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GROUP TAB LOCATOR

Introduction

0 Lubrication & Maintenance

2 Suspension

3 Differential & Driveline

5 Brakes

7 Cooling

8A Audio/Video

8B Chime/Buzzer

8E Electronic Control Modules

8F Engine Systems

8G Heated Systems

8H Horn

8I Ignition Control

8J Instrument Cluster

8L Lamps

8N Power Systems

8O Restraints

8P Speed Control

8Q Vehicle Theft Security

8R Wipers/Washers

8W Wiring

9 Engine

11 Exhaust System

13 Frame & Bumpers

14 Fuel System

19 Steering

21 Transmission

22 Tires/Wheels

23 Body

24 Heating & Air Conditioning

25 Emissions Control

Component and System Index

Service Manual Comment Forms (Rear of Manual)


VA INTRODUCTION 1

INTRODUCTION
TABLE OF CONTENTS

page page

VEHICLE IDENTIFICATION NUMBER THREADED HOLE REPAIR


DESCRIPTION . . . . . . . . . . . . . . . . ..........1 DESCRIPTION - THREADED HOLE REPAIR . . . . 5
INTERNATIONAL SYMBOLS METRIC SYSTEM
DESCRIPTION . . . . . . . . . . . . . . . . ..........2 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FASTENER IDENTIFICATION TORQUE REFERENCES
DESCRIPTION . . . . . . . . . . . . . . . . ..........2 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FASTENER USAGE
DESCRIPTION - FASTENER USAGE .........5

VEHICLE IDENTIFICATION To protect the consumer from theft and possible


fraud the manufacturer is required to include a
NUMBER Check Digit at the ninth position of the Vehicle Iden-
tification Number. The check digit is used by the
DESCRIPTION manufacturer and government agencies to verify the
The Vehicle Identification Number (VIN) plate is authenticity of the vehicle and official documenta-
located on the lower windshield fence next to the left tion. The formula to use the check digit is not
a-pillar. The VIN contains 17 characters that provide released to the general public.
data concerning the vehicle. Refer to the VIN
DECODING INFORMATION table to determine the
identification of a vehicle.

VIN DECODING INFORMATION

POSITION INTERPRETATION CODE = DESCRIPTION


WD2 = Truck
1, 2 & 3 World Manufacturer Code
WD5 = Multi-purpose vehicle
Y = Truck
4 Model
W = Multi-purpose vehicle
D1 = Sprinter, 3000 mm (118 in.) wheelbase, 8,001 up to 9,000 lbs. class G
D2 = Sprinter, 3550 mm (140 in.) wheelbase, 8,001 up to 9,000 lbs. class G
D3 = Sprinter, 4025 mm (158 in.) wheelbase, 8,001 up to 9,000 lbs. class G
D4 = Sprinter, 3550 mm (140 in.) wheelbase, Van 10,001 up to 14,000 lbs.
Class 3
5&6 Model, Cab, Weight D5 = Sprinter, 4025 mm (158 in.) wheelbase, Van 10,001 up to 14,000 lbs.
Class 3
D6 = Sprinter, 3567 mm (140 in.) in connection with 169 wheels, Van 8,001 to
9,000 lbs. class G
D7 = Sprinter, 4042 mm (159 in.) in connection with 169 wheels, Van 8,001 to
9,000 lbs. class G
7&8 Engine 41 = 2.7L 5 cyl. Diesel
9 Check Digit
10 Model Year 3 = 2003
11 Assembly Plant 5 = Düsseldorf Plant, Germany
12 Thru 17 Vehicle Build Sequence
2 INTRODUCTION VA

INTERNATIONAL SYMBOLS the bolt strength. Identification is determined by the


line marks on the top of each bolt head. The actual
bolt strength grade corresponds to the number of line
DESCRIPTION
marks plus 2. The most commonly used metric bolt
The graphic symbols illustrated in the following
strength classes are 9.8 and 10.9. The metric
International Control and Display Symbols Chart
strength class identification number is imprinted on
(Fig. 1) are used to identify various instrument con-
the head of the bolt. The higher the class number,
trols. The symbols correspond to the controls and dis-
the greater the bolt strength. Some metric nuts are
plays that are located on the instrument panel.
imprinted with a single-digit strength class on the
nut face. Refer to the Fastener Identification and
FASTENER IDENTIFICATION Fastener Strength Charts (Fig. 2) and (Fig. 3).

DESCRIPTION
The SAE bolt strength grades range from grade 2
to grade 8. The higher the grade number, the greater

Fig. 1 INTERNATIONAL CONTROL AND DISPLAY SYMBOLS


1 High Beam 13 Rear Window Washer
2 Fog Lamps 14 Fuel
3 Headlamp, Parking Lamps, Panel Lamps 15 Engine Coolant Temperature
4 Turn Warning 16 Battery Charging Condition
5 Hazard Warning 17 Engine Oil
6 Windshield Washer 18 Seat Belt
7 Windshield Wiper 19 Brake Failure
8 Windshield Wiper and Washer 20 Parking Brake
9 Windscreen Demisting and Defrosting 21 Front Hood
10 Ventilating Fan 22 Rear hood (Decklid)
11 Rear Window Defogger 23 Horn
12 Rear Window Wiper 24 Lighter
VA INTRODUCTION 3
FASTENER IDENTIFICATION (Continued)

Fig. 2 FASTENER IDENTIFICATION


4 INTRODUCTION VA
FASTENER IDENTIFICATION (Continued)

Fig. 3 FASTENER STRENGTH


VA INTRODUCTION 5

FASTENER USAGE THREADED HOLE REPAIR


DESCRIPTION - FASTENER USAGE DESCRIPTION - THREADED HOLE REPAIR
Most stripped threaded holes can be repaired using
WARNING: USE OF AN INCORRECT FASTENER a Helicoilt. Follow the vehicle or Helicoilt recommen-
MAY RESULT IN COMPONENT DAMAGE OR PER- dations for application and repair procedures.
SONAL INJURY.

Fasteners and torque specifications references in METRIC SYSTEM


this Service Manual are identified in metric and SAE
format. DESCRIPTION
During any maintenance or repair procedures, it is The metric system is based on quantities of one,
important to salvage all fasteners (nuts, bolts, etc.) ten, one hundred, one thousand and one million.
for reassembly. If the fastener is not salvageable, a The following chart will assist in converting metric
fastener of equivalent specification must be used. units to equivalent English and SAE units, or vise
versa.

CONVERSION FORMULAS AND EQUIVALENT VALUES

MULTIPLY BY TO GET MULTIPLY BY TO GET


in-lbs x 0.11298 = Newton Meters N·m x 8.851 = in-lbs
(N·m)
ft-lbs x 1.3558 = Newton Meters N·m x 0.7376 = ft-lbs
(N·m)
Inches Hg x 3.377 = Kilopascals (kPa) kPa x 0.2961 = Inches Hg
(60° F)
psi x 6.895 = Kilopascals (kPa) kPa x 0.145 = psi
Inches x 25.4 = Millimeters (mm) mm x 0.03937 = Inches
Feet x 0.3048 = Meters (M) M x 3.281 = Feet
Yards x 0.9144 = Meters M x 1.0936 = Yards
mph x 1.6093 = Kilometers/Hr. Km/h x 0.6214 = mph
(Km/h)
Feet/Sec x 0.3048 = Meters/Sec (M/S) M/S x 3.281 = Feet/Sec
mph x 0.4470 = Meters/Sec (M/S) M/S x 2.237 = mph
Kilometers/ x 0.27778 = Meters/Sec (M/S) M/S x 3.600 Kilometers/Hr.
Hr. (Km/h) (Km/h)

COMMON METRIC EQUIVALENTS

1 inch = 25 Millimeters 1 Cubic Inch = 16 Cubic Centimeters


1 Foot = 0.3 Meter 1 Cubic Foot = 0.03 Cubic Meter
1 Yard = 0.9 Meter 1 Cubic Yard = 0.8 Cubic Meter
1 Mile = 1.6 Kilometers

Refer to the 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)

Fig. 4 METRIC CONVERSION CHART


VA INTRODUCTION 7

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-

Fig. 5 TORQUE SPECIFICATIONS


VA LUBRICATION & MAINTENANCE 0-1

LUBRICATION & MAINTENANCE


TABLE OF CONTENTS

page page

FLUID TYPES FLUID FILL/CHECK LOCATIONS


DESCRIPTION INSPECTION - FLUID FILL/CHECK
DESCRIPTION - FUEL REQUIREMENTS - LOCATIONS ....................... ...4
DIESEL ENGINE . . . . . . . . . . . . . . . . . . . . . . .1 PARTS & LUBRICANT RECOMMENDATION
DESCRIPTION - ENGINE COOLANT . . . . . . . .1 STANDARD PROCEDURE - PARTS &
DESCRIPTION - HOAT COOLANT . . . . . . . . . .2 LUBRICANT RECOMMENDATIONS . . . . . . ...5
DESCRIPTION - AXLE . . . . . . . . . . . . . . . . . . .3 HOISTING
DESCRIPTION - BRAKE FLUID . . . . . . . . . . . .3 STANDARD PROCEDURE - HOISTING . . . . . ...5
DESCRIPTION - POWER STEERING FLUID . .3 JUMP STARTING
DESCRIPTION - ENGINE OIL - DIESEL STANDARD PROCEDURE - JUMP STARTING ..6
ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . ...3 TOWING
DESCRIPTION - AUTOMATIC STANDARD PROCEDURE - TOWING . . . . . . ...6
TRANSMISSION FLUID - NAG1 . . . . . . . . . ...4 MAINTENANCE SCHEDULES
OPERATION - AUTOMATIC TRANSMISSION DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . ...7
FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...4 INTERNATIONAL SYMBOLS
FLUID CAPACITIES DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . ...9
SPECIFICATIONS - FLUID CAPACITIES . . . . ...4

FLUID TYPES low the cold-weather advice above, fuel conditioners


should not be required in your vehicle. If available in
your area, a high cetane “premium” diesel fuel may
DESCRIPTION offer improved cold starting and warm-up perfor-
mance.
DESCRIPTION - FUEL REQUIREMENTS -
DIESEL ENGINE DESCRIPTION - ENGINE COOLANT

DESCRIPTION ETHYLENE-GLYCOL MIXTURES

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.

