torsion bar is designed to deform in
order to control the loads being applied to the occu-
pant by the seat belt during a frontal impact, further
reducing the potential for occupant injuries.
8O - 32 RESTRAINTS VA
Fig. 42 Seat Belt Turning Loop Adjuster Remove/ SIDE CURTAIN AIRBAG
Install
1 - SCREW (2) DESCRIPTION
2 - ADJUSTER
3 - B-PILLAR
INSTALLATION
WARNING: To avoid personal injury or death, on
vehicles equipped with airbags, disable the supple-
mental restraint system before attempting any
steering wheel, steering column, airbag, seat belt
tensioner, or instrument panel component diagno-
sis or service. Disconnect and isolate the battery
negative (ground) cable, then wait two minutes for
the system capacitor to discharge before perform-
ing further diagnosis or service. This is the only
sure way to disable the supplemental restraint sys-
tem. Failure to take the proper precautions could
result in accidental airbag deployment.
SPEED CONTROL
TABLE OF CONTENTS
page page
SPECIFICATIONS
TORQUE
CABLE SERVO
DESCRIPTION DESCRIPTION
A cable and a vacuum controlled servo are not used A vacuum controlled servo and control cable are
with this package. This is a cable-less, servo-less sys- not used with this package. This is a cable-less, ser-
tem. The speed control system is electronically con- vo-less system. The speed control system is electron-
trolled by the Engine Control Module (ECM). ically controlled by the Engine Control Module
(ECM).
VA SPEED CONTROL 8P - 3
SWITCH
REMOVAL
The speed control switch is mounted to the back of
the multi-function switch (Fig. 3). The multi-function
switch must be removed first to gain access to the
speed control switch mounting screw.
(1) Remove and isolate negative battery cable from
battery.
(2) Remove multi-function switch. Refer to Multi-
Function Switch Removal/Installation.
(3) Remove switch mounting screw (Fig. 4).
(4) Remove speed control switch from multi-func-
tion switch.
(5) Unplug pigtail electrical connector (Fig. 3) from
instrument panel wiring harness.
INSTALLATION
The speed control switch is mounted to the back of
the multi-function switch (Fig. 3).
VA VEHICLE THEFT SECURITY 8Q - 1
page page
SIREN
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove mounting fasteners.
(3) Disconnect wire harness connector from siren.
INSTALLATION
(1) Connect wire harness connector to siren.
(2) Position siren. Install and tighten mounting
fasteners.
Fig. 5 TRANSPONDER RING (3) Connect battery negative cable.
1 - TRANSPONDER RING
2 - STEERING COLUMN
TRANSPONDER KEY
(5) Remove top cover - cluster (Refer to 23 -
BODY/INSTRUMENT PANEL/TOP COVER - CLUS- DESCRIPTION
TER - REMOVAL). The Sentry Key Immobilizer System (SKIS) which
(6) Disconnect the transponder electrical connector communicates with the Sentry Key Remote Entry
from the SKREEM (Fig. 4). Module (SKREEM), uses a transponder chip that is
(7) Maneuver wiring from instrument panel and integral to each key fob (Fig. 6). Ignition keys are
remove transponder from vehicle. supplied with the vehicle when it is shipped from the
factory. The transponder chip is located within the
INSTALLATION Remote Keyless Entry (RKE) fob.
WIPERS/WASHERS
TABLE OF CONTENTS
page page
WIPERS/WASHERS beneath the cowl top panel at the base of the wind-
shield in the engine compartment.
• Multi-Function Switch - The multi-function
DESCRIPTION
switch is secured to the top of the steering column,
An electrically operated intermittent wiper and
just below the steering wheel. Only the left (lighting)
washer system is standard factory-installed safety
control stalk, right (wiper) control stalk and the haz-
equipment on this model (Fig. 1). The wiper and
ard warning switch button for the multi-function
washer system includes the following major compo-
switch are visible, the remainder of the switch is con-
nents, which are described in further detail else-
cealed beneath the steering column shrouds. The
where in this service information:
multi-function switch contains all of the switches for
• Check Valve - The washer system check valve
both the wiper and washer systems.(Refer to 8 -
is integral to the plumbing fitting located in the
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
washer plumbing between the cowl plenum washer
MULTI-FUNCTION SWITCH - DESCRIPTION)
hose and the two washer nozzle hoses, and is located
8R - 2 WIPERS/WASHERS VA
WIPERS/WASHERS (Continued)
• Rain Sensor - Vehicles equipped with an sion of the washer pump/motor unit, which is located
optional automatic wiper feature have an electronic in a dedicated hole on the top of the sump area near
rain sensor concealed within the base of the rear the back of the windshield washer reservoir on the
view mirror unit on the inside of the laminated wind- right front fender wheel house in the engine com-
shield glass. partment.
• Rain Sensor Control Module - Vehicles • Washer Nozzle - A single washer nozzle with
equipped with an optional automatic wiper feature three separate orifices is secured with integral snap
have an electronic rain sensor control module located features to each wiper arm. The hoses for the washer
under the lower instrument panel above the acceler- nozzles are concealed beneath a molded plastic guide
ator pedal in the passenger compartment of the vehi- on the underside of each wiper arm and routed to the
cle. engine compartment through unique molded plastic
• Washer Fluid Level Switch - The optional elbow fittings located near each wiper pivot at the
washer fluid level switch is integral to a unique ver- base of the windshield.
VA WIPERS/WASHERS 8R - 3
WIPERS/WASHERS (Continued)
• Washer Pump/Motor - Two different washer Hard wired circuitry connects the wiper and
pump/motor units are available for this model. One washer system components to the electrical system of
version has an integral washer fluid level switch that the vehicle. These hard wired circuits are integral to
provides a hard wired input to the instrument cluster several wire harnesses, which are routed throughout
for control of the optional washer fluid indicator. The the vehicle and retained by many different methods.
washer pump/motor unit is located in a dedicated These circuits may be connected to each other, to the
hole on the top of the sump area near the back of the vehicle electrical system and to the wiper and washer
windshield washer reservoir on the right front fender system components through the use of a combination
wheel house in the engine compartment. of soldered splices, splice block connectors, and many
• Washer Reservoir - The washer reservoir is different types of wire harness terminal connectors
located on the right front fender wheel house in the and insulators. Refer to the appropriate wiring infor-
engine compartment. The washer reservoir filler is mation. The wiring information includes wiring dia-
accessed from the right front corner of the engine grams, proper wire and connector repair procedures,
compartment. further details on wire harness routing and reten-
• Wiper Arm - The two unequal length wiper tion, as well as pin-out and location views for the
arms are secured to the two wiper pivots, which various wire harness connectors, splices and grounds.
extend through the cowl panel near the base of the
windshield. The longer arm is installed on the left OPERATION
(driver) side of the windshield. The wiper and washer system is designed to pro-
• Wiper Blade - The two unequal length wiper vide the vehicle operator with a convenient, safe, and
blades are secured to the two wiper arms, and are reliable means of maintaining visibility through the
parked on the glass near the bottom of the wind- windshield glass. The various components of this sys-
shield when the wiper system is not in operation. tem are designed to convert electrical energy pro-
The longer blade is installed on the left (driver) side duced by the vehicle electrical system into the
of the windshield. mechanical action of the wiper blades to wipe the
• Wiper Linkage - The wiper pivots are the only outside surface of the glass, as well as into the
visible components of the wiper linkage. The remain- hydraulic action of the washer system to apply
der of the linkage is concealed within the engine washer fluid stored in an on-board reservoir to the
compartment just behind the hood opening. The area of the glass to be wiped. When combined, these
wiper linkage module includes the two wiper drive components provide the means to effectively main-
links, the wiper motor crank arm, the two wiper piv- tain clear visibility for the vehicle operator by remov-
ots, and the linkage and motor mounting bracket. ing excess accumulations of rain, snow, bugs, mud, or
• Wiper Motor - The wiper motor is secured to other minor debris from the outside windshield glass
the wiper linkage module bracket on the underside of surface that might be encountered while driving the
the cowl panel within the engine compartment. The vehicle under numerous types of inclement operating
wiper motor output shaft and crank arm extend conditions.
through a clearance hole in the mounting bracket, Two wiper systems are available: the standard
where they are connected to a crank arm that drives intermittent wipe system, or an optional automatic
the wiper linkage. wipe system. The vehicle operator initiates all wiper
• Wiper Relay - The wiper relay is located in a and washer system functions with the multi-function
dedicated receptacle on the lower left surface of the switch wiper control stalk that extends from the
fuse block underneath the steering column behind right side of the steering column, just below the
the fuse access panel and the steering column open- steering wheel. Depressing, raising, or pulling the
ing panel. The wiper relay is a passive component on right control stalk of the multi-function switch
vehicles equipped with the optional automatic wiper selects the desired wiper system operating mode (Fig.
system. 2). The wiper system allows the vehicle operator to
• Wiper, Turn Signals, Engine Start Control select from two continuous wiper speeds, Hi or Lo,
Module - The wiper, turn signals and engine start either a fixed interval intermittent wipe mode or an
control module is integral to the fuse block located auto wipe mode (as the vehicle is equipped), and a
underneath the steering column. The fuse block is pulse wipe mode. Pushing the knob on the end of the
concealed behind the fuse access panel and the steer- control stalk towards the steering column activates
ing column opening panel, where it is secured with the washer pump/motor, which dispenses washer
screws to the steering column. The wiper system fluid onto the windshield glass through the washer
functions of this module are passive on vehicles nozzles.
equipped with the optional automatic wiper system. The hard wired inputs to and outputs from the
wiper and washer system components may be diag-
8R - 4 WIPERS/WASHERS VA
WIPERS/WASHERS (Continued)
switch to the low speed brush of the wiper motor.
The intermittent wipe logic circuit monitors the
wiper motor operation through the wiper on/off relay
output circuit, which allows it to determine the
proper timing to begin the next wiper blade sweep.
The normal delay interval is about five seconds.
When the Off position of the multi-function switch
wiper control stalk is selected, one of two events is
possible. The event that will occur depends upon the
position of the wiper blades on the windshield at the
moment that the Off position is selected. If the wiper
blades are in the down position on the windshield
when the Off position is selected, the park switch
that is integral to the wiper motor is closed to
ground, the intermittent wipe logic circuit de-ener-
gizes the wiper relay, and the wiper motor ceases to
Fig. 2 Windshield Wiper/Washer Switch operate.
1 - INTERMITTENT WIPE MODE (OR AUTO WIPE MODE IF If the wiper blades are not in the down position on
EQUIPPED) the windshield at the moment the Off position is
2 - CONTINUOUS LOW SPEED WIPE MODE
3 - CONTINUOUS HIGH SPEED WIPE MODE selected, the park switch is closed to battery current
4 - WASHER MODE through the fused ignition switch output (run-start)
5 - PULSE WIPE MODE circuit. The intermittent wipe logic circuit energizes
the wiper relay and the wiper on-off relay output cir-
nosed and tested using conventional diagnostic tools cuit directs battery current to the low speed brush of
and methods. Refer to the appropriate diagnostic the wiper motor through the normally open contact
information. Refer to the owner’s manual in the vehi- of the wiper relay, then through the internal Off posi-
cle glove box for more information on the features tion circuitry of the multi-function switch. This
and operation of the wiper and washer system. causes the wiper motor to continue running until the
wiper blades are in the down position on the wind-
INTERMITTENT WIPE SYSTEM shield and the park switch is again closed to ground.
When the ignition switch is in the On position, bat- When the Wash position of the control knob on the
tery current from a fuse in the fuse block underneath right control stalk of the multi-function switch is
the steering column is provided through a fused igni- selected, the washer switch circuitry directs battery
tion switch output (run-start) circuit to the intermit- current to the washer pump motor and to the inter-
tent wipe logic circuitry of the wiper, turn signals mittent wipe logic circuitry. When the washer switch
and engine start control module within the fuse is closed with the wiper system turned Off, the inter-
block, the multi-function switch, the wiper relay and mittent wipe logic circuitry operates the wiper motor
the wiper motor park switch. The internal circuitry in the same manner as it does to provide the inter-
of the multi-function switch provides a direct hard mittent wipe mode operation. After the state of the
wired battery current output to the low speed or high washer switch changes to open, the intermittent wipe
speed brushes of the wiper motor when the Low, logic circuitry monitors the wiper motor through the
High, or Pulse position is selected, which causes the wiper on-off relay output circuit, which allows it to
wipers to cycle at the selected speed for as long as monitor the number of wiper blade sweeps. After the
that switch position remains selected. appropriate number of wiper sweeps the intermittent
In order to provide the intermittent wipe and wipe- wipe logic circuitry operates the wiper motor to
after-wash features, the intermittent wipe logic cir- return the wipers to their park position, then de-en-
cuitry of the wiper, turn signals and engine start ergizes the wiper relay.
control module within the fuse block monitors inputs
from the intermittent wipe and washer switch cir- AUTOMATIC WIPE SYSTEM
cuitry of the multi-function switch and the park When the ignition switch is in the On position, bat-
switch in the wiper motor. When the intermittent tery current from a fuse in the fuse block underneath
wipe position is selected with the multi-function the steering column is provided through a fused igni-
switch control stalk, the intermittent wipe logic cir- tion switch output (run-start) circuit to the rain sen-
cuitry responds by energizing the wiper relay and sor control module under the instrument panel, to
calculating the correct delay interval. The energized the rain sensor within the base of the inside rear
wiper relay directs battery current through the inter- view mirror on the windshield, and to the multi-func-
mittent wipe position circuitry of the multi-function
VA WIPERS/WASHERS 8R - 5
WIPERS/WASHERS (Continued)
tion switch. The internal circuitry of the multi-func- OPERATING MODES
tion switch provides direct hard wired battery The components of the wiper and washer system
current outputs to the rain sensor control module to are designed to provide the following operating
indicate the selected wiper operating mode. The con- modes:
trol module logic monitors the inputs from the multi- • Automatic Wipe Mode - On vehicles so
function switch as well as from the rain sensor and equipped, the internal circuitry of the multi-function
the wiper motor park switch in order to provide the switch, the rain sensor control module and the rain
outputs necessary to operate the wiper motor and the sensor work in concert to provide wiper system oper-
washer pump motor as requested. ation automatically whenever moisture is detected on
When the automatic wipe position is selected with the windshield glass.
the multi-function switch control stalk, the rain sen- • Continuous Wipe Mode - The two-speed wiper
sor control module logic circuitry responds by provid- motor, the internal circuitry of the multi-function
ing an acknowledgment sweep of the wipers. The switch, and the wiper system logic circuits work in
rain sensor calculates the correct wiper speed and concert to provide two continuous wipe cycles, low
wiper sweep intervals required to remove the mois- speed or high speed.
ture detected on the windshield glass and provides • Intermittent Wipe Mode - On vehicles so
this input to the rain sensor control module. The con- equipped, the internal circuitry of the multi-function
trol module then energizes and de-energizes the switch, the intermittent wipe circuitry of the wiper,
wiper motor automatically. The automatic wipe logic turn signals and engine start control module in the
will also provide a wipe-after-wash feature to clear fuse block, and the wiper relay work in concert to
washer fluid that is directed onto the windshield provide an intermittent wipe mode with a single,
when the washer system is utilized. fixed delay interval.
When the Off position of the multi-function switch • Pulse Wipe Mode - The internal circuitry of
wiper control stalk is selected, one of two events is the multi-function switch and the wiper system logic
possible. The event that will occur depends upon the circuits work in concert to provide a pulse wipe mode
position of the wiper blades on the windshield at the that will allow the wiper motor to be operated for a
moment that the Off position is selected. If the wiper single, complete wipe cycle.
blades are in the down position on the windshield • Washer Mode - When the washer system is
when the Off position is selected, the park switch activated with the multi-function switch while the
that is integral to the wiper motor is closed to wiper system is operating, washer fluid will be dis-
ground, and the rain sensor control module logic cir- pensed onto the windshield glass through the washer
cuit de-energizes the wiper motor. If the wiper blades nozzles for as long as the washer pump/motor is
are not in the down position at the moment the Off energized.
position is selected, the park switch is an open cir- • Wipe-After-Wash Mode - The wiper system
cuit. The control module logic circuit directs battery logic circuitry provides a wipe-after-wash feature. If
current to the low speed brush of the wiper motor, the wipers are turned Off, this feature will operate
which causes the wiper motor to continue running the washer pump/motor and the wipers for as long as
until the wiper blades are in the down position on the washer system is activated, then provide several
the windshield and the park switch is again closed to additional wipe cycles after the washer system is
ground. deactivated before parking the wiper blades near the
When the Wash position of the control knob on the base of the windshield.
right control stalk of the multi-function switch is
selected with the wiper system turned Off, the rain DIAGNOSIS AND TESTING - WIPER &
sensor control module logic circuitry operates the
WASHER SYSTEM
wiper motor in the same manner as it does to provide
If the wiper motor operates, but the wipers do not
the automatic wipe mode operation. After the state of
move on the windshield, replace the faulty wiper
the washer switch changes to open the control mod-
linkage module. If the washer pump/motor operates,
ule monitors the wiper motor through the wiper park
but no washer fluid is dispensed on the glass; or, if
switch sense circuit, which allows it to monitor the
the wipers operate, but chatter, lift, or do not clear
number of wiper blade sweeps. After the appropriate
the glass, clean and inspect the wiper and washer
number of wiper sweeps the control module operates
system components as required. (Refer to 8 - ELEC-
the wiper motor to return the wipers to their park
TRICAL/WIPERS/WASHERS - CLEANING) and
position, then de-energizes the wiper motor.
(Refer to 8 - ELECTRICAL/WIPERS/WASHERS -
INSPECTION). For diagnosis and testing of the
multi-function switch (Refer to 8 - ELECTRICAL/
LAMPS/LIGHTING - EXTERIOR/MULTI-FUNC-
8R - 6 WIPERS/WASHERS VA
WIPERS/WASHERS (Continued)
TION SWITCH - DIAGNOSIS AND TESTING). windshield, or the rain sensor control module under
Refer to the appropriate wiring information. The wir- the instrument panel.
ing information includes wiring diagrams, proper
wire and connector repair procedures, details of wire WARNING: To avoid personal injury or death, on
harness routing and retention, connector pin-out vehicles equipped with airbags, disable the supple-
information and location views for the various wire mental restraint system before attempting any
harness connectors, splices and grounds. steering wheel, steering column, airbag, seat belt
The hard wired circuits and components of the tensioner, or instrument panel component diagno-
wiper and washer system may be diagnosed and sis or service. Disconnect and isolate the battery
tested using conventional diagnostic tools and proce- negative (ground) cable, then wait two minutes for
dures. However, conventional diagnostic methods the system capacitor to discharge before perform-
may not prove conclusive in the diagnosis of the ing further diagnosis or service. This is the only
intermittent wipe logic circuitry contained within the sure way to disable the supplemental restraint sys-
fuse block underneath the steering column, the rain tem. Failure to take the proper precautions could
sensor within the base of the rear view mirror on the result in accidental airbag deployment.
WIPERS INOPERATIVE IN 1. Faulty or missing fuse. 1. Test and replace the fuse as required.
ALL SWITCH POSITIONS
2. Faulty wiper motor ground circuit. 2. Test and repair the open ground circuit
as required.
3. Faulty multi-function switch feed 3. Test and repair the open fused ignition
circuit. switch output circuit between the fuse and
the multi-function switch as required.
4. Faulty multi-function switch. 4. Test and replace the multi-function switch
as required.
5. Faulty wiper motor. 5. Test and replace the wiper motor as
required.
WIPERS INOPERATIVE IN 1. Faulty wiper relay. 1. Test and replace the wiper relay as
INTERMITTENT POSITION required.
AND NO WIPE AFTER 2. Faulty multi-function switch. 2. Test and replace the multi-function switch
WASH FEATURE as required.
3. Faulty intermittent wipe logic 3. Replace the steering column fuse block
circuit. as required.
WIPERS INOPERATIVE IN 1. Faulty low speed circuit. 1. Test and repair the open low speed
LOW POSITION AND NO circuit between the multi-function switch
PULSE FEATURE and the wiper motor as required.
2. Faulty multi-function switch. 2. Test and replace the multi-function switch
as required.
3. Faulty wiper low speed brush. 3. Test and replace the wiper motor as
required.
WIPERS INOPERATIVE IN 1. Faulty high speed circuit. 1. Test and repair the open high speed
HIGH POSITION circuit between the multi-function switch
and the wiper motor as required.
2. Faulty multi-function switch. 2. Test and replace the multi-function switch
as required.
3. Faulty wiper high speed brush. 3. Test and replace the wiper motor as
required.
VA WIPERS/WASHERS 8R - 7
WIPERS/WASHERS (Continued)
WIPERS DO NOT PARK 1. Faulty motor feed circuit. 1. Test and repair the open fused ignition
AFTER OPERATING switch output circuit to the wiper motor as
required.
2. Faulty park switch output circuit. 2. Test and repair the open or shorted
circuit between the wiper park switch and
the wiper relay as required.
3. Faulty wiper relay. 3. Test and replace the wiper relay as
required.
4. Faulty park switch. 4. Test and replace the wiper motor as
required.
WASHERS INOPERATIVE 1. Faulty washer pump ground 1. Test and repair the open ground circuit
circuit. as required.
2. Faulty washer pump feed circuit. 2. Test and repair the open circuit between
the multi-function switch and the washer
pump as required.
3. Faulty washer pump motor. 3. Test and replace the washer pump as
required.
4. Faulty muli-function switch. 4. Test and replace the multi-function switch
as required.
WIPERS INOPERATIVE IN 1. Faulty or missing fuse. 1. Test and replace the fuse as required.
ALL SWITCH POSITIONS
2. Faulty wiper motor ground circuit. 2. Test and repair the open ground circuit
as required.
3. Faulty wiper motor. 3. Test and replace the wiper motor as
required.
4. Faulty multi-function switch feed 4. Test and repair the open fused ignition
circuit. switch output circuit between the fuse and
the multi-function switch as required.
5. Faulty multi-function switch. 5. Test and replace the multi-function switch
as required.
6. Faulty rain sensor control module 6. Test and repair the open ground circuit
ground circuit. as required.
7. Faulty rain sensor control module 7. Test and repair the open fused ignition
feed circuit. switch output circuit between the fuse and
the rain sensor control module as required.
8. Faulty rain sensor control module. 8. Test and replace the rain sensor control
module as required.
8R - 8 WIPERS/WASHERS VA
WIPERS/WASHERS (Continued)
AUTOMATIC WIPE 1. Faulty rain sensor shielding 1. Test and repair the open shielding
INOPERATIVE (WITH ground circuits. circuits as required.
ACKNOWLEDGE-MENT 2. Faulty rain sensor ground circuit. 2. Test and repair the open ground circuit
WIPE) between the rain sensor and the control
module as required.
3. Faulty faulty rain sensor feed 3. Test and repair the open feed circuit
circuit. between the rain sensor and the control
module as required.
4. Faulty rain sensor signal circuit. 4. Test and repair the open or shorted
signal circuit between the rain sensor and
the control module as required.
5. Faulty rain sensor. 5. Test and replace the rain sensor as
required.
AUTOMATIC WIPE 1. Faulty rain sensor control module. 1. Test and replace the rain sensor control
INOPERATIVE (NO module as required.
ACKNOWLEDGE-MENT
WIPE)
WIPERS INOPERATIVE IN 1. Faulty low speed request circuit. 1. Test and repair the open low speed
LOW POSITION AND NO request circuit between the multi-function
PULSE FEATURE switch and the rain sensor control module
as required.
2. Faulty multi-function switch. 2. Test and replace the multi-function switch
as required.
3. Faulty low speed control circuit. 3. Test and repair the open low speed
control circuit between the rain sensor
control module and the wiper motor as
required.
4. Faulty wiper low speed brush. 4. Test and replace the wiper motor as
required.
WIPERS INOPERATIVE IN 1. Faulty high speed request circuit. 1. Test and repair the open high speed
HIGH POSITION request circuit between the multi-function
switch and the rain sensor control module
as required.
2. Faulty multi-function switch. 2. Test and replace the multi-function switch
as required.
3. Faulty high speed control circuit. 3. Test and repair the open high speed
control circuit between the rain sensor
control module and the wiper motor as
required.
3. Faulty wiper high speed brush. 3. Test and replace the wiper motor as
required.
VA WIPERS/WASHERS 8R - 9
WIPERS/WASHERS (Continued)
WIPERS DO NOT PARK 1. Faulty park switch output circuit. 1. Test and repair the open or shorted
AFTER OPERATING circuit between the wiper park switch and
the rain sensor control module as required.
2. Faulty wiper relay output circuit. 2. Test and repair the open or shorted
circuit between the rain sensor control
module and the wiper relay as required.
3. Faulty wiper relay. 3. Test and replace the wiper relay as
required.
4. Faulty park switch. 4. Test and replace the wiper motor as
required.
5. Faulty intermittent wipe logic 5. Replace the steering column fuse block
circuit. as required.
WASHERS INOPERATIVE 1. Faulty washer pump ground 1. Test and repair the open ground circuit
circuit. as required.
2. Faulty washer pump request 2. Test and repair the open washer pump
circuit. request circuit between the multi-function
switch and the rain sensor control module
as required.
3. Faulty muli-function switch. 3. Test and replace the multi-function switch
as required.
4. Faulty washer pump control 4. Test and repair the open washer pump
circuit. control circuit between the rain sensor
control module and the washer pump as
required.
5. Faulty washer pump motor. 5. Test and replace the washer pump as
required.
CAUTION: Protect the rubber squeegees of the CAUTION: Never introduce petroleum-based clean-
wiper blades from any petroleum-based cleaners, ers, solvents, or contaminants into the washer sys-
solvents, or contaminants. These products can rap- tem. These products can rapidly deteriorate the
idly deteriorate the rubber squeegees. rubber seals and hoses of the washer system, as
well as the rubber squeegees of the wiper blades.
8R - 10 WIPERS/WASHERS VA
WIPERS/WASHERS (Continued)
CAUTION: Never use compressed air to flush the
washer system plumbing. Compressed air pres-
sures are too great for the washer system plumbing
components and will result in further system dam-
age. Never use sharp instruments to clear a
plugged washer nozzle or damage to the nozzle ori-
fice and improper nozzle spray patterns will result.
REMOVAL
(1) Unlatch and open the hood panel.
(2) Disconnect the washer hoses from the three
barbed nipples of the check valve unit (Fig. 5).
REMOVAL
WARNING: TO AVOID PERSONAL INJURY OR
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE SUPPLEMENTAL RESTRAINT SYS-
TEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT
TENSIONER, OR INSTRUMENT PANEL COMPO-
NENT DIAGNOSIS OR SERVICE. DISCONNECT AND
ISOLATE THE BATTERY NEGATIVE (GROUND)
CABLE, THEN WAIT TWO MINUTES FOR THE SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
Fig. 11 Rain Sensor Control Module FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
1 - RAIN SENSOR CONTROL MODULE IS THE ONLY SURE WAY TO DISABLE THE SUP-
2 - CONNECTOR RECEPTACLE PLEMENTAL RESTRAINT SYSTEM. FAILURE TO
3 - MOUNTING TAB (2) TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT.
system through a dedicated take out and connector of
the instrument panel wiring. Concealed and pro- (1) Disconnect and isolate the battery negative
tected within the RSCM housing is the electronic cir- cable.
cuitry of the module. (2) Locate the rain sensor control module on a
The RSCM cannot be repaired and, if damaged or bracket under the instrument panel above the throt-
faulty, the entire module must be replaced. tle pedal (Fig. 12).
OPERATION
The microprocessor-based Rain Sensor Control
Module (RSCM) is only used in vehicles equipped
with an optional automatic wiper system. The RSCM
monitors inputs from the ignition switch, the wiper
and washer switch circuitry of the multi-function
switch on the steering column, the park switch
within the wiper motor, and the rain sensor on the
inside of the windshield glass. Based upon these
inputs the RSCM sends the proper control outputs to
the wiper motor and the washer pump motor to pro-
vide all of the requested wiper and washer system
functions.
The RSCM operates on battery current received
from a fuse in the fuse block on a fused ignition
switch output (run-start) circuit so that the RSCM
will operate whenever the ignition switch is in the
On or Start positions. The RSCM receives ground at
all times through its connection to the instrument
Fig. 12 Rain Sensor Control Module Location
panel wire harness. It is important to note that the
default condition for the wiper system is automatic 1 - INSTRUMENT PANEL
2 - RAIN SENSOR CONTROL MODULE
wipers Off; therefore, if no input is received from the 3 - THROTTLE PEDAL
rain sensor by the RSCM, the automatic wipers will
be disabled and the RSCM will default the wiper and (3) Cut the tie wrap on the control module (Fig.
washer system to normal manual operation for con- 13).
tinuous low or high speed wiper or washer mode.
8R - 16 WIPERS/WASHERS VA
RAIN SENSOR CONTROL MODULE (Continued)
(4) Install a new tie wrap to secure the wire har-
ness to the control module.
(5) Reconnect the battery negative cable.
WASHER HOSES/TUBES
DESCRIPTION
WASHER NOZZLE
DESCRIPTION
OPERATION
The two washer nozzles are designed to dispense
washer fluid into the wiper pattern area on the out-
side of the windshield glass. Pressurized washer fluid
is fed to each nozzle from the washer reservoir by the
washer pump/motor through rubber hoses, which are
attached to a barbed nipple on the underside of each
washer nozzle below the wiper arm. The three ori-
fices of each nozzle causes the pressurized washer
fluid to be emitted generously in several streams
throughout the travel of the wiper arm to more effec-
tively cover a larger area of the glass to be cleaned.
REMOVAL
(1) Using hand pressure, unsnap the washer noz- Fig. 17 Washer Pump/Motor
zle from the wiper arm (Fig. 16). 1 - INLET NIPPLE
(2) Disconnect the hose from the barbed nipple of 2 - WASHER PUMP/MOTOR
3 - CONNECTOR RECEPTACLE
the washer nozzle. 4 - VENT NIPPLE (W/FLUID LEVEL SWITCH ONLY)
5 - WASHER FLUID LEVEL SWITCH HOUSING
INSTALLATION 6 - OUTLET NIPPLE
OPERATION
WASHER RESERVOIR The washer fluid reservoir provides a secure,
on-vehicle storage location for a large reserve of
DESCRIPTION washer fluid for operation of the washer system. The
washer reservoir filler neck provides a clearly
marked and readily accessible point from which to
add washer fluid to the reservoir. The washer/pump
motor unit is located in a sump area near the bottom
of the reservoir to be certain that washer fluid will
be available to the pump as the fluid level in the res-
ervoir becomes depleted. The optional washer fluid
level switch is designed to provide adequate warning
to the vehicle operator that the washer fluid level is
low, before the washer system will no longer operate.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the upper turbocharger heat shield
and the upper air cleaner housing from the engine
Fig. 19 Washer Reservoir compartment (Fig. 20).
1 - CAP
2 - TROUGH (2)
3 - MOUNTING POST (2)
4 - WASHER PUMP/MOTOR
5 - RESERVOIR
6 - MOUNTING HOLE
(5) Remove the washer supply hose from the Fig. 22 Washer Reservoir Mounting
barbed outlet nipple of the washer pump/motor and
1 - RIGHT INNER FENDER
allow the washer fluid to drain into a clean container 2 - STUD NUT
for reuse. 3 - DASH PANEL
(6) Disengage the washer supply hose from the 4 - RIGHT FRONT WHEEL HOUSE
5 - GROMMET (2)
routing trough integral to the top of the washer res- 6 - HOOD PROP
ervoir.
(7) Remove the nut and washer that secures the (5) Install and tighten the nut and washer that
top of the washer reservoir to the stud nut on the secures the top of the washer reservoir to the stud
right inner fender. nut on the right inner fender. Tighten the nut to 6
(8) Pull the washer reservoir inboard far enough to N·m (50 in. lbs.).
disengage the reservoir from the stud nut. (6) Reconnect the washer supply hose to the
(9) Tilt the washer reservoir forward far enough to barbed outlet nipple of the washer pump/motor.
disengage the rear mounting post from the grommet (7) Engage the washer supply hose into the rout-
in the dash panel. ing trough integral to the top of the washer reservoir.
(10) Lift the washer reservoir upward far enough (8) Reconnect the vehicle wire harness connector
to disengage the lower mounting post from the grom- for the washer pump/motor unit to the motor connec-
met in the top of the right front wheel house. tor receptacle.
(11) Remove the washer reservoir from the engine (9) Engage the vehicle wire harness into the rout-
compartment. ing clip integral to the front of the washer reservoir.
(10) Reinstall the upper turbocharger heat shield
INSTALLATION and the upper air cleaner housing into the engine
(1) Position the washer reservoir into the engine compartment (Fig. 20).
compartment. (11) Refill the washer reservoir with the washer
(2) Engage the lower mounting post of the washer fluid drained from the reservoir during the removal
reservoir into the grommet in the top of the right procedure.
front wheel house (Fig. 22). (12) Reconnect the battery negative cable.
(3) Engage the rear mounting post of the washer
reservoir into the grommet in the dash panel.
(4) Position the washer reservoir mounting hole
over the stud nut on the right inner fender (Fig. 21).
8R - 22 WIPERS/WASHERS VA
WIPER ARM
DESCRIPTION
The wiper arms are the rigid members located channel, one end of a long spring is engaged with a
between the wiper pivots that protrude from the cowl wire hook on the underside of the die cast pivot end,
top panel near the base of the windshield and the while the other end of the spring is hooked through
wiper blades on the windshield glass (Fig. 23). These the small hole in the steel strap. The entire wiper
wiper arms feature an over-center hinge that allows arm has a satin black finish applied to all of its vis-
easy access to the windshield glass for cleaning. The ible surfaces.
wiper arm has a die cast metal pivot end with a Near the hook of the wiper arm steel strap is a
large tapered mounting hole at one end. A removable locating hole for the washer nozzle that is mounted
molded black plastic pivot cover fits loosely over and on the wiper arm. A U-shaped molded plastic guard
pivots on the wiper arm hinge pin, then snaps over snaps onto the underside of the strap to conceal and
the pivot end to conceal the wiper arm retaining nut. protect the washer nozzle hose. There are also two
The wide end of a tapered, stamped steel channel small molded plastic washer nozzle hose routing
hinges on and is secured with a hinge pin to the brackets clipped onto the underside of the wiper arm
pivot end of the wiper arm. One end of a long, rigid, pivot end.
stamped steel strap, with a small hole near its pivot The wiper arms for this model are unequal in
end, is riveted and crimped within the narrow end of length, with the longer arm being installed on the
the stamped steel channel. The tip of the wiper blade left (driver) side of the windshield. A wiper arm can-
end of this strap is bent back under itself to form a not be adjusted or repaired. If damaged or faulty, the
small hook. Concealed within the stamped steel entire wiper arm unit must be replaced. The washer
VA WIPERS/WASHERS 8R - 23
WIPER ARM (Continued)
nozzle, nozzle hose, routing brackets, and pivot end (2) Unsnap the end of the pivot cover from the
cover are available for individual service replace- wiper blade pivot end, then pull the cover away from
ment. the wiper arm hinge pin to remove the cover from
the wiper blade.
OPERATION (3) Remove the nut that secures the wiper arm to
The wiper arms are designed to mechanically the wiper pivot shaft.
transmit the motion from the wiper pivots to the (4) If necessary, use a suitable battery terminal
wiper blades. The wiper arm must be properly puller to disengage the wiper arm from the wiper
indexed to the wiper pivot in order to maintain the pivot shaft (Fig. 25).
proper wiper blade travel on the glass. The tapered
mounting hole in the wiper arm pivot end interlocks
with the serrations on the outer circumference of the
wiper pivot shaft, allowing positive engagement and
finite adjustment of this connection. The mounting
nut locks the wiper arm to the threaded end of the
wiper pivot shaft. The spring-loaded wiper arm hinge
controls the down-force applied through the tip of the
wiper arm to the wiper blade on the glass. The hook
formation on the tip of the wiper arm provides a cra-
dle for securing and latching the wiper blade pivot
block to the wiper arm.
REMOVAL
(1) Disconnect the washer nozzle hose from the
elbow fitting on the cowl top panel near the pivot end
of the wiper arm (Fig. 24). Fig. 25 Wiper Arm Puller - Typical
1 - WIPER ARM
2 - WIPER PIVOT SHAFT
3 - BATTERY TERMINAL PULLER
INSTALLATION
NOTE: Be certain that the wiper motor is in the park
position before attempting to install the wiper arms.
Turn the ignition switch to the On position and
move the right (wiper) control stalk of the multi-
function switch to its Off position. If the wiper piv-
ots move, wait until they stop moving, then turn the
ignition switch back to the Off position. The wiper
motor is now in its park position.
Fig. 24 Wiper Arm Remove/Install
1 - PIVOT COVER NOTE: The wiper arms and wiper blades for this
2 - NUT
3 - PIVOT SHAFT model are both unequal in length, with the longer
4 - WASHER NOZZLE HOSE arm and blade being installed on the left (driver)
5 - ELBOW FITTING side of the windshield.
6 - WIPER ARM
REMOVAL INSTALLATION
NOTE: The wiper arms and wiper blades for this NOTE: The wiper arms and wiper blades for this
model are both unequal in length, with the longer model are both unequal in length, with the longer
arm and blade being installed on the left (driver) arm and blade being installed on the left (driver)
side of the windshield. side of the windshield.
(1) Turn the wiper control knob on the end of the (1) Lift the wiper arm off of the windshield glass,
multi-function switch control stalk to the On posi- until the wiper arm hinge is in its over-center posi-
tion. Cycle the wiper blades to a convenient working tion.
location on the windshield by turning the ignition (2) Position the wiper blade near the hook forma-
switch to the On and Off positions. tion on the tip of the arm.
(2) Lift the wiper arm to raise the wiper blade and (3) Insert the hook formation on the tip of the
element off of the glass, until the wiper arm hinge is wiper arm through the opening in the wiper blade
in its over-center position. superstructure ahead of the wiper blade pivot block/
(3) To remove the wiper blade from the wiper arm, latch unit far enough to engage the pivot block with
depress the pivot block latch release tab under the the hook (Fig. 27).
tip of the arm and slide the blade away from the tip (4) Slide the wiper blade pivot block/latch up into
towards the pivot end of the arm far enough to dis- the hook formation on the tip of the wiper arm until
engage the pivot block from the hook formation on the latch release tab snaps into its locked position.
the end of the arm (Fig. 27). Latch engagement will be accompanied by an audible
click.
(5) Gently lower the wiper blade onto the glass.
WIPER LINKAGE
DESCRIPTION
The wiper linkage and pivots are concealed within
the engine compartment below the cowl top panel
(Fig. 28). The ends of the wiper pivot shafts that pro-
trude through dedicated openings in the cowl top
panel to drive the wiper arms and blades are the
only visible components of the wiper linkage module.
The wiper linkage module consists of the following
major components:
• Linkage - The two wiper drive links are each
Fig. 27 Wiper Blade Remove/Install constructed of stamped steel. The left (driver) side
drive link has a plastic socket-type bushing in one
1 - HOOK
2 - WIPER BLADE end, and a plastic sleeve-type bushing in the other
3 - WIPER ARM end. The socket bushing is snap-fit over the ball stud
4 - RELEASE TAB on the left pivot crank arm, while the sleeve bushing
is fit over the longer ball stud on the wiper motor
(4) Extract the hook formation on the tip of the crank arm. The right (passenger) side drive link has
wiper arm from the opening in the wiper blade a plastic socket-type bushing on each end. One end of
superstructure ahead of the wiper blade pivot block/ this drive link is snap-fit over the exposed end of the
latch unit. longer ball stud on the wiper motor crank arm and
captures the sleeve bushing end of the left drive link
CAUTION: Do not allow the wiper arm to spring
beneath it, while the other end is snap-fit over the
back against the glass without the wiper blade in
ball stud on the right pivot crank arm.
place or the glass may be damaged.
• Module Bracket - The linkage module bracket
(5) Gently lower the wiper arm tip onto the glass. consists of a long tubular steel main member that is
crimped to a molded plastic pivot bracket at each end
where the wiper pivots are secured. A stamped steel
mounting plate for the wiper motor is secured with
welds near the center of the main member and is
8R - 26 WIPERS/WASHERS VA
WIPER LINKAGE (Continued)
INSTALLATION (4) Install and tighten the nut and washer that
(1) Reinstall the wiper motor onto the wiper link- secures each wiper pivot housing to the outside of the
age module. (Refer to 8 - ELECTRICAL/WIPERS/ cowl top panel.
WASHERS/FRONT WIPER MOTOR - (5) Reconnect the wiper motor pigtail wire connec-
INSTALLATION). tor to the vehicle wire harness connector.
(2) Carefully position the wiper linkage module (6) Reinstall the ventilation housing onto the dash
and wiper motor to the underside of the cowl top panel and the underside of the cowl top panel (Fig.
panel as a unit (Fig. 30). 29).
(3) Install and tighten the two screws that secure (7) Reinstall the wiper arms onto the wiper pivots.
the wiper linkage module motor bracket to the flange (Refer to 8 - ELECTRICAL/WIPERS/WASHERS/
on the underside of the cowl top panel. Tighten the WIPER ARM - INSTALLATION).
screws to 6 N·m (50 in. lbs.). (8) Reconnect the battery negative cable.
8R - 28 WIPERS/WASHERS VA
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Disconnect the vehicle wire harness connector
for the wiper motor from the motor pigtail wire con-
nector (Fig. 32).
(3) Remove the nut that secures the motor crank
arm to the wiper motor output shaft.
Fig. 31 Wiper Motor (4) If this wiper motor is to be reinstalled, make
1 - TRANSMISSION an index mark between the wiper motor output shaft
2 - PIGTAIL WIRE
3 - MOTOR
and the motor crank arm using a suitable marker.
4 - SCREW (3) (5) Disengage the motor crank arm from the wiper
5 - OUTPUT SHAFT motor output shaft.
(6) Remove the three screws that secure the wiper
The wiper motor is secured with three screws to a motor to the wiper linkage module motor bracket.
motor bracket integral to the wiper linkage module (7) Remove the wiper motor from the wiper link-
bracket located below the cowl top panel in the age module motor bracket.
engine compartment (Fig. 31). The wiper motor out-
put shaft passes through a hole in the motor bracket, INSTALLATION
where a nut secures the wiper motor crank arm to (1) Position the wiper motor to the underside of
the motor output shaft. The two-speed permanent the wiper linkage module motor bracket (Fig. 32).
magnet wiper motor features an integral transmis- (2) Install and tighten the three screws that secure
sion, an internal park switch, and an internal Posi- the wiper motor to the wiper linkage module motor
tive Temperature Coefficient (PTC) circuit breaker. bracket. Tighten the screws to 12 N·m (105 in. lbs.).
The wiper motor cannot be adjusted or repaired. If (3) If this wiper motor is being reinstalled, position
any component of the motor is faulty or damaged, the the motor crank arm on the wiper motor output shaft
entire wiper motor unit must be replaced. so that the index marks made during the removal
procedure are aligned. If this is a new wiper motor
OPERATION installation, the motor crank arm should be installed
The wiper motor operation is controlled by the so that it is pointed toward the left (driver) side of
vehicle operator through battery current inputs the vehicle and parallel with the two wiper drive
received by the wiper motor from the wiper switch links while both wiper blades are positioned on their
circuitry of the multi-function switch on the top of alignment marks near the lower edge of the wind-
the steering column, and from the wiper relay on the shield glass.
fuse block underneath the steering column. The (4) Install and tighten the nut that secures the
wiper motor speed is controlled by current flow to motor crank arm to the wiper motor output shaft.
either the low speed or the high speed set of brushes. Tighten the nut to 12 N·m (105 in. lbs.).
The automatic resetting circuit breaker protects the (5) Reconnect the vehicle wire harness connector
motor from overloads. for the wiper motor to the motor pigtail wire connec-
The park switch consists of a contact disc and tor.
three contacts. The contact disc is mechanically fas- (6) Reconnect the battery negative cable.
tened to and rotated with a gear in the wiper motor
transmission. Two input contacts alternately close
the wiper park switch sense output circuit contact to
VA WIPERS/WASHERS 8R - 29
WIPER MOTOR (Continued)
WIPER RELAY
DESCRIPTION
A wiper relay is standard equipment on all models.
The wiper relay (or intermittent wipe relay) is
located in a dedicated receptacle on the bottom left of
the fuse block on the underside of the steering col-
umn (Fig. 33). The wiper relay is a conventional
International Standards Organization (ISO) micro
relay. Relays conforming to the ISO specifications
have common physical dimensions, current capaci-
ties, terminal patterns, and terminal functions. The
relay is contained within a small, rectangular,
molded plastic housing. The relay is connected to all
of the required inputs and outputs through the
instrument panel wire harness connector by five
Fig. 33 Wiper Relay
male spade-type terminals that extend from the bot-
tom of the relay base. The ISO designation for each 1 - HOUSING
2 - TERMINAL (5)
terminal is molded into the base adjacent to the ter- 3 - BASE
minal. The ISO terminal designations are as follows:
• 30 (Common Feed) - This terminal is con- • 85 (Coil Ground) - This terminal is connected
nected to the movable contact point of the relay. to the ground feed side of the relay control coil.
8R - 30 WIPERS/WASHERS VA
WIPER RELAY (Continued)
• 86 (Coil Battery) - This terminal is connected • The coil battery terminal (86) is connected to the
to the battery feed side of the relay control coil. relay control output of the wiper, turn signals and
• 87 (Normally Open) - This terminal is con- engine start control module within the fuse block
nected to the normally open fixed contact point of the through the wiper relay control circuit. This elec-
relay. tronic circuitry controls the ground path for this cir-
• 87A (Normally Closed) - This terminal is con- cuit internally to energize or de-energize the wiper
nected to the normally closed fixed contact point of relay control coil based upon its programming and
the relay. inputs from the wiper and washer control circuitry of
The wiper relay cannot be adjusted or repaired. If the multi-function switch, the wiper motor park
the relay is damaged or faulty, it must be replaced. switch, and the ignition switch.