DESCRIPTION - HOAT COOLANT COOLANT PERFORMANCE


WARNING: ANTIFREEZE IS AN ETHYLENE-GLYCOL The required ethylene-glycol (antifreeze) and water
BASE COOLANT AND IS HARMFUL IF SWAL- mixture depends upon climate and vehicle operating
LOWED OR INHALED. IF SWALLOWED, DRINK conditions. The coolant performance of various mix-
TWO GLASSES OF WATER AND INDUCE VOMIT- tures follows:
ING. IF INHALED, MOVE TO FRESH AIR AREA. Pure Water-Water can absorb more heat than a
SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT mixture of water and ethylene-glycol. This is for pur-
STORE IN OPEN OR UNMARKED CONTAINERS. pose of heat transfer only. Water also freezes at a
higher temperature and allows corrosion.
WASH SKIN AND CLOTHING THOROUGHLY AFTER
COMING IN CONTACT WITH ETHYLENE-GLYCOL. 100 percent Ethylene-Glycol-The corrosion
KEEP OUT OF REACH OF CHILDREN. DISPOSE OF inhibiting additives in ethylene-glycol need the pres-
GLYCOL BASE COOLANT PROPERLY, CONTACT ence of water to dissolve. Without water, additives
YOUR DEALER OR GOVERNMENT AGENCY FOR form deposits in system. These act as insulation
LOCATION OF COLLECTION CENTER IN YOUR causing temperature to rise. The increased tempera-
AREA. DO NOT OPEN A COOLING SYSTEM WHEN ture can result in engine detonation. In addition, 100
THE ENGINE IS AT OPERATING TEMPERATURE OR percent ethylene-glycol freezes at -22°C (-8°F).
HOT UNDER PRESSURE, PERSONAL INJURY CAN 50/50 Ethylene-Glycol and Water-Is the recom-
RESULT. AVOID RADIATOR COOLING FAN WHEN mended mixture, it provides protection against freez-
ENGINE COMPARTMENT RELATED SERVICE IS ing to -37°C (-34°F). The antifreeze concentration
PERFORMED, PERSONAL INJURY CAN RESULT. must always be a minimum of 44 percent, year-
round in all climates. If percentage is lower, engine
parts may be eroded by cavitation. Maximum protec-
tion against freezing is provided with a 68 percent
antifreeze concentration, which prevents freezing
VA LUBRICATION & MAINTENANCE 0-3
FLUID TYPES (Continued)
down to -67.7°C (-90°F). A higher percentage will DESCRIPTION - ENGINE OIL - DIESEL
freeze at a warmer temperature. Also, a higher per-
ENGINES
centage of antifreeze can cause the engine to over-
heat because specific heat of antifreeze is lower than
SAE VISCOSITY GRADE
that of water.
CAUTION: Low viscosity oils must have the proper
CAUTION: Richer antifreeze mixtures cannot be
API quality.
measured with normal field equipment and can
cause problems associated with 100 percent ethyl- The engine manufacturer strongly recommends the
ene-glycol. use of synthetic engine oils, such as Mobilt 1 SAE
0W-40.
We strongly recommend engine oils that meet the
COOLANT SELECTION AND ADDITIVES
requirements of the API Service Category CI-4 and
The use of aluminum cylinder blocks, cylinder
meet the requirements of Material Standard
heads and water pumps requires special corrosion
MS-6395. Use Mopar or an equivalent oil meeting
protection. Only Mopart Antifreeze/Coolant, 5
the specification MS-6395.
Year/100,000 Mile Formula (glycol base coolant with
Do not add any materials (other than leak detec-
corrosion inhibitors called HOAT, for Hybrid Organic
tion dyes) to the engine oil. Engine oil is an engi-
Additive Technology) is recommended. This coolant
neered product and it’s performance may be impaired
offers the best engine cooling without corrosion when
by supplemental additives.
mixed with 50% distilled water to obtain to obtain a
When topping off engine oil, only use oil of the
freeze point of -37°C (-34°F). If it loses color or
same quality grade and SAE classification.
becomes contaminated, drain, flush, and replace with
The SAE class (viscosity) should be selected in
fresh properly mixed coolant solution.
accordance with the average air temperature for the
CAUTION: Do not use coolant additives that are season of the year.
claimed to improve engine cooling. The temperature limits given for the different SAE
classes should be regarded as guidelines which may
be exceeded temporarily to avoid excessively frequent
DESCRIPTION - AXLE engine oil changes.

NOTE: DaimlerChrysler recommends MoparT lubri-


cant or lubricant conforming to MS-8985.

REAR AXLE
• Synthetic Gear & Axle Lubricant SAE 75W-140

DESCRIPTION - BRAKE FLUID


NOTE: DaimlerChrysler recommends using DOT- 4
or equivalent brake fluid.

BRAKE FLUID
• DOT-4 or equivalent brake fluid.

DESCRIPTION - POWER STEERING FLUID


NOTE: DaimlerChrysler recommends using Mopar
ATF+4 Automatic Transmission fluid or equivalent.

POWER STEERING FLUID OIL VISCOSITY CHART


• Mopar ATF+4 Automatic Transmission fluid or
equivalent.
0-4 LUBRICATION & MAINTENANCE VA
FLUID TYPES (Continued)
Full synthetic oils, such as Mobilt 1 0W-40, is transmission operation and shift feel will remain con-
required if the ASSYST Oil Service Reminder is fol- sistent. Transmission fluid must also be a good con-
lowed. Use of a lower quality oil on this service ductor of heat. The fluid must absorb heat from the
schedule may cause severe engine damage. internal transmission components and transfer that
heat to the transmission case.
DESCRIPTION - AUTOMATIC TRANSMISSION
FLUID - NAG1 FLUID CAPACITIES
NOTE: Refer to Service Procedures in this group for
fluid level checking procedures. SPECIFICATIONS - FLUID CAPACITIES
Shellt 3403 Automatic Transmission Fluid is the DESCRIPTION SPECIFICATION
recommended fluid for the NAG1 DaimlerChrysler
automatic transmission. ENGINE COOLANT
Dexron II fluid IS NOT recommended. Clutch 10 Liters 10.5 Quarts
chatter can result from the use of improper ENGINE OIL
fluid.
9.0L with Filter 9.5 Quarts with Filter
Mopart ATF+4, Automatic Transmission Fluid, or
Replacement Replacement
other fluids meeting MS-9602, may be used if Shellt
3403 Automatic Transmission Fluid is not available. AUTOMATIC TRANSMISSION
Shellt 3403 Automatic Transmission Fluid when Service Fill - NAG1 5.0 L (10.6 pts.)
new is red in color. The ATF is dyed red so it can be O-haul Fill - NAG1 7.7 L (16.3 pts.)
identified from other fluids used in the vehicle such
as engine oil or antifreeze. The red color is not per- Dry fill capacity Depending on type and size of
manent and is not an indicator of fluid condition. As internal cooler, length and inside diameter of cooler
the vehicle is driven, the ATF will begin to look lines, or use of an auxiliary cooler, these figures may
darker in color and may eventually become brown. vary. (Refer to appropriate 21 - TRANSMISSION/
This is normal. AUTOMATIC/FLUID - STANDARD PROCEDURE).
REAR AXLE ± .03L (1 oz.)
FLUID ADDITIVES 8 1/2 1.8 L (4.0 pts.)
DaimlerChrysler strongly recommends against the
FUEL TANK
addition of any fluids to the transmission, other than
those automatic transmission fluids listed above. Primary 100 L (26.4 gal.)*
Exceptions to this policy are the use of special dyes Reserve 10.5 L (2.8 gal.)*
to aid in detecting fluid leaks. *Nominal refill capacities are shown. A variation may
Various “special” additives and supplements exist be observed from vehicle to vehicle due to
that claim to improve shift feel and/or quality. These manufacturing tolerance and refill procedure
additives and others also claim to improve converter
clutch operation and inhibit overheating, oxidation, POWER STEERING SYSTEM
varnish, and sludge. These claims have not been sup- Power steering fluid capacities are dependent on
ported to the satisfaction of DaimlerChrysler and engine/chassis options as well as steering gear/cooler
these additives must not be used. The use of trans- options. Depending on type and size of internal
mission “sealers” should also be avoided, since they cooler, length and inside diameter of cooler lines, or
may adversely affect the integrity of transmission use of an auxiliary cooler, these capacities may vary.
seals. Refer to 19, Steering for proper fill and bleed
procedures.
OPERATION - AUTOMATIC TRANSMISSION
FLUID
The automatic transmission fluid is selected based
FLUID FILL/CHECK
upon several qualities. The fluid must provide a high LOCATIONS
level of protection for the internal components by
providing a lubricating film between adjacent metal INSPECTION - FLUID FILL/CHECK LOCATIONS
components. The fluid must also be thermally stable The fluid fill/check locations and lubrication points
so that it can maintain a consistent viscosity through are located in each applicable group.
a large temperature range. If the viscosity stays con-
stant through the temperature range of operation,
VA LUBRICATION & MAINTENANCE 0-5

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.

NOTE: When a frame-contact type hoist is used,


verify that the lifting pads are positioned properly.
The forward lifting pads should be positioned
against the forward flange of the transmission
crossmember brackets at the bottom of the frame
rail. The real lifting pads should be wedged
Fig. 1 NLGI Symbol between the forward flange of the leaf spring
1 - WHEEL BEARINGS bracket and the frame rail. Safety stands should be
2 - CHASSIS LUBRICATION placed under the frame rails at the front and rear
3 - CHASSIS AND WHEEL BEARINGS
ends (Fig. 2).
When service is required, DaimlerChrysler Corpo-
ration recommends that only Mopart brand parts,
lubricants and chemicals be used. Mopar provides
the best engineered products for servicing
DaimlerChrysler Corporation vehicles.

HOISTING
STANDARD PROCEDURE - HOISTING
Refer to the Owner’s Manual for emergency vehicle
lifting procedures.

WARNING: THE HOISTING AND JACK LIFTING


POINTS PROVIDED ARE FOR A COMPLETE VEHI-
CLE. WHEN A CHASSIS OR DRIVETRAIN COMPO-
NENT IS REMOVED FROM A VEHICLE, THE
CENTER OF GRAVITY IS ALTERED MAKING SOME
HOISTING CONDITIONS UNSTABLE. PROPERLY
SUPPORT OR SECURE VEHICLE TO HOISTING
DEVICE WHEN THESE CONDITIONS EXIST.

FLOOR JACK Fig. 2 HOIST LOCATIONS


When properly positioned, a floor jack can be used 1 - TRANSMISSION CROSSMEMBER SUPPORT
2 - REAR LEAF SPRING MOUNT - FRONT
to lift a vehicle. Support the vehicle in the raised 3 - TRANSMISSION CROSSMEMBER
0-6 LUBRICATION & MAINTENANCE VA

JUMP STARTING (3) On disabled vehicle, place gear selector in park


or neutral and set park brake. Turn off all accesso-
ries.
STANDARD PROCEDURE - JUMP STARTING
(4) Connect jumper cables to booster battery. RED
WARNING: REVIEW ALL SAFETY PRECAUTIONS clamp to positive terminal (+). BLACK clamp to neg-
AND WARNINGS IN THE BATTERY SYSTEM SEC- ative terminal (-). DO NOT allow clamps at opposite
TION OF THE SERVICE MANUAL. (Refer to 8 - end of cables to touch, electrical arc will result.
ELECTRICAL/BATTERY SYSTEM/BATTERY - STAN- Review all warnings in this procedure.
DARD PROCEDURE) (5) On disabled vehicle, connect RED jumper cable
• DO NOT JUMP START A FROZEN BATTERY, clamp to positive (+) terminal. Connect BLACK
PERSONAL INJURY CAN RESULT. jumper cable clamp to engine ground as close to the
• IF EQUIPPED, DO NOT JUMP START WHEN ground cable attaching point as possible.
MAINTENANCE FREE BATTERY INDICATOR DOT IS (6) Start the engine in the vehicle which has the
YELLOW OR BRIGHT COLOR. booster battery, let the engine idle a few minutes,
• DO NOT JUMP START A VEHICLE WHEN THE then start the engine in the vehicle with the dis-
BATTERY FLUID IS BELOW THE TOP OF LEAD charged battery.
PLATES.
CAUTION: Do not crank starter motor on disabled
• DO NOT ALLOW JUMPER CABLE CLAMPS TO
vehicle for more than 15 seconds, starter will over-
TOUCH EACH OTHER WHEN CONNECTED TO A
heat and could fail.
BOOSTER SOURCE.
• DO NOT USE OPEN FLAME NEAR BATTERY. (7) Allow battery in disabled vehicle to charge to
• REMOVE METALLIC JEWELRY WORN ON at least 12.4 volts (75% charge) before attempting to
HANDS OR WRISTS TO AVOID INJURY BY ACCI- start engine. If engine does not start within 15 sec-
DENTAL ARCING OF BATTERY CURRENT. onds, stop cranking engine and allow starter to cool
• WHEN USING A HIGH OUTPUT BOOSTING (15 min.), before cranking again.
DEVICE, DO NOT ALLOW BATTERY VOLTAGE TO
EXCEED 16 VOLTS. REFER TO INSTRUCTIONS DISCONNECT CABLE CLAMPS AS FOLLOWS:
PROVIDED WITH DEVICE BEING USED. • Disconnect BLACK cable clamp from engine
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY ground on disabled vehicle.
RESULT IN PERSONAL INJURY. • When using a Booster vehicle, disconnect
BLACK cable clamp from battery negative terminal.
CAUTION: When using another vehicle as a Disconnect RED cable clamp from battery positive
booster, do not allow vehicles to touch. Electrical terminal.
systems can be damaged on either vehicle. • Disconnect RED cable clamp from battery posi-
tive terminal on disabled vehicle.

TO JUMP START A DISABLED VEHICLE:


(1) Raise hood on disabled vehicle and visually TOWING
inspect engine compartment for:
• Battery cable clamp condition, clean if necessary. STANDARD PROCEDURE - TOWING
• Frozen battery.
• Yellow or bright color test indicator, if equipped. WARNING: Do not tow the vehicle if the key cannot
• Low battery fluid level. be turned in the ignition lock. If the key cannot be
• Generator drive belt condition and tension. turned, the ignition lock remains locked and the
• Fuel fumes or leakage, correct if necessary. vehicle cannot be steered. With the engine not run-
ning there is no power assistance for the braking
CAUTION: If the cause of starting problem on dis- and steering systems. In this case, it is important to
abled vehicle is severe, damage to booster vehicle keep in mind that a considerably higher degree of
charging system can result. effort is necessary to brake and steer the vehicle.
The vehicle must not be towed with the front axle
(2) When using another vehicle as a booster raised and the key in position 2 in the ignition lock
source, park the booster vehicle within cable reach. as the drive wheels could then lock due to the
Turn off all accessories, set the parking brake, place acceleration skid control (ASR)
the automatic transmission in PARK or the manual
transmission in NEUTRAL and turn the ignition
OFF.
VA LUBRICATION & MAINTENANCE 0-7
TOWING (Continued)
If the Engine is Damaged • Do not tow the vehicle by connecting to the front
For towing distances up to 30 miles (about 50 or rear shock absorbers
km) • Do not tow a heavily loaded vehicle. Damage to
• Shift selector lever in “N” position. the vehicle may result. Use a flatbed device to trans-
• Do not exceed a towing speed of 30 m.p.h. (50 port a loaded vehicle.
km/h).
For towing distances greater than 30 mile GROUND CLEARANCE
(about 50 km)
• Remove the propeller shafts leading to the drive CAUTION: If vehicle is towed with wheels removed,
axles. The vehicle can be towed without restriction. install lug nuts to retain brake drums.

A towed vehicle should be raised until lifted wheels


If the Transmission is Damaged
are a minimum 100 mm (4 in) from the ground. Be
• Remove the propeller shafts leading to the drive
sure there is adequate ground clearance at the oppo-
axles. The vehicle can be towed without restriction.
site end of the vehicle, especially when towing over
rough terrain, steep rises in the road or if the vehicle
If the Front Axle is Damaged
is equipped with air dams, spoilers, and/or ground
• Raise the front axle.
effect panels. If necessary, remove the wheels from
• Observe the same towing restrictions as for
the lifted end of the vehicle and lower the vehicle
engine damage.
closer to the ground, to increase the ground clearance
at the opposite end of the vehicle. Install lug nuts on
If the Rear Axle is Damaged
wheel attaching studs to retain brake drums.
• Raise the rear axle.

NOTE: Comply with local legal regulations regard- RAMP ANGLE


ing towing vehicles. If a vehicle with flat-bed towing equipment is used,
the approach ramp angle should not exceed 15
degrees.
SAFETY PRECAUTIONS
TOWING WHEN KEYS ARE NOT AVAILABLE
NOTE: The following safety precautions must be When the vehicle is locked and keys are not avail-
observed when towing a vehicle. able, use a flat bed hauler. A Wheel-lift or Sling-type
device can be used provided all the wheels are lifted
• Secure loose and protruding parts. off the ground using tow dollies.
• Always use a safety chain system that is inde-
pendent of the lifting and towing equipment.
• Do not allow towing equipment to contact the MAINTENANCE SCHEDULES
disabled vehicle’s fuel tank.
• Do not allow anyone under the disabled vehicle DESCRIPTION
while it is lifted by the towing device. The use of Special lubricant additives is not recom-
• Do not allow passengers to ride in a vehicle mended. The use of such additives may affect the
being towed. warranty rights. With regard to legal stipulations
• Always observe state and local laws regarding concerning emissions control, please note that
towing regulations. engines have to be serviced and adjusted in accor-
• Do not tow a vehicle in a manner that could dance with special instructions and using special
jeopardize the safety of the operator, pedestrians or measuring equipment. Modifications to or interfer-
other motorists. ence with the emissions control systems are not per-
• Do not attach tow chains, T-hooks, J-hooks, or a missible.
tow sling to a bumper, steering linkage, drive shafts
or a non-reinforced frame hole. MAINTENANCE - WITHOUT ASSYST
• Remove exhaust pipe tips that interfere with the MAINTENANCE COMPUTER
tow sling and crossbar Maintenance Intervals
• Padding should be placed between the tow sling/ • Oil service – Normal Operation every 10,000
crossbar and any painted surfaces miles or 16,000 km or 12 months.
• When placing tow hooks on the rear axle, posi- • Maintenance service every 20,000 miles or
tion them so they do not damage the brake tubing or 32,000 km.
hoses Additional work must be carried out at yearly
intervals.
0-8 LUBRICATION & MAINTENANCE VA
MAINTENANCE SCHEDULES (Continued)
MAINTENANCE - WITH ASSYST MAINTENANCE Replace the coolant every five years or 100,000
COMPUTER miles.
ASSYST provides information on the best possible Dust Filter for Heating/Ventilation Replace-
timing for maintenance work. ment
The dust filter and the tailgate interior filter are to
NOTE: The engine manufacturer strongly recom- be renewed during routine maintenance service. If
mends the use of synthetic engine oils, such as operating conditions are dusty, these filters should be
TMobil 1 SAE 0W-40. renewed more frequently.

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

ADDITIONAL MAINTENANCE WORK


Automatic transmission once only at 80,000
miles/128000 km
Oil and filter change
During every second maintenance service
Air cleaner without maintenance indicator:
Air cleaner filter element renewal
Check poly-V-belt for wear and signs of damage Fig. 3 INTERNATIONAL SYMBOLS
During every 6th maintenance service
Rear axle
VA SUSPENSION 2-1

SUSPENSION
TABLE OF CONTENTS

page page

FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . 16


REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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

DESCRIPTION N·m Ft. Lbs. In. Lbs.


Lower Ball Joint To 280 206 —
Steering Knuckle
Strut To Steering Knuckle 185 136 —
Strut To Body 100 74 —
Bottom Spring Clamp 130 96 —
Plate To Front Axle
M12 X 1.5 Bolt
Bottom Spring Clamp 65 48 —
Plate To Front Axle
M10 Bolt
Sway Bar Clamp To The 30 22 —
Front Axle
Hexagon Socket Bolt For 12 9 106
Clamping Nut To Adjust
Wheel Bearing Play
Lower Control Arm To 150 110 —
Front Axle Beam
Stop Plate For Lower 60 44 —
Control Arm
Outer Tie Rod End Nut 130 96 —
Outer Tie Rod End Nut 50 37 —
Jam Nut
VA FRONT 2-3
FRONT (Continued)

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

LEAF SPRING WEDGE BLOCK - 9288

Puller Tie Rod C-3894-A

BALL JOINT PRESS - C-4212F

BUSHING REMOVER / INSTALLER-9302

LOWER BALL JOINT REMOVE / INSTALL - 9294


2-4 FRONT VA

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).

Fig. 2 LCA BUSHING INSTALL


1 - SPECIAL TOOL C-4212F (PRESS)
2 - SPECIAL TOOL 9302-1 (DRIVER)
3 - BUSHING
4 - SPECIAL TOOL 9302-2 (SIZER CUP)
5 - LOWER CONTROL ARM
6 - SPECIAL TOOL 9302-4 (RECEIVER CUP)

(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

(3) Install the thrust washer (Fig. 4).


(4) Install the clamping nut (Fig. 4). Tighten to 12
N·m (9 ft. lbs.) and then loosen a half of a turn.
(5) Check for wheel bearing end play. End play
should be 0.02- 0.04 mm (0.000787 - 0.00158 in.)
Fig. 4 FRONT WHEEL HUB WITH SINGLE REAR (Fig. 3) (Refer to 2 - SUSPENSION/FRONT/HUB /
WHEELS (SRW) BEARING - DIAGNOSIS AND TESTING).
1 - CALIPER ADAPTER BOLT (6) Pack the grease cap half with grease and coat
2 - DISC BRAKE CALIPER at the edge with sealant and install the cap (Fig. 4).
3 - INNER BEARING (7) Install the disc brake rotor (Refer to 5 -
4 - WHEEL HUB
5 - DISC BRAKE ROTOR BRAKES/HYDRAULIC/MECHANICAL/ROTORS -
6 - OUTER BEARING INSTALLATION).
7 - THRUST WASHER (8) Install the disc brake caliper adapter (Refer to
8 - CLAMPING NUT
9 - GREASE CAP 5 - BRAKES/HYDRAULIC/MECHANICAL/DISC
10 - LOCKING BOLT BRAKE CALIPER ADAPTER - INSTALLATION).
11 - GREASE SEAL (9) Install the wheel flange ring (if equipped with
12 - STEERING KNUCKLE
dual rear wheels) (Fig. 5).
(10) Install the front tire & wheels assembly
INSTALLATION (Refer to 22 - TIRES/WHEELS/WHEELS - INSTAL-
(1) Install the wheel hub with the tapered roller LATION).
bearing on the stub axle (Fig. 4). (11) Lower the vehicle.
(2) Grease the outer tapered roller bearing thor-
oughly and push onto the steering knuckle (Fig. 4).

NOTE: The smooth side of the thrust washer must


point toward the wheel bearing.
2-6 FRONT VA

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).

Fig. 6 STEERING KNUCKLE


1 - STRUT
2 - STRUT BOLT
3 - STEERING KNUCKLE
4 - LOWER BALL JOINT NUT
5 - OUTER TIE ROD END RETAINING NUT
6 - INNER TIE ROD END
7 - LOWER CONTROL ARM

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).