• The normally open terminal (87) is connected to
OPERATION the output of the wiper motor park switch through
The wiper relay (or intermittent wipe relay) is an the wiper motor park switch sense circuit. This cir-
electromechanical switch that uses a low current cuit can carry either battery current (wipers are not
input from the intermittent wipe logic circuitry in park position) or ground (wipers are in park posi-
within the fuse block underneath the steering column tion), depending upon the status of the wiper park
to control a high current output to the low speed switch.
brush of the wiper motor. The movable common feed • The normally closed terminal (87A) is connected
contact point is held against the fixed normally to battery current through a fused ignition switch
closed contact point by spring pressure. When the output circuit whenever the ignition switch is in the
relay coil is energized, an electromagnetic field is On position.
produced by the coil windings. This electromagnetic The wiper relay can be diagnosed using conven-
field draws the movable relay contact point away tional diagnostic tools and methods.
from the fixed normally closed contact point, and
holds it against the fixed normally open contact REMOVAL
point. When the relay coil is de-energized, spring
pressure returns the movable contact point back WARNING: To avoid personal injury or death, on
against the fixed normally closed contact point. A vehicles equipped with airbags, disable the supple-
resistor or diode is connected in parallel with the mental restraint system before attempting any
relay coil in the relay, and helps to dissipate voltage steering wheel, steering column, airbag, seat belt
spikes and electromagnetic interference that can be tensioner, or instrument panel component diagno-
generated as the electromagnetic field of the relay sis or service. Disconnect and isolate the battery
coil collapses. negative (ground) cable, then wait two minutes for
The wiper relay terminals are connected to the the system capacitor to discharge before perform-
vehicle electrical system through a connector recepta- ing further diagnosis or service. This is the only
cle in the fuse block. The inputs and outputs of the sure way to disable the supplemental restraint sys-
wiper relay include: tem. Failure to take the proper precautions could
• The common feed terminal (30) provides an out- result in accidental airbag deployment.
put to the wiper motor low speed brush through the
wiper control circuitry of the multi-function switch on (1) Disconnect and isolate the battery negative
the steering column. When the wiper relay is de-en- cable.
ergized, the common feed terminal is connected to (2) Remove the fuse access panel from the steering
the input of the relay normally closed terminal (87). column opening cover below the steering column on
When the wiper relay is energized, the common feed the instrument panel.
terminal is connected to the input of the relay nor- (3) Reach through and below the outboard side of
mally open terminal (87A). the fuse access opening to access the wiper relay
• The coil ground terminal (85) is connected to (Fig. 34).
battery current through a fused ignition switch out- (4) Remove the wiper relay by grasping it firmly,
put circuit whenever the ignition switch is in the On releasing the latches and pulling it straight down
position. from the receptacle on the bottom of the fuse block.
VA WIPERS/WASHERS 8R - 31
WIPER RELAY (Continued)
INSTALLATION
WARNING: To avoid personal injury or death, on
vehicles equipped with airbags, disable the supple-
mental restraint system before attempting any
steering wheel, steering column, airbag, seat belt
tensioner, or instrument panel component diagno-
sis or service. Disconnect and isolate the battery
negative (ground) cable, then wait two minutes for
the system capacitor to discharge before perform-
ing further diagnosis or service. This is the only
sure way to disable the supplemental restraint sys-
tem. Failure to take the proper precautions could
result in accidental airbag deployment.
WIRING
TABLE OF CONTENTS
page page
TABLE OF CONTENTS
page page
WARNING: SET THE PARKING BRAKE WHEN • Ohmmeter - Used to check the resistance
WORKING ON ANY VEHICLE. AN AUTOMATIC between two points of a circuit. Low or no resistance
TRANSMISSION SHOULD BE IN PARK. A MANUAL in a circuit means good continuity.
TRANSMISSION SHOULD BE IN NEUTRAL.
CAUTION: Most of the electrical components used
in today’s vehicles are Solid State. When checking
WARNING: OPERATE THE ENGINE ONLY IN A resistance in these circuits use a meter with a 10 -
WELL-VENTILATED AREA. megohm or greater impedance rating. In addition,
make sure the power is disconnected from the cir-
cuit. Circuits that are powered up by the vehicle’s
WARNING: KEEP AWAY FROM MOVING PARTS electrical system can cause damage to the equip-
WHEN THE ENGINE IS RUNNING, ESPECIALLY THE ment and provide false readings.
FAN AND BELTS.
STANDARD PROCEDURE
ELECTROSTATIC DISCHARGE (ESD) SENSITIVE
DEVICES
Fig. 4 Probing Tool All ESD sensitive components are solid state and a
1 - SPECIAL TOOL 6801 symbol (Fig. 5) is used to indicate this. When han-
2 - PROBING END
dling any component with this symbol, comply with
the following procedures to reduce the possibility of
INTERMITTENT AND POOR CONNECTIONS electrostatic charge build up on the body and inad-
Most intermittent electrical problems are caused vertent discharge into the component. If it is not
by faulty electrical connections or wiring. It is also known whether the part is ESD sensitive, assume
possible for a sticking component or relay to cause a that it is.
problem. Before condemning a component or wiring (1) Always touch a known good ground before han-
assembly, check the following items. dling the part. This should be repeated while han-
• Connectors are fully seated dling the part and more frequently after sliding
• Spread terminals, or terminal push out across a seat, sitting down from a standing position,
• Terminals in the wiring assembly are fully or walking a distance.
seated into the connector/component and locked into (2) Avoid touching electrical terminals of the part,
position unless instructed to do so by a written procedure.
• Dirt or corrosion on the terminals. Any amount of (3) When using a voltmeter, be sure to connect the
corrosion or dirt could cause an intermittent problem ground lead first.
• Damaged connector/component casing exposing (4) Do not remove the part form it’s protective
the item to dirt or moisture packing until it is time to install the part.
• Wire insulation that has rubbed through causing (5) Before removing the part from it’s pakage,
a short to ground ground the pakage to a known good ground on the
• Some or all of the wiring strands broken inside vehicle.
of the insulation
• Wiring broken inside of the insulation
INSTALLATION
(1) Insert the removed terminal in the same cavity
on the repair connector.
(2) Repeat steps for each terminal in the connec-
tor, being sure that all wires are inserted into the
proper cavities. For additional connector pin-out
identification, refer to the wiring diagrams.
(3) When the connector is re-assembled, the sec-
ondary terminal lock must be placed in the locked
Fig. 8 Testing for Voltage Drop position to prevent terminal push out.
(4) Replace dress cover (if applicable).
CONNECTOR (5) Connect connector to its mating half/compo-
nent.
REMOVAL (6) Connect battery and test all affected systems.
(1) Disconnect battery.
(2) Release Connector Lock (Fig. 9).
(3) Disconnect the connector being repaired from
its mating half/component.
(4) Remove the dress cover (if applicable) (Fig. 9).
(5) Release the Secondary Terminal Lock, if
required.
(6) Position the connector locking finger away from
the terminal using the proper special tool. Pull on
the wire to remove the terminal from the connector.
8W - 01 - 10 8W-01 WIRING DIAGRAM INFORMATION VA
INSTALLATION
(1) Select a wire from the terminal repair kit that
best matches the color and gage of the wire being
repaired.
(2) Cut the repair wire to the proper length and
remove one–half (1/2) inch of insulation.
(3) Splice the repair wire to the wire harness (see
Fig. 10 Diode Identification wire splicing procedure).
1 - CURRENT FLOW (4) Insert the repaired wire into the connector.
2 - BAND AROUND DIODE INDICATES CURRENT FLOW
3 - DIODE AS SHOWN IN THE DIAGRAMS (5) Install the connector locking wedge, if required,
and reconnect the connector to its mating half/compo-
INSTALLATION nent.
(1) Remove the insulation from the wires in the (6) Re-tape the wire harness starting at 1–1/2
harness. Only remove enough insulation to solder in inches behind the connector and 2 inches past the
the new diode. repair.
(2) Install the new diode in the harness, making (7) Connect battery and test all affected systems.
sure current flow is correct. If necessary, refer to the
appropriate wiring diagram for current flow (Fig. 11).
WIRE SPLICING
When splicing a wire, it is important that the cor-
rect gage be used as shown in the wiring diagrams.
(1) Remove one-half (1/2) inch of insulation from
each wire that needs to be spliced.
(2) Place a piece of adhesive lined heat shrink tub-
ing on one side of the wire. Make sure the tubing will
be long enough to cover and seal the entire repair
area.
(3) Place the strands of wire overlapping each Fig. 14 3 SOLDER SPLICE
other inside of the splice clip (Fig. 12). 1 - SOLDER
2 - SPLICE BAND
3 - SOLDERING IRON
8W-53 WIPERS
Component Page Component Page
Fuse 6 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-2, 3, 4 Washer Pump Motor-Front . . . . . . . . . . . . . 8W-53-3
Fuse Block No. 1 . . . . . . . . . . . . . . . . 8W-53-2, 3, 4 Wiper Motor-Front . . . . . . . . . . . . . . . 8W-53-2, 3, 4
G102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-3 Wiper On/Off Relay . . . . . . . . . . . . . . 8W-53-2, 3, 4
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-4 Wiper Switch . . . . . . . . . . . . . . . . . . . . . 8W-53-2, 3
Multi-Function Switch . . . . . . . . . . . . . . 8W-53-2, 3 Wiper/Turn Signal/Engine Start Control
Washer On/Off Switch . . . . . . . . . . . . . . . . 8W-53-3 Module . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-2, 3
VA 8W-54 TRAILER TOW 8W - 54 - 1
8W-55 NAVIGATION/TELECOMMUNICATIONS
Component Page Component Page
Ctel Antenna Connector . . . . . . . . . . . . . . . 8W-55-4 G203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-55-2
Ctel Connector . . . . . . . . . . . . . . . . . . . . 8W-55-2, 3 Microphone Connector . . . . . . . . . . . . . . . . 8W-55-2
Fuse 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-55-2 Optional Equipment Relay . . . . . . . . . . . . . 8W-55-2
Fuse 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-55-2 Radio . . . . . . . . . . . . . . . . . . . . . . . . . 8W-55-2, 3, 4
Fuse 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-55-4 Radio/Cellular Antenna . . . . . . . . . . . . . . . 8W-55-4
Fuse Block No. 1 . . . . . . . . . . . . . . . . . . . . 8W-55-4 Speaker-Left Front Door Assembly . . . . . 8W-55-2, 3
Fuse Block No. 3 . . . . . . . . . . . . . . . . . . . . 8W-55-2
VA 8W-60 POWER WINDOWS 8W - 60 - 1
A/C SWITCH-ROOF
CAV CIRCUIT FUNCTION
1 16GY/DG/RD LAMP DRIVER
3 16RD/BK FUSED D(+) RELAY NO. 1 OUTPUT
4 16VT A/C FAN MOTOR CONTROL-HIGH SPEED
7 16YL A/C FAN MOTOR CONTROL-LOW SPEED
8 16RD/BK FUSED D(+) RELAY NO. 1 OUTPUT
10 16BR GROUND
CIGAR LIGHTER
CAV CIRCUIT FUNCTION
1 16BR GROUND
2 16RD/YL FUSED B(+)
CLOCKSPRING C1
CAV CIRCUIT FUNCTION
1 16BR GROUND
2 16BK/YL HORN RELAY CONTROL
CLOCKSPRING C2 - YELLOW
CAV CIRCUIT FUNCTION
1 20VT DRIVER AIRBAG SQUIB 1 LINE 1
2 20DG DRIVER AIRBAG SQUIB 1 LINE 2
CTEL CONNECTOR
CAV CIRCUIT FUNCTION
1 18BR GROUND
4 16DG/YL/BK RADIO MUTE
7 18BL/DG SPEAKER-LEFT FRONT (-) CTEL
9 10BR CTEL CONNECTOR CAV 9 TO MICROPHONE CON-
NECTOR CAV 1
10 18BK/BL FUSED OPTIONAL EQUIPMENT RELAY OUTPUT
11 18RD/BK/WT FUSED B(+)
12 18BK/BL FUSED OPTIONAL EQUIPMENT RELAY OUTPUT
16 18BK/YL SPEAKER-LEFT FRONT (+) CTEL
18 10BL CTEL CONNECTOR CAV 18 TO MICROPHONE CON-
NECTOR
DOME LAMP
CAV CIRCUIT FUNCTION
1 16BR GROUND
2 16RD/YL FUSED B(+)
3 16BR/WT FRONT COURTESY LAMPS CONTROL
DOSING PUMP
CAV CIRCUIT FUNCTION
1 16DG DOSING PUMP CONTROL
2 16BR GROUND
HEATER TIMER-AUXILIARY
CAV CIRCUIT FUNCTION
1 16GY/DG/RD LAMP DRIVER
2 16YL (EXCEPT PROGRAM TIMER) HEATER TIMER (CUT-IN SIGNAL)
2 16YL (PROGRAM TIMER) CABIN HEATER CONTROL
4 16BR GROUND
6 16GY/RD HEATER TIMER
9 16BR/WT HEATER TIMER
10 16BK/BL/DG S201 COMMON CIRCUIT
11 16RD FUSED B(+)
12 16BR GROUND
VA 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 47
HORN
CAV CIRCUIT FUNCTION
1 18RD/DG FUSED B(+)
2 18BR GROUND
3 18BK/BL SIREN SIGNAL CONTROL
HORN (VTSS)
CAV CIRCUIT FUNCTION
1 16BK/BR HORN RELAY OUTPUT
2 16BK/YL FUSED IGNITION SWITCH OUTPUT (RUN-START)
8W - 80 - 48 8W-80 CONNECTOR PIN-OUTS VA
INSTRUMENT CLUSTER C1
CAV CIRCUIT FUNCTION
1 20BR FUEL LEVEL SENSOR SIGNAL RETURN
2 20BR/DG AMBIENT TEMPERATURE SENSOR SIGNAL RETURN
4 20WT/GY K-IC/ATC/HBM/CHM
5 20BR/BK PARK BRAKE INDICATOR SIGNAL
7 20BK/DG RIGHT TURN SIGNAL
10 20BL/BK FUEL LEVEL SENSOR SIGNAL (+)
11 20BL/DG AMBIENT TEMPERATURE SENSOR SIGNAL (+)
14 20DG/WT/BL ENGINE COOLANT LEVEL SWITCH SIGNAL
15 20BR/WT FRONT COURTESY LAMPS CONTROL
16 20YL/RD SEAT BELT SWITCH SIGNAL
17 20DG CAN C BUS (-)
18 20DG/WT CAN C BUS (+)
METERING PUMP
CAV CIRCUIT FUNCTION
1 16DG/RD METERING PUMP DRIVER
2 16BR GROUND
8W - 80 - 58 8W-80 CONNECTOR PIN-OUTS VA
MICROPHONE CONNECTOR
CAV CIRCUIT FUNCTION
1 10BR MICROPHONE CONNECTOR CAV 1 TO CTEL CON-
NECTOR CAV 9
2 10BL MICROPHONE CONNECTOR CAV 2 TO CTEL CON-
NECTOR CAV 18
RADIO ANTENNA
CAV CIRCUIT FUNCTION
1 16BK RADIO ANTENNA
2 16BK RADIO ANTENNA W/SHIELD
VA 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 61
RADIO C1 - BLACK
CAV CIRCUIT FUNCTION
A1 20BL/RD/WT VEHICLE SPEED SENSOR OUTPUT
A2 20YL K-TCM/RADIO
A3 18DG/YL/BK CTEL MUTE
A4 16RD/YL FUSED B(+)
A5 16BK RADIO ANTENNA
A6 16GY/DG/RD LAMP DRIVER
A7 16BK/RD FUSED IGNITION SWITCH OUTPUT (ACC-RUN-START)
A8 16BR GROUND
B1 16BR/GY SPEAKER-RIGHT REAR
B2 16WT/GY SPEAKER-RIGHT REAR
B3 18BR/RD SPEAKER-RIGHT FRONT (+)
B4 18BK SPEAKER-RIGHT FRONT (-)
B5 18BR/DG SPEAKER-LEFT FRONT (+)
B6 18BR SPEAKER-LEFT FRONT (-)
B7 16BR/BL SPEAKER-LEFT REAR
B8 16WT/BL SPEAKER-LEFT REAR
RADIO C2
CAV CIRCUIT FUNCTION
1 16BK RADIO ANTENNA W/SHIELD
2 16BK SHIELD
RADIO/CELLULAR ANTENNA
CAV CIRCUIT FUNCTION
1 16BK/RD FUSED IGNITION SWITCH OUTPUT (ACC-RUN-START)
2 16BK RADIO ANTENNA W/SHIELD
3 16BK CELLULAR ANTENNA W/SHIELD
SIREN - BLACK
CAV CIRCUIT FUNCTION
1 18RD/DG FUSED B(+)
2 18BR GROUND
3 18BK/BL SIREN SIGNAL CONTROL
SKREEM TRANSPONDER
CAV CIRCUIT FUNCTION
1 20BR TRANSPONDER COIL (+)
2 - TRANSPONDER COIL (-)
SPEAKER-LEFT REAR
CAV CIRCUIT FUNCTION
1 16BR/BL SPEAKER-LEFT REAR
2 16WT/BL SPEAKER-LEFT REAR
8W - 80 - 66 8W-80 CONNECTOR PIN-OUTS VA
SPEAKER-RIGHT REAR
CAV CIRCUIT FUNCTION
1 16BR/GY SPEAKER-RIGHT REAR
2 16WT/GY SPEAKER-RIGHT REAR
TABLE OF CONTENTS
page
CONNECTOR/GROUND/SPLICE LOCATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CONNECTORS
GROUNDS
SPLICES
Fig. 1 OVERVIEW
VA 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 15
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Fig. 2 OVERVIEW
8W - 91 - 16 8W-91 CONNECTOR/GROUND/SPLICE LOCATION VA
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Fig. 3 OVERVIEW
VA 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 17
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Fig. 4 OVERVIEW
8W - 91 - 18 8W-91 CONNECTOR/GROUND/SPLICE LOCATION VA
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Fig. 5 OVERVIEW
VA 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 19
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Fig. 6 OVERVIEW
8W - 91 - 20 8W-91 CONNECTOR/GROUND/SPLICE LOCATION VA
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Fig. 7 OVERVIEW
VA 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 21
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Fig. 8 OVERVIEW
8W - 91 - 22 8W-91 CONNECTOR/GROUND/SPLICE LOCATION VA
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Fig. 9 OVERVIEW
VA 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 23
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Fig. 10 OVERVIEW
8W - 91 - 24 8W-91 CONNECTOR/GROUND/SPLICE LOCATION VA
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Fig. 11 OVERVIEW
VA 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 25
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Fig. 12 OVERVIEW
8W - 91 - 26 8W-91 CONNECTOR/GROUND/SPLICE LOCATION VA
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Fig. 13 OVERVIEW
VA 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 27
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Fig. 14 OVERVIEW
8W - 91 - 28 8W-91 CONNECTOR/GROUND/SPLICE LOCATION VA
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Fig. 15 OVERVIEW
VA 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 29
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Fig. 16 OVERVIEW
8W - 91 - 30 8W-91 CONNECTOR/GROUND/SPLICE LOCATION VA
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Fig. 17 OVERVIEW
VA 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 31
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Fig. 18 OVERVIEW
8W - 91 - 32 8W-91 CONNECTOR/GROUND/SPLICE LOCATION VA
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Fig. 19 OVERVIEW
VA 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 33
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Fig. 20 OVERVIEW
8W - 91 - 34 8W-91 CONNECTOR/GROUND/SPLICE LOCATION VA
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Fig. 21 OVERVIEW
VA 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 35
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Fig. 22 OVERVIEW
8W - 91 - 36 8W-91 CONNECTOR/GROUND/SPLICE LOCATION VA
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Fig. 23 OVERVIEW
VA 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 37
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Fig. 24 OVERVIEW
8W - 91 - 38 8W-91 CONNECTOR/GROUND/SPLICE LOCATION VA
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Fig. 25 OVERVIEW
VA 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 39
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Fig. 26 OVERVIEW
8W - 91 - 40 8W-91 CONNECTOR/GROUND/SPLICE LOCATION VA
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Fig. 27 OVERVIEW
VA 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 41
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Fig. 28 OVERVIEW
8W - 91 - 42 8W-91 CONNECTOR/GROUND/SPLICE LOCATION VA
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Fig. 29 OVERVIEW
VA 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 43
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Fig. 30 OVERVIEW
VA 8W-97 POWER DISTRIBUTION 8W - 97 - 1
TABLE OF CONTENTS
page page
OPERATION INSTALLATION
The power outlet base or receptacle shell is con- (1) Install the cigar lighter or power outlet mount
nected to ground, and an insulated contact in the into the instrument panel.
bottom of the shell is connected to battery current. (2) Reconnect the instrument panel wire harness
The power outlet receives battery voltage from a fuse connector to the connector receptacle of the cigar
in the fuse block at all times. lighter or the power outlet receptacle base.
(3) Align the splines on the outside of the cigar
DIAGNOSIS AND TESTING - POWER OUTLET lighter or power outlet receptacle base connector
(1) Check for battery voltage at the fused B(+) fuse receptacle with the grooves on the inside of the
in the fuse block. If OK, go to Step 2. If not OK, mount.
repair the open fused B(+) circuit to the battery as (4) Press firmly on the cigar lighter or power out-
required. let receptacle base until the retaining bosses of the
(2) Check for continuity between the inside cir- mount are fully engaged in their receptacles.
cumference of the power outlet receptacle and a good (5) Install the cigar lighter knob and element into
ground. There should be continuity. If OK, go to Step the cigar lighter receptacle base.
3. If not OK, go to Step 4. (6) Reconnect the battery negative cable.
(3) Check for battery voltage at the insulated con-
tact located at the back of the power outlet recepta-
cle. If not OK, go to Step 4. RELAY
(4) Disconnect and isolate the battery negative
cable. Check for continuity between the ground cir- DESCRIPTION
cuit cavity of the power outlet wire harness connector
and a good ground. There should be continuity. If
OK, go to Step 5. If not OK, repair the open ground
circuit to ground as required.
(5) Connect the battery negative cable. Check for
battery voltage at the fused B(+) circuit cavity of the
power outlet wire harness connector. If OK, replace
the faulty power outlet receptacle. If not OK, repair
the open fused B(+) circuit to the fuse in the fuse
block as required.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Pull the cigar lighter knob and element out of
the cigar lighter receptacle base, or unsnap the pro-
tective cap from the power outlet receptacle base. Fig. 1 ISO RELAY
(3) Look inside the cigar lighter or power outlet 30 COMMON FEED
receptacle base and note the position of the rectangu- 85 COIL GROUND
lar retaining bosses of the mount that secures the 86 COIL BATTERY
87 NORMALLY OPEN
receptacle base to the instrument panel. 87A NORMALLY CLOSED
(4) Insert a pair of external snap ring pliers into
the cigar lighter or power outlet receptacle base and A relay (Fig. 1) is an electromechanical device that
engage the tips of the pliers with the retaining switches fused battery current to a electrical compo-
bosses of the mount. nent when the ignition switch is turned to the Acces-
(5) Squeeze the pliers to disengage the mount sory or Run positions, or when controlled by a
retaining bosses from the receptacle base and, using electronic module. The relays are located in the fuse
a gentle rocking motion, pull the pliers and the block.
receptacle base out of the mount. The relay is a International Standards Organiza-
(6) Disconnect the instrument panel wire harness tion (ISO) relay. Relays conforming to the ISO speci-
connector from the connector receptacle of the cigar fications have common physical dimensions, current
lighter or the power outlet receptacle base. capacities, terminal patterns, and terminal functions.
(7) Remove the cigar lighter or power outlet mount A relay cannot be repaired or adjusted and, if
from the instrument panel. faulty or damaged, it must be replaced.
VA 8W-97 POWER DISTRIBUTION 8W - 97 - 5
RELAY (Continued)
ENGINE
TABLE OF CONTENTS
page page
ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 30
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 3 VALVE STEM SEALS
STANDARD PROCEDURE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 31
STANDARD PROCEDURE - COMPRESSION VALVE SPRINGS
TESTING ENGINE . . . . . . . . . . . . . . . . . . . . . . 3 REMOVAL
STANDARD PROCEDURE - CYLINDER REMOVAL - VALVE SPRINGS . . . . . . . . . . . . 31
LEAK DOWN TEST . . . . . . . . . . . . . . . . . . . . . 4 REMOVAL - VALVES . . . . . . . . . . . . . . . . . . . 31
STANDARD PROCEDURE - DETERMINING INSTALLATION
CYLINDER PRESSURE LOSS . . . . . . . . . . . . . 5 INSTALLATION - VALVE SPRINGS ....... . 32
REMOVAL INSTALLATION - VALVES .............. . 33
REMOVAL - ENGINE COVER . . . . . . . . . . . . . 5 ENGINE BLOCK
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 STANDARD PROCEDURE
INSTALLATION STANDARD PROCEDURE - REPLACING
INSTALLATION - ENGINE COVER . . . . . . . . . . 9 ENGINE CORE AND OIL GALLERY PLUGS . . 34
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 9 STANDARD PROCEDURE - MEASURING
SPECIFICATIONS - TORQUE CYLINDER BORES . . . . . . . . . . . . . . . . . . . . 34
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . 11 CRANKSHAFT
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 15 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 34
AIR CLEANER ELEMENT STANDARD PROCEDURE - MEASURE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 CRANKSHAFT AND BLOCK JOURNALS . . . . 34
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
AIR CLEANER HOUSING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 36
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 CRANKSHAFT OIL SEAL - REAR
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
CYLINDER HEAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 20 CRANKSHAFT OIL SEAL - FRONT
STANDARD PROCEDURE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
STANDARD PROCEDURE - CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 38
HEAD BOLT INSPECTION . . . . . . . . . . . . . . . 20 FLYWHEEL
STANDARD PROCEDURE - MEASURE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
CYLINDER HEAD SURFACE . . . . . . . . . . . . . 20 INSTALLATION
REMOVAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 39
REMOVAL - CYLINDER HEAD . . . . . . . . . . . . 21 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 40
REMOVAL - CYLINDER HEAD FRONT PISTON & CONNECTING ROD
COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 41
REMOVAL - CYLINDER HEAD GUIDE RAIL . . 23 STANDARD PROCEDURE
INSTALLATION STANDARD PROCEDURE - CHECKING AND
INSTALLATION - CYLINDER HEAD . . . . . . . . 24 REPAIRING CONNECTING RODS . . . . . . . . . 41
INSTALLATION - CYLINDER HEAD FRONT STANDARD PROCEDURE - MEASURING
COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 PISTON PROTRUSION . . . . . . . . . . . . . . . . . 42
INSTALLATION - CYLINDER HEAD GUIDE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 44
CAMSHAFT(S) PISTON RINGS
STANDARD PROCEDURE - CHECKING STANDARD PROCEDURE - PISTON RING
CAMSHAFT POSITION . . . . . . . . . . . . . . . . . 26 FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 VIBRATION DAMPER
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 28 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
CYLINDER HEAD COVER(S) INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 47
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
9-2 ENGINE VA
STANDARD PROCEDURE - CYLINDER LEAK (7) Connect cylinder leak down tester and follow
INSPECTING Instruction.
DOWN TEST
(1) Warm engine to operating temperature.
INSPECTING
WARNING: DO NOT OPEN COOLING SYSTEM
NOTE: If crankshaft rotates, install retaining lock for
UNLESS COOLANT TEMPERATURE IS BELOW 90C
crankshaft/ring gear.
(194°F). RISK OF INJURY TO SKIN AND EYES AS A
RESULT OF SCALDING WITH HOT COOLANT (1) Pressurize cylinder with compressed air and
WHICH SPLASHES OUT. RISK OF POISONING read off pressure loss at cylinder leak tester. If exces-
FROM SWALLOWING COOLANT. OPEN CAP sive pressure loss exists, determine possible cause
SLOWLY AND RELEASE PRESSURE. STORE COOL- (Refer to 9 - ENGINE - STANDARD PROCEDURE).
ANT IN PROPER CONTAINERS ONLY. WEAR PRO-
TECTIVE GLOVES, CLOTHING AND EYE NOTE: If the retaining lock is installed, remove it,
PROTECTION. rotate engine and install lock once again.
STANDARD PROCEDURE - DETERMINING It is possible to pin point the pressure loss of the
CYLINDER PRESSURE LOSS relevant cylinder by spraying with clean engine oil.
If an increased pressure loss was found with the Engine oil seals off the gap between the piston and
cylinder leak test, inspect the engine by listening at cylinder wall briefly. If a reduced pressure loss now
the cylinder head gasket, air intake area, exhaust, oil occurs for a short time, the cause is very likely to be
fill opening and where injectors and glow plugs enter the pistons, piston rings or cylinder contact surfaces
the cylinder head. Also check the engine coolant in of the relevant cylinder.
the radiator or expansion reservoir for the formation Determining the cause can be falsified by the posi-
of bubbles. tion of the piston ring joints. If suspicion exists that
Possible causes for the pressure loss are: the loss of pressure is caused by the piston ring
POSSIBLE CAUSE FOR PRESSURE LOSS joints being positioned directly one above the other,
fit the parts to the engine and repeat this test after
running the engine for a short time.
CONDITION POSSIBLE CORRECTION
CAUSES
REMOVAL
AIR LOSS 1. Sealing Repair Sealing
THROUGH Surfaces Surfaces
GLOW PLUG,
REMOVAL - ENGINE COVER
INJECTOR, (1) Remove the retaining screws and remove cover
ADJACENT (Fig. 2).
CYLINDERS,
OR AIR
BUBBLES IN
COOLANT
2. Gaskets 2. Replace
Component or
Gasket
3. Cylinder 3. Replace
Head Gasket Cylinder Head
Gasket
(36) Remove the transmission housing to engine (42) Remove the engine ground strap (left side).
mounting bolts. (43) Lower the vehicle.
(37) Remove the starter mounting bolts (Fig. 5). (44) Remove the heater housing filter and lower
(38) Support the transmission with a transmission housing.
jack. (45) Connect the engine lifting fixture #9308 to the
(39) Place a wood block between the transmission engine lifting eyes.
housing and the front frame cross over. (46) Remove the engine mount bolts.
(40) Remove the transmission jack. (47) Remove the transmission oil level indicator
(41) Remove the exhaust bracket (right side). tube mounting bolt.
VA ENGINE 9-9
ENGINE (Continued)
INSTALLATION
INSTALLATION - ENGINE COVER
CAUTION: Care must be taken when installing the
engine cover. Assure the proper routing of the fuel
injector return fuel hose to the banjo bolt fitting in
the left rear corner of the cover. Failure to do so
may pinch or damage the hose causing fuel leakage
or a driveability concern.
INSTALLATION
NOTE: Deburr and seal metal from cross plate
removal with anti corrosion material.
SPECIAL TOOLS
SPECIAL TOOL CROSS REFERENCE CHART
MB MILLER DESCRIPTION
TOOL # TOOL #
N/A 5069-2 FUEL GAUGE
611 589 8927 COMPRESSION TESTER
04 63 00 ADAPTER
611 589 8929 CAMSHAFT LOCKING PINS
03 15 00
611 589 8930 COUNTERHOLDER
00 40 00
N/A 9525 TIMING CHAIN RETAINER
601 589 8932 CRANKSHAFT LOCK
02 40 00
603 589 8934 COUNTERHOLDER
00 40 00
N/A 8938A EXTRACTION CLAW
611 589 8936 FRONT CRANKSHAFT
00 14 00 SEAL INSTALLER
N/A 8938 EXTRACTION CLAW
613 589 8940 VIBRATION DAMPER
#8927 COMPRESSION TESTER ADAPTER
00 33 00 REMOVER
N/A 8941 SLIDE HAMMER
611 589 8942 OIL JET INSTALLER
00 15 00
611 589 8944 REAR MAIN SEAL
01 14 00 INSTALLER
N/A 9312-1 CHAIN SEPARATOR /
RIVETING TOOL
9312-4 THRUST PIECE
N/A 9312-3 PRESSING SCREW
602 589 8951 ASSEMBLY LINKS
02 40 00
N/A 9312-5 THRU ASSEMBLY INSERTS
12
N/A 9285 FUEL LINE WRENCH
N/A 9286 GLOW PLUG PLIERS
N/A 9295 COMPRESSION HOSE
ADAPTER
111 589 9307 VALVE SERVICE TOOLS
25 61 00
N/A 8534-16 ENGINE SUPPORT
FIXTURE ADAPTERS
#8929 CAMSHAFT LOCKING PIN
N/A 9308 ENGINE LIFTING FIXTURE
N/A 9525 TIMING CHAIN GUIDE
N/A 9534 ADAPTOR
N/A 9539 FUEL LINE PLIERS
9 - 16 ENGINE VA
ENGINE (Continued)
#9543 ADAPTOR
AIR CLEANER ELEMENT (4) Disconnect the air intake pressure sensor,
unclip the top of the air cleaner housing and remove
(Fig. 11).
REMOVAL
(5) Take out air cleaner element (Fig. 11).
(1) Remove heat shield.
(6) Detach bottom part of the air cleaner housing
(2) Disconnect air flow sensor from housing (Fig.
at the body (Fig. 11).
10).
(7) Take air intake hose out of inner fender and
(3) Unclip the air cleaner housing lid (Fig. 10).
out of the rubber bushing in the wheel housing liner,
(4) Remove air cleaner element (Fig. 10).
then detach it at the bottom part of the air cleaner
housing (Fig. 11).
(8) Remove bottom portion of the air cleaner hous-
ing out of the rubber bushings in the inner fender
and remove (Fig. 11).
WARNING: NO FIRE, OPEN FLAMES OR SMOKING. (22) Disconnect the fuel line at the rear of the fuel
RISK OF POISONING FROM INHALING AND SWAL- rail (Fig. 14).
LOWING FUEL. RISK OF INJURY FROM SKIN AND (23) Remove upper timing case to cylinder head
EYE CONTACT WITH FUEL. POUR FUELS ONLY bolts (Fig. 15).
INTO SUITABLE AND APPROPRIATELY MARKED
CONTAINERS. WEAR PROTECTIVE CLOTHING NOTE: Loosen cylinder head bolts in the reverse
WHEN HANDLING FUEL. order of the tightening sequence.
(15) Remove the high pressure fuel pump interme- (24) Remove cylinder head bolts and inspect (Refer
diate gear (Fig. 14). to 9 - ENGINE/CYLINDER HEAD - STANDARD
(16) Disconnect the engine side of the engine har- PROCEDURE).
ness and set aside. (25) Remove cylinder head (Fig. 15).
(17) Disconnect the charge air pipe at the cylinder
head and set aside with the engine harness con- NOTE: Carefully clean all mating surfaces and bolt
nected. thread holes. Assure that no oil or grease is present
(18) Remove the turbocharger oil supply line at during reassembly.
the cylinder head and turbocharger (Fig. 14).
(26) Clean all mating surfaces and blow out bolt
(19) Disconnect the turbocharger at the exhaust
thread holes.
manifold (Fig. 14).
(20) Unbolt the transmission oil level indicator
tube fasteners from the cylinder head and engine
block (Fig. 14).
(21) Disconnect the upper radiator hose and by
pass hose at the thermostat housing (Fig. 14).
REMOVAL - CYLINDER HEAD FRONT COVER NOTE: Lower portion of front cover is sealed with
(1) Disconnect negative battery cable. RTV sealant. Carefully tug at front cover until it
(2) Remove engine cover (Refer to 9 - ENGINE - loosens from cylinder head.
REMOVAL).
(7) Raise locking pawl of top guide rail and remove
(3) Remove cylinder head cover (Refer to 9 -
cylinder head front cover (Fig. 16).
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL). NOTE: Dowel pins are use as a guide during
(4) Remove timing chain tensioner (Refer to 9 - assembly and must remain in the proper position to
ENGINE/VALVE TIMING/TMNG BELT/CHAIN assure a good sealing surface.
TENSIONER&PULLEY - REMOVAL).
INSTALLATION - CYLINDER HEAD FRONT (4) Install vacuum pump (Refer to 9 - ENGINE/
COVER ENGINE BLOCK/INTERNAL VACUUM PUMP -
INSTALLATION).
NOTE: Thoroughly clean all mating surfaces with
appropriate solvents to assure that no grease or oil NOTE: Timing chain tensioner must be installed
is present during reassembly. with a new gasket.
(1) Apply sealant to the marked surfaces with a WARNING: USE EXTREME CAUTION WHEN THE
bead thickness of 1.5 ± 0.5 mm (Fig. 18). ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
NOTE: Install front cover of cylinder head within 10 HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
minutes after applying sealant. Do not spread seal- NOT WEAR LOOSE CLOTHES.
ing bead.
9 - 26 ENGINE VA
CYLINDER HEAD (Continued)
(7) Start the engine and inspect for leaks. Care (7) Insert the locking pin (special tool #8929)
must be taken to observe the fuel system warning through first camshaft bearing cap into the hole in
(Refer to 14 - FUEL SYSTEM - WARNING) the left inlet camshaft sprocket (Fig. 19).
CAMSHAFT(S)
STANDARD PROCEDURE - CHECKING
CAMSHAFT POSITION
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE
COVER - REMOVAL).
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove engine cover. (Refer to 9 - ENGINE -
REMOVAL).
INSTALLATION
CAUTION: The camshafts are sensitive to fractur- Fig. 21 CAMSHAFTS AND HOUSING ASSEMBLY
ing. Ensure they are installed free of stress. 1 - CYLINDER HEAD BOLTS
2 - EXHAUST CAMSHAFT
3 - INTAKE CAMSHAFT
4 - CAMSHAFT HOUSING
CAUTION: Pay attention to assignment of cam- 5 - CYLINDER HEAD
shafts. Camshaft code numbers are visible on the
thrust collar of the axial bearing. NOTE: Pay attention to markings on camshaft bear-
ing caps.
(1) Install inlet and exhaust camshafts. (3) Position the piston of cylinder #1 to ignition
TDC.
CAUTION: Install camshafts so that the two holes in
camshaft sprockets are positioned opposite and the NOTE: Pay attention to markings on camshaft bear-
markings of the camshaft and camshaft bearing cap ing caps and follow the tightening procedure below.
are aligned.
NOTE: Do Not use old camshaft sprocket bolts. WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
(9) Fit camshaft sprocket with timing chain fitted
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
on, onto exhaust camshaft paying attention to posi-
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
tion of dowel pin. Tighten bolt to 18N·m (159 lbs.in.).
NOT WEAR LOOSE CLOTHING.
(10) Install timing chain tensioner (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT/CHAIN (17) Start engine and inspect for leaks.Care must
AND SPROCKETS - INSTALLATION). be taken to observe the fuel system warning (Refer to
(11) Inspect/Set basic position of camshafts (Refer 14 - FUEL SYSTEM - WARNING).
to 9 - ENGINE/CYLINDER HEAD/CAMSHAFT(S) - (18) Install engine cover (Refer to 9 - ENGINE
STANDARD PROCEDURE). COVER - INSTALLATION).
(12) Insert slide rail and bolt the driver into the
inlet camshaft. Tighten bolt driver to 50N·m (37 lbs.
in.).
(13) Install front cover at cylinder head.
9 - 30 ENGINE VA
CYLINDER HEAD COVER(S) (2) Insert all fuel injectors, tensioning claws and
lines. Insert new bolts and tighten. (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/FUEL INJEC-
REMOVAL
TOR - INSTALLATION).
(1) Disconnect negative battery cable.
(3) Tighten cylinder head cover bolts to 9 N·m (80
(2) Disconnect the air inlet and set aside.
lbs. in.).
(3) Detach hose from oil separator.
(4) Install and properly route fuel injector and
(4) Disconnect the camshaft position sensor.
glow plug wiring harness, making appropriate con-
(5) Disconnect fuel injector and glow plug harness
nections.
and set aside.
(5) Connect the camshaft position sensor.
(6) Remove fuel high pressure pipes and injectors
(6) Connect the return flow line.
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
(7) Attach oil separator hose.
FUEL INJECTOR - REMOVAL).
(8) Connect negative battery cable.
(7) Disconnect the out let line.
(8) Remove cylinder head cover retaining bolts and WARNING: (Refer to 14 - FUEL SYSTEM - WARN-
remove cover (Fig. 24). ING).
INSTALLATION
WARNING: USE EXTREME CAUTION WHEN ENGINE
NOTE: Do Not tighten the cylinder head cover first. IS OPERATING. DO NOT STAND IN A DIRECT LINE
The fuel injectors are aligned by way of the cylinder WITH FAN. DO NOT PUT YOUR HANDS NEAR PUL-
head cover. LEYS, BELTS OR FAN. DO NOT WEAR LOOSE
CLOTHES.
(1) Fit cylinder head cover with new gasket and
install bolts, hand tight (Fig. 24).
VALVE SPRINGS
REMOVAL
REMOVAL - VALVE SPRINGS
(1) Disconnect negative battery cable.
(2) Remove injectors (Refer to 14 - FUEL SYS-
TEM/FUEL INJECTION/FUEL INJECTOR -
REMOVAL).
(3) Remove cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(4) Remove timing chain tensioner (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - REMOVAL).
(5) Remove front cover at cylinder head (Refer to 9
- ENGINE/CYLINDER HEAD - REMOVAL).
(6) Remove top guide rail (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL). Fig. 25 VALVE COMPRESSOR
(7) Remove camshafts (Refer to 9 - ENGINE/CYL- 1 - VALVE ASSEMBLY TOOL
INDER HEAD/CAMSHAFT(S) - REMOVAL). 2 - VALVE COLLATE
3 - MAGNET
NOTE: The timing chain must be held in up position
so as not to jam during procedure. (13) Remove valve collates (Fig. 25).
(14) Remove top valve spring retainer and valve
(8) Position piston of cylinder to be processed to spring (Fig. 26).
DTC by rotating the crankshaft clockwise.DO NOT (15) Remove valve stem seals (Fig. 27).
crank engine.DO NOT rotate engine backward. (16) Remove bottom valve spring retainer (Fig. 26).
CAUTION: Make sure the crankshaft lock is in posi- NOTE: Inspect all cylinder head components for
tion and properly secured for each cylinder being wear or damage.
serviced. Failure to do so may result in damage to
the vehicle or personal injury. (17) Repeat procedure for each cylinder as neces-
sary.
(9) Install crankshaft lock, special tool #8932.
(10) Seal injector hole with adaptor # 9534 and REMOVAL - VALVES
retain with original tensioning claw. (1) Disconnect negative battery cable.
(11) Connect regulated air supply to special tool # (2) Remove engine cover (Refer to 9 - ENGINE
9534 and pressurize the cylinder to 5 bar (73 psi.). COVER - REMOVAL).
(3) Remove cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
9 - 32 ENGINE VA
VALVE SPRINGS (Continued)
WARNING: Suitably mark the valve and the position
in the cylinder head before removal. Failure to do
so will result in improperly seated valves and pos-
sible engine damage after reassembly.
INSTALLATION - VALVES
WARNING: Valves must be kept in their original
positions in cylinder head. Failure to do so will
result in engine damage.
(10) Repeat procedure for each cylinder as neces- (6) Using a suitable valve spring compressor, com-
sary. press valve spring and install valve keepers.
(11) Remove special tooling from cylinder head. (7) Repeat steps 3 through 7 for each valve as nec-
(12) Position piston of #1 cylinder to ignition TDC. essary.
(13) Install camshafts and check basic position (8) Remove valve assembly from cylinder head.
(Refer to 9 - ENGINE/CYLINDER HEAD/CAM- (9) Install cylinder head on engine block (Refer to
SHAFT(S) - INSTALLATION). 9 - ENGINE/CYLINDER HEAD - INSTALLATION).
(14) Install top guide rail (Refer to 9 - ENGINE/ (10) Install glow plugs (Refer to 8 - ELECTRICAL/
CYLINDER HEAD - INSTALLATION). IGNITION CONTROL/GLOW PLUG - INSTALLA-
(15) Install front cover at cylinder head (Refer to 9 TION).
- ENGINE/CYLINDER HEAD - INSTALLATION). (11) Connect negative battery cable.
(16) Install timing chain tensioner with new gas-
WARNING: US EXTREME CAUTION WHEN THE
ket (Refer to 9 - ENGINE/VALVE TIMING/TIMING
ENGINE IS IN OPERATION. DO NOT STAND IN A
BELT/CHAIN AND SPROCKETS - INSTALLATION)
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
(17) Install cylinder head cover (Refer to 9 -
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
ENGINE/CYLINDER HEAD/CYLINDER HEAD
NOT WEAR LOOSE CLOTHING.
COVER(S) - INSTALLATION).
(12) Start engine and check for leaks. Care must
WARNING: (Refer to 14 - FUEL SYSTEM - WARN-
be taken to observe the fuel system warning (Refer to
ING).
14 - FUEL SYSTEM - WARNING)
(18) Install injectors (Refer to 14 - FUEL SYS- (13) Install engine cover (Refer to 9 - ENGINE
TEM/FUEL INJECTION/FUEL INJECTOR - COVER - INSTALLATION).
INSTALLATION).
9 - 34 ENGINE VA
CAUTION: After bearing has damage has occurred, NOTE: Radial mounting of the main bearings of
replace connecting rods which have suffered over- standard size crankshaft is possible by assigning
heating because of bearing damage. The connect- the color-coded bearing shells.
ing rod must not have any cross scores and
notches.
ASSIGN CRANKSHAFT BEARING SHELLS
(3) Inspect connecting rod. If damage is present, The oil pan rail of the cylinder block is marked
inspect crankshaft, replace as necessary. with chisel punches indicating what bearing shell are
(4) Inspect crankcase. used.
(5) Inspect standard size of crankshaft bearing (9) Assign crankshaft bearing shells.
shells. (10) Mount crankshaft axially.
(6) Inspect crankshaft bearing cap. (11) Inspect crankshaft bearing play.
(7) Mount crankshaft radially.
(8) Inspect crankshaft bearing play.
9 - 36 ENGINE VA
CRANKSHAFT (Continued)
REMOVAL
(1) Remove engine (Refer to 9 - ENGINE -
REMOVAL).
(2) Remove timing case cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL)
(3) Remove end cover. (Refer to 9 - ENGINE/EN-
GINE BLOCK/CRANKSHAFT OIL SEAL - REAR -
REMOVAL).
(4) Remove pistons (Refer to 9 - ENGINE/ENGINE
BLOCK/PISTON & CONNECTING ROD -
REMOVAL).
INSTALLATION
CAUTION: Oil the bearing shells before inserting
crankshaft.
CRANKSHAFT OIL SEAL - (6) Remove the rear main seal/adaptor retaining
bolts and carefully pry the adaptor from the crank-
REAR case at the adaptor shoulders (Fig. 32).
REMOVAL INSTALLATION
This must be done with the transmission removed
from the vehicle. NOTE: Thoroughly clean all mating surfaces with
(1) Disconnect the negative battery cable. the appropriate solvents to assure that no grease or
(2) Raise and support the vehicle. oil is present during reassembly.
(3) Drain the engine oil.
NOTE: Loosen all of the oil pan bolts to assure that NOTE: Carefully position the rear main seal/adaptor
the oil pan gasket is not damaged when removing evenly onto the assembly sleeve. The rear main oil
the rear main oil seal and end cover assembly. seal lip MUST NOT roll over the edge of the tool.
REMOVAL
(1) Disconnect the negative battery cable.
INSTALLATION
(2) Remove the accessory drive belt.
NOTE: Thoroughly clean all mating surfaces with
(3) Install the retaining lock for the crankshaft/
the appropriate solvents to assure that no grease or
ring gear.
oil is present during reassembly.
NOTE: If the hub of the belt pulley/vibration damper
is tight, use a puller to remove it. Do Not tilt the NOTE: Carefully position the front crankshaft seal
puller. The groves of the puller MUST mesh fully evenly onto the timing cover.
into the slots of the belt pulley.
(1) Install the front crankshaft seal.
(2) Install the belt pulley/vibration damper (Refer
NOTE: Inspect the running surface of the belt pulley
to 9 - ENGINE/ENGINE BLOCK/VIBRATION
for wear.
DAMPER - INSTALLATION).
(4) Remove the belt pully/vibration damper. (3) Remove the retaining lock for the crankshaft/
ring gear.
CAUTION: Care must be taken to prevent severe (4) Install the accessory drive belt (Refer to 7 -
damage to the crankshaft and mounting whole for COOLING/ACCESSORY DRIVE/DRIVE BELTS -
the front crankshaft seal. INSTALLATION).
(5) Reconnect the negative battery cable.
(5) Using a suitable prying tool, remove the front (6) Fill the crankcase with the correct engine oil to
crankshaft seal from the timing cover (Fig. 33). the proper level.
VA ENGINE 9 - 39
CRANKSHAFT OIL SEAL - FRONT (Continued)
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHES.
FLYWHEEL
REMOVAL
(1) Remove transmission (Refer to 21 - TRANS-
MISSION/TRANSAXLE/AUTOMATIC - W5J400 -
REMOVAL).
NOTE: A flex rod torque wrench must not be used WARNING: USE EXTREME CAUTION WHEN THE
in order to avoid angle errors when tightening to ENGINE IS IN OPERATION. DO NOT STAND IN A
degrees. DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
(1) Align flywheel and inner and outer washers NOT WEAR LOOSE CLOTHES.
with straight pin. Tighten bolts in two stages. 45N·m
(33 lbs. ft.) then 90° (Fig. 34). (5) Start the vehicle.
(2) Remove the retaining lock from the crankshaft/
starter ring gear.
(3) Install transmission (Refer to 21 - TRANSMIS-
SION/TRANSAXLE/AUTOMATIC - W5J400 -
INSTALLATION).
9 - 40 ENGINE VA
FLYWHEEL (Continued)
INSTALLATION
(1) Raise and support the vehicle.
(2) Remove the generator wiring harness duct at
the crankcase and set aside.
(3) Remove inspection cover (Fig. 35).
(4) Remove the bolts (Fig. 35).
(5) Insert the crankshaft lock #8932 into the
starter ring gear and install the retaining bolts.
Tighten the lock bolts to 9 N·m (80 lbs. in.) (Fig. 35).
(19) Fill the cooing system with proper coolant, to HANDS NEAR THE PULLEYS, BELTS, OR FAN. DO
the proper level (Refer to 7 - COOLING/ENGINE/ NOT WEAR LOOSE CLOTHES.
COOLANT - STANDARD PROCEDURE).
(20) Connect negative battery cable. WARNING: (Refer to 14 - FUEL SYSTEM - WARN-
ING).
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A (21) Start the engine and inspect for leaks.
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
9 - 46 ENGINE VA
PISTON RINGS (4) Place ring in the cylinder bore and push down
with inverted piston to position near lower end of the
STANDARD PROCEDURE - PISTON RING ring travel. Measure ring gap with a feeler gauge fit-
FITTING ting snugly between ring ends (Fig. 43).
(1) Carefully clean the carbon from all ring
grooves. Oil drain openings in the oil ring groove and
pin boss must be clear. DO NOT remove metal from
the grooves or lands. This will change ring-to-groove
clearances and will damage the ring-to-land seating.
(2) Be sure the piston ring grooves are free of
nicks and burrs.
(3) Measure the ring side clearance with a feeler
gauge fitted snugly between the ring land and ring
(Fig. 42). Rotate the ring in the groove. It must move
freely around circumference of the groove.
Fig. 43 Ring
1 - FEELER GAUGE
ITEM SPECIFICATION
Top Compression Ring 0.229 - 0.610 mm
(0.0090 - 0.0240 in.)
Second Compression 0.483 - 0.965 mm
Ring
(0.0190 - 0.080 in.)
Oil Control Ring 0.254 - 1.500 mm
(0.010 - 0.060 in.)
ITEM SPECIFICATION
Top Compression Ring 0.012 - 0.016 mm
(0.0047 - 0.0063 in.)
Second Compression 0.05 - 0.09 mm
Ring
(0.0019 - 0.0035 in.)
Oil Control Ring 0.03 - 0.07 mm
(0.0011 - 0.0027 in.)
VA ENGINE 9 - 47
PISTON RINGS (Continued)
VACUUM PUMP
DESCRIPTION
The vacuum pump is operated by a slotted exten-
sion attached to the vacuum pump shaft. The vac-
uum pump shaft slotted extension fits into, and is
driven by, the exhaust camshaft gear.
The vacuum pump is a constant displacement,
vane-type pump. Vacuum is generated by vanes
mounted in the pump rotor. The rotor is located in
the pump housing and is pressed onto the pump
shaft.
The vacuum pump rotating components are inter-
nally lubricated.
The vacuum pump is not serviceable and must be
replaced as a unit. Do not disassemble or attempt to
repair the pump.
(4) Install accessory drive belt (Refer to 7 - COOL- (3) Remove vacuum pump and seals (Fig. 47)
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL- (4) Clean all sealing surfaces.
LATION).
(5) Install the additional A/C compressor drive belt INSTALLATION
(if equipped). (1) Clean all sealing surfaces.
VA ENGINE 9 - 49
VACUUM PUMP (Continued)
(7) Remove the engine mount nuts and remove the
mount (Fig. 48)
OIL FILTER
REMOVAL
(1) Unscrew the oil filter cap (Fig. 51)
(2) Remove clean and inspect cap gasket, replace
as necessary.
(3) Remove oil filter (Fig. 51).
INSTALLATION
(1) Clean all sealing surfaces. Fig. 51 ENGINE OIL COOLER
(2) Install the engine oil cooler to the timing case 1 - OIL FILTER
cover with a new gasket. Tighten bolts to 14N·m (124 2 - OIL FILTER COVER
3 - GASKET
lbs. in.) (Fig. 50). 4 - BOLT
(3) Reconnect the coolant hoses and tighten 5 - COOLANT HOSE
clamps. 6 - ENGINE OIL COOLER
(4) Install new oil filter and tighten oil filter cap to
25N·m ( 18 lbs. ft.) (Fig. 50). INSTALLATION
(5) Refill cooling system. (1) Inspect oil filter cap gasket, if all right, lubri-
(6) Start engine and inspect for leaks. cate with clean engine oil.
(7) Turn engine off and check engine oil level. Add (2) Install oil filter.
as necessary. (3) Screw oil filter cap to housing and tighten to
25N·m (18 lbs. ft.) (Fig. 51). Adjust oil level as neces-
sary.
9 - 52 ENGINE VA
OIL PAN
REMOVAL
(1) Drain engine oil.
(2) Remove the sway bar retaining bolts and swing
sway bar down and out of the way.
(3) Remove the wiring harness duct from the oil
pan bolts and position out of the way.
(4) Lower the vehicle and remove the turbocharger
upper heat shield.
(5) Connect engine support fixture #8534 using
adaptors #8534–16, to the engine lifting eye and
raise engine slightly (Fig. 54).
(6) Remove engine mounts and raise engine.
(7) Disconnect the oil level sensor.
(8) Remove the transmission cooler lines from the
oil pan bolts and carefully position the lines aside
(9) Remove the oil pan bolts.
(10) Remove oil pan and gasket (Fig. 55). Fig. 54 ENGINE SUPPORT FIXTURE
INSTALLATION
NOTE: Oil pan bolts are of different diameters and
lengths. Care must be take to install the bolts in
their original position (Fig. 57).
OIL PUMP
REMOVAL
REMOVAL
(1) Remove the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL).
(2) Remove the oil pump bolts (Fig. 55).
(3) Press the chain tensioner off of the oil pump
chain, and remove pump from chain.
(4) Remove the oil pump, pick-up tube and O-ring
(Fig. 55).
(1) Connect old oil pump chain and new chain with
temporary link, outer plate and locking element (Fig.
59).
NOTE: Rivet pins of the riveted link individually. Fig. 64 RIVET INSPECTION
(20) Install oil pump (Refer to 9 - ENGINE/LU-
(16) Position riveting tool exactly over middle of BRICATION/OIL PUMP - INSTALLATION).
pin (Fig. 63). (21) Install oil pan (Refer to 9 - ENGINE/LUBRI-
(17) Tighten riveting tool spindle until it stops. CATION/OIL PAN - INSTALLATION).
(18) Remove riveting tool, inspect riveting, re-rivet
if necessary (Fig. 64).
9 - 58 ENGINE VA
OIL PUMP (Continued)
(22) Refill engine with proper oil to the correct
level (Refer to LUBRICATION & MAINTENANCE/
FLUID TYPES - SPECIFICATIONS).
(23) Connect negative battery cable.
(24) Start engine and inspect for leaks.
OIL SENSOR
DESCRIPTION
Oil level, oil temperature and oil quality are
detected by means of an oil sensor located in the oil
pan. The sensor which operates on the capacitance
principle features an integrated electronic circuit
which analyzes the three signals. the signals are con-
stantly relayed to the ECM and over the CAN bus to
the instrument cluster by means of PWM signal.
OPERATION
Oil quality is detected for indicating the need-
based oil change interval. The oil quality is detected
on the basis of the capacitance of the engine oil
(dielectrics, does not conduct electricity), this being Fig. 65 OIL LEVEL SENSOR
as much as six times greater in case of poor quality. 1 - OIL PAN
Oil level and oil quality are separate of each other. 2 - O-RING
3 - WIRING HARNESS
The information is first of all compensated in the 4 - BOLT
ECM before being transmitted over the CAN bus. 5 - OIL LEVEL SENSOR
Faults at the oil sensor are detected by the ECM
and entered into fault memory. The voltage for the (4) Rotate front stabilizer bar upward and secure
oil sensor (approx.5V) is supplied by the ECM. to axle beam. Tighten to 22 lbs.ft. (30 N·m)
(5) Lower the vehicle.
REMOVAL (6) Lower the engine into the mounts.
(1) Disconnect the negative battery cable. (7) Remove engine support fixture.
(2) Raise and support the vehicle. (8) Raise and support the vehicle.
(3) Drain engine oil into a suitable, and appropri- (9) Tighten both engine mount to chassis nuts.
ately marked container. (10) Install and tighten oil drain plug.
(4) Remove engine mount to chassis nuts. (11) Lower vehicle and install the appropriate
(5) Lower vehicle and install engine support. engine oil.
(6) Remove the turbo charger heat shield to radia-
tor support bolts.
(7) Raise engine until the weight of the engine no INTAKE MANIFOLD
longer rests on the engine mounts.
(8) Raise and support the vehicle. REMOVAL
(9) Detach the front stabilizer bar at the front axle
and rotate it downward. WARNING: NO FIRE, SPARKS OR SMOKING.
(10) Unplug the oil level sensor (Fig. 65). STORE FUELS ONLY INTO SUITABLE AND APPRO-
(11) Remove the oil level sensor retaining screw, PRIATELY MARKED CONTAINERS, AND WEAR
oil level sensor and discard the O-ring (Fig. 65). PROTECTIVE CLOTHING. (Refer to 14 - FUEL SYS-
TEM - WARNING).
INSTALLATION
(1) Seat new O-ring on oil level sensor and lubri-
cate O-ring with clean engine oil (Fig. 65).
(2) Install the oil level sensor into the oil pan and
tighten screw to 124 lbs. in.(14N·m) (Fig. 65).
(3) Connect oil level sensor wiring harness connec-
tor (Fig. 65).
VA ENGINE 9 - 59
INTAKE MANIFOLD (Continued)
WARNING: DO NOT OPEN THE COOLING SYSTEM
UNLESS THE COOLANT TEMPERATURE IS BELOW
90°C (194°F). OPEN RADIATOR CAP SLOWLY TO
RELEASE PRESSURE. STORE COOLANT ONLY
INTO SUITABLE AND APPROPRIATELY MARKED
CONTAINERS, WEAR PROTECTIVE CLOTHING AND
EYE PROTECTION.
INSTALLATION
EXHAUST MANIFOLD
NOTE: Exhaust manifold surface must be flat within
REMOVAL 0.006 in. per foot (0.15mm per 300mm) of manifold
(1) Disconnect the negative battery cable. length.
(2) Remove the exhaust heat shield.
(3) Raise and support the vehicle. (1) Inspect exhaust manifold gasket surface for
(4) Remove the turbocharger support bracket. flatness with a straight edge.
(5) Loosen the exhaust pipe to engine bracket fas- (2) Inspect exhaust manifold for cracks or distor-
teners at the rear of the engine block. tion.
(6) Remove the exhaust hanger fasteners at the (3) Install new exhaust manifold gasket over the
muffler. studs.
(7) Disconnect the front exhaust pipe to turbo- (4) Position the exhaust manifold over to studs
charger fastener (Fig. 69). and tighten retaining nuts to 30 N·m (22 lbs.ft.).
(8) Position the front exhaust pipe aside.
(9) Lower the vehicle.
9 - 62 ENGINE VA
EXHAUST MANIFOLD (Continued)
ONLY. RISK OF INJURY TO SKIN AND EYES FROM
SCALDING COOLANT. WEAR PROTECTIVE
GLOVES, CLOTHING AND EYE WEAR.
(1) Disconnect negative battery cable.
(23) Remove timing chain tensioner (Refer to 9 - NOTE: Install timing cover within 10 minutes after
ENGINE/VALVE TIMING/TIMING BELT/CHAIN applying sealant. Do not spread sealant bead.
AND SPROCKETS - REMOVAL)
(24) Remove timing case cover (Fig. 71).
NOTE: Do not seal pressurized oil galleries to the
crankcase. Sealant applied at these points is
entrained by the oil flow and blocks the oil supply
passages.
(3) Remove fuel high pressure lines injectors (7) Remove timing chain tensioner (Refer to 9 -
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/ ENGINE/VALVE TIMING/TIMING BELT/CHAIN
FUEL INJECTOR - REMOVAL). AND SPROCKETS - REMOVAL).
(4) Clean injectors and recesses (Refer to 14 - (8) Remove high pressure pump (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/FUEL INJEC- FUEL SYSTEM/FUEL DELIVERY/FUEL INJEC-
TOR - STANDARD PROCEDURE). TION PUMP - REMOVAL).
(5) Remove cylinder head cover (Refer to 9 - (9) Remove cylinder head front cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD ENGINE/CYLINDER HEAD - REMOVAL).
COVER(S) - REMOVAL). (10) Remove top slide rail (Refer to 9 - ENGINE/
(6) Insert locking pin through first camshaft bear- CYLINDER HEAD - REMOVAL).
ing cap into hole in inlet camshaft sprocket to lock
inlet camshaft.
9 - 66 ENGINE VA
TIMING CHAIN AND SPROCKETS (Continued)
NOTE: Note position of dowel pin for camshaft NOTE: Remove timing case cover carefully. Care
sprocket alignment during reassembly. must be taken not to damage oil pan gasket.
(11) Unbolt exhaust camshaft sprocket and (3) Remove timing chain cover (Refer to 9 -
remove. ENGINE/VALVE TIMING/TIMING BELT / CHAIN
(12) Remove the intake camshaft (Refer to 9 - COVER(S) - REMOVAL).
ENGINE/CYLINDER HEAD/CAMSHAFT(S) - (4) Remove tensioning rail from bearing pin (Fig.
REMOVAL). 75).
(13) Remove intermediate gear and bushing (Fig.
74).
Fig. 76 SPECIAL TOOL 9525 Fig. 77 SPECIAL TOOL #9312–1 WITH INSERT
1 - SPECIAL TOOL 9525 9312–13
1 - SPECIAL TOOL #9312-1
CAUTION: Care must be taken not to drop the tim- 2 - SPECIAL TOOL #9312-13 - INSERT
3 - SPECIAL TOOL #9312-3 - THRUST PIN
ing chain plates into the engine once the timing 4 - SPECIAL TOOL #9312-4 - SPINDLE
chain is separated.
(10) Install fuel high pressure lines and injectors (1) Connect new timing chain, oil hole side up and
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/ old timing chain with the assembly link, the assem-
FUEL INJECTOR - INSTALLATION). bly plate and the assembly locking element, and
(11) Install engine cover (Refer to 9 - ENGINE - secure (Fig. 80).
INSTALLATION).
(12) Connect negative battery cable.
(5) Insert new riveted link with the oil hole up,
and new middle plate into ends of timing chain using
the guide link to hold the middle plate in position
(Fig. 83).
NOTE: When assembling riveting tool, piece Fig. 83 INSERTING NEW TIMING CHAIN LINK
#9312–7 is secured by a screw and #9312–10 can 1 - GUIDE LINK
move loosely on thrust spindle 2 - NEW LINK
3 - SPECIAL TOOL #9312-1
(6) Assemble riveting tool by inserting pieces 4 - TOOL INSERT #9312-7
5 - TOOL INSERT #9312-10
#9312–7 and #9312–10 (Fig. 84). 6 - THRUST PIN #9312-4
VA ENGINE 9 - 71
TIMING CHAIN AND SPROCKETS (Continued)
(8) Remove guide link and riveting tool to change
inserts.
(9) Install insert #9312–6 on riveting tool and
secure with screw (Fig. 86).
(10) Install insert 9312–8 on riveting tool.
INSTALLATION
NOTE: Carefully clean all mating surfaces with
appropriate solvents to assure that no grease or oil Fig. 89 TIMING CHAIN TENSIONER
is present during reassembly.
1 - TIMING CHAIN TENSIONER
2 - TIMING CHAIN TENSIONER SEAL
(1) Install timing chain tensioner with new gasket.
Tighten to 80N·m (59 lbs.ft.). HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
(2) Install idler pulley and accessory drive belt NOT WEAR LOOSE CLOTHES.
(Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE (5) Start the engine and inspect for leaks.
BELTS - INSTALLATION).
(3) Install intake air duct.
(4) Reconnect negative battery cable.
EXHAUST SYSTEM
TABLE OF CONTENTS
page page
OPERATION
The exhaust gases of the engine are directed
through the exhaust manifold into the turbine hous-
ing onto the turbine wheel (Fig. 2). The flow energy
of the exhaust gases cause the turbine wheel to
rotate. Consequently, the compressor wheel, which is
connected through the turbine shaft with the turbine
wheel, is driven at the same speed. The fresh air
inducted by the compressor wheel is compressed and
passed to the engine (Fig. 2).
The charge pressure is controlled by varying the
position of the guide vanes (Fig. 2). The guide stud of
the control linkage of the boost pressure actuator
turns the adjusting ring in the turbine housing (Fig.
2). As a result, all the guide vanes whose guide studs
likewise mesh into the adjusting ring, are also
turned (Fig. 2).
At low speeds, the flow cross-section is reduced by
closing the guide vanes (Fig. 2). Consequently the
speed at which the exhaust gas impacts on the tur-
bine wheel is increased, as a result of which the
speed of the turbocharger and thus the charge pres-
sure rises.
At high engine speeds the guide vanes are increas- Fig. 2 TURBOCHARGER COMPONENTS
ingly opened and the flow cross-section is thus 1 - COMPRESSOR HOUSING
enlarged, as a result of which the speed of the turbo- 2 - GUIDE VANE
3 - GUIDE STUD OF GUIDE VANE
charger reduces and the charge pressure drops. 4 - GUIDE STUD OF CONTROL LINKAGE
5 - CONTROL LINKAGE
6 - ADJUSTING RING
CHARGE AIR COOLER AND 7 - TURBINE HOUSING
8 - BOOST PRESSURE CONTROL UNIT
PLUMBING 1A - EXHAUST GASES TO TURBINE WHEEL
2A - TURBO INLET (FRESH AIR)
3A - TURBO OUTLET (COMPRESSED AIR)
DESCRIPTION 4A - EXHAUST OUTLET
The charge air system consists of the charge air
cooler and charge air cooler piping. radiator. From the charge air cooler the air flows
The charge air cooler is a heat exchanger that uses back into the intake manifold.
air flow from vehicle motion to dissipate heat from
the intake air. As the turbocharger increases air DIAGNOSIS AND TESTING - CHARGE AIR
pressure, the air temperature increases. Lowering COOLER SYSTEM - LEAKS
the intake air temperature increases engine effi-
ciency and power. NOTE: Slight engine oil pooling in the charge air
inlet hose IS NOT premature turbocharger failure.
OPERATION Slight pooling is the normal result of the breather
Intake air is drawn through the air cleaner and system. Test the air breather tube for normal oper-
into the turbocharger compressor housing. Pressur- ation by referring to the appropriate diagnostic
ized air from the turbocharger then flows forward manual.
through the charge air cooler located in front of the
VA EXHAUST SYSTEM 11 - 5
CHARGE AIR COOLER AND PLUMBING (Continued)
Low turbocharger boost pressure and low engine
performance can be caused by leaks in the charge air
cooler or it’s plumbing. The following procedure out-
lines how to check for leaks in the charge air cooler
system.
(1) Loosen clamp and remove turbocharger to air
inlet duct rubber sleeve from turbocharger.
(2) Insert Special Tool 8442 Adapter into the rub-
ber sleeve. Tighten existing clamp to 8 N·m (72
in.lbs.).
TURBOCHARGER
DESCRIPTION
The boost pressure vacuum solenoid is located
under the air filter housing and is responsible for
turbo-charger boost pressure. It generates a control
vacuum in response to a PWM signal from the ECM.
Vacuum is achieved by mixing the system vacuum
(from the vacuum pump) with atmospheric pressure
to a certain degree. The resulting vacuum is sent to
the vacuum unit at the turbocharger (Fig. 4).
OPERATION
The vacuum solenoid receives 12V from the ECM.
The ECM controls the solenoid through a PWM sig-
nal. When the solenoid receives a signal it closes the
passage to atmospheric pressure. The subchamber is
no longer under atmospheric pressure, it’s spring can
push the diaphragm and valve downwards; this
releases the VAC duct. Vacuum can now go from here Fig. 4 CHARGE PRESSURE VACUUM TRANSDUCER
through the throttle hole, filters and out the connec- 1 - CONNECTION TO TURBOCHARGER VACUUM UNIT
tion to the turbocharger vacuum unit (Fig. 5). 2 - VENT
3 - SUPPLY FROM VACUUM PUMP
Fig. 6 TURBOCHARGER
1 - TURBOCHARGER 8 - OIL RETURN LINE
2 - OIL SUPPLY LINE 9 - GASKET
3 - O-RING 10 - VACUUM UNIT
4 - FRONT EXHAUST PIPE 11 - CHARGE AIR HOSE
5 - BRACKET 12 - CLAMP
6 - O-RING 13 - AIR INTAKE HOSE
7 - GASKET 14 - HEAT SHIELD
11 - 8 EXHAUST SYSTEM VA
TURBOCHARGER (Continued)
page page
BUMPERS FRAME
SPECIFICATIONS - TORQUE ...............1 SPECIFICATIONS
FRONT BUMPER - STEPS SPECIFICATIONS - FRAME DIMENSIONS ...4
REMOVAL ............. ................2 SPECIFICATIONS - TORQUE . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . ................2 ENGINE CRADLE CROSSMEMBER
FRONT FASCIA REMOVAL .............................6
REMOVAL ............. ................2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION . . . . . . . . . . ................2 REAR CROSSMEMBER - TRANSMISSION
REAR BUMPER - STEP REMOVAL .............................9
REMOVAL ............. ................3 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLATION . . . . . . . . . . ................3 TRAILER HITCH
REAR FASCIA REMOVAL .............................9
REMOVAL ............. ................3 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . ................3
BUMPERS
SPECIFICATIONS - TORQUE
TORQUE SPECIFICATIONS
INSTALLATION
(1) Install fascia and seat the corners over the sup-
Fig. 3 REAR BUMPER STEP port brackets.
1 - FRAME BOLTS/NUTS (2) (2) Seat bumper support brackets clips below end
2 - BOLTS (4) panel firmly.
3 - BUMPER STEP
4 - REAR FASCIA (3) Install the four plastic rivets to the bumper
step, if equipped.
INSTALLATION (4) Install fascia bolts and tighten to 23 N·m (17
(1) Install bumper step and install support bolts. ft. lbs.).
(2) Tighten bolts to 38 N·m (28 ft. lbs.). (5) Install reflectors and reflector screws.
(3) Install frame bolts/nuts and tighten to 90 N·m
(66 ft. lbs.).
(4) Install fascia. (Refer to 13 - FRAME & BUMPERS/
BUMPERS/REAR FASCIA - INSTALLATION)
13 - 4 FRAME & BUMPERS VA
FRAME INDEX
DESCRIPTION FIGURE
SPECIFICATIONS FRAME DIMENSIONS 5
SPECIFICATIONS - FRAME DIMENSIONS
NOTE: Frame dimensions are listed in metric scale.
VEHICLE PREPARATION
Position the vehicle on a level work surface. Verti-
cal dimensions can be taken from the work surface to
the locations indicated were applicable.
VA FRAME & BUMPERS 13 - 5
FRAME (Continued)
(13) Support engine cradle with suitable lifting Fig. 12 HEAT SHIELD
device. 1 - HEAT SHIELD
(14) Remove four cradle support bolts from each 2 - NUTS
side of the cradle. (Fig. 11)
(21) Using a sharp flat bladed tool, remove identi-
fication plate. (Fig. 13)
INSTALLATION
WARNING: Do not oil or grease the bolts and nuts.
if the bolts and nuts are greased, the trailer hitch
may become detached from the vehicle, possibly Fig. 17 TRAILER HITCH
resulting in a serious risk of injury and/or damage 1 - FRAME BOLTS (8)
to property, including damage to the vehicle. 2 - MOUNTING PLATES (2)
3 - LOCK NUTS (8)
(1) Raise hitch into position. 4 - TRAILER HITCH
5 - BRACKET TO STEP BOLTS (4)
(2) Install the mounting plate and new frame 6 - ANGLE BRACKETS (2)
bolts/nuts and hand tighten bolts. 7 - BRACKET BOLTS (4)
WARNING: Microencapsulated bolts and self-lock- (3) Install the angle bracket microencapsulated
ing nuts may only be used once. If you use bolts/nuts and hand tighten.
microencapsulated bolt or self-locking nuts more (4) Align trailer hitch.
than once, the self-locking function is rendered (5) Tighten the frame mounting bolts to 110 N·m
useless. The trailer hitch may become detached (81 ft. lbs.).
from the vehicle, possibly resulting in a serious risk (6) Tighten microencapsulated angle bracket bolts
of injury and/or damage to property, including dam- to 50 N·m (37 ft. lbs.)
age to the vehicle. (7) Connect trailer socket electrical connector.
VA FUEL SYSTEM 14 - 1
FUEL SYSTEM
TABLE OF CONTENTS
page page
STANDARD PROCEDURE
Fig. 3 WATER IN FUEL SENSOR
STANDARD PROCEDURES - CLEANING FUEL 1 - WIF SENSOR
SYSTEM COMPONENTS 2
3
-
-
WIF DRAIN
FUEL FILTER
4 - FUEL SUPPLY FROM TANK
CAUTION: Cleanliness cannot be overemphasized 5 - FUEL SUPPLY TO HIGH PRESSURE PUMP
when handling or replacing diesel fuel system com-
ponents. This especially includes the fuel injectors, STANDARD PROCEDURE - LOW PRESSURE
high-pressure fuel lines, fuel rail, and fuel injection FUEL PUMP TEST
pump. Very tight tolerances are used with these
parts. Dirt contamination could cause rapid part NOTE: Assure fuel tank quantity and proper fuel
wear and possible plugging of fuel injector nozzle gauge operation. Assure that the fuel pump fuse or
tip holes. This in turn could lead to possible engine relay is not open. Capture any fuel spillage and
misfire. Always wash/clean any fuel system compo- store in appropriately marked containers.
nent thoroughly before disassembly and then air
dry. DO NOT wire brush injector nozzles when
cleaning. Cap or cover any open part after disas- NOTE: When the ignition switch is turned to the On
sembly. Before assembly, examine each part for position the fuel pump will begin to run for 20–30
dirt, grease or other contaminants and clean if nec- seconds and then it stops.
essary. When installing new parts, lubricate them
with clean engine oil or clean diesel fuel only. The low pressure pump draws fuel out of the fuel
tank module mixing bowl and pushes the fuel
towards the fuel filter. If the pressure reading is
below specification, look for damaged or leaking fuel
lines or a restricted fuel filter. If no problem is found
14 - 4 FUEL SYSTEM VA
FUEL SYSTEM (Continued)
with the fuel system replace the low pressure fuel
pump.
(1) Disconnect the negative battery cable.
(2) Connect a fuel gauge to the low pressure fuel
supply to the high pressure pump (Fig. 4).
FUEL DELIVERY
TABLE OF CONTENTS
page page
SPECIFICATIONS
TORQUE
HIGH-PRESSURE LINES
CAUTION: High pressure lines cannot contact each
other or other components. Do not attempt to weld
high-pressure fuel lines or to repair lines that are
damaged. High pressure lines must be replaced at
each disassembly. Use only recommended lines
when replacement of high-pressure fuel line is nec-
essary.
SPANNER WRENCH-6856
Restricted (kinked or bent) high-pressure lines can
cause starting problems, poor engine performance,
engine mis-fire and white smoke from exhaust (Refer
to 14 - FUEL SYSTEM - WARNING).
FUEL FILTER
DESCRIPTION
The fuel filter was designed for improved high alti-
tude operation and for better re-start after the fuel
tank has been completely emptied. The water drain
plug and water in fuel (WIF) sensor are located on
the top of the filter. Water is drained by using the in-
FUEL LINE WRENCH-9285 tank electric fuel pump to generate flow (attach a
hose to the drain plug). The filter has a pressure dif-
ferential of 200–300 mbar (2.9 psi.) when new. When
dirty, the pressure differential rises to 800 mbar (11.6
psi.) (Fig. 2).
REMOVAL
WARNING: NO SPARKS, OPEN FLAMES OR SMOK-
ING. RISK OF POISONING FROM INHALING AND
SWALLOWING FUEL. RISK OF INJURY TO EYES
AND SKIN FROM CONTACT WITH FUEL. POUR
FUELS ONLY INTO SUITABLE AND APPROPRI-
ATELY MARKED CONTAINERS. WEAR PROTECTIVE
CLOTHING.
FUEL LINE PLIERS-9539
VA FUEL DELIVERY 14 - 9
FUEL FILTER (Continued)
CAUTION: DO NOT bend, twist or cut the fuel hose Orginal clamps must be used when servicing the
clamps. The fuel hose clamps through out the fuel fuel system.
system are reusable when using special tool #9539.
Orginal clamps must be used when servicing the NOTE: Capture any fuel spillage and dispose of in
fuel system. appropriately marked container.
(1) Disconnect negative battery cable. (1) Fill new fuel filter with the new diesel fuel
(2) Disconnect the water in fuel (WIF) sensor har- (approximately 0.4 liters)
ness connector (Fig. 2). (2) Carefully seat WIF sensor and tighten bolt to
(3) Release the fuel inlet and outlet hose clamps 13 lbs. in. (1.5 N·m) (Fig. 2)
using special tool #9539 at the fuel filter (Fig. 2). (3) Position fuel filter in bracket and tighten
(4) Remove fuel filter retaining bracket bolt and retaining bolt to 53 lbs. in. (6 N·m) (Fig. 2)
remove fuel filter (Fig. 2). (4) Install fuel lines and re-crimp clamps using
(5) Separate the WIF sensor from the fuel filter special tool #9539 (Fig. 2).
(Fig. 2) (5) Connect the WIF wiring harness connector
(Fig. 2).
(6) Connect negative battery cable.
(7) Start engine and inspect for leaks.
FUEL LINES
REMOVAL - HIGH PRESSURE LINES
WARNING: NO SPARKS, OPEN FLAMES OR SMOK-
ING. RISK OF POISONING FROM INHALING AND
SWALLOWING FUEL. RISK OF INJURY TO EYES
AND SKIN FROM CONTACT WITH FUEL. POUR
FUELS ONLY INTO SUITABLE AND APPROPRI-
ATELY MARKED CONTAINERS. WEAR PROTECTIVE
CLOTHING.
WARNING: NO SPARKS, OPEN FLAMES OR SMOK- (2) Unscrew union nuts of injection lines.
ING. RISK OF POISONING FROM INHALING AND (3) Remove injection lines (Fig. 3).
SWALLOWING FUEL. RISK OF INJURY TO EYES
AND SKIN FROM CONTACT WITH FUEL. POUR INSTALLATION - HIGH PRESSURE LINES
FUELS ONLY INTO SUITABLE AND APPROPRI-
ATELY MARKED CONTAINERS. WEAR PROTECTIVE WARNING: NO SPARKS, OPEN FLAMES OR SMOK-
CLOTHING. ING. RISK OF POISONING FROM INHALING AND
SWALLOWING FUEL. RISK OF INJURY TO EYES
AND SKIN FROM CONTACT WITH FUEL. POUR
CAUTION: DO NOT bend, twist or cut the fuel hose FUELS ONLY INTO SUITABLE AND APPROPRI-
clamps. The fuel hose clamps through out the fuel ATELY MARKED CONTAINERS. WEAR PROTECTIVE
system are reusable when using special tool #9539. CLOTHING.
14 - 10 FUEL DELIVERY VA
FUEL LINES (Continued)
OPERATION
Non-constant fuel system pressure influences the
position of a diaphragm inside the sensor. This
results in a variation in the electrical resistance. The
fuel rail pressure sensor supplies the appropriate
voltage signal to the ECM.
REMOVAL
(1) Disconnect the negative battery cable.
(2) Disconnect the sensor wiring harness connector
(Fig. 4).
INSTALLATION
(1) Install the sealing ring onto the sensor and
screw the fuel pressure sensor into the fuel rail.
(2) Tighten the senor to 60 N·m (44 ft. lbs.), back
it off 90 degrees and retighten to 80 N·m (59 ft. lbs.)
(Fig. 4).
(3) Connect the sensor wiring harness connector.
FUEL PUMP
Fig. 5 HIGH PRESSURE FUEL PUMP
DESCRIPTION
1 - HIGH PRESSURE PUMP
2 - FUEL SUPPY TO FUEL RAIL
DESCRIPTION - HIGH PRESSURE PUMP 3 - FUEL SUPPLY LINE
4 - FUEL RETURN LINE
5 - FUEL TEMPERATURE SENSOR
WARNING: (Refer to 14 - FUEL SYSTEM - WARN- 6 - FUEL QUANTITY CONTROL VALVE
ING) 7 - OIL LEVEL INDICATOR
8 - VACUUM PUMP
The high pressure pump is a fuel regulated radial
piston pump with three pistons arranged at an angle OPERATION
of 120°. The regulation being carried out by the fuel
quantity valve. The high pressure pump is driven at OPERATION
about 1.3 times the speed of the camshaft. Specific
moving parts inside the pump are graphite coated to LOW PRESSURE SIDE
assist with the lubrication process during operation. The fuel supplied by the low pressure pump flows
The high pressure pump is mounted to the front of through the fuel supply (5) at the high pressure
the cylinder head and must be replaced as an assem- pump and is passed to the flow control valve (11) and
bly should a failure occur (Fig. 5). the fuel pressure relief valve (9). Any air entrained
by the fuel is directed through the restrictor (10)
DESCRIPTION - LOW PRESSURE PUMP through the bleed port (7) to the return flow (6). The
The electric fuel pump is located in the fuel tank. quantity control valve (11) controls the amount of
The pump draws warm or hot fuel from the fuel tank fuel that flows along the ring passage (4) through the
module bowl and also draws cool fuel out of the tank. supply ports to the three high pressure pump ele-
The cool fuel is drawn in and is mixed with the fuel ments. To lubricate the plunger and barrel assem-
already in the bowl in a 50–50 mix ratio. Refer to blies when the quantity control valve is closed (over
fuel pump module for servicing (Refer to 14 - FUEL run mode), the fuel is led directly to the circular port
SYSTEM/FUEL DELIVERY/FUEL TANK MODULE by the zero delivery restrictor (10) (Fig. 6).
- REMOVAL).
14 - 12 FUEL DELIVERY VA
FUEL PUMP (Continued)
The fuel pressure relief valve (9) limits the fuel
pressure which exists at the fuel quantity control
valve (11) to approximately 5 bar (72.5 psi). If the
pressure is exceeded, the pressure relief valve opens
and passes the fuel to the return flow (6) (Fig. 6).
The fuel pressure relief valve (9) directs a portion
of the fuel as a lubricant to the eccentric shaft (8)
(Fig. 6).
REMOVAL - HIGH PRESSURE PUMP the pump drive for wear. If wear is present replace
the drive and gear.
(6) Remove bolts attaching high pressure pump
and remove pump (Fig. 8).
(3) Attach high pressure fuel line to pump. Fig. 10 TOP OF FUEL TANK
Tighten to 22N·m (194 lbs.in.) (Fig. 9). 1 - Cooler Lines
(4) Install the viscous fan. 2 - Top of Tank
(5) Connect negative battery cable. 3 - Expansion Tank
4 - Check Valves
(6) Start engine, allow to run, turn engine off and 5 - Check Valve
inspect for leaks (Refer to 14 - FUEL SYSTEM - 6 - Module Lock Ring
WARNING), (Refer to 14 - FUEL SYSTEM - DIAG- 7 - Fuel Pump Module
NOSIS AND TESTING).
(4) The plastic fuel pump module locknut (lock-
ring) is threaded onto fuel tank. Install Special Tool
FUEL PUMP MODULE #6856 to locknut and remove locknut (Fig. 11). The
fuel pump module will spring up slightly after lock-
DESCRIPTION nut is removed.
The fuel pump module is installed in the top of the
fuel tank (Fig. 10). The pump module contains the
following components:
• Electric fuel pump (transfer, or lift pump)
• Fuel reservoir
• Fuel gauge sending unit (fuel level sensor)
• Fuel supply line connection
• Fuel return line connection
Fuel is supplied to the high-pressure fuel injection
pump by the low-pressure fuel transfer (lift) pump. This
electric fuel pump is attached to the fuel pump module.
A low-pressure fuel pump is not attached to the engine.
REMOVAL
CAUTION: To prevent damage to the float rod, the
float and float rod must be removed from the pump
module. This step must be done before the pump
module is removed from the fuel tank.
INSTALLATION
CAUTION: Whenever the fuel pump module is ser-
viced, the rubber gasket must be replaced.
(6) Rotate clip (2) (Fig. 16) to attach rod (3) to clip.
REMOVAL
(1) Disconnect the negative battery cable. Fig. 18 HIGH PRESSURE FUEL PUMP
(2) Disconnect the control valve wiring harness 1 - HIGH PRESSURE PUMP
connector (Fig. 18). 2 - FUEL SUPPY TO FUEL RAIL
3 - FUEL SUPPLY LINE
(3) Remove the valve fasteners and remove the 4 - FUEL RETURN LINE
control valve (Fig. 18). 5 - FUEL TEMPERATURE SENSOR
6 - FUEL QUANTITY CONTROL VALVE
7 - OIL LEVEL INDICATOR
INSTALLATION 8 - VACUUM PUMP
(1) Clean sealing surfaces.
(2) Install new seal on sensor. influences the atomization of fuel at the injector noz-
(3) Position the control valve on to the high pres- zle, and the accuracy of injected quantity during
sure pump and install fasteners (Fig. 15). injection.
(4) Connect wiring harness connector to control
valve (Fig. 15). REMOVAL
(5) Connect negative battery cable. (Refer to 14 - FUEL SYSTEM - WARNING).
(6) Start the engine, allow to run, turn engine off
and inspect for leaks (Refer to 14 - FUEL SYSTEM/ WARNING: NO SPARKS, OPEN FLAMES OR SMOK-
FUEL INJECTION - WARNING). ING. RISK OF POISONING FROM INHALING AND
SWALLOWING FUEL. RISK OF INJURY TO EYES
AND SKIN FROM CONTACT WITH FUEL. POUR
FUEL RAIL FUELS ONLY INTO SUITABLE AND APPROPRI-
ATELY MARKED CONTAINERS. WEAR PROTECTIVE
DESCRIPTION CLOTHING.
The fuel rail acts like a high pressure store. It is
available to all injectors for drawing fuel which has (1) Disconnect negative battery cable.
been compressed by the high pressure injection (2) Remove the engine cover.
pump. The rail pressure sensor, rail pressure control (3) Disconnect the intake manifold air inlet duct
valve, high pressure line, and the return flow line and position aside.
are attached to the fuel rail. (4) Disconnect the fuel rail pressure and control
valve wiring harness connectors.
OPERATION (5) Remove engine harness retaining bolts and
The stored fuel volume inside the rail acts as a unclip the engine harness from the fuel rail.
damper for pressure fluctuations which result (6) Remove injector high pressure lines (Fig. 19)
because of pulsating supply and brief large extrac- (7) Remove fuel rail retaining bolts (Fig. 19).
tions of fuel during injector firing. The rail primarily
VA FUEL DELIVERY 14 - 19
FUEL RAIL (Continued)
CAUTION: When slackening and tightening fuel FUEL. RISK OF INJURY TO EYES AND SKIN FROM
injection line union nuts, counter hold with wrench CONTACT WITH FUEL. POUR FUELS ONLY INTO
at threaded connection. ON NO ACCOUNT exceed SUITABLE AND APPROPRIATELY MARKED CON-
the tightening torque at any time. Do NOT crimp or TAINERS. WEAR PROTECTIVE CLOTHING.
bend lines. (1) Loosely position fuel rail into proper position
on the cylinder head and hand tighten the fasteners.
(2) Connect the fuel pressure control valve harness
NOTE: After removing lines, seal connections and connector (Fig. 19).
ensure cleanliness. (3) Connect the fuel return lines at the banjo bolt
(Fig. 19).
FUEL TANK lift pump) is attached to the fuel pump module. This
module (Fig. 22) is located in the fuel tank. Refer to
Fuel Pump Module for additional information.
DESCRIPTION
The plastic fuel tank (Fig. 20) is mounted to the
frame rails under the left/center side of the vehicle.
REMOVAL
(1) Drain diesel fuel from tank using an approved
The fuel tank contains a serviceable fuel pump mod-
diesel fuel draining station.
ule with an electric fuel pump, and a fuel level send-
(2) Disconnect fuel fill and vent lines from body.
ing unit. The tank is also equipped with 2 fuel lines:
(3) Raise and support vehicle.
a fuel supply line to the fuel pump, and a separate
(4) Support tank with a hydraulic jack.
fuel return line.
(5) Remove 2 fuel tank strap nuts (8) (Fig. 23) and
Fuel Temperature Control: A section of the fuel
position straps (7) towards left side of vehicle.
return line is coiled at the rear section of the tank
(6) Carefully lower tank a few inches and discon-
(Fig. 21). This coiled section is used to help drop the
nect electrical connector at top of fuel pump module.
temperature of fuel returning to the tank. A thermo-
(7) Disconnect fuel supply line at tank.
stat (preheating valve) (3) (Fig. 21) is used to keep
(8) Disconnect fuel return line at tank.
fuel temperature below 160 degrees F. If fuel temper-
(9) Continue to carefully lower tank for removal.
ature is above 160 degrees F, fuel passes first
(10) If fuel pump module is to be removed, thor-
through the coiled cooler lines, and then into the fuel
oughly clean area at top of fuel pump around module.
tank. If fuel temperature is below 160 degrees F, fuel
bypasses the coiled cooler lines, and is returned
directly into the fuel tank.
An electric fuel pump (more commonly referred to
in diesel applications as a fuel transfer pump or fuel
REMOVAL
The fuel level sending unit (fuel level sensor) and
float assembly is located on the side of the fuel pump
module (4) (Fig. 30).
(1) Remove fuel pump module from fuel tank.
Refer to Fuel Pump Module Removal/Installation.
(2) Unplug sensor’s 2–wire harness from pump
module electrical connector.
(3) Before disconnecting wiring from 2–wire har-
ness electrical connector, note position of each wire in
the connector. Record this position.
(4) Disconnect wiring from 2–wire harness electri-
cal connector using a terminal pick / removal tool.
Refer to Special Tools in 8W, Wiring for tool part
numbers.
(5) To remove sending unit from pump module,
press on plastic locking tabs (1) (Fig. 30) while slid- Fig. 31 FUEL LEVEL SENSOR
ing sending unit (4) on its tracks. 1 - RELEASE TABS
2 - ELECTRIC FUEL PUMP
3 - BOTTOM OF FUEL PUMP MODULE
INSTALLATION 4 - SENDING UNIT
(1) Noting their previous positions, connect wires
from 2–wire harness into its connector.
VA FUEL DELIVERY 14 - 25
FUEL INJECTION
TABLE OF CONTENTS
page page
OPERATION
The clearance between the crankshaft position sen-
sor and the flywheel are fixed by the installation
position. Two teeth on the flywheel are missing. The
resulting gap is used by the ECM to detect DTC of
cylinder number one. The crankshaft position is cal-
culated to an accuracy of a fraction of a degree so
that the start and end of injection can occur at
Fig. 5 CAM POSITION SENSOR exactly the right moment. The engine speed signal is
1 - WIRING HARNESS CONNECTOR also processed by the ECM from the crankshaft sen-
2 - CAM POSITION SENSOR
3 - O-RING sor. This signal is then transferred to other control
4 - CYLINDER HEAD COVER modules over the CAN bus.
If the crankshaft position sensor fails, the signal
INSTALLATION that provides reference rotation is missing. Injection
(1) Install camshaft position sensor and tighten may occur at the wrong time and damage the engine.
bolt (Fig. 5). In this case, the ECM will stop triggering the injec-
(2) Reconnect electrical connector (Fig. 5). tors, the engine would cut out, the engine warning
(3) Install engine cover. light would illuminate and the engine will not
(4) Reconnect negative battery cable. restart.