LOWER CONTROL ARM


REMOVAL
(1) Insert spring blocks special tool 9288 between
the spring and the spring clamp plates, While the Fig. 8 LOWER CONTROL ARM
vehicles wheels are on the ground. 1 - STRUT
(2) Raise and support the vehicle. 2 - LOWER CONTROL ARM BOLT
(3) Remove the front wheels (Refer to 22 - TIRES/ 3 - STOP PLATE BOLT
4 - STOP PLATE
WHEELS/WHEELS - REMOVAL). 5 - CALIPER ADPTER BOLT
(4) Remove the disc brake caliper adapter (Refer to 6 - DISC BRAKE CALIPER
5 - BRAKES/HYDRAULIC/MECHANICAL/DISC 7 - LOCKING BOLT
8 - DISC BRAKE ROTOR
BRAKE CALIPER ADAPTER - REMOVAL).Hang 9 - OUTER TIE ROD END RETAINING NUT
the caliper. Do not allow brake hose to support 10 - OUTER TIE ROD END
the caliper weight. 11 - LOWER BALL JOINT NUT
12 - LOWER BALL JOINT
(5) Remove the retaining nut holding the tie rod to 13 - LOWER CONTROL ARM NUTS
the steering knuckle (Fig. 8). 14 - STRUT BOLT
(6) Seperate the tie rod off the steering knuckle
(Fig. 8) using special tool C-3894–A. (2) Install the lower ball joint into the steering
knuckle. Tighten to 280 N·m (206 ft. lbs.).
NOTE: In order to remove tension from the strut, (3) Install the strut bolts to the steering knuckle
Raise the lower control arm approximately 10 mm (Fig. 8). Tighten to 185 N·m (136 ft. lbs.).
with a jack. (4) Install the stop plate (Refer to 2 - SUSPEN-
SION/FRONT/SPRING STOP PLATES - INSTALLA-
(7) Remove the strut bolts from the steering TION).
knuckle (Fig. 8). (5) Lower the lower control arm.
(8) Remove the stop plate bolts and rotate the (6) Attach the tie rod to the steering knuckle (Fig.
plate upwards with the stabilizer link attached (Fig. 8). Tighten the nut to 130 N·m (96 ft. lbs.)
8). (7) Install the disc brake caliper adapter (Refer to
(9) Lower the lower control arm. 5 - BRAKES/HYDRAULIC/MECHANICAL/DISC
(10) Remove the lower ball joint nut from the BRAKE CALIPER ADAPTER - INSTALLATION)
steering knuckle (Fig. 8). (Fig. 8).
(11) Separate the lower ball joint from the knuckle (8) Install the front tire & wheel assembly (Refer
using special tool 9282. to 22 - TIRES/WHEELS/WHEELS - INSTALLA-
(12) Remove the lower control arm nuts and bolts TION).
from the frame (Fig. 8). (9) Lower the vehicle.
(13) Remove the lower control arm. (10) Remove the spring blocks between the spring
and the spring clamp plates, While the vehicles
INSTALLATION wheels are on the ground.
(1) Install the lower control arm to the frame. (11) Roll the vehicle approximately 1 mm forwards
Hand tighten the nuts and bolts. and the backwards, and rock firmly.
(12) Tighten the lower control arm nuts and bolts
NOTE: In order to remove tension from the strut, to the frame to 150 N·m (110 ft. lbs.) (Fig. 8).
Raise the lower control arm approximately 10 mm (13) Apply brake to actuate brake pressure.
with a jack.
2-8 FRONT VA

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).

Fig. 11 STABILIZER BAR


1 - RUBBER MOUNT
2 - STABILIZER LINK
3 - RUBBER MOUNT
4 - NUT
5 - RUBBER MOUNT
6 - CLAMP BRACKET
7 - BOLT

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

REAR REMOVAL - (DRW) . . . . . . . . . . . . . . . . . . . . 14


DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11 INSTALLATION
DIAGNOSIS AND TESTING - SPRING AND INSTALLATION - (SRW) . . . . . . . . . . . . . . . . . 14
SHOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 INSTALLATION - (DRW) . . . . . . . . . . . . . . . . . 14
SPECIFICATIONS - TORQUE CHART . . . . . . . . 12 SPRING SHACKLE
SHOCK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DIAGNOSIS AND TESTING - SHOCK . . . . . . . . 13 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 STABILIZER BAR
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SPRING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13 STABILIZER LINK
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
REMOVAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
REMOVAL - (SRW) . . . . . . . . . . . . . . . . . . . . 14

REAR DIAGNOSIS AND TESTING - SPRING AND


SHOCK
DESCRIPTION A knocking or rattling noise from a shock absorber
The rear suspension is comprised of: may be caused by movement between mounting
• Shock Absorbers bushings and metal brackets or attaching compo-
• Jounce Bumpers nents. These noises can usually be stopped by tight-
• Stabilizer Bar ening the attaching nuts. If the noise persists,
• Leaf Springs inspect for damaged and worn bushings, and attach-
• Drive Axle ing components. Repair as necessary if any of these
conditions exist.
CAUTION: A vehicle should always be loaded so A squeaking noise from the shock absorber may be
the vehicle weight center-line is located immedi- caused by the hydraulic valving and may be intermit-
ately forward of the rear axle. Correct vehicle load- tent. This condition is not repairable and the shock
ing provides proper front tire-to-road contact. This absorber must be replaced.
results in maximum vehicle handling stability and The shock absorbers are not refillable or adjust-
safety. Incorrect vehicle weight distribution can able. If a malfunction occurs, the shock absorber
cause excessive tire tread wear, spring fatigue or must be replaced. To test a shock absorber, hold it in
failure, and erratic steering. an upright position and force the piston in and out of
the cylinder four or five times. The action throughout
each stroke should be smooth and even.
CAUTION: Suspension components with rubber/ure-
The spring eye and shock absorber bushings do not
thane bushings (except stabilizer bar) should be
require any type of lubrication. Do not attempt to
tightened with the vehicle at normal ride height. It is
stop spring bushing noise by lubricating them.
important to have the springs supporting the weight
Grease and mineral oil-base lubricants will deterio-
of the vehicle when the fasteners are torqued. If
rate the bushing rubber.
springs are not at their normal ride position, vehicle
If the vehicle is used for severe, off-road operation,
ride comfort could be affected and premature bush-
the springs should be examined periodically. Check
ing wear may occur.
for broken and shifted leafs, loose and missing clips,
and broken center bolts. Refer to Spring and Shock
Absorber Diagnosis chart for additional information.
2 - 12 REAR VA
REAR (Continued)
SPRING AND SHOCK ABSORBER

CONDITION POSSIBLE CAUSES CORRECTION

SPRING SAGS 1. Broken leaf. 1. Replace spring.

2. Spring fatigue. 2. Replace spring.

SPRING NOISE 1. Loose spring clamp bolts. 1. Tighten to specification.

2. Worn bushings. 2. Replace bushings.


3. Worn or missing spring tip inserts. 3. Replace spring tip inserts.

SHOCK NOISE 1. Loose mounting fastener. 1. Tighten to specification.


2. Worn bushings. 2. Replace shock.
3. Leaking shock. 3. Replace shock.

SPECIFICATIONS - TORQUE CHART


TORQUE SPECIFICATIONS

DESCRIPTION N·m Ft. Lbs. In. Lbs.


Sway Bar Link 95 60 —
Sway Bar Clamp To Axle 25 18 —
(SRW)
Sway Bar Clamp To Axle 70 52 —
(DRW)
Rear Spring To Front Spring Bracket 95 70 —
(SRW)
Rear Spring To Front Spring Bracket 185 136 —
(DRW)
Rear Spring To Rear Spring Bracket 85 63 —
(SRW)
Rear Spring To Rear Spring Bracket 185 136 —
(DRW)
Spring Shackle To Rear Spring Bracket 90 66 —
(SRW)
Spring Shackle To Rear Spring Bracket 185 136 —
(DRW)
U-Bolt To Spring Plate & Axle 170 125 —
(SRW&DRW)
Lower Shock Mounting To Rear Axle 70 52 —
M12 X 1.5 Bolt
Lower Shock Mounting To Rear Axle 110 81 —
M14 X 1.5 Bolt
(SRW&DRW)
Upper Shock Mounting To Frame 80 59 —
(SRW)
Upper Shock Mounting To Frame 140 103 —
(DRW)
VA REAR 2 - 13

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).

Fig. 3 REAR LEAF SPRING WITH DUAL REAR


WHEELS
1 - U-BOLTS
2 - NUT
3 - BOLT
4 - SPRING SHACKLE
5 - U-BOLT MOUNTING NUT
6 - U-BOLT BRACKET ALIGNING PLATE
7 - LEAF SPRING

INSTALLATION
INSTALLATION - (SRW)
NOTE: Larger spring bushing goes toward the front.

(1) Install the spring shackle to the spring (if


Fig. 2 REAR LEAF SPRING WITH SINGLE REAR
removed) (Fig. 2). Tighten to 90 N·m (66 ft. lbs.).
WHEELS
(2) Install the spring to the front spring bracket
1 - NUT
2 - LEAF SPRING
(Fig. 2). Tighten to 95 N·m (70 ft. lbs.).
3 - U-BOLTS (3) Install the spring to the rear spring bracket
4 - PLATE (Fig. 2). Tighten to 85 N·m (63 ft. lbs.).
5 - SPRING BOLT
6 - SHACKLE BOLT
(4) Raise the rear axle and attach the spring plate
7 - SPRING SHACKLE and U-bolts (Fig. 2). Tighten to 170 N·m (125 ft. lbs.).
8 - U-BOLT NUTS (5) Lower the vehicle.

REMOVAL - (DRW) INSTALLATION - (DRW)


(1) Raise and support the vehicle.
(2) Support the rear axle. NOTE: Larger spring bushing goes toward the front.
(3) Remove the U-bolt and spring plate (Fig. 3).
(4) Remove the spring from the front spring (1) Install the spring shackle to the spring (if
bracket (Fig. 3). removed) (Fig. 3). Tighten to 185 N·m (136 ft. lbs.).
(5) Remove the rear spring with the spring shackle (2) Install the spring to the front spring bracket
from the spring bracket (Fig. 3). (Fig. 3). Tighten to 185 N·m (136 ft. lbs.).
(6) Lower the rear axle and remove the rear (3) Install the spring to the rear spring bracket
spring. (Fig. 3). Tighten to 185 N·m (136 ft. lbs.).
(7) Remove the spring shackle from the spring (if (4) Raise the rear axle and attach the spring plate
needed) (Fig. 3). and U-bolts (Fig. 3). Tighten to 170 N·m (125 ft. lbs.).
(5) Lower the vehicle.
VA REAR 2 - 15

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 STANDARD PROCEDURE - TOE


DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 16 ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 17
DIAGNOSIS AND TESTING - PRE-ALIGNMENT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 18
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 16

WHEEL ALIGNMENT
DESCRIPTION
NOTE: Camber and Caster are not adjustable on
this vehicle. (TOE ONLY).

NOTE: Suspension components with rubber/ure-


thane bushings should be tightened with the vehi-
cle at normal ride height. It is important to have the
springs supporting the weight of the vehicle when
the fasteners are torqued. If springs are not at their
normal ride position, vehicle ride comfort could be
affected and premature bushing wear may occur.