14 - 30 FUEL INJECTION VA
CRANKSHAFT POSITION SENSOR (Continued)
REMOVAL
WARNING: NO SPARKS, OPEN FLAMES OR SMOK-
ING. RISK OF POISONING FROM INHALING AND
SWALLOWING FUEL. RISK OF INJURY TO EYES
AND SKIN FROM CONTACT WITH FUEL. POUR
FUELS ONLY INTO SUITABLE AND APPROPRI-
ATELY MARKED CONTAINERS. WEAR PROTECTIVE
Fig. 9 INJECTOR CLASSIFICATION MARKINGS
CLOTHING.
1 - ELECTRICAL CONNECTOR
2 - SIX-DIGIT ALPHANUMERIC CODE
NOTE: When removing injectors, the seal rings and
INJECTOR CLASSIFICATION PROCEDURE retaining stretch bolts must always be replaced.
(1) Turn ignition switch “ON”. Coat the injector body with the anti-seize com-
(2) Using a DRB IIIt and select ENGINE then pound before installing. Keep lubricant away from
MISCELLANEOUS. the injector nozzle.
(3) Select LEARN INJECTORS.
(4) Using the up and down arrows, scroll to the (1) Disconnect negative battery cable.
appropriate injector. (2) Remove engine cover (Refer to 9 - ENGINE -
(5) Using the right and left arrows, set injector to REMOVAL).
proper classification. (3) Remove the fuel return hose locking clamps at
(6) Once injectors are classified, cycle ignition to the injector and remove return hose.
complete. (4) Disconnect the injector electrical connector
(Fig. 10).
STANDARD PROCEDURE - CLEANING FUEL
INJECTORS NOTE: Counterhold injection lines with wrench
socket at threaded connections of injectors.
NOTE: Before cleaning the injector recesses, seal
the injector holes in the injector recesses with the (5) Disconnect fuel injector high pressure line (Fig.
10).
VA FUEL INJECTION 14 - 33
FUEL INJECTOR (Continued)
(6) Remove fuel injector retaining bolt and tension Coat the injector body with the anti-seize com-
claw, then remove the injector and seal (Fig. 10). pound before installing. Keep lubricant away from
the injector nozzle.
NOTE: If injectors are tight, remove with extraction (1) Clean injectors and recesses (Refer to 14 -
claw in place of tensioning claw. If extraction claw FUEL SYSTEM/FUEL INJECTION/FUEL INJEC-
contacts cylinder head cover, remove cylinder head TOR - STANDARD PROCEDURE).
cover. If necessary, remove injectors with threaded (2) Coat injector body with anti seize lubricant
adaptor and discard injector. then install injectors with new seals.
(3) Install tensioning claws with new screws at
(7) Remove injectors (Fig. 10). injectors. Tighten screws in two stages, 7 N·m (62
lbs. in.) then 90° (Fig. 10).
Fig. 10 FUEL INJECTOR REMOVAL / INSTALLATION (8) Program all injector codes into the ECM using
1 - FUEL INJECTOR RETURN LINE the scan tool.
2 - RETAINING CLIP (9) Start engine, allow to run, turn engine off and
3 - INJECTOR HIGH PRESSURE LINE inspect for leaks (Refer to 14 - FUEL SYSTEM -
4 - INJECTOR SEAL
5 - FUEL INJECTOR WARNING).
6 - TENSIONING CLAW
7 - SPECIAL TOOLS #8938 AND # 8937 CAUTION: Care must be taken when installing the
engine cover. Assure the proper routing of the fuel
(8) Clean injectors and recesses (Refer to 14 - injector return fuel hose to the banjo bolt fitting in
FUEL SYSTEM/FUEL INJECTION/FUEL INJEC- the left rear corner of the cover. Failure to do so
TOR - STANDARD PROCEDURE). may pinch or damage the hose causing fuel leakage
or a driveability concern.
INSTALLATION
(10) Install engine cover (Refer to 9 - ENGINE -
WARNING: NO SPARKS, OPEN FLAMES OR SMOK- INSTALLATION)..
ING. RISK OF POISONING FROM INHALING AND
SWALLOWING FUEL. RISK OF INJURY TO EYES
AND SKIN FROM CONTACT WITH FUEL. POUR FUEL PRESSURE SENSOR
FUELS ONLY INTO SUITABLE AND APPROPRI-
ATELY MARKED CONTAINERS. WEAR PROTECTIVE DESCRIPTION
CLOTHING. The fuel rail pressure sensor measures the current
fuel rail pressure and supplies an appropriate voltage
NOTE: When removing injectors, the seal rings and signal to the ECM. The non-constant fuel system
retaining stretch bolts must always be replaced. pressure influences the position of the internal dia-
14 - 34 FUEL INJECTION VA
FUEL PRESSURE SENSOR (Continued)
phragm. This results in a variation in the electrical CAUTION: Care must be taken when installing the
resistance which is analyzed by the ECM. engine cover. Assure the proper routing of the fuel
injector return fuel hose to the banjo bolt fitting in
OPERATION the left rear corner of the cover. Failure to do so
The fuel rail pressure sensor measures the current may pinch or damage the hose causing fuel leakage
fuel rail pressure and sends a voltage signal to the or a driveability concern.
ECM. The ECM then actuates the fuel rail pressure
control valve until the desired rail pressure is (5) Connect negative battery cable.
achieved.
Fig. 16 INLET AIR TEMPERATURE SENSOR Fig. 17 BOOST PRESSURE AND INLET AIR
1 - INTAKE AIR TEMPERATURE SENSOR TEMPERATURE SENSORS
2 - PIPE 1 - CHARGE AIR DUCT
2 - INTAKE AIR TEMPERATURE SENSOR
ohms. For a temperature of 104°F (40°C) the resis- 3 - BOOST PRESSURE SENSOR
tance is approximately 2600 ohms (Fig. 16).
sure allows better control of the variable geometry
turbocharger to suit the driving environment and
REMOVAL
preserve turbocharger durability.
(1) Disconnect the negative battery cable.
(2) Unplug the wiring harness connector at the
intake air temperature sensor.
REMOVAL
(1) Disconnect the negative battery cable.
(3) Press together the sensor locking arms and
(2) Disconnect the sensor electrical connector.
remove the sensor from the charge air pipe (Fig. 17).
(3) Remove the air intake pressure sensor.
INSTALLATION
(1) Position the intake air temperature sensor
INSTALLATION
(1) Positon the pressure sensor in the air cleaner
above the charge air pipe access hole.
cover and install the fasteners (Fig. 18).
(2) Press together the sensor locking tabs, seat the
(2) Connect the electrical connector (Fig. 18).
sensor to the pipe and release tabs (Fig. 17).
(3) Connect the negative battery cable.
(3) Connect negative battery cable.
DESCRIPTION DESCRIPTION
The Mass Air Flow (MAF) Sensor is located in the
An absolute pressure sensor is mounted to the air
air intake port between the air filter and the turbo-
cleaner housing. The sensor is used by the ECM to
charger (Fig. 19). The MAF sensor uses semiconduc-
adjust for changes in altitude and for air intake
tor technology throughout, and is used to calculate
obstructions due to a clogging air cleaner.
the air mass flowing past it per time unit. This mass
is important for determining the exhaust gas recircu-
OPERATION
lation rate. The MAF sensor sends a corresponding
The ECM uses the intake air pressure sensor to
monitor the intake pressure. Monitoring this pres-
14 - 38 FUEL INJECTION VA
MANIFOLD AIR FLOW (MAF) SENSOR (Continued)
(160°C) higher than the temperature of the intake
air. The temperature at the heating resistor is mea-
sured by a sensor resistor in-between.
Because the incoming air has a cooling effect, the
greater the amount of air that flows in, then the
higher the voltage of the heating resistor. The heat-
ing resistor is therefore a measure of mass of air
flowing past. If a temperature change occurs as a
result of a increase or reduction of air flow, the ECM
corrects the voltage at the heating resistor until the
temperature difference is again achieved. This con-
trol voltage is use by the ECM as a unit measure for
metered air mass.
REMOVAL
(1) Disconnect the negative battery cable.
(2) Detach the air hose at the Manifold Air Flow
(MAF) sensor
(3) Unplug the MAF wiring harness connector.
(4) Remove the screws retaining the MAF sensor
to the air cleaner housing, and remove MAF sensor.
OPERATION INSTALLATION
The ECM uses the mass air flow (MAF) sensor to (1) Position the MAF sensor to air cleaner housing
measure air density. The temperature resistor located and install the retaining screws (Fig. 20).
at the front of the MAF sensor measures the temper- (2) Connect the air intake hose to the MAF sensor
ature of the inlet air. By varying the voltage, the and tighten clamp.
electronic circuit regulates the temperature of the (3) connect the MAF wiring harness connector.
heating resistor in the rear so that it is 320° F (4) Connect negative battery cable.
VA FUEL INJECTION 14 - 39
O2 SENSOR heater. The term wide ban refers to the ability of the
O2 sensor to generate a clear signal over a wide air-
fuel ratio measuring range. As a dual sensor, it incor-
DESCRIPTION
porates a second O2 chamber (oxygen pump cell),
The wide band oxygen sensor measures the oxygen
which requires a separate voltage supply.
content in the exhaust gas to control ERG. The sensor
The sensor element combines a sensor cell (8) and
is mounted in the exhaust pipe at a 30 degree angle to
an oxygen pump cell (9). Both cells are made of zir-
prevent the collection of moisture between the sensor
conium-dioxide (ZrO2) and a coated with porous plat-
housing and element. The sensor is located close to the
inum electrodes. The sensor cell operates just like a
turbocharger for a quicker response time.
typical O2 sensor. The oxygen pump cell transport
The oxygen sensor has five wires (heater power and
oxygen ions when voltage is applied.
ground, reference voltage, and 2 wires for a pump cell).
A gas sample chamber (5) is sandwiched between
The oxygen sensor connects to a six wire harness con-
the oxygen pump cell and the sensor cell. A pump
nector. A non serviceable trimming resistor is built into
electrode and sensor cell electrode are located in the
the sensor connector. The resistance is dependent on the
sample chamber. A sample passage (10) connects the
over all length and type of sensor.
sample chamber to the surrounding exhaust gas. A
sensor cell electrode is located in the reference air
OPERATION channel (6), which connects to the outside air (Fig.
The O2 sensor is a planar zirconium dioxide (ZrO2) 21).
dual cell limiting current probe with a integral
Fig. 21 O2 CONSTRUCTION
1 - EXHAUST PIPE 6 - REFERENCE AIR CHANNEL
2 - EXHAUST GAS FLOW 7 - HEATER ELEMENT
3 - O2 SENSOR CONNECTOR 8 - SENSOR CELL
4 - TRIMMING RESISTOR 9 - OXYGEN PUMP CELL
5 - GAS SAMPLE CHAMBER 10 - SAMPLE PASSAGE
14 - 40 FUEL INJECTION VA
O2 SENSOR (Continued)
At high temperatures, certain ceramic materials, temperatures, this can be delayed up to 5 minutes to
such as zirconium-dioxide (ZrO2) become oxygen ion prevent damaging the ceramic coating of the sensor
conductors. In a typical O2 sensor, the ZrO2 is used from water condensation. Once the sensor is heated,
as a solid electrolyte, which contains oxygen ions. the exhaust gas components diffuse through the gas
The solid electrolyte is sandwiched between two plat- sample chamber. Upon reaching the electrodes on the
inum electrodes. The sensor generates a small volt- oxygen pump and concentration cells they reach state
age when oxygen moves from the high concentration of thermodynamic balance (Fig. 22).
side to the low concentration side. The sensor cell measures the difference between
The same hold true if the process is reversed. If the oxygen concentration in the gas sample chamber
voltage is applied to the platinum electrodes, oxygen and the oxygen concentration in the outside air from
can be pumped from one side of the solid electrolyte the reference air channel. A small voltage is gener-
to the other (from cathode to anode), becoming an ated across the sensor, which is proportional to the
oxygen pump. The amount of current flow is directly air-fuel ratio in the sample chamber. At stoichiomet-
proportional to the amount of oxygen pumped by the ric ratio (14.7 lbs. of dry air to 1 part fuel), the cor-
sensor. When the oxygen level on the supply side responding open circuit voltage at the sensor cell is
reaches zero, the current stops. 450 mV. If the stoichiometric ratio in the sampler
The ECM activates the integral heater element to chamber is higher than 1 (excess air) a lower voltage
raise the temperature of the sensor to 700C (192°F). is produced. If the stoichometric ratio is lower than 1
for the ZrO2 to become conductive. The heater ele- (insufficient air) a higher voltage is produced (Fig.
ment is designed to reach temperature with in 8 sec- 22).
onds and maintaining it at this level. In cold
REMOVAL
(1) Disconnect the negative battery cable.
(2) Remove the exhaust heat shield (Fig. 23).
(3) Disconnect the O2 sensor harness connector
(Fig. 23)
(4) Remove the O2 sensor (Fig. 24).
INSTALLATION
(1) Install the oxygen sensor (Fig. 24).
(2) Install the heatshield and tighen fasteners to
9N·m (80 lbs. in.) (Fig. 23).
(3) Properly position the oxygen sensor wiring har-
ness and connect the electrical connector (Fig. 23)
(4) Connect the negative battery cable.
STEERING
TABLE OF CONTENTS
page page
STEERING
DESCRIPTION
CAUTION: Mopar ATF+4 Automatic Transmission
fluid or equivalent is to be used in the power steer-
ing system. No other power steering or automatic
transmission fluid is to be used in the system.
Damage may result to the power steering pump and
system if any other fluid is used, and do not over-
fill.
STEERING NOISE
OBJECTIONAL HISS OR 1. Steering intermediate shaft to dash panel 1. Check and repair seal at dash
WHISTLE seal. panel.
EXCESSIVE PLAY IN STEERING 1. Worn or loose suspension or 1. Inspect and repair as necessary.
WHEEL steering components.
COLUMN
TABLE OF CONTENTS
page page
COLUMN INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SPECIFICATIONS - TORQUE CHART .........5 STEERING WHEEL
INTERMEDIATE SHAFT REMOVAL .............................7
REMOVAL ................... ..........5 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . ..........5
KEY/LOCK CYLINDER
REMOVAL ................... ..........6
COLUMN
SPECIFICATIONS - TORQUE CHART
TORQUE SPECIFICATIONS
INTERMEDIATE SHAFT (10) Remove the spring for the brake pedal from
the steering column.
(11) Remove the fitted bolt from the universal joint
REMOVAL
(Fig. 1).
(1) Disconnect the ground cable from the battery.
(12) Remove the bolts in the steering column
(2) Remove the air bag module from the steering
bracket (Fig. 2).
wheel.
(13) Remove the steering shaft with the universal
(3) Turn the steering wheel and lock the steering
joint off the steering gear drive shaft (Fig. 1).
wheel in the straight ahead position. The position
(14) Pull the steering shaft out of the rubber grom-
of the steering gear must not be altered again
met in the cab floor.
for the entire duration of the work procedure.
(4) Remove the electrical center.
(5) Remove the steering wheel bolt.
INSTALLATION
(1) Install the steering shaft through the rubber
(6) Remove the steering wheel from the steering
grommet in the cab floor. Ensure that the rubber
column.
grommet is properly seated.
(7) Remove the clockspring. Unscrew the retain-
(2) Install the steering shaft with the universal
ing bolts just enough to be able to remove the
joint onto the steering gear shaft (Fig. 1).
clockspring. Do not twist or disassemble the
(3) Install the bolts in the steering column bracket
clockspring.
(Fig. 2). Tighten to 24 N·m (18 ft. lbs.).
(8) Remove the combination switch.
(4) Install the universal joint on the steering gear
(9) Disconnect the electrical connector for the igni-
shaft (Fig. 1). Tighten to 24 N·m (18 ft. lbs.).
tion lock.
19 - 6 COLUMN VA
INTERMEDIATE SHAFT (Continued)
KEY/LOCK CYLINDER
REMOVAL
(1) Remove the securing cover for the central elec-
tronics.
(2) Remove the steering column shroud.
(3) Remove the transponder coil off the ignition
lock (Fig. 3).
Fig. 3 TRANSPONDER
1 - TRANSPONDER
2 - STEERING COLUMN
STEERING WHEEL
REMOVAL
(1) Disconnect the ground cable on the battery.
(2) Remove the air bag module from the steering
wheel.
(3) Turn the steering wheel and lock the steering
wheel in the straight ahead position (Fig. 7).
(4) Remove the steering wheel bolt (Fig. 7).
(5) Remove the steering wheel from the steering
Fig. 5 1/4 TURN LEFT
column (Fig. 7).
1 - STEERING COLUMN
2 - 1/4 TURN TO THE LEFT
GEAR
TABLE OF CONTENTS
page page
GEAR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8 SPECIFICATIONS - TORQUE CHART . . . . . . . . . 9
REMOVAL .............................8
REMOVAL
(1) Siphon the power steering fluid out of the res-
ervoir. Fig. 2 STEERING GEAR REMOVAL / INSTALL
(2) Raise and support the vehicle. 1 - U-JOINT
2 - HIGH PRESSURE POWER STEERING HOSE
(3) Remove the front wheels. 3 - RETURN HOSE
(4) Remove the stabilizer bar from the upper part 4 - OUTER TIE ROD END RETAINING NUT
of the stabilizer link (Refer to 2 - SUSPENSION/ 5 - STEERING GEAR
6 - STEERING GEAR RETAINING BOLT
FRONT/STABILIZER LINK - REMOVAL). 7 - STEERING GEAR NUT
(5) Remove the outer tie rod end nuts and sepa- 8 - WASHER
rate the tie rods from the steering knuckles (Fig. 2) 9 - ENGINE MOUNT BOLT
10 - U-JOINT CLAMPING BOLT
using special tool C-3894–A.
(6) Remove the left outer tie rod end from the
steering gear. INSTALLATION
(1) Install the gear to the vehicle.
VA GEAR 19 - 9
GEAR (Continued)
NOTE: Steering gear must be torqued in a three (6) Install the left outer tie rod end to the steering
step procedure below. gear.
(7) Install both the outer tie rod ends to the steer-
(2) Install the steering gear bolts (Fig. 2). Tighten ing knuckle (Fig. 2). Tighten to 130 N·m (96 ft. lbs.).
to an initial torque of 25 N·m (18 ft. lbs.) Then (8) Install the upper stabilizer bar link to the sta-
torque to 45 N·m (33 ft. lbs.) and a final additional bilizer bar.
90° turn for final torque. (9) Install the front wheels.
(3) Install the universal joint to the steering gear (10) Fill and bleed the power steering system
(Fig. 2). Tighten to 24 N·m (18 ft. lbs.). (Refer to 19 - STEERING/PUMP/FLUID - STAN-
(4) Install both the power steering hoses to the DARD PROCEDURE).
steering gear (Fig. 2). Tighten the high pressure hose (11) Reset toe adjustment.
to 37 N·m (27 ft. lbs.). (12) Check steering system for leaks.
(5) Install the spring clamp plates (Refer to 2 -
SUSPENSION/FRONT/SPRING CLAMP PLATES -
INSTALLATION).
LINKAGE
TABLE OF CONTENTS
page page
SPECIAL TOOLS
FRONT SUSPENSION
PUMP
TABLE OF CONTENTS
page page
The pump is connected to the steering gear via the STANDARD PROCEDURE
pressure hose and the return hose. The pump shaft
has a pressed-on pulley that is belt driven by the STANDARD PROCEDURE - POWER STEERING
crankshaft pulley. PUMP - INITIAL OPERATION
All vehicles are equipped with a power steering
fluid cooler. WARNING: THE FLUID LEVEL SHOULD BE
CHECKED WITH ENGINE OFF TO PREVENT INJURY
NOTE: Power steering pumps are not interchange- FROM MOVING COMPONENTS.
able with pumps installed on other vehicles.
FLUID (8) Remove the core support bolts (4) and discon-
nect the hood latch cable.
(9) Remove the fan bracket bolts (4) to the radiator
STANDARD PROCEDURE (Fig. 2).
(10) Remove the two upper screws for the con-
POWER STEERING PUMP FILL AND BLEED denser (Fig. 2).
(11) Remove the condenser air dam shield.
PROCEDURE
(12) Remove the mounting screws for the cooler
(1) Remove the cap from the fluid reservoir.
tube (Fig. 2).
Check cap seal for damage and replace if
(13) Remove the cooler tube from the vehicle.
needed.
(2) Fill the power steering pump with Mopar
ATF+4 Automatic Transmission fluid or equivalent.
Do not fill fluid beyond the MAX mark.
(3) Raise the vehicles front wheels off the ground.
(4) With the engine off turn the steering wheel
from right to left. Perform this step until all the
bubble formations can no longer be seen in the
power steering reservoir.
(5) Start the engine and turn the steering wheel
with the engine at idle speed then shut the engine off
and check for correct oil level and no bubble in the
system.
(6) Reinstall power steering cap tightly.
(7) Test the system for leaks and proper operation.
TRANSMISSION
TABLE OF CONTENTS
page page
CLUTCH APPLICATION
GEAR RATIO B1 B2 B3 K1 K2 K3 F1 F2
1 3.59 X* X X* X X
2 2.19 X X X* X
3 1.41 X X X
4 1.00 X X X
5 0.83 X X X X*
N N/A X X
R 3.16 X* X X X
* = The shift components required during coast.
21 - 6 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)
FIRST GEAR POWERFLOW
Torque from the torque converter is increased via Front Planetary Gear Set
the input shaft (25) and all three planetary gearsets The annulus gear (8) is driven by the input shaft
and transferred to the output shaft (26). (Fig. 2) (Fig. (25). The sun gear (21) is held against the housing by
3) the locked freewheel F1 (20) during acceleration and
via the engaged multiple-disc holding clutch B1 (4)
during deceleration. The planetary pinion gears (17)
turn on the fixed sun gear (21) and increase the
torque from the annulus gear (8) to the planetary
carrier (13). The planetary carrier (13) moves at a
reduced speed in the running direction of the engine.
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 7
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)
Torque from the torque converter is increased via Front Planetary Gear Set
the input shaft (25) and the center and rear plane- The planetary carrier (13) and sun gear (21) are
tary gearset and transferred to the output shaft (26). connected via the engaged multiple-disc clutch K1
(Fig. 4) (Fig. 5) (7). The planetary gearset is therefore blocked and
turns as a closed unit at the input speed due to the
mechanical connection of the annulus gear (8) and
input shaft.
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 9
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)
Torque from the torque converter is increased via Front Planetary Gear Set
the input shaft (25) and the center planetary gearset The planetary carrier (13) and sun gear (21) are
and transferred to the output shaft (26). (Fig. 6) (Fig. connected via the engaged multiple-disc clutch K1
7) (7). The planetary gearset is therefore locked and
turns as a closed unit at the input speed due to the
mechanical connection of the annulus gear (8) and
input shaft (25).
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 11
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)
Speed and torque are not converted by the direct Front Planetary Gear Set
gear ratio of the 4th gear. Power is transferred from The planetary carrier (13) and sun gear (21) are
the input shaft (25) to the output shaft (26) via three connected via the engaged multiple-disc clutch K1
locked planetary gearsets. (Fig. 8) (Fig. 9) (7). The planetary gearset is therefore locked and
turns as a closed unit at the input speed due to the
mechanical connection of the annulus gear (8) and
the input shaft (25).
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 13
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)
Torque from the torque converter is increased via Front Planetary Gear Set
the input shaft (25) and all three planetary gearsets The annulus gear (8) is driven by the input shaft
and transferred to the output shaft (26). (Fig. 10) (25). The sun gear (21) is held against the housing by
(Fig. 11) the locked freewheel F1 (20) during acceleration and
via the engaged multiple-disc holding clutch B1 (4)
during deceleration. The planetary pinion gears (17)
turn on the fixed sun gear (21) and increase the
torque from the annulus gear (8) to the planetary
carrier (13). The planetary carrier (13) moves at a
reduced speed in the running direction of the engine.
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 15
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)
Torque from the torque converter is increased via Front Planetary Gear Set
the input shaft (25) and all three planetary gearsets The annulus gear (8) is driven by the input shaft
and transferred with reversed direction of rotation to (25). The sun gear (21) is held against the housing by
the output shaft (26). (Fig. 12) (Fig. 13) the locked freewheel F1 (20) during acceleration and
via the engaged multiple-disc holding clutch B1 (4)
during deceleration. The planetary pinion gears (17)
turn on the fixed sun gear (21) and increase the
torque from the annulus gear (8) to the planetary
carrier (13). The planetary carrier (13) moves at a
reduced speed in the running direction of the engine.
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 17
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)
When the 1-2 and 4-5 shift solenoid valve (1) (Fig. (p-S) coming from the shift pressure shift valve (3) is
15) is turned on, the shift valve pressure (p-SV) is directed via the command valve (5) onto clutch K1
directed onto the end face of the command valve (5). (6).
The command valve is moved and the shift pressure
21 - 20 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)
Simultaneously the clutch B1 (7) is subjected to Shift Phase - 1-2 Shift Phase 2
overlap pressure by the overlap regulating valve (2). The B1 (7) (Fig. 16) pressure acting on the end face
The pressure in the clutch B1 (7) as it disengages is of the shift pressure shift valve (3) is replaced by the
controlled during the shift phase depending on working pressure (p-A). The shift pressure is also
engine load by the modulating pressure and the routed to the spring end of the holding valve (4) and
applying clutch pressure (the shift pressure in clutch the holding valve downshifts. The line pressure is
K1). The controlled pressure in clutch B1 (7) is then routed to the command valve (5).
inversely proportional to the capacity of the clutch
being engaged. The rising shift pressure (p-S) at
clutch K1 (6) acts on the annular face of the overlap
regulating valve (2) and reduces the overlap pressure
regulated by the overlap regulating valve (2). When a
corresponding pressure level is reached at the hold-
ing pressure shift valve (4), this valve switches over.
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 21
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)
After the gearchange is complete, the pressure on working pressure (p-A) now passes via the command
the end face of the command valve (5) (Fig. 17) is valve (5) to clutch K1 (6). The multiple-disc holding
reduced via the 1-2 and 4-5 shift solenoid valve (1), clutch B1 (7) is deactivated (unpressurized). The
and the command valve (5) is pushed back to itsbasic spring of the shift pressure shift valve (3) pushes the
position. Via the holding pressure shift valve (4) the valve back to its basic position.
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 23
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)
Shift Phase - 2-1 Shift Phase 1
The pressure in clutch B1 (7) (Fig. 19) acting on allows line pressure (p-A) to pass through the com-
the end face of the 1-2/4-5 holding valve (4) forces the mand valve (5).
valve to up-shift against the spring pressure and
21 - 26 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)
2-1 Shift - First Gear Engaged
After the gear change is complete, the 1-2/4-5 shift (p-A) is switched to the holding clutch B1 (7) and the
solenoid (1) (Fig. 20) is turned off. This reduces the end face of the holding valve by the downshifted com-
pressure on the end face of the 1-2/4-5 command mand valve. The upshifted holding valve also allows
valve (5) to 0 psi and the spring pressure downshift- the remaining pressure in clutch K1 (6) to be vented.
sthe valve to its initial position. The line pressure
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 27
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)
Gear Shift N to D (1st gear) - Engine Started
The TCM monitors the activation sequence via the The 3-4 shift pressure shift valve (14) is moved
speed of the input shaft, which slows down as the against the force of the spring towards the right. At
frictional connection in the multiple-disc holding the same time the 3-4 solenoid valve (10) is ener-
clutch increases. When the speed drops to the speci- gized. This allows shift valve pressure (p-SV) to enter
fied level, the TCM shuts off the power to the 3-4 the spring chamber of the shift valve B2 (9) and to
shift solenoid valve (10) (Fig. 23). The spring cham- reach the end face of the 3-4 command valve (13).
ber of the shift valve B2 (9) is depressurized and The shift valve B2 (9) is held in the upper position
switches downwards. This connects the line to the and the 3-4 command valve (13) switches towards the
opposing face of the piston B2 (6) with the pressure right. At the end face of the 3-4 shift pressure shift
holding valve (11). The pressure on the opposing face valve (14) the working pressure (p-A) is replaced by
of the piston B2 (6) drops to a residual pressure. shift valve pressure (p-SV).
The working pressure (p-A) is formed and travels The 3-4 command valve (13) moves to the left.
via the 2-3 holding pressure shift valve, the 2-3 com- Working pressure (p-A) travels via the holding pres-
mand valve and the ball valve (16) to multi-plate sure shift valve (12) and the 3-4 command valve (13)
clutch K3 (4) and via the 3-4 command valve (13) to to the piston of multiple-disc holding clutch B2 (5).
the end face of the 3-4 shift pressure shift valve (14).
21 - 30 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)
CLUTCH APPLICATION
GEAR RATIO B1 B2 B3 K1 K2 K3 F1 F2
1 3.59 X* X X* X X
2 2.19 X X X* X
3 1.41 X X X
4 1.00 X X X
5 0.83 X X X X*
N N/A X X
R 3.16 X* X X X
* = The shift components required during coast.
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 31
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)
AUTOMATIC TRANSMISSION
REMOVAL
(1) Disconnect the negative (ground) battery cable.
(29) Remove multiple-disc pack B3 (2) (Fig. 45) (30) Unscrew Torx socket bolts (7) (Fig. 45).
and spring washer (3) by removing snap-ring (1) in (31) Remove multiple-disc holding clutch B2 (4)
transmission housing. To facilitate removal of the (Fig. 45) from transmission housing. The externally
snap-ring (1), compress the multiple-disc pack B3 (2). toothed disc carrier for multiple-disc holding clutch
Note which clutch disc is removed just prior to the B2 is also the piston for multiple-disc holding clutch
spring washer (3) for re-assembly. If the clutch discs B3.
are re-used, this disc must be returned to its original (32) Remove parking lock gear (5) (Fig. 45).
position on top of the spring washer.
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 43
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)
ASSEMBLY
(1) Insert parking lock gear (5) (Fig. 46). (a) Put multiple-discs for multiple-disc holding
(2) Install multiple-disc holding clutch B2 (4) in clutch B3 together in the sequence shown in the
transmission housing (6) (Fig. 46). illustration and insert individually.
(3) Screw in both Torx socket bolts (7). Tighten the (b) Using a feeler gauge, determine the play 9L9
bolts to 16 N·m (141 in.lbs.). at three points between the snap ring (7) and outer
multiple-disc (1). B3 clutch clearance should be 1.0-
NOTE: During the measurement the snap ring (7) 1.4 mm (0.039-0.055 in.). Adjust the clearance as
(Fig. 47) must contact the upper bearing surface of necessary.
the groove in the outer multiple-disc carrier (8). (c) Adjust with snap-ring (7), if necessary. Snap-
rings are available in thicknesses of 3.2 mm (0.126
in.), 3.5 mm (0.138 in.), 3.8 mm (0.150 in.), 4.1 mm
NOTE: Pay attention to sequence of discs. If the
(0.162 in.), 4.4 mm (0.173 in.), and 4.7 mm (0.185
original clutch discs are reused, be sure to return
in.).
the disc identified on disassembly as belonging on
(5) Check that the K1 clutch feed hole (1) (Fig. 48)
top of the spring washer (4) to its original location.
in the inner hub of clutch B1 is free before installing
Place new friction multiple-discs in ATF fluid for
clutch B1.
one hour before installing.
(6) Place intermediate plate (3) on converter hous-
(4) Insert and measure spring washer (4) (Fig. 47) ing (2) and align.
and multiple-disc pack B3 (2, 6).
21 - 44 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)
(7) Install the holding clutch B1 (5) (Fig. 49) onto
the converter housing and intermediate plate.
Installed position of clutch B1 in relation to converter
housing is specified by a plain dowel pin in clutch B1
(arrow).
(8) Install the bolts to hold clutch B1 (5) (Fig. 49)
to the converter housing.
(9) Securely tighten multiple-disc holding clutch
B1 (5) on converter housing (2) to 10 N·m (88.5
in.lbs.).
(10) Install new torque converter hub seal (1) (Fig.
50) into the oil pump using Seal Installer 8902A.
(11) Install new oil pump outer o-ring seal onto oil
pump (Fig. 50).
(12) Install oil pump (6) and securely tighten.
Tighten the oil pump bolts to 20 N·m (177 in.lbs.).
Fig. 47 Measure B3 Clutch Clearance (13) Using grease, insert sealing rings (7) (Fig. 51)
1 - OUTER DISC - 6.5 MM 5 - PISTON in the groove so that the joint remains together.
(0.256 IN.) (14) Install the K1 (1) clutch onto the B1 clutch
2 - OUTER DISCS - 1.8 MM 6 - FRICTION DISCS
(0.071 IN.) (Fig. 51).
3 - OUTER DISCS - 1.8 MM 7 - SNAP-RING (15) Install input shaft with clutch K2 (6) and
(0.071 IN.) front gear set (1) (Fig. 51).
4 - SPRING WASHER 8 - B3 DISC CARRIER
(16) Install front washer (5) and thrust needle
bearing (4) (Fig. 51).
(17) Install output shaft with center and rear gear
set and clutch K3 (3) (Fig. 51).
(18) Using grease, install both Teflon rings in the
groove at the rear of the output shaft so that the
joint stays together.
(19) Mount transmission housing on converter
housing.
(20) Screw in Torx socket bolts through the trans-
mission housing into the converter housing. Tighten
the bolts to 20 N·m (177 in.lbs.).
(21) Measure end-play between park pawl gear
and grooved ball bearing in order to select the proper
geartrain end-play shim.
(22) Place Gauge Bar 6311 (1) on transmission
housing. Using a depth gauge, measure from the
Fig. 48 Check K1 Feed Hole gauge bar (1) to the parking lock gear (2) (Fig. 52).
(23) Using a depth gauge, measure from the
1 - K1 CLUTCH FEED HOLE
Gauge Bar 6311 (1) to the contact surface of the out-
NOTE: The intermediate plate can generally be used put shaft bearing (2) in the transmission housing.
several times. The plate must not be coated with (Fig. 53)
sealant
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 45
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)
Fig. 52 Measure From Transmission Housing to Fig. 53 Measure From Transmission Housing To
Park Gear Rear Bearing Contact Surface
1 - GAUGE BAR 6311 1 - GAUGE BAR 6311
2 - PARK GEAR 2 - OUTPUT SHAFT BEARING CONTACT SURFACE
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 47
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)
(24) Subtract the first figure from the second fig- (28) Install the retaining ring (1) (Fig. 55). Ensure
ure to determine the current end-play of the trans- that the retaining ring is seated correctly in the
mission. Select a shim such that the end-play will be groove.
0.3-0.5 mm (0.012-0.020 in.). Shims are available in (29) Check that there is no play between the bear-
thicknesses of 0.2 mm (0.008 in.), 0.3 mm (0.012 in.), ing and the retaining ring using feeler gauge.
0.4 mm (0.016 in.), and 0.5 mm (0.020 in.). (30) There must be no play between the retaining
(25) Install the selected end-play shim. ring and the bearing. If the ring cannot be installed,
a thinner ring must be used. If there is play between
the ring and the bearing, a thicker ring must be
installed. Retaining rings are available in thick-
nesses of 2.0 mm (0.079 in.), 2.1 mm (0.083 in.), and
2.2 mm (0.087 in.).
(33) Install the output shaft washer onto the out- Fig. 59 Stake Output Shaft Nut
put shaft.
1 - STAKING TOOL 9078
(34) Install a new transmission rear seal into the 2 - PROPELLER FLANGE
transmission case with Seal Installer 8902A (1) (Fig. 3 - STAKING PIN
57).
(39) Press downward on the staking tool (1) until
the staking pin (3) contacts the output shaft nut
flange (2) (Fig. 59).
(40) Strike the Driver handle C-4171 with a suit-
able hammer until the output shaft nut is securely
staked to the output shaft.
(41) Install electrohydraulic unit (2). Tighten the
bolts to 8 N·m (71 in.lbs.).
(42) Install oil filter (4) (Fig. 60).
(43) Install oil pan (5) (Fig. 60). Tighten the bolts
to 8 N·m (71 in.lbs.).
(44) Install guide bushing (12) (Fig. 60).
(45) Install the torque converter (Fig. 61).
INSTALLATION
(1) Coat outside of the torque converter hub with
long-term grease, install the torque converter into
the transmission.
(2) Measure distance 9A9 (Fig. 62) from torque con-
verter to transmission housing. If the torque con-
verter is properly installed, distance “A” will be 55
mm (2.17 in.).
Fig. 62 Torque Converter Installation Depth
A - TORQUE CONVERTER INSTALLED DISTANCE
21 - 50 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)
(3) Move the torque converter (1) (Fig. 63) to (7) Move the transmission into position on the
shown position. Check position of torque converter dowel pins and install two bolts (A, B) (Fig. 65) on
through housing opening (2) when installing trans- the top of the transmission. Torque the bolts to 38
mission. N·m (28 ft.lbs.).
(4) Move driving plate (1) (Fig. 64) to shown posi- (8) Install the bolt to hose the vent hose bracket to
tion. the transmission. Torque the bolt to 38 N·m (28
ft.lbs.).
(9) Install the bolt to hold the ground strap to the
transmission. Torque the bolt to 38 N·m (28 ft.lbs.).
(10) Install bolts (A) (Fig. 65) on underside of
transmission. Torque the bolts to 38 N·m (28 ft.lbs.).
(11) Install rear engine cross member (4) (Fig. 65).
First install the nuts (5) at the outside ends of the
engine crossmember. Then install the bolts (1) of the
transmission mount. Torque the bolts and nuts to 45
N·m (33 ft.lbs.).
(5) Ensure the dowel pins are installed in their (12) Remove the wooden block supporting the
correct position at the transmission housing flange. engine and remove the hydraulic jack.
(6) Place transmission onto a hydraulic transmis-
sion jack and raise the transmission into position.
Secure transmission on hydraulic jack with a strap
or ask an assistant to hold it.
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 51
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)
(13) Install the torque converter bolts.
(a) Install the first pair bolts (2) (Fig. 66) at cir-
cumference of driving plate snug only.
(b) To install bolts, position a ratchet with long
extension and joint nut as shown.
(c) Rotate engine by hand until the next pair of
bolts (2) are in front of opening. Rotate engine for-
wards at crankshaft. Install the next pair of bolts
snug only.
(d) Rotate engine by hand until the final pair of
bolts (2) are in front of opening. Rotate engine for-
wards at crankshaft. Install and torque the bolts to
50 N·m (37 ft.lbs.).
(e) Rotate engine by hand and tighten the first
two bolt pairs to 50 N·m (37 ft.lbs.).
(f) Install the plastic torque converter access
cover (1) (Fig. 67) to the back of the engine flange.
(g) Install the steering gear (1) (Fig. 68) onto the
chassis crossmember. Tighten both steering gear
bolts first to 25 N·m (18.5 ft.lbs.). Tighten both
steering gear bolts next to 45 N·m (33 ft.lbs.).
Tighten both steering gear bolts next an additional
90°. Fig. 67 Torque Converter Access Cover
1 - TORQUE CONVERTER ACCESS COVER
2 - BOLT
(b) Push lower connection of oil filler pipe (1) Fig. 76 Oil Drain Plug
(Fig. 75) into the fill hole in the side of the trans- 1 - SEAL
mission housing. 2 - DRAIN PLUG
(c) Install bolts (2) (Fig. 75) to cylinder head.
Tighten the bolts to 8 N·m (71 in.lbs.). (22) Lower vehicle and fill transmission with cor-
(d) Install bolt (3) (Fig. 75) to transmission rect automatic transmission fluid (Refer to 21 -
flange and bolt (2) to transmission housing. TRANSMISSION/AUTOMATIC - NAG1/FLUID AND
Tighten the bolt to 8 N·m (71 in.lbs.). FILTER - STANDARD PROCEDURE).
(21) Install the oil drain plug (2) (Fig. 76) with a (23) Road test the vehicle and verify the repair.
new seal into the transmission oil pan. Tighten the
drain plug to 20 N·m (14.5 ft.lbs.).
21 - 54 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)
TORQUE SPECIFICATIONS
MB MILLER DESCRIPTION
TOOL # TOOL #
N/A C-3339 DIAL INDICATOR SET
N/A C-4171 DRIVE HANDLE Bar, Gauge - 6311
N/A 6311 GAUGE BAR
N/A 8266 END-PLAY SET
N/A 8266-18 END-PLAY ADAPTER
N/A 8863B DIPSTICK
140 586 8900 MULTI-USE SPRING
13 43 00 COMPRESSOR
208 589 8901 PRESSING TOOL
00 21 00
N/A 8902A SEAL INSTALLER
N/A 9078 STAKING TOOL
N/A 9082 BEARING REMOVER
N/A 9287 BEARING INSTALLER End Play Set - 8266
Dipstick - 8863B
21 - 78 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
INPUT CLUTCHES (Continued)
INPUT CLUTCHES
DESCRIPTION
OPERATION
The input clutches (Fig. 78) produce a non-positive locked with the annulus gear (11) of the center plan-
locking connection between two elements of a plane- etary gear set via the externally toothed disc carrier
tary gear set or between one element from each of (13) and the center planetary carrier (10) on which
two planetary gear sets in order to transmit the drive the internally toothed discs are seated. Annulus gear
torque. (16) and annulus gear (11) turn at the same speed as
If the piston (20) on multi-plate clutch K1 (1) is the input shaft (21)
subjected to oil pressure, it presses the internal and If the multi-plate clutch K3 (5) is actuated via the
external discs of the disc set together. The sun gear piston (7), the piston compresses the disc set. The
(17) is locked with the planetary carrier (15) via the sun gear (12) of the center planetary gear set is
externally toothed disc carrier (19) and the internally locked with the sun gear (9) of the rear planetary
toothed disc carrier (18). The front planetary gear set gear set via the externally toothed disc carrier (6)
is thus locked and turns as a closed unit. and the internally toothed disc carrier (8). Sun gear
If the multi-plate clutch K2 (2) is actuated via the (12) and sun gear (9) turn at the same speed.
piston (14), the piston compresses the disc set. The
annulus gear (16) of the front planetary gear set is
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 81
INPUT CLUTCH K1
DISASSEMBLY
(1) Remove snap-ring (11) (Fig. 79) from outer (4) Remove snap-ring (1).
multiple-disc carrier (6). (5) Take out disc spring (7) and remove piston (6)
(2) Take multiple-disc pack (12) out of outer mul- by carefully blowing compressed air into the drilled
tiple-disc carrier (6). Note which clutch disc is oil feed passage.
removed just prior to the spring plate (8) for re-as- (6) Remove snap-ring (3) and take out front free-
sembly. If the clutch discs are re-used, this disc must wheeling clutch F1 (2). Take care when removing the
be returned to its original position on top of the F1 clutch to prevent the clutch sprags from falling
spring plate. out. If this occurs, the clutch must be replaced.
(3) Place Multi-use Spring Compressor 8900 (2)
(Fig. 80) on the spring plate and compress the spring ASSEMBLY
until the snap-ring (1) is exposed. (1) Install piston (6) (Fig. 81) in the outer multi-
ple-disc carrier (1). Check sealing rings (4 and 5),
replace if necessary. The rounded off edges of the
sealing rings must point outwards.
21 - 82 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
INPUT CLUTCH K1 (Continued)
(2) Insert disc spring (7) (Fig. 81). Insert disc
spring with the curvature towards the piston.
(3) Insert spring plate (8). Insert spring plate with
the curvature towards the sun gear. Check sealing
ring (9), replace if necessary.
(4) Place Multi-use Spring Compressor 8900 (2)
(Fig. 82) on spring plate and compress the spring
until the groove of the snap-ring (1) is exposed.
(5) Insert snap-ring (1) (Fig. 81). After installing,
check snap-ring for correct seat.
INPUT CLUTCH K2
DISASSEMBLY
(1) Remove snap-ring (19) from the K1 inner mul-
tiple-disc carrier with integrated front gear set (2)
and take off hollow gear (18).
(2) Remove input shaft with clutch K2 (5) (Fig.
86).
(3) Remove needle thrust bearing (3).
(4) Remove snap-ring (17) (Fig. 86) from K2 outer
multiple-disc carrier.
(5) Take out multiple-disc pack (16). Note which
clutch disc is removed just prior to the disc spring
(14) for re-assembly. If the clutch discs are re-used,
this disc must be returned to its original position on
top of the disc spring.
Fig. 85 Input Clutch K1 Stack-up - Single Sided
(6) Take out disc spring (14) (Fig. 86).
Discs
(7) Fit Multi-use Spring Compressor 8900 (1) (Fig.
1 - OUTER MULTIPLE DISCS
2 - OUTER MULTIPLE DISC - 4.0MM (0.158 IN.)
87) onto spring retainer (12) and press until snap-
3 - K1 OUTER DISC CARRIER ring (2) is released.
4 - SNAP-RING (8) Remove snap-ring (2) (Fig. 86).
5 - INNER MULTIPLE DISCS
6 - DISC SPRING
(9) Take out disc spring (10) and pull piston (9) out
7 - PISTON of outer multiple-disc carrier.
ASSEMBLY
(1) Install piston (6) (Fig. 93) in the outer multi- NOTE: Pay attention to the sequence of discs. If the
ple-disc carrier (8). Check sealing ring (7), replace if original clutch discs are reused, be sure to return
necessary. The rounded off edges of the sealing ring the disc identified on disassembly as belonging on
must point outwards. top of the spring plate (3) to its original location.
(2) Insert disc spring (5). Insert disc spring with
the curvature towards the piston.
(3) Mount the Multi-use Spring Compressor 8900 NOTE: Place new friction multiple-discs in ATF fluid
(9) on the spring plate and clamp until the snap-ring for one hour before installing.
groove is exposed.
(5) Install disk spring (3) and multiple-disc pack
(4) Insert snap-ring (4). The collar of the snap-ring
(2) in outer multiple-disc carrier (8).
must point towards the multiple-disc pack.
(6) Insert snap-ring (1).
CAUTION: When working with double sided friction (7) Measure the K3 clutch clearance by mounting
discs, an externally lugged steel plate is installed Pressing Tool 8901 (1) (Fig. 94) on outer multiple
first, followed by a friction disc, and continuing on disc.
until all the required discs are installed. When work- (8) Using a lever press, compress pressing tool as
ing with single sided friction discs, an externally far as the stop (then the marking ring is still visible,
lugged disc is installed first, followed by an inter- see small arrow).
nally lugged disc, and continuing on until all the (9) For transmissions using double sided friction
required discs are installed. All single sided discs discs, use a feeler gauge to determine the play 9L9
are installed with the friction side up. (Fig. 95) at three points between the snap-ring (8)
and outer multiple-disc (2).
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 91
INPUT CLUTCH K3 (Continued)
0.106 in.) for three friction disc versions, 2.4-2.8 mm
(0.095-0.110 in.) for four disc versions, and 2.5-2.9
mm (0.099-0.114 in.) for five disc versions.
(12) Adjust with snap-ring (8), if necessary. Snap-
rings are available in thicknesses of 2.0 mm (0.079
in.), 2.3 mm (0.091 in.), 2.6 mm (0.102 in.), 2.9 mm
(0.114 in.), 3.2 mm (0.126 in.), and 3.5 mm (0.138
in.).
ELECTROHYDRAULIC UNIT
DESCRIPTION
Command Valve
Each shift group possesses one command valve (3)
(Fig. 102). The 1-2 / 4-5 and 2-3 command valves are
installed in the shift valve housing, the 3-4 command
valve is installed in the valve housing. The command
valve switches the shift group from the stationary
phase to the shift phase and back again.
Each shift group possesses one holding pressure Each shift group possesses one shift pressure shift
shift valve (1) (Fig. 103). The 1-2 / 4-5 and 2-3 hold- valve (4) (Fig. 104). The 1-2 / 4-5 and 2-3 shift pres-
ing pressure shift valves are installed in the shift sure shift valves are installed in the shift valve hous-
valve housing; the 3-4 holding pressure shift valve is ing; the 3-4 shift pressure shift valve is installed in
installed in the valve housing. The holding pressure the valve housing. It assigns the shift pressure (p-S)
shift valve allocates the working pressure to one to the activating actuator and the overlap pressure
actuator of a shift group. (p-Ü) regulated by the overlap regulating valve to the
deactivating actuator.
Shift Pressure Shift Valve
The lubrication pressure regulating valve (1) (Fig. Shift Valve Pressure Regulating Valve
105) is located in the valve housing of the electrohy-
draulic control module. The valve controls the fluid
to lubricate and cool the mechanical part of the
transmission, and limits the pressure in the torque
converter.
Shift Pressure Shift Valve clutch K1 (2) is activated, the end face of the shift
When the multiple-disc brake B1 (3) is activated, valve is unpressurized during the stationary and
the working pressure (p-A) is applied to the end face shift phases, so the shift state is maintained during
of the 1-2 / 4-5 shift pressure shift valve (4) (Fig. 115) the shift phase in this case too.
via the command valve (1). Its shift state is main-
tained during the shift phase by substituting the
shift element pressure acting on its end face (and
which is variable during the shift phase) with a cor-
responding constant pressure. When the multi-plate
21 - 102 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
ELECTROHYDRAULIC UNIT (Continued)
Lubrication Pressure Regulating Valve Regulating Valve Pressure Regulating Valve
Fig. 116 Lubrication Pressure Regulating Valve Fig. 118 Regulating Valve Pressure Regulating Valve
1 - LUBRICATION PRESSURE REGULATING VALVE 1 - REGULATING VALVE PRESSURE REGULATING VALVE
At the working pressure regulating valve surplus The regulating valve pressure (p-RV) is set at the
oil is diverted to the lubrication pressure regulating regulating valve pressure regulating valve (1) (Fig.
valve (1) (Fig. 116), from where the lubrication pres- 118) in relation to the working pressure (p-A) as far
sure (p-Sm) is used in regulated amounts to supply as the maximum pressure.
the transmission lubrication system including the
torque converter. Shift Valve Pressure Regulating Valve
REMOVAL
Fig. 123 Remove Electrohydraulic Unit Fig. 124 Electrical Unit Components
1 - HEAT SHIELD 1 - SOLENOID CAP
2 - ELECTROHYDRAULIC UNIT 2 - SOLENOID CAP
3 - BOLT 3 - BOLT - M6X32
4 - OIL FILTER 4 - BOLT - M6X30
5 - OIL PAN 5 - LEAF SPRING
6 - CLAMPING ELEMENT 6 - MODULATING PRESSURE REGULATING SOLENOID VALVE
7 - BOLT 7 - SHIFT PRESSURE REGULATING SOLENOID
8 - DRAIN PLUG 8 - 3-4 SHIFT SOLENOID
9 - DRAIN PLUG GASKET 9 - TORQUE CONVERTER LOCK-UP SOLENOID
10 - 13-PIN PLUG CONNECTOR 10 - 1-2/4-5 SHIFT SOLENOID
11 - BOLT 11 - 2-3 SHIFT SOLENOID
12 - GUIDE BUSHING 12 - ELECTRICHYDRAULIC CONTROL MODULE
13 - SHIFT PLATE
DISASSEMBLY
A - Operating and Lubricating Pressure Regulating
(1) Remove electrohydraulic unit from the vehicle.
valves and 2-3 Overlap valve
(Refer to 21 - TRANSMISSION/AUTOMATIC
B - 1-2/4-5 Shift Group and Shift, Shift Valve, and
TRANSMISSION - NAG1/ELECTROHYDRAULIC
Regulating Valve Pressure Regulating Valves
UNIT - REMOVAL)
C - 3-4 Shift Group
(2) Remove solenoid caps (1, 2) (Fig. 124).
D - 2-3 Shift Group, TCC Lock-up, and B2 Regu-
(3) Unscrew Torxt socket bolts (3, 4) (Fig. 124).
lating Valves
NOTE: Pay attention to the different lengths of the
NOTE: Pay great attention to cleanliness for all
TorxT socket bolts.
work on the shift plate. Fluffy cloths must not be
(4) Remove leaf springs (5). used. Leather cloths are particularly good. After dis-
(5) Withdraw solenoid valves (6 - 11) from shift mantling, all parts must be washed and blown out
plate (13). with compressed-air, noting that parts may be
blown away.
NOTE: Check O-rings on solenoid valves for dam-
age and replace if necessary. (9) Unbolt leaf spring (5) (Fig. 126).
(10) Unscrew Torxt bolts (1) (Fig. 126).
(6) Bend away retaining lug on stiffening rib on (11) Remove valve housing (2) from valve body (4)
transmission oil temperature sensor. (Fig. 126).
(7) Remove electrohydraulic control module (12) (12) Remove sealing plate (3).
from the shift plate (13). (13) Remove the strainers (1, 2) for the modulating
(8) Note the locations of the major shift valve pressure and shift pressure control solenoid valves
group components for assembly reference. (Fig. 125) (Fig. 127) from the valve housing.
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 105
ELECTROHYDRAULIC UNIT (Continued)
Fig. 125 Shift Valve Group Locations Fig. 127 Solenoid Valve Strainer Locations
A - OPERATING AND LUBRICATING PRESSURE REGULATING 1 - SOLENOID VALVE STRAINERS
VALVES AND 2-3 OVERLAP VALVE
B - 1-2/4-5 SHIFT GROUP AND SHIFT, SHIFT VALVE, AND
REGULATING VALVE PRESSURE REGULATING VALVES
C - 3-4 SHIFT GROUP
D - 2-3 SHIFT GROUP, TCC LOCK-UP AND B2 REGULATING
VALVES
Fig. 126 Shift Plate Components NOTE: A total of 12 valve balls are located in the
1 - BOLTS - 29
valve body, four made from plastic (4) and eight
2 - VALVE HOUSING from steel (1, 3).
3 - SEALING PLATE
4 - VALVE BODY (15) Note the location of all check balls (1, 3, 4)
5 - LEAF SPRING
(Fig. 129) and the central strainer (2) for re-installa-
(14) Remove the strainer (1) (Fig. 128) in the inlet tion. Remove all check balls (1, 3, 4) and the central
to torque converter lock-up control solenoid valve. strainer (2).
(16) Remove the screws holding the side covers to
the valve body and valve housing.
21 - 106 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
ELECTROHYDRAULIC UNIT (Continued)
(17) Remove all valves and springs from the valve
body (1) (Fig. 130). Check all valves for ease of move-
ment and shavings.
Fig. 132 Pressure Feed Valve Location Fig. 133 Pressure Feed Valve Location
1 - PRESSURE FEED VALVE 1 - PRESSURE FEED VALVE
NOTE: The sleeves and pistons of the overlap reg- (6) Install all check balls (1, 3, 4) (Fig. 136) and
ulating valves must not be mixed up. the central strainer (2).
(7) Install the strainer (1) (Fig. 137) in the inlet to
(2) Install all valves and springs from the valve torque converter lock-up control solenoid valve.
body (1) (Fig. 134). Check all valves for ease of move- (8) Position the sealing plate (3) onto the valve
ment and shavings. body (4) (Fig. 138).
(3) Install the screws to hold the side covers to the (9) Install the valve housing (2) onto the valve
valve body. Tighten the screws to 4 N·m (35 in.lbs.). body (4) and sealing plate (3).
(4) Install all valves and springs into the valve (10) Install the shift plate Torxt bolts (1) (Fig.
housing (2) (Fig. 135). Check all valves for ease of 138). Tighten the bolts to 8 N·m (71 in.lbs.).
movement and shavings. (11) Install leaf spring (5) (Fig. 138).
(5) Install the screws to hold the side covers to the (12) Install the strainers (1, 2) for the modulating
valve housing. Tighten the screws to 4 N·m (35 pressure and shift pressure control solenoid valves
in.lbs.). (Fig. 139) into the valve housing.
(13) Install the electrohydraulic control module
NOTE: A total of 12 valve balls are located in the (12) onto the shift plate (13) (Fig. 140).
valve body, four made from plastic (4) and eight (14) Bend the retaining lug on stiffening rib on
from steel (1, 3). transmission oil temperature sensor to retain the
electrohydraulic control module.
(15) Install the solenoid valves (6 - 11) into shift
plate (13).
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 109
ELECTROHYDRAULIC UNIT (Continued)
Fig. 136 Check Balls and Strainer Location Fig. 137 Converter Lock-up Solenoid Valve Strainer
1 - STEEL CHECK BALLS Location
2 - CENTRAL STRAINER 1 - CONVERTER LOCK-UP SOLENOID STRAINER
3 - STEEL CHECK BALLS
4 - PLASTIC CHECK BALLS
5 - PLAIN DOWEL PIN
21 - 110 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
ELECTROHYDRAULIC UNIT (Continued)
INSTALLATION
(1) Position the electrohydraulic unit in the trans-
mission housing.
(2) Insert selector valve (1) (Fig. 141) in driver of
detent plate (2). When installing the electrohydraulic
control module in the transmission housing, the plas-
Fig. 139 Solenoid Valve Strainer Locations tic part of the selector valve (1) must engage in the
1 - SOLENOID VALVE STRAINERS driver of the detent plate (2).
(3) Install the Torxt socket bolts (3) (Fig. 142) and
NOTE: Check O-rings on solenoid valves for dam- torque to 8 N·m (71 in.lbs.).
age and replace if necessary. (4) Install a new oil filter (4) (Fig. 142).
(5) Install oil pan (5) (Fig. 142) and torque the oil
(16) Install the leaf springs (5). pan bolts to 8 N·m (71 in.lbs.).
(17) Install the Torxt socket bolts (3, 4) (Fig. 140). (6) Install the oil drain plug (8) (Fig. 142) with a
Tighten the bolts to 8 N·m (71 in.lbs.). new drain plug gasket (9). Torque the drain plug to
20 N·m (177 in.lbs.).
NOTE: Pay attention to the different lengths of the
TorxT socket bolts.
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 111
ELECTROHYDRAULIC UNIT (Continued)
(7) Install the guide bushing (2) (Fig. 142) into the
transmission housing and install the bolt (11) to hold
the guide bushing in place.
Fig. 142 Remove Electrohydraulic Unit Fig. 144 Install Heat Shield
1 - HEAT SHIELD 1 - SCREW
2 - ELECTROHYDRAULIC UNIT 2 - HEAT SHIELD
3 - BOLT 3 - BOLT
4 - OIL FILTER
5 - OIL PAN (10) Position the heat shield (2) (Fig. 144) onto the
6 - CLAMPING ELEMENT transmission housing and install the screw (1) and
7 - BOLT
8 - DRAIN PLUG bolt (3) to hold the shield in place.
9 - DRAIN PLUG GASKET (11) Fill the transmission with the correct oil
10 - 13-PIN PLUG CONNECTOR (Refer to LUBRICATION & MAINTENANCE/FLUID
11 - BOLT
12 - GUIDE BUSHING TYPES - DESCRIPTION) using the standard proce-
dure (Refer to 21 - TRANSMISSION/AUTOMATIC -
NAG1/FLUID AND FILTER - STANDARD PROCE-
DURE - TRANSMISSION FILL).
21 - 112 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
FLUID CONTAMINATION
Transmission fluid contamination is generally a
result of:
• adding incorrect fluid
• failure to clean dipstick and fill tube when
checking level Fig. 147 Remove Dipstick Tube Cap Lock
• engine coolant entering the fluid 1 - LOCKING PIN
• internal failure that generates debris 2 - TUBE CAP
3 - DIPSTICK TUBE
• overheat that generates sludge (fluid break-
down)
contusions and burns if you insert your hands into
• failure to replace contaminated converter after
the engine when it is started or when it is running.
repair
Secure vehicle to prevent it from moving off by
The use of non-recommended fluids can result in
itself. Wear properly fastened and close-fitting work
transmission failure. The usual results are erratic
clothes. Do not touch hot or rotating parts.
shifts, slippage, abnormal wear and eventual failure
(4) Actuate the service brake. Start engine and let
due to fluid breakdown and sludge formation. Avoid
it run at idle speed in selector lever position 9P9.
this condition by using recommended fluids only.
(5) Shift through the transmission modes several
The dipstick cap and fill tube should be wiped
times with the vehicle stationary and the engine
clean before checking fluid level. Dirt, grease and
idling
other foreign material on the cap and tube could fall
(6) Warm up the transmission, wait at least 2 min-
into the tube if not removed beforehand. Take the
utes and check the oil level with the engine running.
time to wipe the cap and tube clean before withdraw-
Push the Oil Dipstick 8863A in up to the stop on the
ing the dipstick.
electrohydraulic unit and pull out again, read off oil
Engine coolant in the transmission fluid is gener-
level, repeat if necessary.
ally caused by a cooler malfunction. The only remedy
is to replace the radiator as the cooler in the radiator NOTE: The dipstick will protrude from the fill tube
is not a serviceable part. If coolant has circulated approximately 75mm (3 inches) when installed.
through the transmission, an overhaul is necessary.
The torque converter should be replaced whenever (7) Check transmission oil temperature.
a failure generates sludge and debris. This is neces-
sary because normal converter flushing procedures NOTE: The true transmission oil temperature can
will not remove all contaminants. only be read by a scan tool in REVERSE or any for-
ward gear position. (Refer to 21 - AUTOMATIC
TRANSMISSION- NAG1/TRANSMISSION TEMPERA-
STANDARD PROCEDURE TURE SENSOR/PARK-NEUTRAL SWITCH - OPERA-
TION)
CHECK OIL LEVEL
(1) Verify that the vehicle is parked on a level sur- (8) The transmission Oil Dipstick 8863A has indi-
face. cator marks every 10mm. Determine the height of
(2) Remove locking pin (1) (Fig. 147). Remove the the oil level on the dipstick and using the height, the
plate of the locking pin with a suitable tool and press transmission temperature, and the Transmission
out the pin remaining in the cap downwards. Fluid Graph (Fig. 148), determine if the transmission
(3) Remove cap (2). oil level is correct.
(9) Add or remove oil as necessary and recheck the
WARNING: Risk of accident from vehicle starting off oil level.
by itself when engine running. Risk of injury from
21 - 114 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
FLUID AND FILTER (Continued)
DESCRIPTION
DISASSEMBLY
ASSEMBLY
NOTE: The side of the freewheeling clutch F2 (3)
with the markings (directional arrow, part number,
etc.) must be up when the clutch is installed in the
sun gear (4).
REMOVAL
HOLDING CLUTCHES
DESCRIPTION
Three (Fig. 163) multiple-disc holding clutches, the
front, B1 (1), middle, B3 (4), and rear multiple disc
clutches, B2 (5), are located in the planetary gear
sets in the transmission housing.
A multiple-disc holding clutch consists of a number
of internally toothed discs (10) on an internally
toothed disc carrier and externally toothed discs (9)
on an externally toothed disc carrier, which is rigidly
connected to the transmission housing.
Fig. 161 Install Bottom Section Of Center
Instrument Panel
1 - SCREW
2 - BOTTOM CENTER PART OF INSTRUMENT PANEL
ASSEMBLY
NOTE: Check vulcanized gasket, replace if neces-
sary.
HOLDING CLUTCH B2
DISASSEMBLY
(1) Remove snap ring (1) (Fig. 173).
(2) Take multiple-disc pack B2 (2) and disc spring
(3) out of the outer multiple-disc carrier B2 (8). The
outer multiple-disc carrier for the multi-disc holding
clutch B2 is the piston for the multiple-disc holding
clutch B3 at the same time. Note which clutch disc is
removed just prior to the disc spring (3) for re-assem-
bly. If the clutch discs are re-used, this disc must be
returned to its original position on top of the disc
spring.
(3) Place the Multi-use Spring Compressor 8900 on
the spring disc (14) and compress the spring until
the groove for the snap-ring is exposed.
(4) Remove snap-ring (16) (Fig. 173).
(5) Remove spring plate (15) and disc spring (14).
(6) Separate piston guide ring (13) and the B2 pis-
Fig. 172 Install the Teflon Rings
ton (10) from the B3 piston (8) by blowing com-
1 - TEFLON RINGS
2 - PLATE CARRIER HUB
pressed air into the bore (D) (Fig. 174).
(7) Press piston guide ring (13) out of the B2 pis-
(12) Install the teflon rings (1) (Fig. 172) onto the ton (10).
B1 plate carrier hub (2). (8) Separate piston guide (4) from the B3 piston
(13) Coat Teflon rings (1) lightly with grease and (8) by blowing compressed air into the bore (A) (Fig.
insert in the groove so that the joint remains 174).
together.
21 - 128 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
HOLDING CLUTCH B2 (Continued)
OPERATION
OPERATION
DISASSEMBLY
INSTALLATION
(1) Install output shaft bearing in the rear trans- Fig. 194 Install Output Shaft Seal
mission housing. Using Bearing Installer 9287 (1) 1 - SEAL INSTALLER 8902A
(Fig. 192), install the output shaft bearing (2) into 2 - TRANSMISSION CASE
the transmission housing. The closed side of the
plastic cage must point towards the parking (6) Install a new transmission rear seal into the
lock gear. transmission case with Seal Installer 8902A (1) (Fig.
(2) Install the retaining ring (1) (Fig. 193). Ensure 194).
that the retaining ring is seated correctly in the (7) Verify that the transmission is in PARK in
groove. order to prepare for the installation of the output
(3) Check that there is no play between the bear- shaft nut.
ing and the retaining ring using feeler gauge. (8) Install the propeller shaft flange onto the out-
(4) There must be no play between the retaining put shaft and install an new flange nut. Tighten the
ring and the bearing. If the ring cannot be installed, flange nut to 120 N·m (88.5 ft.lbs.).
a thinner ring must be used. If there is play between (9) Stake the output shaft nut to the output shaft
the ring and the bearing, a thicker ring must be as follows.Place the Staking Tool 9078 (2) and Driver
installed. Retaining rings are available in thick- Handle C-4171 onto the output shaft.
nesses of 2.0 mm (0.079 in.), 2.1 mm (0.083 in.), and (10) Rotate the Staking Tool 9078 (2) until the
2.2 mm (0.087 in.). alignment pin (3) engages the output shaft notch (4)
(5) Install the output shaft washer onto the output (Fig. 195).
shaft.
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 137
OUTPUT SHAFT BEARING (Continued)
(1) Position the new output shaft seal over the out-
Fig. 196 Stake Output Shaft Nut put shaft and against the transmission case.
1 - STAKING TOOL 9078 (2) Use Seal Installer 8902A (1) (Fig. 197) to
2 - PROPELLER FLANGE
3 - STAKING PIN install the seal.
(3) Verify that the transmission is in PARK in
(11) Press downward on the staking tool (1) until order to prepare for the installation of the output
the staking pin (3) contacts the output shaft nut shaft nut.
flange (2) (Fig. 196). (4) Install the propeller shaft flange onto the out-
(12) Strike the Driver handle C-4171 with a suit- put shaft and install an new flange nut. Tighten the
able hammer until the output shaft nut is securely flange nut to 120 N·m (88.5 ft.lbs.).
staked to the output shaft. (5) Stake the output shaft nut to the output shaft
(13) Install the propeller shaft (Refer to 3 - DIF- as follows.Place the Staking Tool 9078 (2) and Driver
FERENTIAL & DRIVELINE/PROPELLER SHAFT/ Handle C-4171 onto the output shaft.
PROPELLER SHAFT - INSTALLATION). (6) Rotate the Staking Tool 9078 (2) until the
alignment pin (3) engages the output shaft notch (4)
(Fig. 198).
(7) Press downward on the staking tool until the
staking pin (3) contacts the output shaft nut flange
(2) (Fig. 199).
21 - 138 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
OUTPUT SHAFT SEAL (Continued)
INSTALLATION
(1) Route the park lock cable through the instru-
ment panel between the steering column and the
shift lever assembly (SLA).
(2) Install the park lock cable (2) (Fig. 205) to the
ignition switch.
(3) Tighten the park lock cable (2) (Fig. 206) to the
Fig. 202 Disengage Park Lock Cable From SLA ignition switch.
1 - PARK LOCK CABLE COUPLING
(4) Install the lower steering column shroud.
2 - LOCK TAB (5) Connect the park lock cable coupling (1) (Fig.
3 - BOLT 207) to the shift lever assembly (SLA). Press locking
4 - SHIFT LEVER ASSEMBLY (SLA)
5 - CONNECTOR
tab (2) together and push coupling (1) against the
spring force into the SLA, twist through 90° (right or
left) until locked.
21 - 140 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
PARK LOCK CABLE (Continued)
PLANETARY GEARTRAIN The annulus gear (1) (Fig. 215) and sun gear (3)
elements of a planetary gear system are alternately
driven and braked by the actuating elements of the
DESCRIPTION
multi-plate clutch and multiple-disc brake. The plan-
etary pinion gears (2) can turn on the internal gear-
ing of the annulus gear (1) and on the external
gearing of the sun gear (3). This allows for a variety
of gear ratios and the reversal of the rotation direc-
tion without the need for moving gear wheels or shift
collars. When two components of the planetary gear
set are locked together, the planetary gear set is
locked and turns as a closed unit.
The torque and engine speed are converted accord-
ing to the lever ratios and the ratio of the number of
teeth on the driven gears to that on the drive gears,
and is referred to as the gear ratio. The overall ratio
of a number of planetary gear sets connected in
series is obtained by multiplying the partial ratios.
DISASSEMBLY
Fig. 214 Planetary Geartrain (1) Remove upper two visible Teflon rings (1) (Fig.
1 - ANNULUS GEAR 216) from output shaft.
2 - PLANETARY PINION GEARS (2) Remove retaining ring (11), shim (10), thrust
3 - SUN GEAR
4 - PLANETARY CARRIER needle bearing (9) and thrust washer (8) from output
shaft.
Three planetary gear sets (Fig. 214) are used to (3) Remove clutch K3 (7).
produce the different gear ratios. These are located (4) Remove rear tubular shaft/freewheeling clutch
in the mechanical part of the transmission as the F2 (6) (Fig. 216) from output shaft.
front, middle and rear planetary gear sets. (5) Remove rear gear set (5) with integrated tubu-
lar shaft of center gear set from output shaft.
OPERATION (6) Remove thrust washer (4).
Fig. 216 Output Shaft with Center and Rear Planetary Geartrain
1 - TEFLON RINGS 7 - DRIVING CLUTCH K3
2 - OUTPUT SHAFT WITH CENTER PLANETARY CARRIER 8 - THRUST WASHER
3 - NEEDLE BEARING 9 - AXIAL NEEDLE BEARING
4 - THRUST WASHER 10 - SHIM
5 - REAR PLANETARY GEAR SET 11 - RETAINING RING
6 - REAR HOLLOW SHAFT/FREEWHEELING CLUTCH F2
Fig. 217 Output Shaft with Center and Rear Planetary Geartrain
1 - TEFLON RINGS 7 - DRIVING CLUTCH K3
2 - OUTPUT SHAFT WITH CENTER PLANETARY CARRIER 8 - THRUST WASHER
3 - NEEDLE BEARING 9 - AXIAL NEEDLE BEARING
4 - THRUST WASHER 10 - SHIM
5 - REAR PLANETARY GEAR SET 11 - RETAINING RING
6 - REAR HOLLOW SHAFT/FREEWHEELING CLUTCH F2
Fig. 219 Remove Top Section Of Center Instrument Fig. 221 Disengage Park Lock Cable From SLA
Panel 1 - PARK LOCK CABLE COUPLING
1 - SHIFT LEVER ASSEMBLY FRAME TRIM 2 - LOCK TAB
2 - STORAGE COMPARTMENT 3 - BOLT
3 - TOP CENTER PART OF INSTRUMENT PANEL 4 - SHIFT LEVER ASSEMBLY (SLA)
4 - SCREW 5 - CONNECTOR
5 - PLUG CONNECTIONS
6 - ASHTRAY (6) Pry ball socket (4) of transmission shift cable
off ball knob at the SLA. Use a suitable slotted
screwdriver.
(7) Unscrew bolts (1) (Fig. 222).
(8) Move selector lever to position 9P9.
(9) Remove the SLA (2) from the vehicle.
INSTALLATION
(1) Position the shift lever assembly (SLA) onto
the vehicle.
(2) Install the bolts to hold the SLA to the vehicle.
Tighten the bolts to 6 N·m (53 in.lbs.).
(3) Connect the park lock cable coupling (1) (Fig.
223) to the SLA. Press locking tab (2) together and
push coupling (1) against the spring force into the
SLA, twist through 90° (right or left) until locked.
(4) Connect the connector plug (5) to the SLA.
Fig. 227 Modulating Pressure Control Solenoid Fig. 228 Torque Converter Lockup Clutch PWM
Valve Solenoid Valve
1 - MODULATING PRESSURE CONTROL SOLENOID VALVE 1 - TORQUE CONVERTER LOCKUP CLUTCH PWM SOLENOID
2 - CONTACT SPRING VALVE
3 - CONDUCTOR TRACK 2 - CONTACT SPRING
4 - VALVE HOUSING SHIFT PLATE 3 - CONDUCTOR TRACK
5 - CONDUCTOR TRACK 4 - VALVE HOUSING OF SHIFT PLATE
6 - CONTACT SPRING 5 - O-RING
6 - CONDUCTOR TRACK
7 - CONTACT SPRING
The modulating pressure regulating solenoid valve
(1) has an interference fit and is sealed off to the
valve body of the shift plate (4) by a seal (arrow). The
SHIFT PRESSURE CONTROL SOLENOID VALVE
The shift pressure control solenoid valve (1) (Fig.
contact springs (2) at the solenoid valve engage in a
229) is located in the shell of the electric valve con-
slot in the conductor tracks (3). The force of the con-
trol unit and pressed against the shift plate by a
tact springs (2) ensures secure contacts.
spring.
TORQUE CONVERTER LOCKUP CLUTCH PWM Its purpose is to control the shift pressure depend-
ing on the continuously changing operating condi-
SOLENOID VALVE tions, such as load and gear change.
The torque converter lockup clutch PWM solenoid The shift pressure regulating solenoid valve (1) has
valve (1) (Fig. 228) is located in the shell of the elec- an interference fit and is sealed off to the valve body
tric valve control unit and pressed against the shift of the shift plate (4) by a seal (arrow). The contact
plate by a spring. springs (2) at the solenoid valve engage in a slot in
The PWM solenoid valve (1) for the torque con- the conductor tracks (3). The force of the contact
verter lockup controls the pressure for the torque springs (2) ensures secure contacts.
converter lockup clutch.
The torque converter lockup PWM solenoid valve
(1) is sealed off to the valve body of the shift plate (4)
by an O-ring (5) and a seal (arrow). The contact
springs (2) at the solenoid valve engage in a slot in
the conductor tracks (3). The force of the contact
springs (2) ensures secure contacts.
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 151
SOLENOID (Continued)
UPSHIFT/DOWNSHIFT SOLENOID VALVES
Fig. 231 Modulating Pressure Control Solenoid Fig. 232 Torque Converter Lockup Clutch PWM
Valve Solenoid Valve
1 - MODULATING PRESSURE CONTROL SOLENOID VALVE 1 - TORQUE CONVERTER LOCKUP CLUTCH PWM SOLENOID
2 - CONTACT SPRING VALVE
3 - CONDUCTOR TRACK 2 - CONTACT SPRING
4 - VALVE HOUSING SHIFT PLATE 3 - CONDUCTOR TRACK
5 - CONDUCTOR TRACK 4 - VALVE HOUSING OF SHIFT PLATE
6 - CONTACT SPRING 5 - O-RING
6 - CONDUCTOR TRACK
7 - CONTACT SPRING
The modulating pressure regulating solenoid valve
(1) (Fig. 231) assigns a proportional pressure to the The torque converter lockup PWM solenoid (1)
current which is controlled by the TCM according to (Fig. 232) valve converts pulse-wave-modulated cur-
the load. rent controlled by the TCM into the appropriate
hydraulic control pressure (p-S/TCC).
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 153
SOLENOID (Continued)
SHIFT PRESSURE CONTROL SOLENOID VALVE
TEMPERATURE SENSOR/
PARK-NEUTRAL CONTACT
Fig. 235 Transmission Temperature Sensor
DESCRIPTION 1 - TRANSMISSION TEMPERATURE SENSOR
OPERATION
TURBINE
As the fluid that was put into motion by the impel-
ler blades strikes the blades of the turbine, some of
the energy and rotational force is transferred into the
turbine and the input shaft. This causes both of them
(turbine and input shaft) to rotate in a clockwise
direction following the impeller. As the fluid is leav-
21 - 160 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
TORQUE CONVERTER (Continued)
TORQUE CONVERTER CLUTCH (TCC) NO EMCC
Under No EMCC conditions, the TCC Solenoid is
OFF. There are several conditions that can result in
NO EMCC operations. No EMCC can be initiated
due to a fault in the transmission or because the
TCM does not see the need for EMCC under current
driving conditions.
PARTIAL EMCC
Partial EMCC operation modulates the TCC Sole-
noid (duty cycle) to obtain partial torque converter
clutch application. Partial EMCC operation is main-
tained until Full EMCC is called for and actuated.
During Partial EMCC some slip does occur. Partial
EMCC will usually occur at low speeds, low load and
light throttle situations.
FULL EMCC
During Full EMCC operation, the TCM increases
the TCC Solenoid duty cycle to full ON after Partial
EMCC control brings the engine speed within the
desired slip range of transmission input speed rela-
tive to engine rpm.
Fig. 247 Torque Converter Lock-up Clutch GRADUAL-TO-NO EMCC
1 - TURBINE
2 - IMPELLER
This operation is to soften the change from Full or
3 - STATOR Partial EMCC to No EMCC. This is done at mid-
4 - INPUT SHAFT throttle by decreasing the TCC Solenoid duty cycle.
5 - STATOR SHAFT
6 - PISTON
7 - COVER SHELL REMOVAL
8 - INTERNALLY TOOTHED DISC CARRIER (1) Remove transmission and torque converter
9 - CLUTCH PLATE SET
10 - EXTERNALLY TOOTHED DISC CARRIER from vehicle.
11 - TURBINE DAMPER (2) Place a suitable drain pan under the converter
housing end of the transmission.
In a standard torque converter, the impeller (2)
and turbine (1) are rotating at about the same speed CAUTION: Verify that transmission is secure on the
and the stator (3) is freewheeling, providing no lifting device or work surface, the center of gravity
torque multiplication. By applying the turbine’s pis- of the transmission will shift when the torque con-
ton and friction material (9) (Fig. 247), a total con- verter is removed creating an unstable condition.
verter engagement can be obtained. The result of this The torque converter is a heavy unit. Use caution
engagement is a direct 1:1 mechanical link between when separating the torque converter from the
the engine and the transmission. transmission.
The clutch can be engaged in second, third, fourth,
and fifth gear ranges. (3) Pull the torque converter forward until the cen-
The TCM controls the torque converter by way of ter hub clears the oil pump seal.
internal logic software. The programming of the soft- (4) Separate the torque converter from the trans-
ware provides the TCM with control over the torque mission.
converter solenoid. There are four output logic states
that can be applied as follows: INSTALLATION
• No EMCC Check converter hub and drive flats for sharp
• Partial EMCC edges, burrs, scratches, or nicks. Polish the hub and
• Full EMCC flats with 320/400 grit paper or crocus cloth if neces-
• Gradual-to-no EMCC sary. The hub must be smooth to avoid damaging the
pump seal at installation.
(1) Lubricate oil pump seal lip with transmission
fluid.
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 161
TORQUE CONVERTER (Continued)
INSTALLATION
TIRES/WHEELS
TABLE OF CONTENTS
page page
TIRES/WHEELS
DIAGNOSIS AND TESTING - TIRE AND WHEEL
RUNOUT
Radial runout is the difference between the high
and low points on the tire or wheel (Fig. 1).
Lateral runout is the wobble of the tire or wheel.
Radial runout of more than 1.5 mm (.060 inch)
measured at the center line of the tread may cause
the vehicle to shake.
Lateral runout of more than 2.0 mm (.080 inch)
measured near the shoulder of the tire may cause the
vehicle to shake.
Sometimes radial runout can be reduced. Relocate
the wheel and tire assembly on the mounting studs
(See Method 1). If this does not reduce runout to an
acceptable level, the tire can be rotated on the wheel. Fig. 1 Checking Tire/Wheel/Hub Runout
(See Method 2). 1 - RADIAL RUNOUT
2 - LATERAL RUNOUT
22 - 2 TIRES/WHEELS VA
TIRES/WHEELS (Continued)
METHOD 1 (RELOCATE WHEEL ON HUB)
(1) Drive vehicle a short distance to eliminate tire
flat spotting from a parked position.
(2) Check wheel bearings and adjust if adjustable
or replace if necessary.
(3) Check the wheel mounting surface.
(4) Relocate wheel on the mounting, two studs
over from the original position.
(5) Tighten wheel nuts until all are properly
torqued, to eliminate brake distortion.
(6) Check radial runout. If still excessive, mark
tire sidewall, wheel, and stud at point of maximum
runout and proceed to Method 2.
STANDARD PROCEDURE - TIRE ROTATION CAUTION: 3500 Dual rear tires have a new tire rota-
Tires on the front and rear axles operate at differ- tion pattern. This is to accommodate the asymmet-
ent loads and perform different steering, driving, and rical design of the ON/OFF road tires and the use of
braking functions. For these reasons, the tires wear the outlined white letter (OWL) tires. When replac-
at unequal rates. They may also develop irregular ing a flat, the spare tire may have to be remounted
wear patterns. These effects can be reduced by rotat- on the rim or installed at a different location to
ing the tires according to the maintenance schedule maintain the correct placement of the asymmetrical
in the Owners Manual. This will improve tread life, design or the (OWL).
traction and maintain a smooth quiet ride.
The recommended method of tire rotation is (Fig.
9) & (Fig. 10). Other methods can be used, but may
not provide the same tire longevity benefits.
SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
TIRES
DESCRIPTION
DESCRIPTION - TIRES
Tires are designed and engineered for each specific
vehicle. They provide the best overall performance
for normal operation. The ride and handling charac-
teristics match the vehicle’s requirements. With
proper care they will give excellent reliability, trac-
tion, skid resistance, and tread life.
Driving habits have more effect on tire life than
any other factor. Careful drivers will obtain in most
cases, much greater mileage than severe use or care-
less drivers. A few of the driving habits which will
shorten the life of any tire are:
• Rapid acceleration
• Severe brake applications
• High speed driving
• Excessive speeds on turns
• Striking curbs and other obstacles
Radial-ply tires are more prone to irregular tread
wear. It is important to follow the tire rotation inter-
val shown in the section on Tire Rotation, (Refer to
22 - TIRES/WHEELS - STANDARD PROCEDURE).
This will help to achieve a greater tread life.
Fig. 11 Tire Identification
TIRE IDENTIFICATION
Tire type, size, aspect ratio and speed rating are DESCRIPTION - RADIAL – PLY TIRES
encoded in the letters and numbers imprinted on the Radial-ply tires improve handling, tread life and
side wall of the tire. Refer to the chart to decipher ride quality, and decrease rolling resistance.
the tire identification code (Fig. 11). Radial-ply tires must always be used in sets of
Performance tires have a speed rating letter after four. Under no circumstances should they be used on
the aspect ratio number. The speed rating is not the front only. They may be mixed with temporary
always printed on the tire sidewall. These ratings spare tires when necessary. A maximum speed of 50
are: MPH is recommended while a temporary spare is in
• Q up to 100 mph use.
• R up to 106 mph Radial-ply tires have the same load-carrying capac-
• S up to 112 mph ity as other types of tires of the same size. They also
• T up to 118 mph use the same recommended inflation pressures.
• U up to 124 mph The use of oversized tires, either in the front or
• H up to 130 mph rear of the vehicle, can cause vehicle drive train fail-
• V up to 149 mph ure. This could also cause inaccurate wheel speed
• Z more than 149 mph (consult the tire manu- signals when the vehicle is equipped with Anti-Lock
facturer for the specific speed rating) Brakes.
An All Season type tire will have either M + S, M The use of tires from different manufactures on the
& S or M–S (indicating mud and snow traction) same vehicle is NOT recommended. The proper tire
imprinted on the side wall. pressure should be maintained on all four tires.
OPERATION
The wheel (Fig. 19) has raised sections between
the rim flanges and the rim well. Initial inflation of STANDARD PROCEDURE
the tire forces the bead over these raised sections. In
case of tire failure, the raised sections hold the tire STANDARD PROCEDURE - WHEEL
in position on the wheel until the vehicle can be REPLACEMENT
brought to a safe stop. The wheel stud/lugs are designed for specific appli-
cations. They must be replaced with equivalent parts.
Do not use replacement parts of lesser quality or a
substitute design.
Before installing the wheel, be sure to remove any
build up of corrosion on the wheel mounting surfaces.
Ensure wheels are installed with good metal-to-metal
contact. Improper installation could cause loosening
of wheel nuts. This could affect the safety and han-
dling of your vehicle.
To install the wheel, first position it properly on
the mounting surface. All wheel nuts should then be
tightened just snug. Gradually tighten them in
sequence to the proper torque specification. Never
use oil or grease on studs.
Wheels must be replaced if they have:
• Excessive runout
• Bent or dented
• Leak air through welds
Fig. 19 Safety Rim • Have damaged bolt holes
1 - FLANGE Wheel repairs employing hammering, heating, or
2 - RIDGE welding are not allowed.
3 - WELL Original equipment wheels are available through
your dealer. Replacement wheels from any other
DIAGNOSIS AND TESTING source should be equivalent in:
• Load carrying capacity
WHEEL INSPECTION • Diameter
Inspect wheels for: • Width
• Excessive run out • Offset
• Dents or cracks • Mounting configuration
• Damaged wheel lug nut holes Failure to use equivalent replacement wheels may
• Air Leaks from any area or surface of the rim affect the safety and handling of your vehicle.
Replacement with used wheels is not recommended.
NOTE: Do not attempt to repair a wheel by hammer- Their service history may have included severe treat-
ing, heating or welding. ment.
If a wheel is damaged an original equipment
replacement wheel should be used. When obtaining
22 - 12 TIRES/WHEELS VA
WHEELS (Continued)
STANDARD PROCEDURE - DUAL REAR WHEEL • Install the cone washers for the outer wheel
before installing the lug nuts (Fig. 22).
INSTALLATION
The tires on both wheels must be completely raised
off the ground when tightening the lug nuts. This
will ensure correct wheel centering and maximum
wheel clamping.
Before installing the wheel to the wheel ring flange
make sure that all the cone washers are installed on
the wheel flange ring (Fig. 20).
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the wheel lug studs (SRW) (Fig. 24).
(3) Remove the lug nuts (DRW) On vehicles with
dual rear wheels do not pry off the front hub
cap the lug nuts must be removed in order to
remove the hub cap. (Fig. 23).
BODY
TABLE OF CONTENTS
page page
PANEL REINFORCEMENT • Panel repair for both flexible and rigid panels
Structural repair procedures for rigid panels with are basically the same. The primary difference
large cracks and holes will require a reinforcement between flexible panel repair and rigid panel repair
backing. Reinforcements can be made with several is in the adhesive materials used (Fig. 5).
VA BODY 23 - 7
BODY (Continued)
PATCHING PANELS
An panel that has extensive puncture type damage
can be repaired by cutting out the damaged material
(Fig. 7). Use a suitable reciprocating saw or cut off
wheel to remove the section of the panel that is dam-
aged. The piece cut out can be used as a template to
shape the new patch. It is not necessary to have
Fig. 5 FIBERGLASS TAPE access to the back of the panel to install a patch.
VISUAL INSPECTION Bevel edges of cutout at 20 degrees to expose a larger
Composite materials can mask the severity of an bonding area on the outer side. This will allow for an
accident. Adhesive bond lines, interior structure of increased reinforcement areas.
the doors, and steel structures need to be inspected
carefully to get a true damage assessment. Close PANEL PATCH FABRICATIONS
inspection may require partial removal of interior A patch can be fabricated from any rigid fiberglass
trim or inner panels. panel that has comparable contour with the repair
Identify the type of repair: Puncture or Crack - area. Lift gates and fenders can be used to supply
Damage that has penetrated completely through the patch material. If existing material is not available
panel. Damage is confined to one general area; a or compatible, a patch can be constructed with adhe-
panel section is not required. However, a backer sive and reinforcement mesh (dry wall tape). Perform
panel, open fiberglass tape, or matted material must the following operation if required:
be bonded from behind (Fig. 7) (Fig. 6). (1) Cover waxed paper or plastic with adhesive
backed nylon mesh (dry wall tape) larger than the
PANEL SURFACE PREPARATION patch required (Fig. 8).
If a body panel has been punctured, cracked, or (2) Tape waxed paper or plastic sheet with mesh to
crushed, the damaged area must be removed from a surface that has a compatible contour to the repair
the panel to achieve a successful repair. All spider area.
web cracks leading away from a damaged area must
23 - 8 BODY VA
BODY (Continued)
PANEL PATCH INSTALLATION
(1) Make a paper or cardboard pattern the size
and shape of the cutout hole in the panel.
(2) Trim 3 mm (0.125 in.) from edges of pattern so
patch will have a gap between connecting surfaces.
(3) Using the pattern as a guide, cut the patch to
size.
(4) Cut scrap pieces of patch material into 50 mm
(2 in.) squares to use as patch supports to sustain
the patch in the cutout.
(5) Drill 4 mm (0.160 in.) holes 13 mm (0.5 in.) in
from edge of cutout hole (Fig. 7).
(6) Drill 4 mm (0.160 in.) holes 13 mm (0.5 in.)
away from edge of patch across from holes drilled
around cutout.
Fig. 7 DAMAGED PANEL CUTOUT AND PATCH (7) Drill 3 mm (0.125 in.) holes in the support
1 - CUTOUT squares 13 mm (0.5 in.) from the edge in the center
2 - DAMAGED BODY PANEL
3 - 4 MM (0.160 IN.) HOLES
of one side.
4 - PATCH CUT TO SIZE (8) Scuff the backside of the body panel around the
cutout hole with a scuff pad or sandpaper.
(3) Apply a liberal coat of adhesive over the rein- (9) Mix enough adhesive to cover one side of all
forcement mesh (Fig. 8). If necessary apply a second support squares.
or third coat of adhesive and mesh after firs coat has (10) Apply adhesive to cover one side of all support
cured. The thickness of the patch should be the same squares.
as the repair area. (11) Using number 8 sheet metal screws, secure
(4) After patch has cured, peel waxed paper or support squares to back side of body panel with
plastic from the back of the patch. adhesive sandwiched between the panel and squares
(5) If desired, a thin film coat of adhesive can be (Fig. 9).
applied to the back of the patch to cover mesh for
added strength.
SPECIFICATIONS
TORQUE SPECIFICATIONS
DOOR - FRONT
TABLE OF CONTENTS
page page
CHECK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 LATCH STRIKER
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
DOOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 LOCK CYLINDER
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
ADJUSTMENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 15 TRIM PANEL
DOOR GLASS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15 WINDOW REGULATOR - POWER
EXTERIOR HANDLE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16 WINDOW REGULATOR - MANUAL
HINGE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17
LATCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
DOOR
REMOVAL Fig. 4 FRONT DOOR CHECK - BODY
(1) Disconnect and isolate battery negative cable. 1 - DOOR
(2) Remove mirror. (Refer to 23 - BODY/EXTERI- 2 - A-PILLAR BOLTS
OR/SIDE VIEW MIRROR - REMOVAL) 3 - DOOR CHECK
(3) Position aside the wiring boot and disconnect
the electrical connectors. (Fig. 3)
ADJUSTMENTS
ADJUSTMENT
NOTE: Door adjustment measurements should be
taken from stationary or welded body panels like
the roof, rocker or quarter panels.
• During adjustment procedures, it is recom-
mended that all the hinge fasteners be loosened
except for the upper most fasteners. Adjustments
can be made using the upper bolts to hold the door
with final torque of the fasteners occurring after
correct door positioning is achieved.
• A suitable body sealant should be used when
removing or moving the hinges.
DOOR GLASS
REMOVAL
(1) Remove the regulator. (Refer to 23 - BODY/
DOOR - FRONT/WINDOW REGULATOR - POWER
or MANUAL - REMOVAL)
(2) Remove reinforcement bolts. (Fig. 6)
(3) Carefully lower glass into door and out of run
channel.
(4) Remove glass from door. Fig. 7 GLASS SUPPORT
1 - WOOD WEDGE (or equivalent)
INSTALLATION 2 - WINDOW GLASS
(1) Carefully place glass into door and slide up
into run channel. (5) Install the regulator. (Refer to 23 - BODY/
(2) Using wood wedge, tape or equivalent, secure DOOR - FRONT/WINDOW REGULATOR - POWER
glass in the up position. (Fig. 7) or MANUAL - INSTALLATION)
(3) Install reinforcement and install the bolts.
(4) Tighten the reinforcement bolts to 21 N·m (18
ft. lbs.).
23 - 16 DOOR - FRONT VA
(3) Pull rear of handle out away from door and dis-
engage the latch levers.
(4) Slide handle towards the rear of door and
remove.
VA DOOR - FRONT 23 - 17
EXTERIOR HANDLE (Continued)
(3) Slide exterior handle towards rear of door and
install bolt. (Fig. 12)
HINGE
REMOVAL
NOTE: It is not necessary to remove the door to
replace the hinges if they are replaced one at a
time.
INSTALLATION
(1) Install lock cylinder into exterior handle.