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

CONDITION POSSIBLE CAUSES CORRECTION

FRONT END NOISE 1. Loose or worn wheel bearing. 1. Replace wheel bearing.

2. Loose or worn steering or 2. Tighten or replace components as


suspension components. necessary.
3. Loose or worn steering or 3. Tighten or replace components as
suspension components. necessary.

EXCESSIVE PLAY IN 1. Loose or worn wheel bearing. 1. Replace wheel bearing.


STEERING
2. Loose or worn steering or 2. Tighten or replace components as
suspension components. necessary.
3. Loose or worn steering gear. 3. Replace steering gear.

FRONT WHEELS SHIMMY 1. Loose or worn wheel bearing. 1. Replace wheel bearing.

2. Loose or worn steering or 2. Tighten or replace components as


suspension components. necessary.
3. Tires worn or out of balance. 3. Replace or balance tires.
4. Alignment. 4. Align vehicle to specifications.

VEHICLE INSTABILITY 1. Loose or worn wheel bearing. 1. Replace wheel bearing.

2. Loose or worn steering or 2. Tighten or replace components as


suspension components. necessary.
3. Tire pressure. 3. Adjust tire pressure.
4. Alignment. 4. Align vehicle to specifications.

EXCESSIVE STEERING 1. Loose or worn steering gear. 1. Replace steering gear.


EFFORT
2. Column coupler binding. 2. Replace coupler.
3. Tire pressure. 3. Adjust tire pressure.
4. Alignment. 4. Align vehicle to specifications.

VEHICLE PULLS TO ONE 1. Tire pressure. 1. Adjust tire pressure.


SIDE 2. Tire. 2. Criss-Cross Front Tires.
3. Alignment. 3. Align vehicle to specifications.
4. Loose or worn steering or 4. Tighten or replace components as
suspension components. necessary.
5. Radial tire lead. 5. Rotate or replace tire as necessary.
6. Brake pull. 6. Repair brake as necessary.
7. Weak or broken spring. 7. Replace spring.

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

DESCRIPTION N·m Ft. Lbs. In. Lbs.


Outer Tie Rod End Jam 50 37 -
Nut
VA DIFFERENTIAL & DRIVELINE 3-1

DIFFERENTIAL & DRIVELINE


TABLE OF CONTENTS

page page

PROPELLER SHAFT ......................1 REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

PROPELLER SHAFT

TABLE OF CONTENTS
page page

PROPELLER SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6


DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . .1 CENTER BEARING
STANDARD PROCEDURE .. . . . . . . . . . . . . . . .3 REMOVAL .............................8
SPECIFICATIONS . . . . . . ... . . . . . . . . . . . . . . .5 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SPECIAL TOOLS ...... ... . . . . . . . . . . . . . . .5
PROPELLER SHAFT
REMOVAL ........... ..................6

PROPELLER SHAFT Driveline vibration can be from loose or damaged


engine mounts.
Propeller shaft vibration increases with vehicle
DIAGNOSIS AND TESTING
speed. A vibration within a specific speed is not usu-
ally caused by a out of balanced propeller shaft.
PROPELLER SHAFT VIBRATION
Worn universal joints or an incorrect propeller shaft
Out-of-round tires or wheels that are out of bal-
angle, usually cause such a vibration.
ance, will cause a low frequency vibration.
3-2 PROPELLER SHAFT VA
PROPELLER SHAFT (Continued)
DRIVELINE VIBRATION

Drive Condition Possible Cause Correction


Propeller Shaft Noise 1) Undercoating or other foreign 1) Clean exterior of shaft and wash
material on shaft. with solvent.
2) Loose U-joint clamp screws. 2) Install new clamps and screws
and tighten to proper torque.
3) Loose or bent U-joint yoke or 3) Install new yoke.
excessive runout.
4) Incorrect driveline angularity. 4) Measure and correct driveline
angles.
5) Rear spring center bolt not in 5) Loosen spring u-bolts and seat
seat. center bolt.
6) Worn U-joint bearings. 6) Install new U-joint.
7) Propeller shaft damaged or out 7) Installl new propeller shaft.
of balance.
8) Broken rear spring. 8) Install new rear spring.
9) Excessive runout or unbalanced 9) Re-index propeller shaft, test,
condition. and evaluate.
10) Excessive drive pinion gear 10) Re-index propeller shaft and
shaft runout. evaluate.
11) Excessive axle yoke deflection. 11) Inspect and replace yoke if
necessary.
12) Excessive transfer case runout. 12) Inspect and repair as necessary.
Universal Joint Noise 1) Loose U-joint clamp screws. 1) Install new clamps and screws
and tighten to proper torque.
2) Lack of lubrication. 2) Replace as U-joints as
necessary.

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.

PROPELLER SHAFT RUNOUT


(1) Clean the propeller shaft surface where the
dial indicator will contact the shaft.
(2) The dial indicator must be installed perpendic-
ular to the shaft surface.
(3) Measure runout at the center and ends of the
shaft away from weld areas, to ensure weld process
will not effect the measurements.
(4) Refer to Runout Specifications chart.
(5) If propeller shaft is out of specification, remove
propeller shaft and index the shaft 180°. Install the
propeller shaft and measure shaft runout again.
Fig. 1 Clamp Screw At Position 1 (6) If propeller shaft is now within specifications,
1 - CLAMP
mark shaft and yokes for proper orientation.
2 - SCREWDRIVER (7) If propeller shaft runout is not within specifica-
tions, check runout of the transmission and axle.
Correct as necessary and repeat propeller shaft
runout measurement.
(8) Replace propeller shaft if the runout still
exceeds the limits.

RUNOUT SPECIFICATIONS

Front of Shaft 0.020 in. (0.50 mm)


Center of Shaft 0.025 in. (0.63 mm)
Rear of Shaft 0.020 in. (0.50 mm)
note:
Measure front/rear runout approximately 76 mm (3 in.)
from the weld seam at each end of the shaft tube for
tube lengths over 30 inches. For tube lengths under
30 inches, the maximum allowed runout is 0.50 mm
Fig. 2 Two Clamp Screws At The Same Position
(0.020 in.) for the full length of the tube.

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.

NOTE: Always make measurements from front to


rear and from the same side of the vehicle.
Fig. 3 Clamp Screws Separated
1 - ⁄ INCH
12 (5) Place Inclinometer 7663 on yoke bearing (A)
parallel to the shaft. Center bubble in sight glass and
record measurement.
3-4 PROPELLER SHAFT VA
PROPELLER SHAFT (Continued)
This measurement will give you the transmis- (9) Subtract smaller figure from larger (C minus
sion yoke Output Angle (A). B) to obtain axle Input Operating Angle.
(6) Rotate propeller shaft 90 degrees and place Refer to rules and example in (Fig. 4) for addi-
inclinometer on yoke bearing parallel to the shaft. tional information.
Center bubble in sight glass and record measure-
ment. This measurement can also be taken at the RULES
rear end of the shaft. • Good cancellation of U-joint operating angles
This measurement will give you the Propeller should be within 1degree.
Shaft Angle (C). • Operating angles should be less than 3 degrees.
(7) Rotate propeller shaft 90 degrees and place • At least 1/2 of one degree continuous operating
inclinometer on companion flange yoke bearing par- (propeller shaft) angle.
allel to the shaft. Center bubble in sight glass and
record measurement. TWO/THREE-PIECE PROPELLER SHAFT
This measurement will give you the Pinion The procedure to measure the propeller shaft
Flange Input Angle (B). angles involved with a two/three-piece (Fig. 5) propel-
(8) Subtract smaller figure from larger (C minus ler shaft is the same as those for a one-piece propel-
A) to obtain Transmission Output Operating ler shaft.
Angle.

Fig. 4 UNIVERSAL JOINT ANGLE EXAMPLE


1 - 4.9° Angle (C) 4 - 3.0° Angle (A)
2 - 3.2° Angle (B) 5 - Output Yoke
3 - Input Yoke
VA PROPELLER SHAFT 3-5
PROPELLER SHAFT (Continued)

Fig. 5 UNIVERSAL JOINT ANGLE


1 - YOKES MUST BE IN SAME PLANE

SPECIFICATIONS
TORQUE SPECIFICATIONS

DESCRIPTION N·m Ft. Lbs. In. Lbs.


Propeller shaft to
70 52 -
transmission bolt
Propeller shaft to axle bolt 70 52 -
Retaining bracket to frame
100 74 -
floor bolt
Center Bearing support to
95 70 -
frame floor bolt
Center Bearing to support
105 77 -
nut

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

Fig. 6 ALIGNMENT MARKS


1 - ALIGNMENT MARK
2 - BOOT
3 - ALIGNMENT MARK
INSTALLER 9275 4 - CENTER BEARING

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)

Fig. 8 2 PIECE PROPELLER SHAFT


1 - FLANGE BOLT 6 - NUT
2 - BEARING 7 - BRACKET
3 - PROPELLER SHAFT 8 - RETAINING BRACKET
4 - REAR AXLE 9 - COLLARED BOLT
5 - CABLE BRACKET 10 - TRANSMISSION

Fig. 9 3 PIECE PROPELLER SHAFT


1 - FLANGE BOLT 7 - BRACKET
2 - INTERMEDIATE BEARING 8 - RETAINING BRACKET
3 - CENTER SHAFT 9 - BOLT
4 - REAR SHAFT 10 - FRONT SHAFT
5 - REAR AXLE 11 - TRANSMISSION
6 - NUT
3-8 PROPELLER SHAFT VA

CENTER BEARING
REMOVAL
(1) Remove propeller shaft.
(2) Mark shafts for installation alignment (Fig.
10).

Fig. 12 CENTER BEARING


1 - SNAP-RING
2 - CENTER BEARING
3 - WASHER
4 - SHAFT
5 - PROTECTIVE CAP

NOTE: The bearing splitter must be positioned


Fig. 10 ALIGNMENT MARKS behind the thrust washer of the bearing.
1 - ALIGNMENT MARK
2 - BOOT
3 - ALIGNMENT MARK
4 - CENTER BEARING

(3) Loosen both collar clamps (Fig. 11).

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)

INSTALLATION (2) Install snap-ring.


(1) Press center bearing on propeller shaft with (3) Coat propeller shaft spline with universal
protective caps and washer with Installer 9275 (Fig. grease.
14). (4) Push rubber boot onto propeller shaft.
(5) Push together propeller shaft. Pay attention to
alignment markings for installation position.
(6) Ensure rubber seal is correctly installed and
attach new collar clamps.
(7) Install propeller shaft.

Fig. 14 CENTER BEARING INSTALLATION


1 - INSTALLER
2 - CENTER BEARING
3 - 10 REAR AXLE VA

REAR AXLE

TABLE OF CONTENTS
page page

REAR AXLE AXLE BEARINGS/SEALS


DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17
DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . 10 AXLE SHAFTS - DUAL REAR WHEELS
STANDARD PROCEDURE - DRAIN AND FILL . . 11 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12 AXLE HUB BEARINGS/SEALS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 13 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 14 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20
AXLE SHAFTS PINION SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 22

REAR AXLE GEAR NOISE


Axle gear noise can be caused by insufficient lubri-
DESCRIPTION cant, incorrect backlash, incorrect pinion depth, tooth
The axle housings consist of a cast iron center sec- contact, worn/damaged gears, or the carrier housing
tion with axle tubes extending from either side. The not having the proper offset and squareness.
tubes are pressed into and welded to the differential Gear noise usually happens at a specific speed
housing to form a one-piece axle housing. The SRW range. The noise can also occur during a specific type
axle has semi-floating axle shafts, DRW has full- of driving condition. These conditions are accelera-
floating axle shafts. tion, deceleration, coast, or constant load.
When road testing, first warm-up the axle fluid by
NOTE: Axle seals, axle bearings, pinion seal and driving the vehicle at least 5 miles and then acceler-
differential cover are the only serviceble compo- ate the vehicle to the speed range where the noise is
nents. If differential is damaged/noisy the axle must the greatest. Shift out-of-gear and coast through the
be replaced. peak-noise range. If the noise stops or changes
greatly:
• Check for insufficient lubricant.
OPERATION • Incorrect ring gear backlash.
The axle receives power from the transmission • Gear damage.
through the rear propeller shaft. The rear propeller Differential side gears and pinions can be checked
shaft is connected to the pinion gear which rotates by turning the vehicle. They usually do not cause
the differential through the gear mesh with the ring noise during straight-ahead driving when the gears
gear bolted to the differential case. The engine power are unloaded. The side gears are loaded during vehi-
is transmitted to the axle shafts through the pinion cle turns. A worn pinion shaft can also cause a snap-
mate and side gears. The side gears are splined to ping or a knocking noise.
the axle shafts.
BEARING NOISE
DIAGNOSIS AND TESTING The axle shaft, differential and pinion bearings can
all produce noise when worn or damaged. Bearing
NOTE: Axle seals, axle bearings, pinion seals and noise can be either a whining, or a growling sound.
differential cover are the only serviceble compo- Pinion bearings have a constant-pitch noise. This
nents. If differential is damaged/noisy the axle must noise changes only with vehicle speed. Pinion bearing
be replaced. noise will be higher pitched because it rotates at a
faster rate. Drive the vehicle and load the differen-
tial. If bearing noise occurs, the rear pinion bearing
is the source of the noise. If the bearing noise is
VA REAR AXLE 3 - 11
REAR AXLE (Continued)
heard during a coast, the front pinion bearing is the for the noise, a mechanics stethoscope is helpful in
source. isolating the source of a noise.
Differential bearings usually produce a low pitch
noise. Differential bearing noise is similar to pinion STANDARD PROCEDURE - DRAIN AND FILL
bearing noise. The pitch of differential bearing noise
is also constant and varies only with vehicle speed. NOTE: Drain oil when warm.
Axle shaft bearings produce noise and vibration
when worn or damaged. The noise generally changes (1) Clean area around oil fill plug and drain plug.
when the bearings are loaded. Road test the vehicle. (2) Remove oil drain plug and drain oil (Fig. 1).
Turn the vehicle sharply to the left and to the right. (3) Install oil drain plug and tighten to N·m 100
This will load the bearings and change the noise (74 ft. lbs.).
level. Where axle bearing damage is slight, the noise (4) Remove oil fill plug and fill housing up to bot-
is usually not noticeable at speeds above 30 mph. tom edge of oil fill hole (Fig. 1).
(5) Install oil fill plug and tighten to N·m 100 (74
LOW SPEED KNOCK ft. lbs.).
Low speed knock is generally caused by a worn
U-joint or by worn side-gear thrust washers. A worn
pinion shaft bore will also cause low speed knock.

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.

Fig. 2 SINGLE REAR WHEEL AXLE


1 - REAR SPRING 12 - WEAR INDICATOR CONNECTOR
2 - U-BRACKET 13 - BRAKE HOSE
3 - PLATE 14 - WHEEL BOLT
4 - NUT 15 - BOLT
5 - BRAKE CABLE 16 - NUT
6 - REAR AXLE 17 - PROPELLER SHAFT
7 - ABL LEVER 18 - BOLT
8 - NUT 19 - ABS SENSOR
9 - SHOCK ABSORBER 20 - SENSOR BUSHING
10 - BOLT 21 - VENT LINE
11 - WEAR INDICATOR CABLE
VA REAR AXLE 3 - 13
REAR AXLE (Continued)

Fig. 3 DUAL REAR WHEEL AXLE


1 - SPRING 11 - WEAR INDICATOR CONNECTOR
2 - SPRING SHACKLE 12 - BRAKE HOSE
3 - PLATE 13 - LUG NUT
4 - COLLAR NUT 14 - NUT
5 - BRAKE CABLE 15 - WASHER
6 - REAR AXLE 16 - BOLT
7 - ALB LEVER 17 - SHOCK ABSORBER
8 - NUT 18 - PROPELLER SHAFT
9 - BOLT 19 - BOLT
10 - WEAR INDICATOR CABLE 20 - ABS SENSOR
21 - SENSOR BUSHING

(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

DESCRIPTION N·m Ft. Lbs. In. Lbs.


Drain Plug 100 74 -
Fill Plug 100 74 -
Differential Cover Bolts 65 48 -
Axle Bearing Cap Bolts 72 53 -
Axle Grooved Nut 500 369 -
Axle Shaft Hub Nut 65 48 -
*Hub Inner Nut 300 221 -
Hub Outer Nut 250 184 -
*Follow service procedure for torque sequence.

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

WRENCH 9279 AXLE SHAFTS


REMOVAL
(1) Remove wheels.
(2) Detach front brake cable.
(3) Pull ABS sensor together with clamp bushing
out of bearing cap (Fig. 4).
(4) Remove brake disk at rear axle. Attach brake
caliper with lines connected in wheel house.
(5) Remove brake shoes of parking brake.
(6) Remove brake control cable lock.
(7) Remove bearing cap bolts and pull axle shaft
out of axle tube (Fig. 4).
(8) Remove seal/gasket.
FLANGE PULLER 8992
INSTALLATION
(1) Install sealing ring.
(2) Install rear axle shaft in the axle tube (Fig. 5).
(3) Install new bearing cap bolts and tighten to 72
N·m (53 ft. lbs.) (Fig. 6).

NOTE: Tighten bolts diagonally across.

(4) Install brake control cable lock.


(5) Install parking brake shoes.
(6) Install brake disk and calipers.
WRENCH 9290 (7) Coat clamping bush with acid-free grease.
Insert ABS sensor with clamping bush fully into the
mounting hole.
(8) Install front brake cable.
(9) Operate brake pedal several times until brake
pads contact brake discs (brake pressure built up).
(10) Install wheels.

INSTALLER 9291
3 - 16 REAR AXLE VA
AXLE SHAFTS (Continued)

Fig. 4 AXLE SHAFT


1 - REAR AXLE 11 - BOLT
2 - BRAKE SHOE 12 - WHEEL BOLT
3 - PRESSURE SPRING 13 - BRAKE ADJUSTER
4 - RETURN SPRING 14 - REAR AXLE SHAFT
5 - RETURN SPRING 15 - GASKET
6 - CABLE LOCK 16 - BRAKE CABLE
7 - PARK BRAKE CABLE 17 - BOLT
8 - LOCKING PIN 18 - ABS SENSOR
9 - BOLT 19 - SENSOR BUSHING
10 - BRAKE DISC

Fig. 5 AXLE SHAFT AND TUBE Fig. 6 BEARING CAP BOLTS


1 - AXLE SHAFT FLANGE 1 - BEARING CAP BOLTS
2 - AXLE TUBE 2 - BEARING CAP
3 - AXLE BEARINGS 3 - AXLE SHAFT FLANGE
4 - DUST SHIELD
VA REAR AXLE 3 - 17

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).

Fig. 9 BEARING NUT AND LOCKING RING


1 - BEARING NUT
2 - LOCKING RING

(5) Push Plate 9277 between bearing cover and


Fig. 7 LOCKING RING rear axle shaft (Fig. 10).
1 - BEARING NUT
2 - PUNCH
3 - LOCKING RING
4 - BEARING

(3) Loosen bearing nut with Wrench 9279 (Fig. 8).

NOTE: Bearing nut with groove on left rear axle


shaft has a left-hand thread. Bearing nut without
groove on right rear axle shaft has a right-hand
thread. To dismantling insert two wheel mounting
bolts into the axle shaft and clamp in a vise.

Fig. 10 AXLE BEARING REMOVAL TOOL


1 - AXLE SHAFT
2 - PLATE

(6) Place axle shaft with plate in a press.


(7) Press axle shaft through the bearing cover and
tapered roller bearings (Fig. 11).
(8) Remove tapered roller bearing, sealing ring,
dust shield and bearing cap from axle shaft (Fig. 12).
(9) Drive shaft seal out of bearing cover with a
hammer and drift.
Fig. 8 BEARING NUT WRENCH
1 - AXLE SHAFT INSTALLATION
2 - BEARING NUT (1) Clean sealing surface of bearing cap.
3 - WRENCH (2) Drive axle shaft seal into bearing cover using
4 - BEARING
Installer 9278 (Fig. 13).
3 - 18 REAR AXLE VA
AXLE BEARINGS/SEALS (Continued)

Fig. 11 PRESSING BEARING Fig. 13 SEAL INSTALLER


1 - AXLE SHAFT 1 - INSTALLER
2 - BEARING 2 - BEARING COVER
3 - PLATE

Fig. 14 BEARINGS AND RACE


Fig. 12 AXLE SHAFT ASSEMBLY
1 - BEARINGS
1 - AXLE SHAFT 6 - BEARING 2 - RACE
2 - BEARING COVER 7 - SEALING RING
3 - RADIAL SHAFT SEAL 8 - LOCKING RING
4 - GASKET 9 - BEARING NUT
NOTE: The flat side of the locking ring must point
5 - DUST SHIELD towards the nut (Fig. 15). The locking ring is fitted
to ensure that the pressing is done over the inner
NOTE: Install flush to a max. 3 mm (0.12 in.) deep bearing race only. The flat on the locking ring must
inside the bearing cover. be aligned with the flat on the axle shaft otherwise
the axle shaft will be damaged.
(3) Check roller bearing, replace according to con-
dition. (7) Place axle shaft through the hole in Plate 9277
and position the assembly in a press (Fig. 16).
NOTE: Thoroughly grease roller bearings prior to (8) Press tapered roller bearing onto rear axle
installation. shaft as far as the stop.
(4) Install bearing cover with axle shaft seal, new CAUTION: In order to avoid damaging the bearing,
gasket and dust shield on the axle shaft. the outer race must be turned while pressing on.
(5) Install tapered roller bearings and race on the
axle shaft (Fig. 14). (9) Screw on bearing nut and tighten nut with
(6) Install new locking ring on axle shaft. Wrench 9279 to 500 N·m (369 ft. lbs.).
VA REAR AXLE 3 - 19
AXLE BEARINGS/SEALS (Continued)

Fig. 15 BEARING AND SHAFT Fig. 17 LOCKING RING


1 - LOCKING RING 1 - BEARING NUT
2 - AXLE SHAFT 2 - BEARING
3 - BEARING 3 - LOCKING RING
4 - DUST SHIELD 4 - SEALING RING

AXLE SHAFTS - DUAL REAR


WHEELS
REMOVAL
(1) Remove wheels
(2) Remove axle shaft hub nuts (Fig. 18).
(3) Pull out axle shaft.