(2) Install exterior handle. (Refer to 23 - BODY/
DOOR - FRONT/EXTERIOR HANDLE - INSTALLA-
TION)
VA DOOR - FRONT 23 - 19
WINDOW REGULATOR -
POWER
REMOVAL
(1) Lower front window approximately 2 cm (3/4
Fig. 20 MANUAL REGULATOR ASSEMBLY in.).
1 - DOOR
(2) Disconnect and isolate battery negative cable.
2 - CARRIER PLATE BOLTS (3) Remove door trim panel. (Refer to 23 - BODY/
3 - CARRIER PLATE DOOR - FRONT/TRIM PANEL - REMOVAL)
4 - REGULATOR ASSEMBLY
5 - SEALING STRIP
(4) Disconnect electrical connector. (Fig. 22)
6 - REGULATOR RIVETS (4)
7 - WINDOW CRANK/TRIM RING
8 - TRIM PANEL
9 - CLIPS
10 - WINDOW FRAME MOLDING
11 - REGULATOR
INSTALLATION
(1) Install regulator onto carrier plate and install
new rivets.
(2) Install regulator lift arm into glass guide rail
and install regulator assembly.
(3) Install carrier bolts and tighten to 10 N·m (89
in. lbs.).
(4) Replace tape securing wire harness to regulator
assembly.
(5) Remove glass support.
(6) Connect the electrical connector.
(7) Connect battery negative cable.
(8) Verify correct window operation.
Fig. 24 REGULATOR ASSEMBLY MOUNTING (9) Install trim panel. (Refer to 23 - BODY/DOOR -
1 - CARRIER PLATE BOLTS (3) FRONT/TRIM PANEL - INSTALLATION)
2 - CARRIER PLATE
3 - REGULATOR MOTOR
4 - TAPE
23 - 22 DOOR - FRONT VA
WINDOW REGULATOR -
MANUAL
REMOVAL
(1) Disconnect and isolate battery negative cable.
(2) Remove door trim panel. (Refer to 23 - BODY/
DOOR - FRONT/TRIM PANEL - REMOVAL)
(3) Using wood wedge, tape or equivalent, secure
glass in the up position. (Fig. 26)
INSTALLATION
(1) Install regulator onto carrier plate and install
new rivets.
(2) Install regulator lift arm into glass guide rail
and install regulator assembly.
(3) Install carrier bolts and tighten to 10 N·m (89
in. lbs.).
(4) Remove glass support.
(5) Connect battery negative cable.
(6) Verify correct window operation.
(7) Install trim panel. (Refer to 23 - BODY/DOOR -
FRONT/TRIM PANEL - INSTALLATION)
DOORS - REAR
TABLE OF CONTENTS
page page
CHECK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 33
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 HINGE
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
DOOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 34
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 INSIDE HANDLE ACTUATOR
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 26 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 30 LATCH
ADJUSTMENTS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 30 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 35
DOOR GLASS TRIM PANEL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 31 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 35
EXTERIOR HANDLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
CHECK INSTALLATION
(1) Install the receiver and replace the rivets.
REMOVAL (2) Install d-pillar trim, if equipped. (Refer to 23 -
(1) Open door and disengage check arm from BODY/INTERIOR/D-PILLAR TRIM - INSTALLA-
receiver. (Fig. 1) TION)
(2) Remove the screws and remove the check arm. (3) Install check arm and screws.
(3) Remove the d-pillar trim, if equipped. (Refer to (4) Tighten the screws to 10 N·m (89 idn. lbs.).
23 - BODY/INTERIOR/D-PILLAR TRIM -
REMOVAL)
(4) Remove the rivets and remove the receiver.
DOOR
REMOVAL
(1) Disconnect and isolate battery negative cable.
(2) Open door and disengage check arm from
receiver. (Fig. 2)
(3) Using a grease pencil or equivalent, mark the
outline of the door hinges on the door to aid in instal-
lation.
(4) Support door with a suitable lifting device.
(5) Remove the bolts and remove the door. (Fig. 3)
INSTALLATION
CAUTION: If the door is being replaced a suitable
seam sealer must be used prior to painting.
ADJUSTMENTS
ADJUSTMENT
NOTE: Door adjustment measurements should be
taken from stationary or welded body panels like Fig. 9 HINGE ADJUSTMENT
the roof, rocker or quarter panels.
1 - BODY
2 - ALLEN SCREW
(1) Check door gap around door. (Refer to 23 - 3 - HINGE
BODY/BODY STRUCTURE/GAP AND FLUSH -
SPECIFICATIONS) (6) Open doors and tighten torx bolts to 25 N·m
(2) Open doors and loosen the torx bolts. (Fig. 8) (18 ft. lbs.).
(7) Loosen door striker and adjust so right door is
flush with the left door. (Fig. 10)
EXTERIOR HANDLE
REMOVAL
(1) Remove handle bolt. (Fig. 13)
(3) Pull rear of handle out away from door and dis-
engage the latch levers.
(4) Slide handle towards the rear of door and
remove.
VA DOORS - REAR 23 - 33
EXTERIOR HANDLE (Continued)
HINGE
REMOVAL
NOTE: It is not necessary to remove the door to
replace the hinges if they are replaced one at a time.
INSTALLATION
(1) Install hinge and install bolts.
(2) Tighten bolts to 25 N·m (18 ft. lbs.).
(3) Adjust door if necessary. (Refer to 23 - BODY/
DOOR - FRONT/DOOR - ADJUSTMENTS)
INSTALLATION
(1) Connect the latch cable.
(2) Install handle and screws.
(3) Install trim cover.
Fig. 20 LATCH
LATCH 1
2
-
-
DOOR LOCK KNOB
ELECTRIC
3 - CABLE
REMOVAL 4
5
-
-
LOCK ROD
LATCH ASSEMBLY
(1) Disconnect and isolate battery negative cable. 6 - ELECTRICAL CONNECTORS ROUTING
(2) Remove right side trim panel. (Refer to 23 - 7 - SCREWS (3)
BODY/DOORS - REAR/TRIM PANEL - REMOVAL)
VA DOORS - REAR 23 - 35
LATCH (Continued)
INSTALLATION INSTALLATION
(1) Connect electrical connectors and cable to latch (1) Install upper trim panel and replace rivets.
assembly. (2) Install lower trim and install push pin fasten-
(2) Install latch in door and install screws. ers, if equipped.
(3) Connect lock rod. (3) Install interior handle, if equipped. (Refer to 23
(4) Install right side trim panel. (Refer to 23 - - BODY/DOORS - REAR/INSIDE HANDLE ACTUA-
BODY/DOORS - REAR/TRIM PANEL - INSTALLA- TOR - INSTALLATION)
TION)
(5) Connect battery negative cable.
TRIM PANEL
REMOVAL
(1) Remove trim and interior handle, if equipped
(Fig. 21). (Refer to 23 - BODY/DOORS - REAR/IN-
SIDE HANDLE ACTUATOR - REMOVAL)
(2) Remove push pin fasteners, if equipped.
(3) Using a trim stick C-4755 or equivalent,
remove the lower trim panel.
(4) Remove rivets and remove upper trim panel, if
equipped.
DOORS - SLIDING
TABLE OF CONTENTS
page page
EXTERIOR HANDLE
REMOVAL
(1) Remove trim cap. (Fig. 1)
(2) Remove bolt.
(3) Push handle back and remove.
INSTALLATION
(1) Install handle into door opening and push back
so the three catch points lock in place on both sides.
(Fig. 1)
(2) Install bolt and tighten to 10 N·m (89 in. lbs.).
(3) Install trim cap.
INSTALLATION
(1) Install roller arm into upper track from back.
(2) Position roller arm on door and install the
bolts.
(3) Tighten bolts to 25 N·m (18 ft. lbs.).
(4) Adjust door as necessary. (Refer to 23 - BODY/
DOORS - SLIDING/SLIDING DOOR - ADJUST-
MENTS) Fig. 4 CENTER ROLLER ARM
1 - TRIM COVER
2 - SLIDING DOOR
CENTER ROLLER ARM 3
4
-
-
CENTER ROLLER ARM RUBBER COVER
CENTER ROLLER ARM
5 - BOLT
REMOVAL
(1) Remove trim cover. (Fig. 4)
23 - 38 DOORS - SLIDING VA
CENTER ROLLER ARM (Continued)
INSTALLATION
(1) Position roller arm in guide track.
(2) Install arm into door opening and line up tab
with marks made previously.
(3) Install bolt and tighten to 45 N·m (33 ft. lbs.).
(4) Install rubber cover.
(5) Adjust door if necessary. (Refer to 23 - BODY/
DOORS - SLIDING/SLIDING DOOR - ADJUST-
MENTS)
(6) Install trim panel if necessary. (Refer to 23 -
BODY/DOORS - SLIDING/TRIM PANEL - INSTAL-
LATION)
(7) Install trim cover.
INSTALLATION
(1) Install roller arm and install door screws.
(2) Tighten screws to 25 N·m (18 ft. lbs.).
(3) Install stepwell scuff pad and install screws.
(4) Adjust door if necessary. (Refer to 23 - BODY/
DOORS - SLIDING/SLIDING DOOR - ADJUST-
MENTS)
INSTALLATION
(1) Thoroughly clean all residue from the center
track attachment area of the door.
(2) Wipe area clean with a 50% solution of water
and alcohol and wipe dry.
(3) Remove protective foil from piece of adhesive
strip on center track.
(4) Apply new center track and apply pressure of
approximately 40 p.s.i. over the entire surface of the
track.
(5) Install the front bolts and tighten to 10 N·m
(89 in. lbs.).
(6) Install the interior nuts and tighten to 10 N·m
(89 in. lbs.). Fig. 10 LOCK ASSEMBLY FASTENERS
(7) Install quarter trim panel. (Refer to 23 - 1 - SCREWS
BODY/INTERIOR/QUARTER TRIM PANEL - 2 - POWER LOCK ACTUATOR
INSTALLATION) 3 - LATCH/LOCK CONTROL ASSEMBLY
4 - EXTERIOR DOOR LEVER
(8) Install the center roller arm. (Refer to 23 -
BODY/DOORS - SLIDING/CENTER ROLLER ARM -
INSTALLATION)
(9) Install the center track end piece and install
the screw.
23 - 40 DOORS - SLIDING VA
LATCH / LOCK CONTROL (Continued)
(5) Disconnect lock knob rod. (Fig. 11) (3) Tighten bolts to 10 N·m (89 in. lbs.).
(6) Disconnect cable. (4) Connect electrical connectors.
(5) Install trim panel. (Refer to 23 - BODY/DOORS
- SLIDING/TRIM PANEL - INSTALLATION)
(6) Connect battery negative cable.
REAR LATCH
REMOVAL
(1) Disconnect and isolate battery negative cable.
(2) Remove trim panel. (Refer to 23 - BODY/
DOORS - SLIDING/TRIM PANEL - REMOVAL)
(3) Remove the screws and remove the latch from
door.
(4) Disconnect electrical connector, if equipped.
(5) Disconnect control cable.
INSTALLATION
(1) Position latch/lock control assembly at door and
connect the latch control assembly and lock rod.
(2) Install assembly and install new bolts. Make
sure that the lever of the door handle is in front of
the lever of the inside door lock. (Fig. 12)
INSTALLATION
(1) Connect control cable.
(2) Connect electrical connector, if equipped.
(3) Position latch in door and install screws.
(4) Tighten screws to 10 N·m (89 in. lbs.).
(5) Install trim panel. (Refer to 23 - BODY/DOORS
- SLIDING/TRIM PANEL - INSTALLATION)
(6) Connect battery negative cable.
Fig. 12 LOCK ASSEMBLY FASTENERS
1 - SCREWS
2 - POWER LOCK ACTUATOR
3 - LATCH/LOCK CONTROL ASSEMBLY
4 - EXTERIOR DOOR LEVER
VA DOORS - SLIDING 23 - 41
INSTALLATION
(1) Install striker and bolts.
(2) Tighten bolts to 25 N·m (18 ft. lbs.)
(3) Adjust striker if necessary. (Refer to 23 -
BODY/DOORS - SLIDING/SLIDING DOOR -
ADJUSTMENTS)
ADJUSTMENTS
ADJUSTMENT
NOTE: Door adjustment measurements should be
taken from stationary or welded body panels like
the roof, rocker or quarter panels. Fig. 19 ADJUST CENTER ROLLER ARM
A suitable body sealant should be used when 1 - BOLT
removing or moving the hinges. 2 - CENTER ROLLER ARM
(1) Remove bolts and remove striker. (Fig. 18) (2) Tighten bolt to 45 N·m (33 ft. lbs.).
(3) Loosen upper roller arm screws. (Fig. 20)
(4) Loosen lower roller arm screws.
(5) Adjust front ridge pattern by raising or lower-
ing door.
Flush Adjustment
(1) Loosen upper roller arm screw. (Fig. 21)
(2) Loosen lower roller arm screws.
STABILIZER
REMOVAL
(1) Remove screws and remove stabilizers. (Fig.
Fig. 21 IN/OUT ADJUST 23)
1 - IN/OUT ADJUSTMENT SCREW - UPPER ARM
2 - IN/OUT ADJUSTMENT SCREWS - LOWER ARM
INSTALLATION
Upper
(1) Install trim panel and replace rivets.
Lower
(1) Install the trim panel and push pin fasteners.
(2) Install the inside handle actuator. (Refer to 23 -
BODY/DOORS - SLIDING/INSIDE HANDLE
ACTUATOR - INSTALLATION)
(3) Install stop bumper, bolts and adjust if neces-
sary. (Refer to 23 - BODY/DOORS - SLIDING/SLID- Fig. 25 Glass & Weatherstrip Seal Installation
ING DOOR - ADJUSTMENTS) 1 - BODY PANEL
2 - WEATHERSTRIP SEAL
3 - INSTALLATION CORD
4 - WINDOW OPENING
VA EXTERIOR 23 - 47
EXTERIOR
TABLE OF CONTENTS
page page
INSTALLATION
(1) Install the door and bolts.
(2) Connect filler cap tether.
(3) Close doors.
GRILLE
REMOVAL Fig. 1 GRILLE
(1) Remove screw rivets. (Fig. 1) 1 - UPPER SCREW
(2) Loosen lower screws. 2 - GRILLE
3 - LOWER SCREWS (2)
(3) Remove upper screws. 4 - SCREW RIVETS
(4) Remove grille.
INSTALLATION
INSTALLATION (1) Install bracket.
(1) Install grille. (2) Install screws.
(2) Install upper screw. (3) Install push-pin fasteners.
(3) Tighten lower screws.
(4) Install screw rivets.
RADIATOR CROSSMEMBER
LICENSE PLATE BRACKET REMOVAL
(1) Remove grille. (Refer to 23 - BODY/EXTERI-
REMOVAL OR/GRILLE - REMOVAL)
(1) Remove two lower push-pin fasteners (2) Remove headlamps. (Refer to 8 - ELECTRI-
(2) Remove two screws. CAL/LAMPS/LIGHTING - EXTERIOR/FRONT
(3) Remove bracket. LAMP UNIT - REMOVAL)
(3) Remove heat shield. (Fig. 2)
(4) Remove retaining clamps and rubber mounts.
23 - 48 EXTERIOR VA
RADIATOR CROSSMEMBER (Continued)
(5) Remove bolts.
(6) Remove crossmember and disconnect hood cable.
Passenger Side
(1) If equipped, pull wire harness through door.
(2) Install mirror and bolts.
(3) Tighten the bolts to 25 N·m (18 ft. lbs.).
Fig. 5 SIDE VIEW MIRROR - GLASS
NOTE: If vehicle is not equipped with power mir- 1 - MIRROR GLASS
2 - ELECTRICAL CONNECTORS
rors, skip to step 6. 3 - GUIDES
HOOD
TABLE OF CONTENTS
page page
HINGE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 51
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 LATCH RELEASE HANDLE
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 50 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
HOOD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 52
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 PROP ROD
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 50 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
ADJUSTMENTS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 52
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 51 SAFETY LATCH
LATCH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 52
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 51
LATCH RELEASE CABLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
INSTALLATION
(1) Position hinge on vehicle and align reference
marks.
(2) Install cowl bolts and tighten to 23 N·m (17 ft.
lbs.).
(3) Install hood nuts and tighten to 23 N·m (17 ft.
lbs.).
(4) Check and adjust hood if necessary. (Refer to
23 - BODY/HOOD/HOOD - ADJUSTMENTS) Fig. 1 HOOD
1 - PROP ROD RETAINING CLIP
2 - PROP SPRING
HOOD 3 - PROP ROD
4 - HINGE
5 - NUTS (2)
REMOVAL
(1) Raise and support hood. INSTALLATION
(2) Remove the prop rod retaining clip. (Fig. 1) (1) Position hood on hinges.
(3) Separate the prop and spring from the hood. (2) Install nuts finger-tight.
(4) Using a grease pencil or equivalent, mark loca- (3) Connect spring and prop onto hood and install
tion of hood hinges on hood for installation align- the retaining spring.
ment.
VA HOOD 23 - 51
HOOD (Continued)
(4) Align hinges with installation reference marks LATCH
and tighten bolts to 23 N·m (17 ft. lbs.).
(5) Check and adjust as necessary. (Refer to 23 -
REMOVAL
BODY/HOOD/HOOD - ADJUSTMENTS)
(1) Remove bolts and remove latch. (Fig. 3)
(2) Disconnect latch cable.
ADJUSTMENTS
ADJUSTMENT
SPECIFICATIONS
DESCRIPTION SPECIFICATION
Left and right hood gaps 5 ± 0.5 mm
Flush offset for ≤ 1.0 mm
hood/fender
INSTALLATION
(1) Connect latch cable to release handle.
(2) Install handle and install the screws.
PROP ROD
REMOVAL
(1) Open and support hood.
(2) Remove the prop rod retaining clip. (Fig. 1)
(3) Separate the prop and spring from the hood.
(4) Remove nut and position the washer bottle
aside. (Fig. 4)
(5) Remove stud nut and remove hood prop. (Fig. 5)
INSTALLATION
(1) Install hood prop and install the stud nut.
(2) Position washer bottle back and install the nut
and washer.
(3) Connect spring and prop onto hood and install
the retaining spring. Fig. 6 SAFETY LATCH
1 - SAFETY LATCH
2 - BOLTS
SAFETY LATCH
INSTALLATION
REMOVAL (1) Install the latch and install the bolts.
(1) Open hood. (2) Adjust the latch if necessary. (Refer to 23 -
(2) Using a grease pencil or equivalent, mark the BODY/HOOD/HOOD - ADJUSTMENTS)
position of the safety latch to aid installation.
VA INSTRUMENT PANEL 23 - 53
INSTRUMENT PANEL
TABLE OF CONTENTS
page page
CLUSTER BEZEL
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT Fig. 1 CLUSTER BEZEL
AND POSSIBLE PERSONAL INJURY. 1 - CLUSTER BEZEL
2 - SCREWS (2)
3 - ELECTRICAL CONNECTOR
(1) Disconnect and isolate the battery negative 4 - ELECTRICAL CONNECTORS
cable.
(2) Unscrew screws. (Fig. 1)
(3) Using a trim stick C-4755 or equivalent, sepa-
rate cover.
(4) Disconnect electrical connectors and remove
bezel.
23 - 54 INSTRUMENT PANEL VA
CLUSTER BEZEL (Continued)
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
INSTALLATION
(1) Connect electrical connector.
(2) Install ash receiver and install the two screws.
(3) Connect battery negative cable.
CUP HOLDER
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
Fig. 3 INSTRUMENT PANEL CENTER BEZEL NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
1 - SCREWS (4)
2 - BEZEL TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
23 - 56 INSTRUMENT PANEL VA
CUP HOLDER (Continued)
(1) Remove rubber mat from both cup holders. INSTALLATION
(2) Unscrew screws (1) and remove cup holder top
section (2). (Fig. 4) WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
INSTALLATION
(1) Connect electrical connector and install glove box.
(2) Install three screws.
VA INSTRUMENT PANEL 23 - 57
Fig. 10 POWER DISTRIBUTION CENTER Fig. 12 PASSENGER SIDE AIR NOZZLE COVER
1 - BOLT 1 - FRONT SCREWS (2)
2 - POWER DISTRIBUTION CENTER 2 - BRACKET
3 - GROUND NUT 3 - BRACKET SCREWS
4 - WASHER 4 - NOZZLE COVER
5 - NUT 5 - INSTRUMENT PANEL
6 - GROUND WIRE
VA INSTRUMENT PANEL 23 - 59
INSTRUMENT PANEL ASSEMBLY (Continued)
(15) Remove screws and remove left side cover. (20) Remove instrument panel top cover screws
(Fig. 13) and cover. (Fig. 15)
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
• WHEN REMOVING A DEPLOYED AIRBAG, RUB- Fig. 21 ALIGNMENT CUTOUT - 1
BER GLOVES, EYE PROTECTION, AND A LONG- 1 - CUTOUT
SLEEVED SHIRT SHOULD BE WORN. THERE MAY 2 - HEATER HOUSING
BE DEPOSITS ON THE AIRBAG UNIT AND OTHER
INTERIOR SURFACES. IN LARGE DOSES, THESE
DEPOSITS MAY CAUSE IRRITATION TO THE SKIN
AND EYES.
• USE EXTREME CARE TO PREVENT ANY FOR-
EIGN MATERIAL FROM ENTERING THE PASSEN-
GER AIRBAG, OR BECOMING ENTRAPPED
BETWEEN THE PASSENGER AIRBAG CUSHION
AND THE PASSENGER AIRBAG DOOR. FAILURE TO
OBSERVE THIS WARNING COULD RESULT IN
OCCUPANT INJURIES UPON AIRBAG DEPLOY-
MENT.
• THE PASSENGER AIRBAG DOOR MUST
NEVER BE PAINTED. REPLACEMENT PASSENGER
AIRBAGS ARE SERVICED WITH DOORS IN THE
ORIGINAL COLORS. PAINT MAY CHANGE THE WAY
IN WHICH THE MATERIAL OF THE AIRBAG DOOR
RESPONDS TO AN AIRBAG DEPLOYMENT. FAIL- Fig. 22 ALIGNMENT CUTOUT - 2
URE TO OBSERVE THIS WARNING COULD RESULT 1 - CUTOUT
2 - HEATER HOUSING
IN OCCUPANT INJURIES UPON AIRBAG DEPLOY-
MENT.
(5) Tighten steering column bolts to 25 N·m (18 ft.
(1) Install the instrument panel. lbs.).
(6) Install ignition transponder onto column lock.
NOTE: The guides on the bottom of the instrument (Fig. 18)
panel must engage in the cutouts on the left and
right next to the heater housing. (Fig. 21) (Fig. 22) NOTE: The dome on the transponder must engage
into the groove on the ignition switch.
(2) Route wire harness through the panel.
(3) Install and tighten 12 instrument panel screws. (7) Install brake pedal spring. (Fig. 17)
(Fig. 20) (8) Install vent hose. (Fig. 16)
(9) Install instrument panel top cover and screws.
CAUTION: The position of the steering gear must (Fig. 15)
not be altered. (10) Install right outer and inner air nozzles. (Fig.
13)
(4) Raise steering column into position and install (11) Install right side cover and screws.
the bolts. (Fig. 19) (12) Wrap protective mat around connectors
behind instrument cluster.
23 - 62 INSTRUMENT PANEL VA
INSTRUMENT PANEL ASSEMBLY (Continued)
(13) Install left outer and inner air nozzles.
(14) Install left side cover and screws.
(15) Install passenger side air nozzle cover and
bracket and install the screws. (Fig. 12)
(16) Position Power Distribution Center (PDC) in
vehicle and connect electrical connectors. (Fig. 11)
(17) Install PDC and install bolt and nut. (Fig. 10)
(18) Install PDC ground cable and nut.
(19) Install steering column shroud and install the
two screws and one nut. (Fig. 9)
(20) Install PDC cover and twist lock 1/4 turn to
secure in place. (Fig. 8)
(21) Connect electrical connectors and cables to air
conditioning push-button module and install. (Fig. 7)
(22) Install center bezel. (Refer to 23 - BODY/IN-
STRUMENT PANEL/INSTRUMENT PANEL CEN-
TER BEZEL - INSTALLATION)
(23) Install left and right speakers. (Refer to 8 -
ELECTRICAL/AUDIO/SPEAKER - INSTALLATION)
(24) Install passenger airbag. (Refer to 8 - ELEC-
TRICAL/RESTRAINTS/PASSENGER AIRBAG -
INSTALLATION)
(25) Install instrument cluster. (Refer to 8 - ELEC- Fig. 23 Instrument Cluster Remove/Install
TRICAL/INSTRUMENT CLUSTER - INSTALLA- 1 - SCREW (2)
TION) 2 - COVER
(26) Install cup holder. (Refer to 23 - BODY/IN- 3 - SCREW (2)
4 - INSTRUMENT CLUSTER
STRUMENT PANEL/CUP HOLDER - INSTALLA- 5 - LOOP (2)
TION)
(27) Install glove compartment. (Refer to 23 - INSTALLATION
BODY/INSTRUMENT PANEL/GLOVE BOX -
INSTALLATION) WARNING: ON VEHICLES EQUIPPED WITH AIR-
(28) Install radio. (Refer to 8 - ELECTRICAL/AU- BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
DIO/RADIO - INSTALLATION) ATTEMPTING ANY STEERING WHEEL, STEERING
(29) Connect battery negative cable. COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
TOP COVER - CLUSTER NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
REMOVAL TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WARNING: ON VEHICLES EQUIPPED WITH AIR- WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE TO TAKE THE PROPER PRECAUTIONS COULD
ATTEMPTING ANY STEERING WHEEL, STEERING RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
COLUMN, SEAT BELT TENSIONER, OR INSTRU- AND POSSIBLE PERSONAL INJURY.
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY (1) Position the cover and install the screws.
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Twist cover lock 1/4 turn and remove Power INSTALLATION
Distribution Center cover. (Fig. 27)
(2) Remove nut and screws and remove steering WARNING: ON VEHICLES EQUIPPED WITH AIR-
column shroud. (Fig. 28) BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MENT PANEL COMPONENT DIAGNOSIS OR SER-
VICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO DISCHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
INTERIOR
TABLE OF CONTENTS
page page
INTERIOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 70
CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 HEADLINER
A-PILLAR TRIM REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 71
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 68 QUARTER TRIM PANEL
ASSIST HANDLE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 72
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 68 REAR VIEW MIRROR
B-PILLAR TRIM REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 INSTALLATION
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 69 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 72
BULKHEAD TRIM PANEL INSTALLATION - REAR VIEW MIRROR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 SUPPORT BRACKET . . . . . . . . . . . . . . . . . . . 72
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 69 STEPWELL SCUFF PADS
CARPETS AND FLOOR MATS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 73
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 70 SUN VISOR
COWL TRIM REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 73
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 70
D-PILLAR TRIM
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
INTERIOR
CAUTION
CAUTION:: Do not attempt to remove interior trim
panels/moldings without first removing the neces-
sary adjacent panels. To avoid damaging the pan-
els, ensure that all the screws and clips are
removed before attempting to remove an interior
trim panel/molding. Trim panels are somewhat flex-
ible but can be damaged if handled improperly.
A-PILLAR TRIM
REMOVAL
(1) Using a trim stick C-4755 or equivalent, sepa-
rate the top of the a-pillar trim.
(2) Pull top of a-pillar trim out and pull trim up
and remove. (Fig. 1)
B-PILLAR TRIM
REMOVAL
(1) Remove the lower seat belt anchor bolt. (Fig. 4)
Fig. 2 A-PILLAR SUPPORT FOAM (2) Pull door opening weatherstrip away from
1 - SUPPORT FOAM flange along the b-pillar. (Fig. 5)
2 - SCREWS (4) (3) Using a trim stick C-4755 or equivalent,
release the trim clips and remove the trim. (Fig. 6)
INSTALLATION
(1) Install the foam support and install the screws.
(2) Install the a-pillar trim bottom and push the
top in toward a-pillar.
(3) Seat the retaining clips fully.
ASSIST HANDLE
REMOVAL
(1) Hold the handle in the down position and
remove the screws. (Fig. 3)
INSTALLATION
(1) Install the handle and install the screws.
INSTALLATION
(1) Install the upper panel and replace rivets.
(2) Install the lower panel and replace rivets.
D-PILLAR TRIM (3) Remove the push pin fasteners and remove the
rear air front duct cover.
(4) Disconnect the electrical connector at front of
REMOVAL
cover.
(1) Remove the three plastic twist screws and
(5) Remove the push pin fasteners and remove the
remove the panel.
rear air middle duct cover.
(6) Disconnect the electrical connector.
INSTALLATION (7) Remove the three push-pins and three screws
(1) Install the panel and install the three twist
and remove the rear air cover.
screws.
(8) Remove the duct work.
VA INTERIOR 23 - 71
HEADLINER (Continued)
(9) Release clips at front and rear of headliner and (8) Install the second and third row seats. (Refer
remove. to 23 - BODY/SEATS/SEAT - INSTALLATION)
(9) Connect battery negative cable.
Number 4 Section
(1) Disconnect and isolate battery negative cable. Number 3 Section
(2) Remove the third and fourth row seats. (Refer (1) Position the headliner in vehicle and seat fully.
to 23 - BODY/SEATS/SEAT - REAR - REMOVAL)
NOTE: If vehicle is not equipped with rear air con-
NOTE: If vehicle is not equipped with rear air con- ditioning unit, skip to step 8.
ditioning unit, skip to step 8.
(2) Install rear air unit duct work.
(3) Remove the push pin fasteners and remove the (3) Install the rear air unit rear cover and install
rear air front duct cover. the three screws and push-pins.
(4) Disconnect the electrical connector at front of (4) Connect the electrical connector and install the
cover. middle duct work cover.
(5) Remove the push pin fasteners and remove the (5) Install the push pin fasteners.
rear air middle duct cover. (6) Connect the electrical connector and install the
(6) Disconnect the electrical connector. front duct work cover.
(7) Remove the three push-pins and three screws (7) Install the push pin fasteners.
and remove the rear air cover. (8) Install the third and fourth row seats. (Refer to
(8) Remove the duct work. 23 - BODY/SEATS/SEAT - INSTALLATION)
(9) Release clips at front and rear of headliner and (9) Connect battery negative cable.
remove.
Number 4 Section
INSTALLATION (1) Position the headliner in vehicle and seat fully.
Cab Section NOTE: If vehicle is not equipped with rear air con-
(1) Position the headliner in vehicle and seat fully. ditioning unit, skip to step 8.
(2) Install dome light. (Refer to 8 - ELECTRICAL/
(2) Install rear air unit duct work.
LAMPS/LIGHTING - INTERIOR/CARGO LAMP
(3) Install the rear air unit rear cover and install
UNIT - INSTALLATION)
the three screws and push-pins.
(3) Install assist handle. (Refer to 23 - BODY/IN-
(4) Connect the electrical connector and install the
TERIOR/ASSIST HANDLE - INSTALLATION)
middle duct work cover.
(4) Install b-pillar trim. (Refer to 23 - BODY/IN-
(5) Install the push pin fasteners.
TERIOR/B-PILLAR TRIM - INSTALLATION)
(6) Connect the electrical connector and install the
(5) Install the sun visors. (Refer to 23 - BODY/IN-
front duct work cover.
TERIOR/SUN VISOR - INSTALLATION)
(7) Install the push pin fasteners.
(6) Install the a-pillar trim. (Refer to 23 - BODY/
(8) Install the third and fourth row seats. (Refer to
INTERIOR/A-PILLAR TRIM - INSTALLATION)
23 - BODY/SEATS/SEAT - INSTALLATION)
(7) Connect battery negative cable.
(9) Connect battery negative cable.
Number 2 Section
(1) Position the headliner in vehicle and seat fully. QUARTER TRIM PANEL
NOTE: If vehicle is not equipped with rear air con-
ditioning unit, skip to step 8. REMOVAL
(2) Install rear air unit duct work. Passenger Van
(3) Install the rear air unit rear cover and install (1) Remove seats as necessary. (Refer to 23 -
the three screws and push-pins. BODY/SEATS/SEAT - REMOVAL)
(4) Connect the electrical connector and install the (2) Remove d-pillar trim if necessary. (Refer to 23 -
middle duct work cover. BODY/INTERIOR/D-PILLAR TRIM - REMOVAL)
(5) Install the push pin fasteners. (3) Using a trim stick C-4755 or equivalent, sepa-
(6) Connect the electrical connector and install the rate the push-pin fasteners and remove trim panels.
front duct work cover.
(7) Install the push pin fasteners.
23 - 72 INTERIOR VA
QUARTER TRIM PANEL (Continued)
Cargo Van (5) Apply adhesive accelerator to the bracket con-
(1) Remove bolts and remove tie down rings, if tact surface on the windshield glass. Allow the accel-
equipped. erator to dry for one minute. Do not touch the glass
(2) Remove rivets and remove paneling contact surface after the accelerator has been
applied.
INSTALLATION (6) Install the bracket according to the following
instructions:
Passenger Van (a) Apply one drop of adhesive at the center of
(1) Position trim panels and seat push-pin fasten- the bracket contact-surface on the windshield
ers fully. glass.
(2) Install d-pillar trim, if necessary. (Refer to 23 - (b) Apply an even coat of adhesive to the contact
BODY/INTERIOR/D-PILLAR TRIM - INSTALLA- surface on the bracket.
TION) (c) Align the bracket with the marked position
(3) Install seats, if necessary. (Refer to 23 - BODY/ on the windshield glass.
SEATS/SEAT - INSTALLATION) (d) Press and hold the bracket in place for at
least one minute.
Cargo Van
NOTE: Verify that the mirror support bracket is cor-
(1) Install paneling and replace rivets.
rectly aligned, because the adhesive will cure rap-
(2) Install tie down rings and bolts, if equipped.
idly.
REAR VIEW MIRROR (7) Allow the adhesive to cure for 8-10 minutes.
Remove any excess adhesive with an alcohol-damp-
ened cloth.
REMOVAL (8) Allow the adhesive to cure for an additional
(1) Slide mirror off support bracket. 8-10 minutes before installing the mirror.
SUN VISOR
REMOVAL
(1) Remove the support screws and remove the
visor. (Fig. 10)
INSTALLATION
(1) Install scuff pad and install the screws. Fig. 10 SUN VISOR
(2) Install the trim plugs. 1 - SUN VISOR
(3) Install the seat bracket, if necessary. 2 - SCREWS
3 - SUPPORTS (2)
INSTALLATION
(1) Position visor and support on header.
(2) Install the screws.
23 - 74 PAINT VA
PAINT
TABLE OF CONTENTS
page page
SEATS
TABLE OF CONTENTS
page page
ARMREST
REMOVAL
(1) Remove the screws and remove the armrest
cover.
(2) Remove the three bolts and remove the arm-
rest from the seat back.
INSTALLATION
(1) Install the armrest and install the three bolts.
(2) Install the armrest cover and install the
screws.
HEADREST
REMOVAL
(1) Press the release button and remove the head-
rest. (Fig. 1) Fig. 1 HEAD REST
1 - HEADREST
INSTALLATION 2 - RELEASE BUTTON
(1) Insert headrest posts into seat back and seat
fully.
VA SEATS 23 - 77
SEAT - FRONT
REMOVAL
(1) Disconnect and isolate battery negative cable.
(2) Remove the seat belt anchor bolt.
(3) Remove the seat bolts.
(4) Disconnect the electrical connectors, if
equipped.
INSTALLATION
(1) Remove stop screw.
Fig. 2 FRONT SEAT (2) Install seat back locking spline side first.
1 - SEAT BELT ANCHOR BOLT
2 - BOLTS (6) NOTE: For better centering of seat back in the
mounting bore during installation, operate the seat
INSTALLATION back release lever once.
(1) Position seat in vehicle and connect the electri-
cal connectors, if equipped. (3) Install the spline side seat back bolt.
(2) Install the mounting bolts and tighten to 25 (4) Install remaining seat back side.
N·m (18 ft. lbs.).
(3) Install the seat belt anchor and bolt. NOTE: It may be necessary to press the guide tabs
(4) Tighten anchor bolt to 35 N·m (26 ft. lbs.). apart slightly.
(5) Connect battery negative cable.
(5) Install the remaining seat back bolt.
(6) Tighten the seat back bolts to 20 N·m (15 ft.
SEAT BACK - FRONT lbs.).
(7) Place seat back in the foremost position until
the hold down spring latches audibly.
REMOVAL (8) Install stop bolt and tighten to 20 N·m (15 ft.
(1) Disconnect and isolate battery negative cable.
lbs.).
(2) Remove seat cushion. (Refer to 23 - BODY/
(9) Connect the lumbar support hose, if equipped.
SEATS/SEAT CUSHION - FRONT - REMOVAL)
(10) Check seat back operation.
(3) Verify that seat back is in full upright position.
(11) Install the seat cushion. (Refer to 23 - BODY/
(4) Disconnect lumbar support hose, if equipped.
SEATS/SEAT CUSHION - FRONT - INSTALLA-
(Fig. 3)
TION)
(5) Remove seat back bolts and remove seat back.
23 - 78 SEATS VA
INSTALLATION
(1) Install the adjuster onto the seat track and
install the bolts.
(2) Install the seat back. (Refer to 23 - BODY/
SEATS/SEAT BACK - FRONT - INSTALLATION)
(3) Install the seat cushion. (Refer to 23 - BODY/
Fig. 4 STANDARD SEAT CUSHION
SEATS/SEAT CUSHION - FRONT - INSTALLA-
1 - SEAT CUSHION TION)
2 - MOUNTING POINTS
3 - SCREWS (2) (4) Install the seat. (Refer to 23 - BODY/SEATS/
SEAT - FRONT - INSTALLATION)
INSTALLATION
(1) Install the panel and install the screws.
SEAT BACK CUSHION/COVER - (10) Install the seat back shield. (Refer to 23 -
BODY/SEATS/REAR SEAT BACK SHIELD -
REAR INSTALLATION)
(11) Install seat. (Refer to 23 - BODY/SEATS/
REMOVAL SEAT - REAR - INSTALLATION)
(1) Remove seat. (Refer to 23 - BODY/SEATS/
SEAT - REAR - REMOVAL)
(2) Remove seat back shield. (Refer to 23 - BODY/ SEAT CUSHION/COVER - REAR
SEATS/REAR SEAT BACK SHIELD - REMOVAL)
(3) Remove seat belts as necessary to remove REMOVAL
cover. (Refer to 8 - ELECTRICAL/RESTRAINTS/ (1) Remove seat. (Refer to 23 - BODY/SEATS/
REAR SEAT BELT & RETRACTOR - REMOVAL) SEAT - REAR - REMOVAL)
(4) Remove seat belt buckles as necessary. (Refer (2) Remove seat back shield. (Refer to 23 - BODY/
to 8 - ELECTRICAL/RESTRAINTS/REAR SEAT SEATS/REAR SEAT BACK SHIELD - REMOVAL)
BELT BUCKLE - REMOVAL) (3) Remove the lower seat belt anchors as neces-
(5) Remove the headrests. (Refer to 23 - BODY/ sary.(Refer to 8 - ELECTRICAL/RESTRAINTS/REAR
SEATS/HEADREST - REMOVAL) SEAT BELT & RETRACTOR - REMOVAL)
(6) Remove the headrest sleeves. (4) Remove seat belt buckles as necessary. (Refer
(7) Partially de-trim upper seat back. to 8 - ELECTRICAL/RESTRAINTS/REAR SEAT
(8) Remove the retaining covers at seat belt BELT BUCKLE - REMOVAL)
guides. (5) Partially de-trim lower part of seat back.
(9) Route belts through guides. (6) Separate the cushion/cover j-straps and remove
(10) Separate j-straps at seat back cover and the seat cushion and cover from seat frame.
remove cover/cushion.
INSTALLATION
INSTALLATION (1) Install seat cushion and cover.
(1) Install seat back cushion and cover. (2) Connect the cover j-straps.
(2) Connect j-straps. (3) Position seat back cover, back.
(3) Route belts through guides. (4) Install the seat belt buckles. (Refer to 8 -
(4) Install retaining covers at seat belt guides. ELECTRICAL/RESTRAINTS/REAR SEAT BELT
(5) Position upper seat back cover back into place. BUCKLE - INSTALLATION)
(6) Install the headrest sleeves. (5) Install the seat belt anchors. (Refer to 8 -
(7) Install the headrests. (Refer to 23 - BODY/ ELECTRICAL/RESTRAINTS/REAR SEAT BELT &
SEATS/HEADREST - INSTALLATION) RETRACTOR - INSTALLATION)
(8) Install the seat belt buckles. (Refer to 8 - (6) Install the seat back shield. (Refer to 23 -
ELECTRICAL/RESTRAINTS/REAR SEAT BELT BODY/SEATS/REAR SEAT BACK SHIELD -
BUCKLE - INSTALLATION) INSTALLATION)
(9) Install the seat belts. (Refer to 8 - ELECTRI- (7) Install seat. (Refer to 23 - BODY/SEATS/SEAT
CAL/RESTRAINTS/REAR SEAT BELT & RETRAC- - REAR - INSTALLATION)
TOR - INSTALLATION)
VA STATIONARY GLASS 23 - 81
STATIONARY GLASS
TABLE OF CONTENTS
page page
INSTALLATION
(1) Install the weatherstrip seal on the window
glass. Verify that the glass is seated in the groove
around the edge of the seal.
(2) Insert an installation cord in the weatherstrip Fig. 1 Glass & Weatherstrip Seal Installation
seal inner groove. 1 - BULKHEAD TRIM PANEL
2 - WEATHERSTRIP SEAL
NOTE: Use mineral spirits as a lubricant to aid seal 3 - INSTALLATION CORD
installation in the window opening. 4 - TRIM PANEL FRAME
(3) Position the glass and seal in the trim panel QUARTER WINDOW
opening.
(4) Pull the installation cord outward and force the REMOVAL
seal lip over the panel flange around the edge of the (1) Position an assistant outside the vehicle to
opening. (Fig. 1) receive the glass and weatherstrip seal.
(5) Seat the seal inner lip on the panel flange. (2) Start at an inside, upper corner. Separate the
Press against the lip around the edge of the seal. seal from the window opening. Push the glass and
seal outward from the window opening. Remove the
NOTE: Remove any mineral spirits with a clean
glass and seal.
cloth after glass installation.
(3) Clean the window opening.
(6) Verify that the seal is seated in the trim panel
opening. INSTALLATION
(1) Install the weatherstrip seal on the window
glass. Verify that the glass is seated in the groove
around the edge of the seal.
(2) Insert an installation cord in the weatherstrip
seal inner groove.
23 - 82 STATIONARY GLASS VA
QUARTER WINDOW (Continued)
NOTE: Use mineral spirits as a lubricant to aid seal IT TAKES AT LEAST 24 HOURS FOR URETHANE
installation in the window opening. ADHESIVE TO CURE. IF IT IS NOT CURED, THE
WINDSHIELD MAY NOT PERFORM PROPERLY IN
(3) Position the glass and seal in the window open- AN ACCIDENT.
ing. • URETHANE ADHESIVES ARE APPLIED AS A
(4) Pull the installation cord outward and force the SYSTEM. USE GLASS CLEANER, GLASS PREP
seal lip over the panel flange around the edge of the SOLVENT, GLASS PRIMER, PVC (VINYL) PRIMER
opening. AND PINCH WELD (FENCE) PRIMER PROVIDED BY
(5) Seat the seal inner lip on the panel flange. THE ADHESIVE MANUFACTURER. IF NOT, STRUC-
Press against the lip around the edge of the seal. TURAL INTEGRITY COULD BE COMPROMISED.
• DAIMLERCHRYSLER DOES NOT RECOMMEND
NOTE: Remove any mineral spirits with a clean GLASS ADHESIVE BY BRAND. TECHNICIANS
cloth after glass installation. SHOULD REVIEW PRODUCT LABELS AND TECHNI-
CAL DATA SHEETS, AND USE ONLY ADHESIVES
(6) Verify that the seal is seated in the window
THAT THEIR MANUFACTURES WARRANT WILL
opening (Fig. 2).
RESTORE A VEHICLE TO THE REQUIREMENTS OF
(7) Test the window for water leaks. (Refer to 23 -
FMVSS 212. TECHNICIANS SHOULD ALSO INSURE
BODY - DIAGNOSIS AND TESTING - WATER
THAT PRIMERS AND CLEANERS ARE COMPATIBLE
LEAKS)
WITH THE PARTICULAR ADHESIVE USED.
• BE SURE TO REFER TO THE URETHANE MAN-
UFACTURER’S DIRECTIONS FOR CURING TIME
SPECIFICATIONS, AND DO NOT USE ADHESIVE
AFTER ITS EXPIRATION DATE.
• VAPORS THAT ARE EMITTED FROM THE URE-
THANE ADHESIVE OR PRIMER COULD CAUSE
PERSONAL INJURY. USE THEM IN A WELL-VENTI-
LATED AREA.
• SKIN CONTACT WITH URETHANE ADHESIVE
SHOULD BE AVOIDED. PERSONAL INJURY MAY
RESULT.
• ALWAYS WEAR EYE AND HAND PROTECTION
WHEN WORKING WITH GLASS.
WINDSHIELD SAFETY PRECAUTIONS CAUTION: Cover instrument panel and vents to pro-
tect against splinters and damage.
WARNING: DO NOT OPERATE THE VEHICLE
WITHIN 24 HOURS OF WINDSHIELD INSTALLATION.
VA STATIONARY GLASS 23 - 83
WINDSHIELD (Continued)
(4) Using a trim stick C-4755 or equivalent, (6) Using a windshield cut-out wire separate the
remove windshield seal. (Fig. 3) adhesive. (Fig. 5)
WEATHERSTRIP/SEALS
TABLE OF CONTENTS
page page
INSTALLATION
(1) Install outer belt weatherstrip.
(2) Install glass run channel and install the
screws.
(3) Install the door glass. (Refer to 23 - BODY/
DOOR - FRONT/DOOR GLASS - INSTALLATION)
23 - 88 BODY STRUCTURE VA
BODY STRUCTURE
TABLE OF CONTENTS
page page
NOTE:
All measurements are in mm.
VA BODY STRUCTURE 23 - 89
GAP AND FLUSH (Continued)
NOTE: NOTE:
All measurements are in mm. All measurements are in mm.
OPENING DIMENSIONS
SPECIFICATIONS
BODY OPENING DIMENSIONS INDEX
DESCRIPTION FIGURE
WINDSHIELD OPENING 4
page page
FASTENER TORQUE
CONTROLS
TABLE OF CONTENTS
page page
REMOVAL
The refrigerant system can remain fully-charged
during compressor clutch, pulley, or coil replacement.