Fig. 16 PRESSING AXLE SHAFT


1 - PRESS
2 - AXLE SHAFT
3 - PLATE

NOTE: Bearing nut with groove on left rear axle


shaft has a left-hand thread. Bearing nut without
groove on right rear axle shaft has a right-hand
thread.

(10) Bend locking ring with a hammer and punch


at both grooves in the bearing nut (Fig. 17).
Fig. 18 AXLE SHAFT
NOTE: The grooved nut must be locked in both 1 - WHEEL HUB
directions of rotation. 2 - AXLE SHAFT
3 - AXLE NUT
(11) Install sealing ring onto roller bearing race
(Fig. 17). INSTALLATION
(12) Install rear axle shaft. (1) Coat axle shaft flange with Hylomar SQ 32 M
sealant.
3 - 20 REAR AXLE VA
AXLE SHAFTS - DUAL REAR WHEELS (Continued)
(2) Slide axle shaft into axle tube.
(3) Install axle shaft hub nuts and tighten to N·m
65 (48 ft. lbs.).
(4) Install wheels.

AXLE HUB BEARINGS/SEALS


REMOVAL
(1) Remove brake caliper with support.
(2) Remove axle shaft.
(3) Back-off parking brakes.
(4) Remove outer hub nut with Wrench 9290 (Fig.
19).
(5) Remove locking plate, inner hub nut and thrust
washer (Fig. 19).

Fig. 20 SENSOR RING & OIL SEAL


1 - ABS SENSOR RING
2 - SEAL

Fig. 19 HUB NUTS


1 - NUTS
2 - LOCKING PLATE
3 - THRUST WASHER

(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. 24 INNER HUB NUT


1 - HUB
2 - NUT

Fig. 22 OUTER HUB BEARING


1 - HUB
2 - BEARING

(10) Install thrust washer (Fig. 23).

Fig. 25 LOCKING PLATE


1 - HUB
2 - PLATE

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.

NOTE: If it is not possible to spin rear axle shafts


manually, detach rear brake cables.

(3) Drain rear axle oil.


(4) Remove propeller shaft.
(5) Spin pinion flange by hand and check axial
play of bearing.

CAUTION: There must not be any thrust bearing


play. If play excess or there are particles (shavings)
in the drained oil, replace gear assembly. Fig. 27 FLANGE PULLER
1 - FLANGE PULLER
(6) Mark installation position of collared nut (Fig. 2 - PINION FLANGE
26) with respect to drive pinion.

Fig. 26 COLLARED NUT Fig. 28 PINION SEALS


1 - PINION FLANGE 1 - SEALS
2 - COLLARED NUT 2 - AXLE

(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)

Fig. 29 PINION SEAL INSTALLER Fig. 31 BEND COLLAR OF NUT


1 - AXLE 1 - COLLARED NUT
2 - INSTALLER 2 - DRIFT

(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.).

CAUTION: The total friction moment must not be


obtained by slackening the collared nut. Avoid over-
tightening the collared nut otherwise the compres-
sion ring inside will be compressed and will have to
be replaced. This requires total disassembly of the
gear set.

(12) Cut the collar of the tightened collared nut


(Fig. 30).

Fig. 32 FILL PLUG


1 - FILL PLUG
2 - DRAIN PLUG

(16) Screw in oil filler plug and tighten to 100 N·m


(74 ft. lbs.).
(17) Install wheels at rear axle.
(18) Operate brake pedal several times until brake
pads contact brake discs (brake pressure built up).
(19) Attach rear brake cables if removed and
adjust parking brake.

Fig. 30 COLLARED NUT


(13) Bend collar so it touches the wall of the slot
in the pinion shaft (Fig. 31).
VA BRAKES 5-1

BRAKES
TABLE OF CONTENTS

page page

BRAKES - BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 BRAKES - ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

BRAKES - BASE

TABLE OF CONTENTS
page page

BRAKES - BASE REMOVAL - FRONT (DRW) . . . . . . . . . . . . . . 12


DIAGNOSIS AND TESTING - BASE BRAKE REMOVAL - REAR (SRW) . . . . . . . . . . . . . . . 12
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 REMOVAL - REAR (DRW) . . . . . . . . . . . . . . . 12
STANDARD PROCEDURE INSTALLATION
STANDARD PROCEDURE - MANUAL INSTALLATION - FRONT (SRW) ...... . . . . 12
BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 INSTALLATION - FRONT (DRW) . . . . . . . . . . 13
STANDARD PROCEDURE - PRESSURE INSTALLATION - REAR (SRW) ....... . . . . 13
BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 INSTALLATION - REAR (DRW) ....... . . . . 13
HYDRAULIC/MECHANICAL DISC BRAKE CALIPER ADAPTER
SPECIFICATIONS REMOVAL
SPECIFICATIONS - TORQUE CHART . . . . . . . 5 REMOVAL - FRONT . . . . . . . . . . . . . . . . . . . . 13
BASE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . 6 REMOVAL - REAR . . . . . . . . . . . . . . . . . . . . . 13
SPECIAL TOOLS INSTALLATION
BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 INSTALLATION - FRONT . . . . . . . . . . . . . . . . 14
BRAKE LINES INSTALLATION - REAR . . . . . . . . . . . . . . . . . 14
STANDARD PROCEDURE FLUID
STANDARD PROCEDURE - ISO FLARING . . . 8 DIAGNOSIS AND TESTING - BRAKE FLUID
STANDARD PROCEDURE - DOUBLE CONTAMINATION . . . . . . . . . . . . . . . . . . . . . 14
INVERTED FLARING . . . . . . . . . . . . . . . . . . . . 8 STANDARD PROCEDURE - BRAKE FLUID
BRAKE PADS/SHOES LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
REMOVAL SPECIFICATIONS
REMOVAL - FRONT (SRW) . . . . . . . . . . . . . . . 9 BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . . 14
REMOVAL - FRONT (DRW) . . . . . . . . . . . . . . . 9 FLUID RESERVOIR
REMOVAL - REAR (16” WHEELS) (SRW) ....9 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
REMOVAL - REAR (15” WHEELS) (SRW) ....9 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
REMOVAL - REAR (DRW) . . . . . . . . . . . . . . . 10 ALB LEVER
INSTALLATION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION - FRONT (SRW) . . . . . . . . . . 10 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION - FRONT (DRW) . . . . . . . . . . 11 ALB CONTROLLER
INSTALLATION - REAR (16” WHEELS) REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
(SRW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION - REAR (16” WHEELS) ADJUSTMENTS
(SRW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION - REAR (DRW) . . . . . . . . . . . 11 MASTER CYLINDER
DISC BRAKE CALIPERS DIAGNOSIS AND TESTING - MASTER
REMOVAL CYLINDER/POWER BOOSTER . . . . . . . . . . . 16
REMOVAL - FRONT (SRW) . . . . . . . . . . . . . . 11
5-2 BRAKES - BASE VA

STANDARD PROCEDURE - MASTER SPECIAL TOOLS


CYLINDER BLEEDING . . . . . . . . . . . . . . . . . . 17 PARK BRAKE . . . . . . . . . . . . . . . . . . . . . . . . 23
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 CABLE TENSIONER
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
PEDAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 CABLES
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19 REMOVAL
POWER BRAKE BOOSTER REMOVAL - FRONT . . . . . . . . . . . . . . . . . . . . 24
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 19 REMOVAL - REAR . . . . . . . . . . . . . . . . . . . . . 24
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 INSTALLATION
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 INSTALLATION - FRONT . . . . . . . . . . . . . . . . 24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19 INSTALLATION - REAR . . . . . . . . . . . . . . . . . 25
ROTORS ADJUSTMENTS
REMOVAL ADJUSTMENT - PARKING BRAKE CABLES . 25
REMOVAL - FRONT (SRW) . . . . . . . . . . . . . . 19 LEVER
REMOVAL - REAR (SRW) . . . . . . . . . . . . . . . 20 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
REMOVAL - FRONT (DRW) . . . . . . . . . . . . . . 20 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 26
REMOVAL - REAR (DRW) . . . . . . . . . . . . . . . 20 SHOES
INSTALLATION REMOVAL
INSTALLATION - FRONT (SRW) . . . . . . . . . . 21 REMOVAL - (SRW) . . . . . . . . . . . . . . . . . . . . 26
INSTALLATION - REAR (SRW) .. . . . . . . . . . 21 REMOVAL - (DRW) . . . . . . . . . . . . . . . . . . . . 26
INSTALLATION - FRONT (DRW) . . . . . . . . . . 21 CLEANING - REAR DRUM IN HAT BRAKE . . . . 27
INSTALLATION - REAR (DRW) .. . . . . . . . . . 21 INSTALLATION
SUPPORT PLATE INSTALLATION - (SRW) . . . . . . . . . . . . . . . . . 27
REMOVAL - REAR . . . . . . . . . . . . . . . . . . . . . . 22 INSTALLATION - (DRW) . . . . . . . . . . . . . . . . . 27
INSTALLATION - REAR . . . . . . . . . . . . . . . . . . . 22 ADJUSTMENTS
PARKING BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 27
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . 22

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.

STANDARD PROCEDURE - PRESSURE


BLEEDING
Use Mopar brake fluid, or an equivalent quality
fluid meeting SAE and DOT 4 standards only. Use
fresh, clean fluid from a sealed container at all times.
Follow the manufacturers instructions carefully
when using pressure equipment. Do not exceed the
tank manufacturers pressure recommendations. Gen-
erally, a tank pressure of 15-20 psi is sufficient for
bleeding.
Fill the bleeder tank with recommended fluid and
purge air from the tank lines before bleeding.
Do not pressure bleed without a proper master cyl-
inder adapter. The wrong adapter can lead to leak-
Fig. 1 Bleed Hose Setup age, or drawing air back into the system.
1 - BLEED HOSE
2 - FLUID CONTAINER PARTIALLY FILLED WITH FLUID

HYDRAULIC/MECHANICAL
SPECIFICATIONS
SPECIFICATIONS - TORQUE CHART
TORQUE SPECIFICATIONS

DESCRIPTION N·m Ft. Lbs. In. Lbs.


Brake Lines 14 — 124
Master Cylinder To Brake 28 — 248
Booster Nut
Brake Caliper Adapter 90 66 —
Rear
M12 X 1.5 Bolt
Brake Caliper Adapter 170 125 —
Rear
M14 X 1.5 Bolt
Brake Caliper Adapter 170 125 —
Front
Disc Brake Rotor Locking 23 — 204
Bolt
Front or Rear
Wear Indicator To Caliper 10 — 89
Bolt
Front or Rear
5-6 BRAKES - BASE VA
HYDRAULIC/MECHANICAL (Continued)

DESCRIPTION N·m Ft. Lbs. In. Lbs.