The compressor clutch can be serviced in the vehicle.
Fig. 1 A/C Compressor Clutch (1) Disconnect and isolate the battery negative
1 - BOLT cable.
2 - CLUTCH PLATE (2) Remove the serpentine drive belt (Refer to 7 -
3 - PULLEY AND BEARING
4 - FIELD COIL COOLING/ACCESSORY DRIVE/DRIVE BELTS -
5 - SNAP RING (2) REMOVAL).
6 - SHIM (3) Disconnect the engine wire harness connector
for the compressor clutch coil from the clutch coil
• A/C pressure transducer
wire harness connector on the top of the compressor.
• Air temperature sensor
(4) Remove the retainer securing the compressor
• CAN bus messages
clutch coil lead on the top of the compressor.
The compressor clutch is de-energized under any of
(5) Remove the bolt that secures the compressor
the following conditions:
clutch to the compressor shaft (Fig. 2). If necessary, a
• Blocked compressor (thermal fuse in the pulley)
band-type oil filter wrench or strap wrench can be
• Low pressure in the system
placed around the clutch plate to aid in bolt removal.
• Low evaporator temperature
• Hard acceleration (WOT)
• High coolant temperatures
STANDARD PROCEDURE
A/C COMPRESSOR CLUTCH AIR GAP
If a new clutch plate and/or clutch pulley are being
used, the air gap between the clutch plate and clutch
pulley must be checked using the following proce-
dure:
(1) Using feeler gauges, measure the air gap
between the clutch plate and the clutch pulley fric-
tion surfaces.
(2) If the air gap is not between specifications
(Refer to 24 - HEATING & AIR CONDITIONING -
SPECIFICATIONS), add or subtract shims until the Fig. 2 Compressor Shaft Bolt and Clutch Plate
desired air gap is obtained. 1 - COMPRESSOR CLUTCH PLATE
2 - COMPRESSOR SHAFT BOLT
NOTE: The shims may compress after tightening
the compressor shaft bolt. Check the air gap in four (6) Tap the clutch plate lightly with a plastic mal-
or more places on the clutch plate to verify that the let to release it from the splines on the compressor
shaft. Remove the clutch plate and shim(s) from the
VA CONTROLS 24 - 9
A/C COMPRESSOR CLUTCH (Continued)
compressor shaft (Fig. 3). Be certain not to lose (8) Remove the screw that secures the clutch coil
the shim or shims. wire harness connector bracket and ground clip to
the top of the compressor housing.
CAUTION: Do not pry between the clutch plate and (9) Using snap ring pliers (Special Tool C-4574 or
the pulley to remove it from the compressor shaft. equivalent), remove the external snap ring that
Prying may damage the clutch plate. secures the compressor clutch coil to the front of the
compressor, then slide the clutch coil off of the com-
pressor (Fig. 5).
INSPECTION
Compressor clutch components should always be
inspected closely before they are reinstalled. The
clutch plate and clutch pulley are mated at the fac-
tory using a burnishing operation. No attempt should
be made to separately replace the compressor clutch
pulley or clutch plate. The clutch coil may be serviced
separately.
(1) Examine the friction surfaces of the clutch pul-
ley and the clutch plate for wear. The clutch pulley
and clutch plate should be replaced if there is exces-
sive wear or scoring.
(2) Examine the friction surfaces of the clutch pul-
ley and the clutch plate for oil contamination. If the
friction surfaces are oily, the clutch pulley and clutch
plate should be replaced. Also inspect the shaft and
nose area of the compressor for oil. Remove the felt
packing from around the compressor shaft in the
compressor front cover. If the felt is saturated with
Fig. 4 Pulley Snap Ring oil, the compressor front shaft seal is leaking and the
1 - SNAP RING compressor will also have to be replaced.
24 - 10 CONTROLS VA
A/C COMPRESSOR CLUTCH (Continued)
(3) Check the clutch pulley bearing for roughness
or excessive leakage of grease. Replace the clutch
pulley and clutch plate if the bearing is faulty.
INSTALLATION
(1) Align the dowel pin on the back of the clutch
field coil with the hole in the compressor front cover,
and position the clutch coil onto the compressor. Be
certain that the cluch coil wire harness leads are
properly oriented and routed so that they are not
pinched between the compressor front cover and the
clutch coil.
(3) Install and tighten the screw that secures the NOTE: The shims may compress after tightening
clutch coil wire harness connector bracket and the shaft bolt. Check the air gap in four or more
ground clip to the top of the compressor housing. places to verify the air gap is still correct. Spin the
(4) Install the pulley onto the front of the compres- pulley before performing a final check of the air
sor. If necessary, place a block of wood on the friction gap.
surface and tap gently with a hammer (Fig. 6).
(9) If a new clutch plate and/or clutch pulley are
CAUTION: Do not mar the friction surfaces of the being installed, the air gap between the clutch plate
pulley. and clutch pulley must be checked (Refer to 24 -
HEATING & AIR CONDITIONING/CONTROLS/A/C
(5) Using snap ring pliers (Special Tool C-4574 or COMPRESSOR CLUTCH - STANDARD PROCE-
equivalent), install the external snap ring (bevel side DURE).
facing outward) that secures the clutch pulley to the (10) Install the retainer that secures the compres-
front cover of the compressor. Be certain that the sor clutch coil lead to the top of the compressor.
snap ring is properly fully and properly seated in the (11) Reconnect the engine wire harness connector
groove. to the clutch coil lead on the top of the compressor.
(6) If the original clutch plate and clutch pulley (12) Reinstall the serpentine accessory drive belt
are to be reused, reinstall the original shim(s) on the (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE
compressor shaft against the shoulder. If a new BELTS - INSTALLATION).
clutch plate and/or clutch pulley are being used, (13) Reconnect the battery negative cable.
install a trial stack of shims 1.0 mm (0.040 in.) thick (14) If a new clutch plate and/or clutch pulley are
on the compressor shaft against the shoulder. being installed, the new clutch components must be
(7) Install the clutch plate onto the compressor burnished (Refer to 24 - HEATING & AIR CONDI-
shaft. TIONING/CONTROLS/A/C COMPRESSOR CLUTCH
(8) Install and tighten the compressor shaft bolt. If - STANDARD PROCEDURE).
necessary, a band-type oil filter wrench or a strap
VA CONTROLS 24 - 11
A/C COMPRESSOR CLUTCH (b) If the A/C clutch coil current reading is above
specifications, the coil is shorted and must be
COIL replaced.
TESTS
(1) Verify the battery state of charge (Refer to 8 -
ELECTRICAL/BATTERY SYSTEM/BATTERY -
DIAGNOSIS AND TESTING).
(2) Connect an ammeter (0 to 10 ampere scale
selected) in series with the clutch coil feed terminal.
Connect a voltmeter (0 to 20 volt scale selected) to
measure voltage across the battery and the clutch
coil.
(3) With the A/C-heater control in the A/C mode
and the blower motor at low speed, start the engine
and allow it to run at a normal idle speed.
(4) The A/C compressor clutch should engage Fig. 7 A/C-Heater Control
immediately, and the clutch coil supply voltage OPERATION
should be within two volts of the battery voltage. If To control the interior temperature, the A/C-heater
the coil supply voltage is OK, go to Step 5. If the coil control uses the actual values from the temperature
supply voltage is not within two volts of battery volt- sensors and the CAN bus and compares them with
age, test the clutch coil feed circuit for excessive volt- the nominal value of the temperature control switch.
age drop and repair as necessary. The A/C-heater control is diagnosed using a DRBIIIt
(5) For the acceptable A/C clutch coil current draw scan tool. Refer to Body Diagnostic Procedures.
specificationsrefer to 24 - HEATING & AIR CONDI- The A/C-heater control is diagnosed using a
TIONING - SPECIFICATIONS. Specifications apply DRBIIIt scan tool. Refer to Body Diagnostic Proce-
for a work area temperature of 21° C (70° F). If volt- dures.
age is more than 12.5 volts, add electrical loads by The A/C-heater control cannot be adjusted or
turning on electrical accessories until voltage reads repaired and, if faulty or damaged, it must be
below 12.5 volts. replaced.
(a) If the A/C clutch coil current reading is zero,
the coil is open and must be replaced.
24 - 12 CONTROLS VA
A/C HEATER CONTROL (Continued)
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN AN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the front license plate bracket (Refer
to 23 - BODY/EXTERIOR/LICENSE PLATE
BRACKET - REMOVAL).
(3) Remove the ambient temperature sensor from
the front fascia through the access hole in the fascia
(Fig. 11).
(4) Disconnect the wire harness connector from the
Fig. 10 Air Outlet Temperature Sensor sensor and remove the sensor from the vehicle.
1 - HEATER HOUSING
2 - AIR OUTLET TEMPERATURE SENSOR
INSTALLATION
(1) Install the air outlet temperature sensor onto
the heater housing.
(2) Connect the wire harness connector to the air
outlet temperature sensor.
(3) Install the heater-A/C control into the instru-
ment panel (Refer to 24 - HEATING & AIR CONDI-
TIONING/CONTROLS/A/C HEATER CONTROL -
INSTALLATION).
(4) Reconnect the battery negative cable.
AMBIENT TEMPERATURE
SENSOR
DESCRIPTION
Ambient air temperature is connected to the Fig. 11 Ambient Temperature Sensor
instrument cluster through a two-wire harness lead 1 - AMBIENT TEMPERATURE SENSOR
and connector of the vehicle electrical system. The 2 - FRONT FASCIA
instrument cluster sends out a message on the CAN
bus to the ATC control module. The ambient temper- INSTALLATION
ature sensor is a variable resistor mounted to the (1) Connect the wire harness connector to the
front licence plate bracket. ambient temperature sensor.
(2) Install the sensor onto the front fascia through
OPERATION the access hole in the fascia.
The ambient temperature sensor is a variable (3) Install the front license plate bracket (Refer to
resistor that operates on a five-volt reference signal 23 - BODY/EXTERIOR/LICENSE PLATE BRACKET
sent to it by the instrument cluster. The resistance in - INSTALLATION).
the sensor changes as temperature changes. Based (4) Reconnect the battery negative cable.
upon the resistance in the sensor, the instrument
cluster sends the ATC control module a specific volt-
age on the temperature sensor signal circuit, which
24 - 16 CONTROLS VA
BLOWER MOTOR RESISTOR (2) Disconnect the wire harness connector from the
blower motor resistor block.
BLOCK (3) Check for continuity between each of the
blower motor switch input terminals of the resistor
DESCRIPTION and the resistor output terminal. In each case there
This temperature control system uses a blower should be continuity. If OK, repair the wire harness
motor resistor. The blower motor resistor is mounted circuits between the blower motor switch and the
to the top of ventilation housing located in the engine blower motor resistor or blower motor as required. If
compartment. The blower motor resistor can be not OK, replace the faulty blower motor resistor.
accessed for service without removing any other com-
ponents. REMOVAL
(1) Disconnect and isolate the battery negative
OPERATION cable.
The blower motor resistor block has multiple resis- (2) Depress resistor block locking tab and remove
tor wires. Each resistor wire changes the resistance resistor block from the ventilation housing by sliding
in the blower motor current path to change the the resistor block inboard (Fig. 12).
blower motor speed. The blower motor switch directs (3) Depress two locking tabs and unplug the wire
the current through the correct resistor wire to harness connector from the blower motor resistor
obtain the selected speed. block.
With the blower motor switch in the lowest speed (4) Remove the blower motor resistor from the
position, voltage for the motor is applied through all engine compartment.
of the resistor wires. Each higher speed selected with
the blower motor switch applies the blower motor
current path through fewer of the resistor wires,
increasing the blower motor speed. When the blower
motor switch is in the highest speed position, the
blower motor resistor is bypassed and the blower
motor circuit receives a direct path to battery volt-
age.
The blower motor resistor block cannot be repaired
and, if faulty or damaged, it must be replaced.
OPERATION
The evaporator temperature sensor monitors the
temperature of the A/C evaporator. The sensor will
change its internal resistance in response to the tem-
24 - 18 CONTROLS VA
EVAPORATOR TEMPERATURE SENSOR (Continued)
(14) Install the radio (Refer to 8 - ELECTRICAL/
AUDIO/RADIO - INSTALLATION).
(15) Reconnect the negative battery cable.
IN-CAR TEMPERATURE
SENSOR
DESCRIPTION
The in-car temperature sensor measures the actual
air temperature within the passenger compartment.
The in-car temperature sensor is located inside of the
A/C-heater control behind a vented panel (Fig. 14)
and is not a separate serviceable component. The
A/C-heater control must be replaced if there is a fault
relating to the in-car temperature sensor.
INSTALLATION
(1) Install the probe of the evaporator temperature
sensor between the fins of the A/C evaporator.
DIAGNOSIS AND TESTING NOTE: Install the control cable of bottom adjust-
ment lever to the front adjustment wheel of the A/C-
IN-CAR TEMPERATURE SENSOR heater control.
The in-car temperature sensor is diagnosed by per-
(3) Hold the A/C-heater control in its installation
forming the ATC Function Test using the DRBIIIt
position.
scan tool. Refer to Body Diagnostic Procedures. For
circuit descriptions and diagrams, refer to the appro- NOTE: While holding the A/C-heater control in the
priate wiring information. installation position, verify that the control cables
are not twisted.
MODE DOOR CABLES (4) Turn the mode control knob on the A/C-heater
control to the nine-o-clock position.
REMOVAL (5) Turn the upper mode door lever counter-clock-
The air distribution control cables (mode door wise until it reaches its stop and install the cable
cables) can be removed and installed without having into the retainer in this position (arrow).
to remove the instrument panel from the vehicle. (6) Turn the lower mode door lever clockwise until
(1) Disconnect and isolate the negative battery cable. it reaches its stop and install the cable into the
(2) Remove the center bezel from the instrument retainer in this position (arrow).
panel (Refer to 23 - BODY/INSTRUMENT PANEL/IN- (7) Operate the mode control and verify that the
STRUMENT PANEL CENTER BEZEL - REMOVAL). mode door cables are properly adjusted.
(3) Remove the A/C-heater control (Refer to 24 - (8) Install the A/C-heater control and the two
HEATING & AIR CONDITIONING/CONTROLS/A/C retaining screws. Tighten the screws to 2 N·m (17 in.
HEATER CONTROL - REMOVAL). lbs.).
(4) Mark and disconnect the control cables from (9) Install the center bezel onto the instrument
the A/C-heater control. panel (Refer to 23 - BODY/INSTRUMENT PANEL/
(5) Mark and disconnect the control cables from INSTRUMENT PANEL CENTER BEZEL - INSTAL-
the HVAC housing retainers (Fig. 15). LATION).
(6) Disconnect the control cables from the mode (10) Reconnect the negative battery cable.
door levers and remove the cables from the vehicle.
RECIRCULATION DOOR (3) Disconnect the vacuum line from the recircula-
tion door actuator.
ACTUATOR (4) Remove the two screws that secure the recircu-
lation door actuator to the ventilation housing.
DESCRIPTION (5) Disconnect the actuator shaft from the recircu-
This vehicle uses a two-position vacuum operated lation door pivot lever and remove the actuator from
recirculation door actuator to move the recirculation the vehicle.
door. Vacuum supply to the recirculation door actua-
tor is controlled by an integral electronic control sole-
noid. The recirculation door actuator is mounted on
the outboard side of the ventilation housing above
the blower motor in the engine compartment.
OPERATION
The recirculation door actuator uses engine vac-
uum, which is controlled by an integral electrical
solenoid. The electrical solenoid is connected to the
A/C-heater control through the vehicle electrical sys-
tem by a dedicated two-wire lead and connector. The
output shaft of the recirculation door actuator is
keyed to a pivot shaft, which is keyed to the recircu-
lation door shaft. The recirculation door actuator can
move the recirculation door in two directions.
The recirculation door actuator is controlled by an
electrical switch that is integral to the A/C-heater
control. When the rotary-type mode control is moved
to the recirculation position, a signal is sent to the Fig. 17 Recirculation Door Actuator
electrical solenoid within the recirculation door
1 - WIRE HARNESS CONNECTOR
actuator. This signal causes the solenoid to open a 2 - RECIRCULATION DOOR ACTUATOR
port to engine vacuum which pulls the output shaft 3 - SCREW (2)
into the actuator, which moves the recirculation-air 4 - PIVOT LEVER
5 - ACTUATOR SHAFT
door. The actuator is spring loaded so the door moves 6 - VACUUM LINE
to the fresh-air position when no vacuum is supplied
through the electrical solenoid. INSTALLATION
The recirculation door actuator can be diagnosed (1) Connect the actuator shaft to the recirculation
by performing the ATC Function Test using a door pivot lever.
DRBIIIt scan tool. Refer to Body Diagnostic Proce- (2) Install the two screws that secure the recircu-
dures. lation door actuator to the ventilation housing.
The recirculation door actuator cannot be repaired Tighten the screws to 2 N·m (17 in. lbs.).
and, if faulty or damaged, it must be replaced. (3) Connect the vacuum line to the recirculation
door actuator.
REMOVAL (4) Connect the wire harness connector to the
(1) Disconnect and isolate the battery negative recirculation door actuator.
cable. (5) Reconnect the battery negative cable.
(2) Disconnect the wire harness connector from the
recirculation door actuator (Fig. 17).
VA DISTRIBUTION 24 - 21
DISTRIBUTION
TABLE OF CONTENTS
page page
AIR OUTLETS
REMOVAL
WARNING: DISABLE THE SUPPLEMENTAL
RESTRAINT SYSTEM BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, DRIVER
AIRBAG, PASSENGER AIRBAG, SEAT BELT TEN-
SIONER, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE SYSTEM
CAPACITOR TO DISCHARGE BEFORE PERFORM-
ING FURTHER DIAGNOSIS OR SERVICE. THIS IS
THE ONLY SURE WAY TO DISABLE THE SUPPLE-
MENTAL RESTRAINT SYSTEM. FAILURE TO TAKE
Fig. 1 Air Filter Element THE PROPER PRECAUTIONS COULD RESULT IN
1 - VENTILATION HOUSING INSULATION BLANKET ACCIDENTAL AIRBAG DEPLOYMENT AND POSSI-
2 - LOCKING CLIP (2) BLE PERSONAL INJURY.
3 - AIR FILTER
(1) Disconnect and isolate the battery negative
cable.
24 - 22 DISTRIBUTION VA
AIR OUTLETS (Continued)
(2) If servicing the driver side air outlets, remove
the instrument cluster bezel (Refer to 23 - BODY/IN-
STRUMENT PANEL/CLUSTER BEZEL -
REMOVAL).
(3) If servicing the passenger side air outlets,
remove the passenger side airbag (Refer to 8 - ELEC-
TRICAL/RESTRAINTS/PASSENGER AIRBAG -
REMOVAL).
(4) If servicing the passenger side air outlets,
remove the passenger side air nozzle reinforcing
plate screws and the reinforcing plate (Fig. 2).
(5) If servicing the passenger side air outlets,
remove the passenger side air nozzle assembly using
a trim stick or other suitable wide flat blade tool,
until the snap features on the nozzle assembly are
released.
FLOOR DISTRIBUTION DUCTS (5) Install the defroster ducts (Refer to 24 - HEAT-
ING & AIR CONDITIONING/DISTRIBUTION/DE-
FROSTER DUCTS - INSTALLATION).
REMOVAL
(6) Install the instrument panel (Refer to 23 -
(1) Remove the instrument panel (Refer to 23 -
BODY/INSTRUMENT PANEL/INSTRUMENT
BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL ASSEMBLY - INSTALLATION).
PANEL ASSEMBLY - REMOVAL).
(2) Remove the defroster ducts (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION/ HVAC HOUSING
DEFROSTER DUCTS - REMOVAL).
(3) Remove the screws that secure the left and
REMOVAL
right floor distribution ducts to the instrument panel
support (Fig. 6). WARNING: ON VEHICLES EQUIPPED WITH AIR-
(4) Remove floor distribution ducts from the center BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
floor distribution duct. ATTEMPTING ANY STEERING WHEEL, STEERING
(5) Remove the shift mechanism (Refer to 21 - COLUMN, OR INSTRUMENT PANEL COMPONENT
TRANSMISSION/TRANSAXLE/AUTOMATIC - DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
NAG1/SHIFT MECHANISM - REMOVAL). LATE THE BATTERY NEGATIVE (GROUND) CABLE,
(6) Remove center floor distribution duct from the THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
heater housing. TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN AN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
DISASSEMBLY
(1) Remove the HVAC housing from the vehicle
Fig. 7 Ventilation Housing (Refer to 24 - HEATING & AIR CONDITIONING/
1 - NUT (5) DISTRIBUTION/HVAC HOUSING - REMOVAL).
2 - WASHER (5)
3 - VENTILATION HOUSING (2) Place the HVAC housing in the upright position
4 - HOUSING COVER on a work bench, making allowance for leakage of
fluids.
(11) Disconnect the heater hoses from the heater (3) Remove the gasket located at the A/C evapora-
core. tor and heater core tubes and the gasket that seals
(12) Disconnect the heater hoses from the heater the ventilation housing to the HVAC housing (Fig. 9).
core tubes. Install plugs in, or tape over the opened (4) Remove the 12 screws that secure the two
heater core tubes. housing halves together.
(13) Remove the two bolts securing the refrigerant (5) Seperate the two housing halves.
lines to the evaporator tubes and disconnect the lines (6) Remove the heater core from the lower hous-
from the tubes. Install plugs in, or tape over all of ing.
the opened refrigerant line fittings. (7) Remove the wire harness.
(14) Remove the seals from the refrigerant line fit-
tings and discard.
24 - 26 DISTRIBUTION VA
HVAC HOUSING (Continued)
PLUMBING
TABLE OF CONTENTS
page page
SYSTEM LOW
DIAGNOSIS AND TESTING (1) Position the vehicle in a wind-free work area.
This will aid in detecting small leaks.
REFRIGERANT SYSTEM LEAKS (2) Bring the refrigerant system up to operating
temperature and pressure. This is done by allowing
WARNING: REVIEW THE WARNINGS AND CAU-
the engine to run with the air conditioning system
TIONS IN THE FRONT OF THIS SECTION BEFORE
turned on for five minutes.
PERFORMING THE FOLLOWING OPERATION.
(3) With the engine not running, use a electronic
(Refer to 24 - HEATING & AIR CONDITIONING/
R-134a leak detector and search for leaks. Because
PLUMBING - WARNING) (Refer to 24 - HEATING &
R-134a refrigerant is heavier than air, the leak detec-
AIR CONDITIONING/PLUMBING - CAUTION)
tor probe should be moved slowly along the bottom
If the air conditioning system is not cooling prop- side of all refrigerant lines, connector fittings and
erly, determine if the refrigerant system is fully- components.
charged. (Refer to 24 - HEATING & AIR (4) To inspect the evaporator coil for leaks, insert
CONDITIONING - DIAGNOSIS AND TESTING - the electronic leak detector probe into the center
A/C PERFORMANCE) instrument panel outlet. Set the blower motor switch
An electronic leak detector designed for R-134a to the lowest speed position, the A/C button in the
refrigerant is recommended for locating and confirm- On position, and select the Recirculation Mode.
ing refrigerant system leaks. Refer to the operating
instructions supplied by the equipment manufacturer STANDARD PROCEDURE
for proper care and use of this equipment.
An oily residue on or near refrigerant system lines,
REFRIGERANT SYSTEM SERVICE EQUIPMENT
connector fittings, components, or component seals
can indicate the general location of a possible refrig- WARNING: EYE PROTECTION MUST BE WORN
erant leak. However, the exact leak location should WHEN SERVICING AN AIR CONDITIONING REFRIG-
be confirmed with an electronic leak detector prior to ERANT SYSTEM. TURN OFF (ROTATE CLOCKWISE)
component repair or replacement. ALL VALVES ON THE EQUIPMENT BEING USED,
To detect a leak in the refrigerant system, perform BEFORE CONNECTING TO OR DISCONNECTING
one of the following procedures: FROM THE REFRIGERANT SYSTEM. FAILURE TO
OBSERVE THESE WARNINGS MAY RESULT IN PER-
SYSTEM EMPTY SONAL INJURY.
(1) Evacuate the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS- WARNING: REVIEW THE WARNINGS AND CAU-
TEM EVACUATE) TIONS IN THE FRONT OF THIS SECTION BEFORE
(2) Connect and dispense 0.283 kilograms (0.625 PERFORMING THE FOLLOWING OPERATION.
pounds or 10 ounces) of R-134a refrigerant into the (Refer to 24 - HEATING & AIR CONDITIONING/
evacuated refrigerant system. (Refer to 24 - HEAT- PLUMBING - WARNING) (Refer to 24 - HEATING &
ING & AIR CONDITIONING/PLUMBING - STAN- AIR CONDITIONING/PLUMBING - CAUTION)
24 - 32 PLUMBING VA
PLUMBING (Continued)
When servicing the air conditioning system, a charge service port. This port is located on the liquid
R-134a refrigerant recovery/recycling/charging sta- line between the condenser and the reciver-drier.
tion that meets SAE Standard J2210 must be used. RECOVERY/RECYCLING/EVACUATION/CHARG-
Contact an automotive service equipment supplier for ING HOSE The center manifold hose (Yellow, or
refrigerant recovery/recycling/charging equipment. White, with Black stripe) is used to recover, evacu-
Refer to the operating instructions supplied by the ate, and charge the refrigerant system. When the low
equipment manufacturer for proper care and use of or high pressure valves on the manifold gauge set
this equipment. are opened, the refrigerant in the system will escape
A manifold gauge set may be needed with some through this hose.
recovery/recycling/charging equipment (Fig. 1). The
service hoses on the gauge set being used should REFRIGERANT SYSTEM RECOVERY
have manual (turn wheel), or automatic back-flow
valves at the service port connector ends. This will WARNING: REVIEW THE WARNINGS AND CAU-
prevent refrigerant from being released into the TIONS IN THE FRONT OF THIS SECTION BEFORE
atmosphere. PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - WARNING) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION)
(12) EXAMPLE: The ambient temperature is 21° refrigerant oil that is circulated throughout the
C (70° F). The evaporator inlet tube temperature is refrigerant system with the refrigerant.
12° C (54° F) and the evaporator outlet tube temper- The A/C compressor draws in low-pressure refrig-
ature is 10° C (50° F). Subtract the inlet tube tem- erant vapor from the A/C evaporator through its suc-
perature from the outlet tube temperature. The tion port. It then compresses the refrigerant into a
difference is -2° C (-4° F). With a -2° C (-4° F) tem- high-pressure, high-temperature refrigerant vapor,
perature differential at 21° C (70° F) ambient tem- which is then pumped to the A/C condenser through
perature, the system is fully charged. the compressor discharge port.
(13) Add enough refrigerant to bring the refriger- The A/C compressor cannot be repaired. If faulty or
ant system up to a full charge. damaged, the entire compressor must be replaced.
(14) Remove the jumper wire from the low pres- The compressor clutch, pulley, and coil, are available
sure cycling clutch switch wire harness connector for service.
and plug the connector back into the switch.
DIAGNOSIS AND TESTING
A/C COMPRESSOR
A/C COMPRESSOR NOISE
When investigating an air conditioning related
DESCRIPTION
noise, you must first know the conditions under
The standard front A/C system uses a Denso
which the noise occurs. These conditions include:
7SBU16C double-acting, variable swash plate-type
weather, vehicle speed, transmission in gear or neu-
A/C compressor. This A/C compressor has a label
tral, engine speed, engine temperature, and any
identifying the use of R-134a refrigerant and both
other special conditions. Noises that develop during
the suction and discharge ports located on the cylin-
air conditioning operation can often be misleading.
der head.
For example: What sounds like a failed front bearing
The optional A/C compressor used for add-on rear
or connecting rod, may be caused by loose bolts, nuts,
A/C systems is a Denso 10S17C ten cylinder, double-
mounting brackets, or a loose compressor clutch
acting swash plate-type A/C compressor. This A/C
assembly.
compressor has a label identifying the use of R-134a
Drive belts are speed sensitive. At different engine
refrigerant and has a fixed displacement of 170 cubic
speeds and depending upon belt tension, belts can
centimeters (10.374 cubic inches), and has both the
develop noises that are mistaken for a compressor
suction and discharge ports located on the cylinder
noise. Improper belt tension can cause a misleading
head at the rear of the compressor.
noise when the compressor clutch is engaged, which
may not occur when the compressor clutch is disen-
OPERATION gaged. Check the serpentine drive belt condition and
The A/C compressor is driven by the engine
tension as described in Cooling before beginning this
through an electric clutch, drive pulley and belt
procedure.
arrangement. The A/C compressor is lubricated by
VA PLUMBING 24 - 35
A/C COMPRESSOR (Continued)
(1) Select a quiet area for testing. Duplicate the REMOVAL
complaint conditions as much as possible. Switch the
compressor on and off several times to clearly iden- DENSO 7SBU16C A/C COMPRESSOR
tify the compressor noise. Listen to the compressor
while the clutch is engaged and disengaged. Probe WARNING: Refer to the applicable warnings and
the compressor with an engine stethoscope or a long cautions for this system before performing the fol-
screwdriver with the handle held to your ear to bet- lowing operation (Refer to 24 - HEATING & AIR
ter localize the source of the noise. CONDITIONING/PLUMBING - WARNING - A/C
(2) Loosen all of the compressor mounting hard- PLUMBING) and (Refer to 24 - HEATING & AIR CON-
ware and retighten. Tighten the compressor clutch DITIONING/PLUMBING - CAUTION - A/C PLUMB-
mounting nut. Be certain that the clutch coil is ING). Failure to follow the warnings and cautions
mounted securely to the compressor, and that the could result in possible personal injury or death.
clutch plate and pulley are properly aligned and have
the correct air gap. (Refer to 24 - HEATING & AIR
CONDITIONING/CONTROLS/A/C COMPRESSOR NOTE: The A/C compressor may be removed and
CLUTCH - INSTALLATION) repositioned without disconnecting the refrigerant
(3) To duplicate a high-ambient temperature condi- lines or discharging the refrigerant system. Dis-
tion (high head pressure), restrict the air flow charging is not necessary if servicing the compres-
through the condenser. Install a manifold gauge set sor clutch, clutch coil or the engine.
to be certain that the discharge pressure does not
exceed 2760 kPa (400 psi). (1) Disconnect and isolate the negative battery
(4) Check the refrigerant system plumbing for cable.
incorrect routing, rubbing or interference, which can (2) Recover the refrigerant from the refrigerant
cause unusual noises. Also check the refrigerant lines system (Refer to 24 - HEATING & AIR CONDITION-
for kinks or sharp bends that will restrict refrigerant ING/PLUMBING - STANDARD PROCEDURE -
flow, which can cause noises. (Refer to 24 - HEAT- REFRIGERANT SYSTEM RECOVERY).
ING & AIR CONDITIONING/PLUMBING - CAU- (3) Remove the serpentine drive belt (Refer to 7 -
TION - REFRIGERANT HOSES/LINES/TUBES COOLING/ACCESSORY DRIVE/BELTS-DRIVE -
PRECAUTIONS) REMOVAL).
(5) If the noise is from opening and closing of the (4) Disconnect the wire harness connector from the
high pressure relief valve, reclaim, evacuate, and A/C compressor clutch coil.
recharge the refrigerant system. (Refer to 24 - HEAT- (5) Remove the bolts that secure the A/C suction
ING & AIR CONDITIONING/PLUMBING - STAN- and discharge lines to the A/C compressor.
DARD PROCEDURE - REFRIGERANT RECOVERY) (6) Disconnect the A/C suction and discharge lines
(Refer to 24 - HEATING & AIR CONDITIONING/ from the A/C compressor and remove and discard the
PLUMBING - STANDARD PROCEDURE - REFRIG- O-ring seals (Fig. 2).
ERANT SYSTEM EVACUATE) (Refer to 24 - (7) Install plugs in, or tape over the opened refrig-
HEATING & AIR CONDITIONING/PLUMBING - erant line fittings and the compressor ports.
STANDARD PROCEDURE - REFRIGERANT SYS- (8) Raise the vehicle on a hoist.
TEM CHARGE)If the high pressure relief valve still (9) If equipped with an add-on rear A/C system,
does not seat properly, replace the a/c compressor. remove the lower A/C compressor and position it out
(Refer to 24 - HEATING & AIR CONDITIONING/ of the way (Refer to 24 - HEATING & AIR CONDI-
PLUMBING/A/C COMPRESSOR - REMOVAL) TIONING/PLUMBING/A/C COMPRESSOR -
(6) If the noise is from liquid slugging on the suc- REMOVAL - DENSO 10S17).
tion line, check the refrigerant oil level and the (10) Support the A/C compressor and remove the
refrigerant system charge. (Refer to 24 - HEATING compressor mounting bolts.
& AIR CONDITIONING/PLUMBING/REFRIGER- (11) Remove the A/C compressor from the engine
ANT OIL - STANDARD PROCEDURE) (Refer to 24 - compartment.
HEATING & AIR CONDITIONING/PLUMBING -
SPECIFICATIONS - CHARGE CAPACITY).
(7) If the noise continues, replace the compressor
and repeat Step 1.
24 - 36 PLUMBING VA
A/C COMPRESSOR (Continued)
(4) Remove the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/BELTS-DRIVE -
REMOVAL).
(5) Disconnect the wire harness connector from the
clutch field coil of the A/C compressor (Fig. 3).
(6) Remove the bolts that secure the A/C suction
and discharge lines to the A/C compressor.
(7) Disconnect the A/C suction and discharge lines
from the A/C compressor and remove and discard the
O-ring seals.
(8) Install plugs in, or tape over the opened refrig-
erant line fittings and the compressor ports.
(9) Remove the bolts that secure the A/C compres-
sor to the mounting bracket.
(10) Remove the A/C compressor from the engine
compartment.
REMOVAL
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
WARNING) and (Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING - CAUTION).
OPERATION
Refrigerant enters the evaporator from the expan-
sion valve as a low-temperature, low-pressure liquid.
As air flows over the fins of the evaporator, the
humidity in the air condenses on the fins, and the
heat from the air is absorbed by the refrigerant. Heat
absorption causes the refrigerant to boil and vapor-
ize. The refrigerant becomes a low-pressure gas
before it leaves the evaporator.
The evaporator cannot be repaired and, if faulty or
damaged, it must be replaced.
Fig. 6 HVAC Housing
REMOVAL 1 - SCREW (12)
2 - UPPER HOUSING
WARNING: ON VEHICLES EQUIPPED WITH AIR- 3 - A/C EVAPORATOR
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE 4 - EVAPORATOR O-RING SEAL (2)
4 - EVAPORATOR GASKET
ATTEMPTING ANY STEERING WHEEL, STEERING 6 - VENTILATION HOUSING GASKET
COLUMN, OR INSTRUMENT PANEL COMPONENT 7 - LOWER HOUSING
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- 8 - WIRING HARNESS
9 - BOLT (3)
LATE THE BATTERY NEGATIVE (GROUND) CABLE, 10 - HEATER CORE
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS- 11 - HEATER CORE TUBE ASSEMBLY
TEM CAPACITOR TO DISCHARGE BEFORE PER- 12 - HEATER CORE TUBE GASKET
13 - HEATER CORE TUBE O-RING SEAL (2)
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
INSTALLATION
CAUTIONS COULD RESULT IN AN ACCIDENTAL NOTE: If the A/C evaporator is being replaced, add
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL 60 milliliters (2 fluid ounces) of refrigerant oil to the
INJURY. refrigerant system. Use only refrigerant oil of the
type recommended for the A/C compressor in the
WARNING: REVIEW THE WARNINGS AND CAU- vehicle.
TIONS IN THE FRONT OF THIS SECTION BEFORE
(1) Install the A/C evaporator into the lower half of
PERFORMING THE FOLLOWING OPERATION (Refer
the HVAC housing.
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
(2) Assemble the HVAC housing (Refer to 24 -
WARNING) and (Refer to 24 - HEATING & AIR CON-
HEATING & AIR CONDITIONING/DISTRIBUTION/
DITIONING/PLUMBING - CAUTION).
HVAC HOUSING - ASSEMBLY).
VA PLUMBING 24 - 41
A/C EVAPORATOR (Continued)
(3) Install the HVAC housing (Refer to 24 - HEAT- A Restricted Orifice: There will be low suction
ING & AIR CONDITIONING/DISTRIBUTION/HVAC pressure and no cooling. This may be caused by
HOUSING - INSTALLATION). debris in the refrigerant system. If debris is believed
to be the cause, recycle the refrigerant and replace
the A/C expansion valve and the receiver-drier.
A/C EXPANSION VALVE
REMOVAL
DESCRIPTION
The “H” valve type thermal expansion valve (TXV) WARNING: REFER TO THE APPLICABLE WARN-
is mounted in the engine compartment between the INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
liquid and suction lines and the evaporator. PERFORMING THE FOLLOWING OPERATION (Refer
The expansion valve is a factory calibrated unit to 24 - HEATING & AIR CONDITIONING/PLUMBING -
and cannot be adjusted or repaired. If faulty or dam- WARNING) and (Refer to 24 - HEATING & AIR CON-
aged, the expansion valve must be replaced. DITIONING/PLUMBING - CAUTION).
OPERATION
The electric coolant pump is controlled by the ATC
A/C-heater control and is only operational under the
following conditions:
(1) Vehicle speed below 27 Km/h (17 mph).
(2) Coolant temperature above 65° C (150° F) but
less than 110° C (230 ° F).
(3) Any blower motor speed setting.
(4) Temperature heat setting above the halfway
setting (60% heat).
(5) The pump will turn off at speeds above 48
Km/h (30 mph).
(6) The pump will turn off if the coolant tempera-
ture rises above 110° C (230 ° F).
REMOVAL
(1) Disconnect and isolate the negative battery cable.
(2) Partially drain the engine cooling system (Refer
to 7 - COOLING/ENGINE/COOLANT - STANDARD
PROCEDURE - DRAINING COOLANT SYSTEM).
(3) Disconnect the wire harness connector from the
Fig. 7 A/C Expansion Valve electric coolant pump (Fig. 8).
1 - EVAPORATOR TUBE TAPPING PLATE (4) Loosen both hose clamps from the electric cool-
2 - O-RING SEAL (2)
3 - A/C EXPANSION VALVE ant pump.
4 - BOLT (2) (5) Using a twisting motion gently remove both
5 - A/C SUCTION LINE heater hoses from the electric coolant pump.
6 - NUT
7 - A/C LIQUID LINE (6) Remove the two electric coolant pump bracket
8 - O-RING SEAL (2) retaining nuts from the body studs.
(7) Remove the electric coolant pump from the
(6) Lubricate new rubber O-ring seals with clean vehicle.
refrigerant oil and install them on the liquid and suc-
tion line fittings.
(7) Connect the liquid line fitting to the A/C expan-
sion valve.
(8) Connect the suction line fitting to the A/C
expansion valve.
(9) Install the nut that secures the suction line
and liquid line fittings to the stud on the A/C expan-
sion valve. Tighten the nut to 10 N·m (89 in. lbs.).
(10) Reconnect the negative battery cable.
(11) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE).
(12) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE).
OPERATION
Engine coolant is circulated through the heater
hoses to the heater core whenever the heater water
valve is cycled open by the ATC A/C-heater control.
As the coolant flows through the heater core, heat
removed from the engine is transferred to the heater
core fins and tubes. Air directed through the heater
core picks up the heat from the heater core fins. The
heater water valve controls the heater output air
temperature by controlling the amount of heated
engine coolant flowing through the heater core. The
blower motor speed controls the volume of air flowing
through the HVAC housing.
The heater core cannot be repaired and, if faulty or
damaged, it must be replaced.
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING Fig. 9 HVAC Housing
COLUMN, OR INSTRUMENT PANEL COMPONENT 1 - SCREW (12)
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- 2 - UPPER HOUSING
3 - A/C EVAPORATOR
LATE THE BATTERY NEGATIVE (GROUND) CABLE, 4 - EVAPORATOR O-RING SEAL (2)
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS- 4 - EVAPORATOR GASKET
TEM CAPACITOR TO DISCHARGE BEFORE PER- 6 - VENTILATION HOUSING GASKET
7 - LOWER HOUSING
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS 8 - WIRING HARNESS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG 9 - BOLT (3)
SYSTEM. FAILURE TO TAKE THE PROPER PRE- 10 - HEATER CORE
11 - HEATER CORE TUBE ASSEMBLY
CAUTIONS COULD RESULT IN AN ACCIDENTAL 12 - HEATER CORE TUBE GASKET
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL 13 - HEATER CORE TUBE O-RING SEAL (2)
INJURY.
24 - 44 PLUMBING VA
HEATER CORE (Continued)
INSTALLATION (7) Remove the routing clip retaining nut and dis-
(1) If the heater core tube assembly was removed engage the routing clip retainer on top of the left
from the heater core, lubricate two new rubber frame rail from the front section of the liquid line.
O-ring seals with clean engine coolant and install (8) Remove the A/C pressure sensor from the front
them onto the heater core fitting. liquid line fitting (Refer to 24 - HEATING & AIR
(2) If required, connect the heater core tube CONDITIONING/CONTROLS/A/C PRESSURE
assembly to the heater core and install the three TRANSDUCER - REMOVAL).
retaining bolts. Tighten the bolts to 5 N·m (45 in. (9) Remove the bolt that secures the front section
lbs.). of the liquid line to the top of the receiver/drier (Fig.
(3) Install the heater core into the bottom half of 10).
the HVAC housing. (10) Disconnect the front section of the liquid line
(4) Assemble the HVAC housing (Refer to 24 - from the receiver/drier and remove and discard the
HEATING & AIR CONDITIONING/DISTRIBUTION/ O-ring seal.
HVAC HOUSING - ASSEMBLY). (11) Install plug in, or tape over the opened liquid
(5) Install the HVAC housing (Refer to 24 - HEAT- line fitting and the receiver/drier inlet port.
ING & AIR CONDITIONING/DISTRIBUTION/HVAC (12) Remove the front section of the A/C liquid line
HOUSING - INSTALLATION). from the engine compartment.
LIQUID LINE
REMOVAL
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
WARNING) and (Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING - CAUTION).
RECEIVER/DRIER
DESCRIPTION
The receiver/drier is mounted in a bracket secured
to the left front strut tower in the engine compart-
ment. The receiver/drier is connected between the
front and rear sections of the A/C liquid line between
the condenser outlet and the evaporator inlet.
The receiver/drier cannot be repaired. If the receiv-
er/drier is faulty or damaged, or if the refrigerant
system has been contaminated or left open to the
atmosphere for an indeterminable period or if the
compressor has failed, it must be replaced.
Fig. 12 Receiver/Drier
OPERATION 1 - RECEIVER/DRIER
The receiver/drier performs a filtering action to 2 - A/C LIQUID LINE (REAR SECTION)
prevent foreign material in the refrigerant from con- 3 - A/C PRESSURE TRANSDUCER
taminating the A/C expansion valve. A desiccant bag 4 - A/C LIQUID LINE (FRONT SECTION)
5 - CLAMP
is mounted inside the receiver/drier canister to
absorb any moisture which may have entered and
INSTALLATION
become trapped within the refrigerant system. In
addition, during periods of high demand A/C opera- NOTE: If the receiver/drier is being replaced, add 30
tion, the receiver/drier acts as a reservoir to store milliliters (1 fluid ounce) of refrigerant oil to the
surplus refrigerant. Refrigerant enters the receiver/ refrigerant system. Use only refrigerant oil of the
drier as a high-pressure, low-temperature liquid. type recommended for the A/C compressor in the
vehicle.
REMOVAL
(1) Position the receiver/drier onto the mounting
WARNING: REVIEW THE WARNINGS AND CAU- bracket on the front left strut tower.
TIONS IN THE FRONT OF THIS SECTION BEFORE (2) Tighten the clamp that secures the receiver/
PERFORMING THE FOLLOWING OPERATION (Refer drier to the mounting bracket.
VA PLUMBING 24 - 47
RECEIVER/DRIER (Continued)
(3) Remove the tape or plugs from the liquid line REFRIGERANT OIL
fittings and the receiver/drier ports.
(4) Lubricate new rubber O-ring seals with clean
DESCRIPTION
refrigerant oil and install them on the liquid line fit-
The refrigerant oil used in R-134a refrigerant sys-
tings.
tems is a synthetic-based, PolyAlkylene Glycol (PAG),
(5) Connect the front and rear sections of the liq-
wax-free lubricant. Mineral-based R-12 refrigerant
uid line to the receiver/drier.
oils are not compatible with PAG oils, and should
(6) Install the bolts that secures the liquid line fit-
never be introduced to an R-134a refrigerant system.
tings to the receiver/drier. Tighten the bolts to 7 N·m
There are different PAG oils available, and each
(62 in. lbs.).
contains a different additive package. The A/C com-
(7) Evacuate the refrigerant system (Refer to 24 -
pressors for this vehicle are designed to use an ND-8
HEATING & AIR CONDITIONING/PLUMBING -
PAG refrigerant oil. Use only the refrigerant oil of
STANDARD PROCEDURE - REFRIGERANT SYS-
this type to service the refrigerant system.
TEM EVACUATE).
(8) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
OPERATION
After performing any refrigerant recovery or recy-
STANDARD PROCEDURE - REFRIGERANT SYS-
cling operation, always replenish the refrigerant sys-
TEM CHARGE).
tem with the same amount of the recommended
refrigerant oil as was removed. Too little refrigerant
REFRIGERANT oil can cause compressor damage, and too much can
reduce air conditioning system performance.
DESCRIPTION PAG refrigerant oil is much more hygroscopic than
The refrigerant used in this air conditioning sys- mineral oil, and will absorb any moisture it comes
tem is a HydroFluoroCarbon (HFC), type R-134a. into contact with, even moisture in the air. The PAG
Unlike R-12, which is a ChloroFluoroCarbon (CFC), oil container should always be kept tightly capped
R-134a refrigerant does not contain ozone-depleting until it is ready to be used. After use, recap the oil
chlorine. R-134a refrigerant is a non-toxic, non-flam- container immediately to prevent moisture contami-
mable, clear, and colorless liquefied gas. nation.
Even though R-134a does not contain chlorine, it
must be reclaimed and recycled just like CFC-type STANDARD PROCEDURE
refrigerants. This is because R-134a is a greenhouse
gas and can contribute to global warming. REFRIGERANT OIL LEVEL
When an A/C system is assembled at the factory,
OPERATION all components except the compressor are refrigerant
R-134a refrigerant is not compatible with R-12 oil free. After the refrigerant system has been
refrigerant in an air conditioning system. Even a charged and operated, the refrigerant oil in the com-
small amount of R-12 added to an R-134a refrigerant pressor is dispersed throughout the refrigerant sys-
system will cause compressor failure, refrigerant oil tem. The receiver-drier, evaporator, condenser, and
sludge or poor air conditioning system performance. compressor will each retain a significant amount of
In addition, the PolyAlkylene Glycol (PAG) synthetic the needed refrigerant oil.
refrigerant oils used in an R-134a refrigerant system It is important to have the correct amount of oil in
are not compatible with the mineral-based refriger- the refrigerant system. This ensures proper lubrica-
ant oils used in an R-12 refrigerant system. tion of the A/C compressor. Too little oil will result in
R-134a refrigerant system service ports, service damage to the A/C compressor. Too much oil will
tool couplers and refrigerant dispensing bottles have reduce the cooling capacity of the A/C system.
all been designed with unique fittings to ensure that It will not be necessary to check the oil level in the
an R-134a system is not accidentally contaminated A/C compressor or to add oil, unless there has been
with the wrong refrigerant (R-12). There are also an oil loss. An oil loss may occur due to a rupture or
labels posted in the engine compartment of the vehi- leak from a refrigerant line, a connector fitting, a
cle and on the compressor identifying to service tech- component, or a component seal. If a leak occurs, add
nicians that the air conditioning system is equipped 30 milliliters (1 fluid ounce) of refrigerant oil to the
with R-134a. refrigerant system after the repair has been made.
Refrigerant oil loss will be evident at the leak point
by the presence of a wet, shiny surface around the
leak.
24 - 48 PLUMBING VA
REFRIGERANT OIL (Continued)
Refrigerant oil must be added when a receiver/drier,
A/C evaporator, or A/C condenser are replaced. See the
Refrigerant Oil Capacities chart. When an A/C compres-
sor is replaced, the refrigerant oil must be drained from
the old compressor and measured. Drain all of the
refrigerant oil from the new compressor, then fill the
new compressor with the same amount of refrigerant oil
that was drained out of the old compressor.
REFRIGERANT OIL CAPACITIES
Component ml fl oz
Total A/C System Fill 410 13.9
Receiver/Drier 30 1.0
A/C Condenser 30 1.0
A/C Evaporator 60 2.0
Drain and measure the oil
A/C Compressor from the old compressor -
Fig. 13 A/C Expansion Valve
see text.
1 - EVAPORATOR TUBE TAPPING PLATE
2 - O-RING SEAL (2)
3 - A/C EXPANSION VALVE
SUCTION LINE 4 - BOLT (2)
5 - A/C SUCTION LINE
6 - NUT
REMOVAL 7 - A/C LIQUID LINE
8 - O-RING SEAL (2)
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE (11) Remove the A/C suction line from the engine
PERFORMING THE FOLLOWING OPERATION (Refer compartment.
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
WARNING) and (Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING - CAUTION).
INSTALLATION (6) Remove the bolts that secure the heater water
(1) Position the A/C suction line into the engine valve bracket.
compartment. (7) Remove the bracket and pulsed water control
(2) Remove plugs or tape from the suction line fit- valve from the engine compartment.
ting and the compressor suction port. (8) Turn the bracket slightly and remove the water
(3) Lubricate a new rubber O-ring seal with clean valve from the rubber mounts.
refrigerant oil and install it onto the suction line fit- (9) If necessary, remove the rubber mounts from
ting. the bracket or water valve.
(4) Connect the A/C suction line to the A/C com-
pressor.
(5) Install the bolt that secures the A/C suction
line to the A/C compressor. Tighten the bolt to 23
N·m (17 ft. lbs.).
(6) Remove the tape or plugs from the liquid and
suction line fittings and both expansion valve ports.
(7) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them on the liquid and suc-
tion line fittings.
(8) Connect the A/C liquid and suction lines to the
A/C expansion valve.
(9) Install the nut that secures the A/C liquid and
suction lines to the A/C expansion valve. Tighten the
nut to 10 N·m (89 in. lbs.).
(10) Position the metal routing clip around the A/C
suction line and install the routing clip onto the body
stud.
(11) Install the routing clip retaining nut. Tighten
the nut to 5 N·m (45 in. lbs.).
(12) Install the plastic routing clip retainer onto
the A/C suction line.
(13) Reconnect the negative battery cable. Fig. 15 Heater Water Valve
(14) Evacuate the refrigerant system (Refer to 24 - 1 - HEATER WATER VALVE
HEATING & AIR CONDITIONING/PLUMBING - 2 - HOSE CLAMP (3)
STANDARD PROCEDURE - REFRIGERANT SYS- 3 - HEATER HOSE (3)
4 - RUBBER MOUNT (2)
TEM EVACUATE). 5 - BOLTS (2)
(15) Charge the refrigerant system (Refer to 24 - 6 - BRACKET
HEATING & AIR CONDITIONING/PLUMBING - 7 - RUBBER MOUNT
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE). INSTALLATION
(1) If removed, install the rubber mounts to the
heater water valve or bracket.
WATER VALVE (2) Turn bracket slightly to the right and install
the heater water valve to the bracket.
REMOVAL (3) Install the water valve and mounting bracket
(1) Disconnect and isolate the negative battery into the engine compartment.
cable. (4) Install the two bracket retaining bolts. Tighten
(2) Partially drain the engine cooling system the bolts to 5 N·m (45 in. lbs.).
(Refer to 7 - COOLING/ENGINE/COOLANT - STAN- (5) Using a twisting motion gently install the
DARD PROCEDURE - DRAINING COOLING SYS- heater hoses onto the water valve.
TEM). (6) Tighten the hose clamps securely.
(3) Disconnect the wire harness connector from the (7) Connect the wire harness connector to the
heater water valve (Fig. 15). heater water valve.
(4) Loosen the hose clamps from the heater water (8) Reconnect the negative battery cable.
valve. (9) Fill the engine cooling system (Refer to 7 -
(5) Using a twisting motion gently remove the COOLING/ENGINE/COOLANT - STANDARD PRO-
heater hoses from the heater water valve. CEDURE - COOLING SYSTEM FILL).
24 - 50 CABIN HEATER VA
CABIN HEATER
TABLE OF CONTENTS
page page
CABIN HEATER when the temperature control is set to/or above the
upper set point. The supplemental cabin heater can
operate in a full or partial load range as well as an
DESCRIPTION
idle mode, all dependent on the engine coolant tem-
Vehicles equipped with the diesel engine are also
perature. The heater unit will also turn off if the
equipped with a supplemental cabin heater. This
temperature control is set to less than the lower set
cabin heater is mounted under the vehicle and oper-
point. The supplemental cabin heater can take up to
ates similar to an oil fired furnace. The heater burns
three minutes to completely shut down when either
small amounts of fuel to provide additional heat to
the heater temperature is set below the lower set
the coolant. Coolant is routed from the engine, to the
point or the vehicle ignition is turned off.
supplemental cabin heater and then to the front
The supplemental cabin heater only operates when
heater core. This provides additional heat to the pas-
the engine is running, the mileage exceeds 8 kilome-
senger compartment. The supplemental cabin heater
ter (5 mph) and the fuel tank volume exceeds 1/8 of a
system is interfaced to the vehicles on-board com-
tank. The heater should start if the coolant temper-
puter systems and DRBIIIt diagnostics.
ature is below 40° C (104° F).
The supplemental cabin heater has an electronic
control module that monitors the heat output of the NOTE: Do not apply a strong vacuum directly on
heater. The cabin heater operates at full load (5 kW), the supplemental cabin heater exhaust line. Place
half load or idle mode (no additional heat) depending the vacuum within 75 mm (3 inches) of the exhaust
on engine coolant temperature. port. Too strong of a vacuum can prevent the heater
from starting. The heater control module monitors
OPERATION the blower speed and combustion during its start-
The supplemental cabin heater is activated by up.
using the temperature control on the A/C-heater con-
trol. The supplemental cabin heater is activated
VA CABIN HEATER 24 - 51
CABIN HEATER (Continued)
SYMPTOMS DIAGNOSIS
INSTALLATION
(1) Install the air intake pipe assembly and install
the two retaining screws. Tighten the screws to 7
N·m (62 in. lbs.).
VA EMISSIONS CONTROL 25 - 1
EMISSIONS CONTROL
TABLE OF CONTENTS
page page
EVAPORATIVE EMISSIONS
TABLE OF CONTENTS
page page
CRANKCASE VENTILATION
HEATER
REMOVAL
(1) Disconnect the negative battery cable.
(2) Remove the turbocharger heat shield.
(3) Disconnect the CCV heater wiring harness con-
nector.
(4) Using a slight twisting motion, separate the
CCV breather tube from the heater.
(5) Separate the CCV heater from the turbo-
charger air inlet duct.
INSTALLATION
(1) Clean all mating surfaces.
(2) Insert the CCV heater into the turbocharger
inlet hose aligning the arrow on the heater with the
tab on the hose (Fig. 1).
(3) Connect and properly seat the CCV breather
hose on the CCV heater (Fig. 1).
(4) Connect the wiring harness connector to the
CCV heater (Fig. 1). Fig. 1 CCV HEATER
(5) Install the turbocharger heat shield. 1 - BREATHER HOSE
(6) Connect the negative battery cable. 2 - HARNESS CONNECTOR
3 - TURBOCHANGER INLET HOSE
4 - HEATER ALIGNMENT AREA
5 - CCV HEATER
25 - 2 EVAPORATIVE EMISSIONS VA
TABLE OF CONTENTS
page page
EXHAUST GAS
RECIRCULATION
DESCRIPTION
The EGR system can provide up to 35% exhaust
gas recirculation. The EGR operates during all
engine speed and load conditions. At wide open throt-
tle, it provides a 5% recirculation rate. The EGR
shuts down during high engine idle to avoid carbon
build up on the valve. The EGR also deactivates if
the EGR temperature is too high. The EGR also has
a self cleaning function that opens and closes twice
after the engine has been shut off to eliminate soot
deposits.
Apart from the charge air distribution manifold
and the mixing chamber, the intake manifold also
includes a finned EGR cooler. Coolant flows through
the cooler to reduce the temperature of the recircu-
lated gas after it was cooled by running through the
cylinder head. The management of this temperature
significantly reduces emissions (Fig. 1).
VA EXHAUST GAS RECIRCULATION 25 - 5
EXHAUST GAS RECIRCULATION (Continued)
INSTALLATION
(1) Clean all gasket mating surfaces.
(2) Position the EGR positioner to the intake man-
ifold with a new gasket, install bolts and tighten to
124 lbs.in (14 N·m) (Fig. 3).
(3) Connect the EGR positioner electrical connec-
tor (Fig. 3).
(4) Inspect the seal of the charge air inlet tube,
replace as necessary (Fig. 3).
(5) Seat the charge air tube with gasket into the
intake manifold and push down on the charge air
tube retaining clip.
(6) Refill the cooling system (Refer to 7 - COOL-
ING/ENGINE/COOLANT - STANDARD PROCE-
DURE).
(7) Connect negative battery cable.
VALVE COOLER
DESCRIPTION
The exhaust gas recirculation (EGR) cooler is an
integrated part of the EGR valve. Coolant flows Fig. 4 EGR AND COOLER
around the exhaust gasses, cooling them before they 1 - EGR VALVE
2 - EGR COOLER
are remixed with the incoming air and reburned in 3 - INTAKE MANIFOLD
the combustion chamber (Fig. 4).
The EGR valve and Cooler are serviced as an
assembly, refer to (Refer to 25 - EMISSIONS CON-
TROL/EXHAUST GAS RECIRCULATION/VALVE -
REMOVAL).
VA INDEX 1
Description Group-Page Description Group-Page Description Group-Page
INDEX
A-PILLAR TRIM . . . . . . . . . . . . . . . . . . . . . . 23-67 CIGAR LIGHTER OUTLET . . . . . . . . . . . . 8W-97-1 FRONT POSITION LAMP BULB . . . . . . . . . . 8L-14
A/C COMPRESSOR CLUTCH COIL . . . . . . . . 24-11 CIRCUIT BREAKER . . . . . . . . . . . . . . . . . 8W-97-2 FRONT SEAT BELT & RETRACTOR . . . . . . . 8O-19
A/C COMPRESSOR CLUTCH . . . . . . . . . . . . . 24-7 CLEARANCE LAMP BULB . . . . . . . . . . . . . . . 8L-9 FRONT SEAT BELT BUCKLE . . . . . . . . . . . . 8O-22
A/C COMPRESSOR . . . . . . . . . . . . . . . . . . . 24-34 CLEARANCE LAMP UNIT . . . . . . . . . . . . . . . . 8L-9 FRONT TURN/PARK/SIDE MARKER LAMP
A/C CONDENSER . . . . . . . . . . . . . . . . . . . . . 24-37 CLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J-14 BULB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-15
A/C DISCHARGE LINE . . . . . . . . . . . . . . . . . 24-39 CLOCKSPRING . . . . . . . . . . . . . . . . . . . . . . 8O-12 FRONT WHEEL SPEED SENSOR . . . . . . . . . . 5-30
A/C EVAPORATOR . . . . . . . . . . . . . . . . . . . . 24-40 CLUSTER BEZEL . . . . . . . . . . . . . . . . . . . . . 23-53 FUEL DELIVERY . . . . . . . . . . . . . . . . . . . . . . . 14-5
A/C EXPANSION VALVE . . . . . . . . . . . . . . . . 24-41 COLUMN . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-5 FUEL DOSING PUMP . . . . . . . . . . . . . . . . . . 24-53
A/C HEATER CONTROL . . . . . . . . . . . . . . . . 24-11 CONNECTOR . . . . . . . . . . . . . . . . . . . . . . 8W-01-9 FUEL DRAIN TUBES . . . . . . . . . . . . . . . . . . . 14-8
A/C PRESSURE TRANSDUCER . . . . . . . . . . 24-12 CONNECTOR/GROUND/SPLICE LOCATION . 8W-97-1 FUEL FILL DOOR . . . . . . . . . . . . . . . . . . . . . 23-47
ABS INDICATOR . . . . . . . . . . . . . . . . . . . . . . . 8J-9 CONTROLLER ANTILOCK BRAKE . . . . . . . . . 8E-3 FUEL FILTER CLOGGED INDICATOR . . . . . . 8J-16
ACCELERATOR PEDAL POSITION COOLANT LEVEL SENSOR . . . . . . . . . . . . . . . 7-13 FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . 14-8
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-27 COOLANT LOW INDICATOR . . . . . . . . . . . . . 8J-14 FUEL GAUGE . . . . . . . . . . . . . . . . . . . . . . . . 8J-17
ACCESSORY SWITCH BEZEL . . . . . . . . . . . . 23-54 COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 FUEL INJECTOR . . . . . . . . . . . . . . . . . . . . . . 14-30
ADR INDICATOR . . . . . . . . . . . . . . . . . . . . . . 8J-9 COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 FUEL LEVEL SENDING UNIT / SENSOR . . . 14-24
AIR CLEANER ELEMENT . . . . . . . . . . . . . . . . 9-19 COWL TRIM . . . . . . . . . . . . . . . . . . . . . . . . 23-70 FUEL LINE . . . . . . . . . . . . . . . . . . . . . . . . . . 24-54
AIR CLEANER HOUSING . . . . . . . . . . . . . . . . 9-19 CRANKCASE VENTILATION BREATHER . . . . . 25-2 FUEL LINES . . . . . . . . . . . . . . . . . . . . . . . . . . 14-9
AIR FILTER . . . . . . . . . . . . . . . . . . . . . . . . . 24-21 CRANKCASE VENTILATION HEATER . . . . . . . 25-1 FUEL PRESSURE SENSOR . . . . . . . . . . . . . 14-33
AIR OUTLET TEMPERATURE SENSOR . . . . 24-14 CRANKSHAFT OIL SEAL - FRONT . . . . . . . . . 9-38 FUEL PRESSURE SOLENOID . . . . . . . . . . . . 14-34
AIR OUTLETS . . . . . . . . . . . . . . . . . . . . . . . 24-21 CRANKSHAFT OIL SEAL - REAR . . . . . . . . . . 9-37 FUEL PUMP MODULE . . . . . . . . . . . . . . . . . 14-15
AIRBAG CONTROL MODULE . . . . . . . . . . . . . 8O-8 CRANKSHAFT POSITION SENSOR . . . . . . . . 14-29 FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . 14-11
AIRBAG INDICATOR . . . . . . . . . . . . . . . . . . . 8J-10 CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . 9-34 FUEL QUANTITY CONTROL VALVE . . . . . . . 14-17
ALB CONTROLLER . . . . . . . . . . . . . . . . . . . . 5-15 CUP HOLDER . . . . . . . . . . . . . . . . . . . . . . . . 23-55 FUEL RAIL PRESSURE SENSOR . . . . . . . . . 14-10
ALB LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 CYLINDER HEAD COVER(S) . . . . . . . . . . . . . 9-30 FUEL RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . 14-18
AMBIENT TEMPERATURE INDICATOR . . . . . . 8J-11 CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . 9-20 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 14-1
AMBIENT TEMPERATURE SENSOR . . . . . . . 24-15 D-PILLAR TRIM . . . . . . . . . . . . . . . . . . . . . . 23-70 FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-20
ANTENNA BODY & CABLE . . . . . . . . . . . . . . 8A-1 DAYTIME RUNNING LAMP RELAY . . . . . . . . 8L-9 FUEL TEMPERATURE SENSOR . . . . . . . . . . 14-36
ARMREST . . . . . . . . . . . . . . . . . . . . . . . . . . 23-76 DEFROSTER DUCTS . . . . . . . . . . . . . . . . . . 24-23 FUSE BLOCK #1 . . . . . . . . . . . . . . . . . . . 8W-97-2
ASH RECEIVER . . . . . . . . . . . . . . . . . . . . . . 23-55 DIODE . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-01-10 FUSE BLOCK #2 . . . . . . . . . . . . . . . . . . . 8W-97-3
ASH RECEIVER/CIGAR LIGHTER LAMP DISC BRAKE CALIPER ADAPTER . . . . . . . . . 5-13 GAP AND FLUSH . . . . . . . . . . . . . . . . . . . . . 23-88
UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-29 DISC BRAKE CALIPERS . . . . . . . . . . . . . . . . . 5-11 GEAR SELECTOR INDICATOR . . . . . . . . . . . 8J-18
ASSIST HANDLE . . . . . . . . . . . . . . . . . . . . . 23-68 DOME LAMP/INTRUSION SENSOR BULB . . 8L-32 GEARSHIFT CABLE . . . . . . . . . . . . . . . . . . 21-119
AUDIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-1 DOME LAMP/INTRUSION SENSOR . . . . . . . 8L-32 GENERATOR DECOUPLER PULLEY . . . . . . . 8F-19
AUTOMATIC TRANSMISSION NAG1 - DOME/READING LAMP BULB . . . . . . . . . . . 8L-31 GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . 8F-18
SERVICE INFORMATION . . . . . . . . . . . . . . . . 21-2 DOME/READING LAMP UNIT . . . . . . . . . . . . 8L-31
AXLE BEARINGS/SEALS . . . . . . . . . . . . . . . . 3-17 DOOR GLASS . . . . . . . . . . . . 23-15, 23-31, 23-46 GLOVE BOX . . . . . . . . . . . . . . . . . . . . . . . . . 23-56
AXLE HUB BEARINGS/SEALS . . . . . . . . . . . . 3-20 DOOR JAMB SWITCH . . . . . . . . . . . . . . . . . 8L-33 GLOW PLUG RELAY . . . . . . . . . . . . . . . . . . . . 8I-2
AXLE SHAFTS - DUAL REAR WHEELS . . . . . 3-19 DOOR LOCK MOTOR . . . . . . . . . . . . . . . . . . . 8N-1 GLOW PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . 8I-2
AXLE SHAFTS . . . . . . . . . . . . . . . . . . . . . . . . 3-15 DOOR OPENING SEALS . . . . . . . . . . . . . . . . 23-87 GRILLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-47
B-PILLAR TRIM . . . . . . . . . . . . . . . . . . . . . . 23-68 DOOR . . . . . . . . . . . . . . . . . . . . . . . . 23-14, 23-25 HCU (HYDRAULIC CONTROL UNIT) . . . . . . . 5-31
BACKLITE - BULKHEAD TRIM PANEL . . . . . 23-81 DRIVE BELTS . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 HEADLAMP LEVELING MOTOR . . . . . . . . . . 8L-16
BACKUP LAMP BULB . . . . . . . . . . . . . . . . . . 8L-5 DRIVER AIRBAG . . . . . . . . . . . . . . . . . . . . . 8O-16 HEADLAMP LEVELING SWITCH . . . . . . . . . 8L-17
BASECOAT/CLEARCOAT FINISH . . . . . . . . . . 23-74 DRIVER HEATED SEAT SWITCH . . . . . . . . . 8G-10 HEADLINER . . . . . . . . . . . . . . . . . . . . . . . . . 23-70
BATTERY CABLES . . . . . . . . . . . . . . . . . . . . 8F-14 ELECTRIC COOLANT PUMP . . . . . . . . . . . . . 24-42
BATTERY HOLDDOWN . . . . . . . . . . . . . . . . . 8F-13 ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . 5-29 HEADREST . . . . . . . . . . . . . . . . . . . . . . . . . . 23-76
BATTERY SYSTEM . . . . . . . . . . . . . . . . . . . . . 8F-1 ELECTROHYDRAULIC UNIT . . . . . . . . . . . . . 21-92 HEATED GLASS . . . . . . . . . . . . . . . . . . . . . . . 8G-1
BATTERY TRAY . . . . . . . . . . . . . . . . . . . . . . 8F-16 ENGINE BLOCK HEATER . . . . . . . . . . . . . . . . 7-14 HEATED MIRRORS . . . . . . . . . . . . . . . . . . . . 8G-8
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-6 ENGINE BLOCK . . . . . . . . . . . . . . . . . . . . . . . 9-34 HEATED SEAT ELEMENT . . . . . . . . . . . . . . . 8G-11
BELT TENSIONERS . . . . . . . . . . . . . . . . . . . . . 7-5 ENGINE CONTROL MODULE . . . . . . . . . . . . . 8E-3 HEATED SEAT RELAY . . . . . . . . . . . . . . . . . 8G-11
BLOWER MOTOR RESISTOR BLOCK . . . . . . 24-16 ENGINE COOLANT TEMP SENSOR . . . . . . . . 7-14 HEATED SEAT SENSOR . . . . . . . . . . . . . . . . 8G-12
BLOWER MOTOR SWITCH . . . . . . . . . . . . . 24-17 ENGINE COOLANT THERMOSTAT . . . . . . . . . 7-15 HEATED SEATS . . . . . . . . . . . . . . . . . . . . . . . 8G-9
BLOWER MOTOR . . . . . . . . . . . . . . . . . . . . 24-23 ENGINE CRADLE CROSSMEMBER . . . . . . . . 13-6
BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-1 ENGINE TEMPERATURE GAUGE . . . . . . . . . 8J-15 HEATER CORE . . . . . . . . . . . . . . . . . . . . . . . 24-43
BOOST PRESSURE SENSOR . . . . . . . . . . . . 14-27 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 HEATER UNIT . . . . . . . . . . . . . . . . . . . . . . . 24-55
BRAKE INDICATOR . . . . . . . . . . . . . . . . . . . 8J-12 ENTRY/EXIT LAMP BULB . . . . . . . . . . . . . . 8L-33 HEATING & AIR CONDITIONING . . . . . . . . . . 24-1
BRAKE LAMP SWITCH . . . . . . . . . . . . . . . . . 8L-6 ENTRY/EXIT LAMP UNIT . . . . . . . . . . . . . . . 8L-34 HIGH BEAM HEADLAMP BULB . . . . . . . . . . 8L-17
BRAKE LINES . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 ESP INDICATOR . . . . . . . . . . . . . . . . . . . . . . 8J-16 HIGH BEAM INDICATOR . . . . . . . . . . . . . . . 8J-18
BRAKE PADS/SHOES . . . . . . . . . . . . . . . . . . . . 5-9 EVAPORATOR TEMPERATURE SENSOR . . . 24-17 HINGE . . . . . . . . . . . . . . . . . . 23-17, 23-34, 23-50
BRAKE WEAR INDICATOR . . . . . . . . . . . . . . 8J-13 EXHAUST GAS RECIRCULATION . . . . . . . . . . 25-4 HOISTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-5
BRAKE/PARK LAMP BULB . . . . . . . . . . . . . . . 8L-7 EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . 9-61 HOLDING CLUTCH B1 . . . . . . . . . . . . . . . . 21-123
BRAKES - ABS . . . . . . . . . . . . . . . . . . . . . . . . 5-29 EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . . . 11-3
BRAKES - BASE . . . . . . . . . . . . . . . . . . . . . . . . 5-2 EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . 11-1 HOLDING CLUTCH B2 . . . . . . . . . . . . . . . . 21-127
BULKHEAD TRIM PANEL . . . . . . . . . . . . . . . 23-69 EXHAUST TUBE . . . . . . . . . . . . . . . . . . . . . . 24-52 HOLDING CLUTCHES . . . . . . . . . . . . . . . . . 21-121
BUMPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1 EXTERIOR HANDLE . . . . . . . 23-16, 23-32, 23-36 HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-50
CABIN HEATER . . . . . . . . . . . . . . . . . . . . . . 24-50 FAN DRIVE VISCOUS CLUTCH . . . . . . . . . . . 7-16 HORN SWITCH . . . . . . . . . . . . . . . . . . . . . . . 8H-1
CABLE TENSIONER . . . . . . . . . . . . . . . . . . . . 5-23 FASTENER IDENTIFICATION . . . . . . . . . . . Intro.-2 HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H-1
CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8P-2 FASTENER USAGE . . . . . . . . . . . . . . . . . . . Intro.-5 HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-15
CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24 FINESSE SANDING/BUFFING & POLISH . . . 23-75 HUB / BEARING . . . . . . . . . . . . . . . . . . . . . . . . 2-4
CAMSHAFT POSITION SENSOR . . . . . . . . . . 14-28 FLOOR DISTRIBUTION DUCTS . . . . . . . . . . 24-24 HVAC HOUSING . . . . . . . . . . . . . . . . . . . . . . 24-24
CAMSHAFT(S) . . . . . . . . . . . . . . . . . . . . . . . . 9-26 FLUID AND FILTER . . . . . . . . . . . . . . . . . . 21-112
CARGO LAMP SWITCH . . . . . . . . . . . . . . . . 8L-30 FLUID CAPACITIES . . . . . . . . . . . . . . . . . . . . . 0-4 HYDRAULIC/MECHANICAL . . . . . . . . . . . . . . . 5-5
CARGO/DOME LAMP BULB . . . . . . . . . . . . . 8L-29 FLUID COOLER TUBE . . . . . . . . . . . . . . . . . 19-14 IGNITION CONTROL . . . . . . . . . . . . . . . . . . . . 8I-1
CARGO/DOME LAMP UNIT . . . . . . . . . . . . . 8L-29 FLUID FILL/CHECK LOCATIONS . . . . . . . . . . . . 0-4 IN-CAR TEMPERATURE SENSOR . . . . . . . . 24-18
CARPETS AND FLOOR MATS . . . . . . . . . . . 23-69 FLUID RESERVOIR . . . . . . . . . . . . . . . . . . . . 5-15 INLET HOSE . . . . . . . . . . . . . . . . . . . . . . . . 24-56
CATALYTIC CONVERTER . . . . . . . . . . . . . . . . 11-3 FLUID TYPES . . . . . . . . . . . . . . . . . . . . . . . . . . 0-1 INPUT CLUTCH K1 . . . . . . . . . . . . . . . . . . . 21-81
CENTER BEARING . . . . . . . . . . . . . . . . . . . . . . 3-8 FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-39 INPUT CLUTCH K2 . . . . . . . . . . . . . . . . . . . 21-84
CENTER HIGH MOUNTED STOP LAMP FOG LAMP BULB . . . . . . . . . . . . . . . . . . . . . 8L-10 INPUT CLUTCH K3 . . . . . . . . . . . . . . . . . . . 21-88
BULB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-8 FOG LAMP RELAY . . . . . . . . . . . . . . . . . . . . 8L-11 INPUT CLUTCHES . . . . . . . . . . . . . . . . . . . . 21-79
CENTER HIGH MOUNTED STOP LAMP FOG LAMP SWITCH . . . . . . . . . . . . . . . . . . . 8L-12
UN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-8 FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-4 INPUT SPEED SENSORS . . . . . . . . . . . . . . 21-132
CENTER ROLLER ARM . . . . . . . . . . . . . . . . 23-37 FREEWHEELING CLUTCH . . . . . . . . . . . . . 21-116 INSIDE HANDLE ACTUATOR . . . . . . 23-34, 23-37
CENTER TRACK . . . . . . . . . . . . . . . . . . . . . . 23-38 FRONT BUMPER - STEPS . . . . . . . . . . . . . . . 13-2 INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . 8J-2
CENTRAL TIMER MODULE . . . . . . . . . . . . . . 8E-1 FRONT DOOR INNER BELT INSTRUMENT PANEL ANTENNA CABLE . . . . 8A-1
CHARGE AIR COOLER AND PLUMBING . . . . 11-4 WEATHERSTRIP . . . . . . . . . . . . . . . . . . . . . 23-87 INSTRUMENT PANEL ASSEMBLY . . . . . . . . 23-57
CHARGING INDICATOR . . . . . . . . . . . . . . . . 8J-13 FRONT DOOR OUTER BELT INSTRUMENT PANEL CENTER BEZEL . . . . . 23-55
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . 8F-17 WEATHERSTRIP . . . . . . . . . . . . . . . . . . . . . 23-87 INSTRUMENT PANEL DUCTS . . . . . . . . . . . 24-28
CHECK VALVE . . . . . . . . . . . . . . . . . . . . . . . 8R-11 FRONT FASCIA . . . . . . . . . . . . . . . . . . . . . . . 13-2 INTAKE AIR PRESSURE SENSOR . . . . . . . . 14-37
CHIME/BUZZER . . . . . . . . . . . . . . . . . . . . . . . 8B-1 FRONT LAMP UNIT . . . . . . . . . . . . . . . . . . . 8L-13 INTAKE AIR TEMPERATURE SENSOR . . . . . 14-36
2 INDEX VA
Description Group-Page Description Group-Page Description Group-Page
INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . 9-58 PROP ROD . . . . . . . . . . . . . . . . . . . . . . . . . 23-52 STARTING SYSTEM . . . . . . . . . . . . . . . . . . . 8F-24
INTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . 23-67 PROPELLER SHAFT . . . . . . . . . . . . . . . . . 3-1, 3-6 STEERING COLUMN OPENING COVER . . . . 23-66
INTERMEDIATE SHAFT . . . . . . . . . . . . . . . . . 19-5 STEERING WHEEL . . . . . . . . . . . . . . . . . . . . . 19-7
INTERNATIONAL SYMBOLS . . . . . . . . . . . . . . . 0-9 QUARTER TRIM PANEL . . . . . . . . . . . . . . . . 23-71 STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-1
INTERNATIONAL SYMBOLS . . . . . . . . . . . Intro.-2 QUARTER WINDOW . . . . . . . . . . . . . . . . . . 23-81 STEPWELL SCUFF PADS . . . . . . . . . . . . . . . 23-72
INTRUSION SENSOR . . . . . . . . . . . . . . . . . . . 8Q-2 RADIATOR CROSSMEMBER . . . . . . . . . . . . 23-47 STRUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
JUMP STARTING . . . . . . . . . . . . . . . . . . . . . . . 0-6 RADIATOR FAN . . . . . . . . . . . . . . . . . . . . . . . 7-13 SUCTION LINE . . . . . . . . . . . . . . . . . . . . . . . 24-48
KEY/LOCK CYLINDER . . . . . . . . . . . . . . . . . . 19-6 RADIATOR PRESSURE CAP . . . . . . . . . . . . . . 7-18 SUN VISOR . . . . . . . . . . . . . . . . . . . . . . . . . 23-73
KNUCKLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16 SUPPORT PLATE . . . . . . . . . . . . . . . . . . . . . . 5-22
LAMPS/LIGHTING - EXTERIOR . . . . . . . . . . . 8L-2 RADIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-2 SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8P-3
LAMPS/LIGHTING - INTERIOR . . . . . . . . . . 8L-27 RAIN SENSOR CONTROL MODULE . . . . . . 8R-14 TACHOMETER . . . . . . . . . . . . . . . . . . . . . . . 8J-25
LATCH / LOCK CONTROL . . . . . . . . . . . . . . 23-39 RAIN SENSOR . . . . . . . . . . . . . . . . . . . . . . . 8R-11 TAIL LAMP UNIT . . . . . . . . . . . . . . . . . . . . . 8L-24
LATCH RELEASE CABLE . . . . . . . . . . . . . . . 23-51 REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 TAILPIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
LATCH RELEASE HANDLE . . . . . . . . . . . . . . 23-52 REAR BUMPER - STEP . . . . . . . . . . . . . . . . . 13-3 TEMPERATURE SENSOR/PARK-NEUTRAL
LATCH STRIKER . . . . . . . . . . . . . . . . . . . . . 23-18 REAR CROSSMEMBER - TRANSMISSION . . . 13-9 CONTACT . . . . . . . . . . . . . . . . . . . . . . . . . . 21-153
LATCH . . . . . . . . . . . . . . . . . . 23-18, 23-34, 23-51 REAR FASCIA . . . . . . . . . . . . . . . . . . . . . . . . 13-3 TERMINAL . . . . . . . . . . . . . . . . . . . . . . . 8W-01-10
LEFT MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . 9-49 REAR LATCH STRIKER . . . . . . . . . . . . . . . . 23-41 THREADED HOLE REPAIR . . . . . . . . . . . . . Intro.-5
LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 REAR LATCH . . . . . . . . . . . . . . . . . . . . . . . . 23-40 TIE ROD END . . . . . . . . . . . . . . . . . . . . . . . . 19-11
LICENSE PLATE BRACKET . . . . . . . . . . . . . . 23-47 REAR SEAT BACK SHIELD . . . . . . . . . . . . . . 23-79 TIME DELAY RELAY . . . . . . . . . . . . . . . . . . . 8L-34
LICENSE PLATE LAMP BULB . . . . . . . . . . . 8L-18 REAR SEAT BELT & RETRACTOR . . . . . . . . 8O-26 TIMING CHAIN AND SPROCKETS . . . . . . . . . 9-64
LICENSE PLATE LAMP UNIT . . . . . . . . . . . . 8L-19 REAR SEAT BELT BUCKLE . . . . . . . . . . . . . 8O-28 TIMING CHAIN COVER . . . . . . . . . . . . . . . . . 9-62
LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-10 REAR SIDE MARKER LAMP BULB . . . . . . . 8L-21 TIMING CHAIN TENSIONER . . . . . . . . . . . . . . 9-73
LIQUID LINE . . . . . . . . . . . . . . . . . . . . . . . . 24-44 REAR TURN LAMP BULB . . . . . . . . . . . . . . 8L-22 TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-6
LOCK CYLINDER . . . . . . . . . . . . . . . . . . . . . 23-18 REAR VIEW MIRROR . . . . . . . . . . . . . . . . . 23-72 TIRES/WHEELS . . . . . . . . . . . . . . . . . . . . . . . 22-1
LOW BEAM HEADLAMP BULB . . . . . . . . . . 8L-19 REAR WHEEL SPEED SENSOR . . . . . . . . . . . 5-30 TONE WHEEL . . . . . . . . . . . . . . . . . . . . . . . . 5-31
LOW FUEL INDICATOR . . . . . . . . . . . . . . . . 8J-19 REAR WINDOW DEFOGGER GRID . . . . . . . . 8G-6 TOP COVER - CLUSTER . . . . . . . . . . . . . . . . . 23-62
LOW OIL LEVEL INDICATOR . . . . . . . . . . . . 8J-19 REAR WINDOW DEFOGGER RELAY . . . . . . . 8G-3 TOP COVER - TRAY . . . . . . . . . . . . . . . . . . . 23-63
LOWER BALL JOINT . . . . . . . . . . . . . . . . . . . . 2-6 REAR WINDOW DEFOGGER SWITCH . . . . . . 8G-4 TOP COVER . . . . . . . . . . . . . . . . . . . . . . . . . 23-64
LOWER CONTROL ARM . . . . . . . . . . . . . . . . . 2-7 TORQUE CONVERTER HUB SEAL . . . . . . . 21-161
LOWER ROLLER ARM . . . . . . . . . . . . . . . . . 23-38 RECEIVER/DRIER . . . . . . . . . . . . . . . . . . . . . 24-46 TORQUE CONVERTER . . . . . . . . . . . . . . . . 21-155
MAINTENANCE INDICATOR . . . . . . . . . . . . . 8J-20 RECIRCULATION DOOR ACTUATOR . . . . . . 24-20 TORQUE REFERENCES . . . . . . . . . . . . . . . Intro.-7
MAINTENANCE SCHEDULES . . . . . . . . . . . . . . 0-7 REFRIGERANT OIL . . . . . . . . . . . . . . . . . . . 24-47 TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-6
MALFUNCTION INDICATOR LAMP (MIL) . . . 8J-21 REFRIGERANT . . . . . . . . . . . . . . . . . . . . . . . 24-47 TRACTION CONTROL INDICATOR . . . . . . . . 8J-26
MANIFOLD AIR FLOW (MAF) SENSOR . . . . 14-37 RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-97-4 TRACTION CONTROL MALFUNCTION
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . 5-16 REMOTE KEYLESS ENTRY INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . 8J-26
MASTER LOCK SWITCH . . . . . . . . . . . . . . . . 8N-1 TRANSMITTER . . . . . . . . . . . . . . . . . . . . . . . 8N-1 TRAILER HITCH . . . . . . . . . . . . . . . . . . . . . . . 13-9
METRIC SYSTEM . . . . . . . . . . . . . . . . . . . Intro.-5 REPEATER LAMP BULB . . . . . . . . . . . . . . . . 8L-23 TRANSMISSION CONTROL MODULE . . . . . . 8E-6
MODE DOOR CABLES . . . . . . . . . . . . . . . . . 24-19 REPEATER LAMP UNIT . . . . . . . . . . . . . . . . 8L-23 TRANSPONDER KEY . . . . . . . . . . . . . . . . . . . 8Q-4
MULTI-FUNCTION INDICATOR . . . . . . . . . . . 8J-21 RESTRAINTS . . . . . . . . . . . . . . . . . . . . . . . . . 8O-1 TRIM PANEL . . . . . . . . . . . . . 23-19, 23-35, 23-46
MULTI-FUNCTION SWITCH . . . . . . . . . . . . . 8L-20 RIGHT MOUNT . . . . . . . . . . . . . . . . . . . . . . . 9-50 TURBOCHARGER SYSTEM . . . . . . . . . . . . . . 11-3
O2 SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . 14-39 ROTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . 11-6
ODOMETER . . . . . . . . . . . . . . . . . . . . . . . . . 8J-22 SAFETY LATCH . . . . . . . . . . . . . . . . . . . . . . 23-52 TURN SIGNAL INDICATOR . . . . . . . . . . . . . . 8J-27
OIL COOLER & LINES . . . . . . . . . . . . . . . . . . 9-50 SEAT - FRONT . . . . . . . . . . . . . . . . . . . . . . . 23-77 TURN SIGNAL RELAY . . . . . . . . . . . . . . . . . 8L-25
OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . 9-51 SEAT - REAR . . . . . . . . . . . . . . . . . . . . . . . . 23-79 UPPER ROLLER ARM . . . . . . . . . . . . . . . . . 23-37
OIL JET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-52 SEAT ADJUSTERS - FRONT . . . . . . . . . . . . . 23-78 VACUUM PUMP . . . . . . . . . . . . . . . . . . . . . . . 9-48
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-53 SEAT BACK - FRONT . . . . . . . . . . . . . . . . . . 23-77 VALVE COOLER . . . . . . . . . . . . . . . . . . . . . . . 25-7
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-55 SEAT BACK CUSHION/COVER - REAR . . . . . 23-80 VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . 9-31
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . 21-133 SEAT BELT SWITCH . . . . . . . . . . . . . . . . . . 8O-30 VALVE STEM SEALS . . . . . . . . . . . . . . . . . . . 9-31
OIL SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . 9-58 SEAT BELT TENSIONER . . . . . . . . . . . . . . . . 8O-30
OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-50 SEAT BELT TURNING LOOP ADJUSTER . . . 8O-32 VEHICLE IDENTIFICATION NUMBER . . . . . Intro.-1
OPENING DIMENSIONS . . . . . . . . . . . . . . . . 23-90 SEAT CUSHION - FRONT . . . . . . . . . . . . . . . 23-78 VEHICLE THEFT SECURITY . . . . . . . . . . . . . . 8Q-1
OUTPUT SHAFT BEARING . . . . . . . . . . . . . 21-134 SEAT CUSHION/COVER - REAR . . . . . . . . . . 23-80 VIBRATION DAMPER . . . . . . . . . . . . . . . . . . . 9-47
OUTPUT SHAFT SEAL . . . . . . . . . . . . . . . . 21-137 SEATBELT INDICATOR . . . . . . . . . . . . . . . . . 8J-24 VOLTAGE REGULATOR . . . . . . . . . . . . . . . . . 8F-23
PAINT TOUCH-UP . . . . . . . . . . . . . . . . . . . . 23-74 SECURITY SYSTEM MODULE . . . . . . . . . . . . 8Q-2 WAIT-TO-START INDICATOR . . . . . . . . . . . . 8J-28
PAINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-74 SENTRY KEY REMOTE ENTRY MODULE . . . . 8Q-2 WASHER FLUID INDICATOR . . . . . . . . . . . . 8J-29
PARK BRAKE INDICATOR . . . . . . . . . . . . . . 8J-23 SERVO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8P-2 WASHER FLUID LEVEL SWITCH . . . . . . . . . 8R-16
PARK BRAKE SWITCH . . . . . . . . . . . . . . . . . 8L-21 SHIFT MECHANISM . . . . . . . . . . . . . . . . . . 21-145 WASHER HOSES/TUBES . . . . . . . . . . . . . . . 8R-17
PARK LOCK CABLE . . . . . . . . . . . . . . . . . . 21-138 SHOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 WASHER NOZZLE . . . . . . . . . . . . . . . . . . . . 8R-18
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . 5-22 SHOES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 WASHER PUMP/MOTOR . . . . . . . . . . . . . . . 8R-18
PARTS & LUBRICANT SIDE CURTAIN AIRBAG . . . . . . . . . . . . . . . . 8O-33 WASHER RESERVOIR . . . . . . . . . . . . . . . . . 8R-20
RECOMMENDATION . . . . . . . . . . . . . . . . . . . . 0-5 SIDE IMPACT SENSOR . . . . . . . . . . . . . . . . 8O-37 WATER IN FUEL SENSOR . . . . . . . . . . . . . . 14-25
PASSENGER AIRBAG BRACKET . . . . . . . . . 8O-26 SIDE VIEW MIRROR - GLASS . . . . . . . . . . . 23-49 WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . 7-19
PASSENGER AIRBAG . . . . . . . . . . . . . . . . . 8O-22 SIDE VIEW MIRROR . . . . . . . . . . . . . . . . . . 23-48 WATER VALVE . . . . . . . . . . . . . . . . . . . . . . . 24-49
PASSENGER HEATED SEAT SWITCH . . . . . 8G-12 SIREN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-4 WATER-IN-FUEL INDICATOR . . . . . . . . . . . . 8J-29
PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 SLIDING DOOR . . . . . . . . . . . . . . . . . . . . . . 23-41 WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . 2-16
PINION SEAL . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . 21-149 WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-11
PISTON & CONNECTING ROD . . . . . . . . . . . . 9-41 SPARE TIRE CARRIER . . . . . . . . . . . . . . . . . 22-10 WINDOW MOTOR . . . . . . . . . . . . . . . . . . . . . 8N-5
PISTON RINGS . . . . . . . . . . . . . . . . . . . . . . . 9-46 SPEAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-2 WINDOW REGULATOR - MANUAL . . . . . . . 23-22
PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . 21-141 SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . 8P-1 WINDOW REGULATOR - POWER . . . . . . . . 23-20
PLANETARY GEARTRAIN . . . . . . . . . . . . . . 21-143 SPEEDOMETER . . . . . . . . . . . . . . . . . . . . . . 8J-24 WINDSHIELD . . . . . . . . . . . . . . . . . . . . . . . . 23-82
SPRING CLAMP PLATES . . . . . . . . . . . . . . . . . 2-9 WIPER ARM . . . . . . . . . . . . . . . . . . . . . . . . 8R-22
POWER BRAKE BOOSTER . . . . . . . . . . . . . . . 5-19 SPRING SHACKLE . . . . . . . . . . . . . . . . . . . . . 2-15 WIPER BLADE . . . . . . . . . . . . . . . . . . . . . . . 8R-24
POWER DISTRIBUTION CENTER . . . . . . . 8W-97-3 SPRING STOP PLATES . . . . . . . . . . . . . . . . . . 2-9 WIPER LINKAGE . . . . . . . . . . . . . . . . . . . . . 8R-25
POWER DISTRIBUTION . . . . . . . . . . . . . . 8W-97-1 SPRING . . . . . . . . . . . . . . . . . . . . . . . . . 2-8, 2-13 WIPER MOTOR . . . . . . . . . . . . . . . . . . . . . . 8R-28
POWER MIRROR SWITCH . . . . . . . . . . . . . . 8N-3 STABILIZER BAR . . . . . . . . . . . . . . . . . . 2-9, 2-15 WIPER RELAY . . . . . . . . . . . . . . . . . . . . . . . 8R-29
POWER MIRRORS . . . . . . . . . . . . . . . . . . . . 8N-3 STABILIZER LINK . . . . . . . . . . . . . . . . . 2-10, 2-15 WIPERS/WASHERS . . . . . . . . . . . . . . . . . . . . 8R-1
POWER OUTLET . . . . . . . . . . . . . . . . . . . 8W-97-3 STABILIZER . . . . . . . . . . . . . . . . . . . . . . . . . 23-45 WIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-01-11
POWER WINDOW SWITCH . . . . . . . . . . . . . . 8N-5 STARTER MOTOR RELAY . . . . . . . . . . . . . . 8F-30 WIRING DIAGRAM INFORMATION . . . . . 8W-01-1
POWER WINDOWS . . . . . . . . . . . . . . . . . . . . 8N-5 STARTER MOTOR . . . . . . . . . . . . . . . . . . . . 8F-29
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