Pedal Bracket to Firewall 23 — 204
Booster To Pedal Bracket 25 — 221
Brake Caliper Guide Pins 25 — 221
M8 Bolt
Brake Caliper Guide Pins 30 — 266
M10 Bolt
ALB Operating Linkage 34 25 300
Lever To The Rear Axle
Wheel Flange Ring To 200 148 —
Rotor
Rear
Wheel Flange Ring To 180 133 —
Rotor
Front

BASE BRAKE DESCRIPTION SPECIFICATION


Front Disc Brake Rotor 0.05 mm (0.0019 in.)
NOTE: Do not resurface the disc brake rotors if
Max. Lateral Runout
they are out of specifications. (Sprinter Van Rotors
DRW
must be replaced with new disc brake rotors only).
Front Disc Brake Rotor 0.02 mm (0.0007 in.)
Max. Axial Runout
SPECIFICATIONS DRW
Front Disc Brake Rotor 22 mm (0.866 in.)
DESCRIPTION SPECIFICATION New
Front Disc Brake Caliper Dual Piston Sliding SRW
Type Front Disc Brake Rotor 19 mm (0.748 in.)
Rear Disc Brake Caliper Single Piston Sliding Wear Limit
Type SRW
Disc Brake Caliper Bosch Front Disc Brake Rotor 0.05 mm (0.0019 in.)
Max. Lateral Runout
Rear Disc Brake Rotor 22 mm (0.866 in.) SRW
New
DRW Front Disc Brake Rotor 0.02 mm (0.0007 in.)
Max. Axial Runout
Rear Disc Brake Rotor 19 mm (0.748 in.) SRW
Wear Limit
DRW Rear Disc Brake Rotor 12 mm (0.47 in.)
New
Rear Disc Brake Rotor .1 mm (0.0007 in.) Models 901,902
Max. Lateral Runout
DRW Rear Disc Brake Rotor 10 mm (0.40 in.)
Wear Limit
Rear Disc Brake Rotor .02 mm (0.0039 in.) Models 901,902
Max. Axial Runout
DRW Rear Disc Brake Rotor .1 mm (0.0007 in.)
Max. Lateral Runout
Front Disc Brake Rotor 22 mm (0.866 in.) Models 901,902
New
DRW Rear Disc Brake Rotor 0.02 mm (0.0007 in.)
Max. Axial Runout
Front Disc Brake Rotor 19 mm (0.748 in.) Models 901,902
Wear Limit
DRW
VA BRAKES - BASE 5-7
HYDRAULIC/MECHANICAL (Continued)

DESCRIPTION SPECIFICATION SPECIAL TOOLS


Rear Disc Brake Rotor 16 mm (0.629 in.)
New BRAKES
Models 690.611/63/64,
903 SPECIAL TOOL CROSS REFERENCE CHART
Rear Disc Brake Rotor 14 mm (0.55 in.)
Wear Limit MB MILLER DESCRIPTION
Models 690.611/63/64, TOOL # TOOL #
903 N/A C-4007-A GAUGE SET
Rear Disc Brake Rotor .1 mm (0.0007 in.) N/A 9297 ADAPTERS, BRAKE
Max. Lateral Runout PRESSURE
Models 690.611/63/64, 000 589 99296 BRAKE PEDAL WINCH
903 18 31 00
Rear Disc Brake Rotor 0.02 mm (0.0007 in.)
Max. Axial Runout
Models 690.611/63/64,
903
Rear Disc Brake Rotor 16 mm (0.629 in.)
New
Models WD2.YD141,
YD241, YD341, YD441,
YD541, WD5.WD141,
WD241, WD341
Rear Disc Brake Rotor 14 mm (0.55 in.)
Wear Limit GAUGE SET - C-4007-A
Models WD2.YD141,
YD241, YD341, YD441,
YD541, WD5.WD141,
WD241, WD341
Rear Disc Brake Rotor .1 mm (0.0007 in.)
Max. Lateral Runout
Models WD2.YD141,
YD241, YD341, YD441,
YD541, WD5.WD141,
WD241, WD341
Rear Disc Brake Rotor 0.02 mm (0.0007 in.)
Max. Axial Runout
Models WD2.YD141, ADAPTERS, BRAKE PRESSURE - 9297
YD241, YD341, YD441,
YD541, WD5.WD141,
WD241, WD341
Brake Booster Vacuum Diaphragm
Type

BRAKE PEDAL WINCH - 9296


5-8 BRAKES - BASE VA

BRAKE LINES STANDARD PROCEDURE - DOUBLE INVERTED


FLARING
A preformed metal brake tube is recommended and
STANDARD PROCEDURE preferred for all repairs. However, double-wall steel
tube can be used for emergency repair when factory
STANDARD PROCEDURE - ISO FLARING replacement parts are not readily available.
A preformed metal brake tube is recommended and (1) Cut off damaged tube with Tubing Cutter.
preferred for all repairs. However, double-wall steel (2) Ream cut edges of tubing to ensure proper
tube can be used for emergency repair when factory flare.
replacement parts are not readily available. (3) Install replacement tube nut on the tube.
To make a ISO flare use an ISO flaring tool kit. (4) Insert tube in flaring tool.
(1) Cut off damaged tube with Tubing Cutter. (5) Place gauge form over the end of the tube.
(2) Remove any burrs from the inside of the tube. (6) Push tubing through flaring tool jaws until
(3) Install tube nut on the tube. tube contacts recessed notch in gauge that matches
(4) Position the tube in the flaring tool flush with tube diameter.
the top of the tool bar (Fig. 2). Then tighten the tool (7) Tighten the tool bar on the tube
bar on the tube. (8) Insert plug on gauge in the tube. Then swing
(5) Install the correct size adaptor on the flaring compression disc over gauge and center tapered flar-
tool yoke screw. ing screw in recess of compression disc (Fig. 3).
(6) Lubricate the adaptor. (9) Tighten tool handle until plug gauge is
(7) Align the adaptor and yoke screw over the tube squarely seated on jaws of flaring tool. This will start
(Fig. 2). the inverted flare.
(8) Turn the yoke screw in until the adaptor is (10) Remove the plug gauge and complete the
squarely seated on the tool bar. inverted flare.

Fig. 3 Inverted Flare Tools


Fig. 2 ISO Flaring
1 - ADAPTER
2 - LUBRICATE HERE
3 - PILOT
4 - FLUSH WITH BAR
5 - TUBING
6 - BAR ASSEMBLY
VA BRAKES - BASE 5-9

BRAKE PADS/SHOES (7) Remove the brake pads (Fig. 5).

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).

NOTE: Seal off the line ends and connection


threads in the brake calipers with plugs. Also check
brake hoses for signs of cracks.

(5) Remove the brake caliper guide bolt (Fig. 4).


Fig. 5 FRONT DISC BRAKE PADS WITH DUAL
(6) Remove the brake caliper (Fig. 4).
REAR WHEELS
(7) Remove the brake pads (Fig. 4).
1 - DISC BRAKE CALIPER
2 - GUIDE PIN/BOLT
3 - WEAR INDICATOR
4 - BRAKE PADS
5 - BRAKE CALIPER ADAPTER

REMOVAL - REAR (16” WHEELS) (SRW)


(1) Unscrew the cap from the brake fluid reservoir.
(2) Raise and support the vehicle.
(3) Remove the rear wheels (Refer to 22 - TIRES/
WHEELS/WHEELS - INSTALLATION).
(4) Remove the wear indicator cable and the wear
indicator (Fig. 6).

NOTE: Seal off the line ends and connection


threads in the brake calipers with plugs. Also check
brake hoses for signs of cracks.

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).

REMOVAL - FRONT (DRW) REMOVAL - REAR (15” WHEELS) (SRW)


(1) Unscrew the cap from the brake fluid reservoir. (1) Unscrew the cap from the brake fluid reservoir.
(2) Raise and support the vehicle. (2) Raise and support the vehicle.
(3) Remove the front wheels (Refer to 22 - TIRES/ (3) Remove the rear wheels (Refer to 22 - TIRES/
WHEELS/WHEELS - REMOVAL). WHEELS/WHEELS - INSTALLATION).
(4) Remove the wear indicator cable and the wear (4) Remove the wear indicator cable and the wear
indicator (Fig. 5). indicator (Fig. 7).

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).

NOTE: Seal off the line ends and connection


threads in the brake calipers with plugs. Also check
brake hoses for signs of cracks.

(5) Remove the brake caliper guide pins (Fig. 8).


(6) Remove the brake caliper from the caliper
adapter (Fig. 8).
(7) Remove the retaining spring (Fig. 8).
(8) Remove the pads (Fig. 8).

Fig. 6 REAR DISC BRAKE PADS - 16(WHEELS


(SRW)
1 - AXLE
2 - RETAINING SPRING
3 - OUTBOARD PADS
4 - INBOARD PAD
5 - DISC BRAKE CALIPER
6 - WEAR INDICATOR
7 - GUIDE PIN
8 - DUST CAP

(6) Fold the top section of the brake caliper up


(Fig. 7).
(7) Remove the pads (Fig. 7).

Fig. 8 REAR DISC BRAKE PADS WITH DUAL REAR


WHEELS
1 - WEAR INDICATOR
2 - GUIDE PIN/BOLT
3 - DISC BRAKE CALIPER
4 - RETAINING SPRING
5 - DISC BRAKE PADS
6 - CALIPER ADAPTER

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 (16” WHEELS) (SRW)


(1) Install the brake pads (Fig. 7).
(2) Install the wear indicator cable and the wear
indicator (Fig. 7). Tighten to 10 N·m (89 in. lbs.).

NOTE: Do not install the brake hose twisted and


ensure freedom of movement.

(3) Install the brake caliper to brake caliper


adapter (Fig. 7). Tighten the guide pin to 30 N·m
(266 in. lbs.) for M10 bolt.
(4) Install the rear wheels (Refer to 22 - TIRES/
WHEELS/WHEELS - INSTALLATION).
(5) Lower the vehicle.
Fig. 9 FRONT DISC BRAKE CALIPER
INSTALLATION - REAR (DRW) 1
2
- WEAR INDICATOR CABLE
- WEAR INDICATOR
(1) Install the brake pads (Fig. 8). 3 - BOLT
(2) Install the wear indicator cable and the wear 4 - BRAKE HOSE
5 - DISC BRAKE CALIPER/ADAPTER
indicator (Fig. 8). Tighten to 10 N·m (89 in. lbs.). 6 - ADAPTER BOLTS

NOTE: Do not install the brake hose twisted and


ensure freedom of movement.
5 - 12 BRAKES - BASE VA
DISC BRAKE CALIPERS (Continued)

REMOVAL - FRONT (DRW)


(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. 10).

NOTE: Seal off the line ends and connection


threads in the brake calipers with plugs. Also check
brake hoses for signs of cracks.

(5) Remove the brake hose at the brake caliper


(Fig. 10).
(6) Remove the brake caliper guide bolt (Fig. 10).
(7) Remove the brake caliper (Fig. 10).
Fig. 11 REAR DISC BRAKE CALIPER
1 - BRAKE HOSE
2 - BANJO BOLT
3 - WEAR INDICATOR
4 - CALIPER ADAPTER BOLTS
5 - DISC BRAKE CALIPER
6 - WEAR INDICATOR

REMOVAL - REAR (DRW)


(1) Unscrew the cap from the brake fluid reservoir.
(2) Raise and support the vehicle.
(3) Remove the rear wheels (Refer to 22 - TIRES/
WHEELS/WHEELS - INSTALLATION).
(4) Remove the wear indicator cable and the wear
indicator (Fig. 12).

NOTE: Seal off the line ends and connection


Fig. 10 DISC BRAKE CALIPER WITH DUAL REAR threads in the brake calipers with plugs. Also check
WHEELS brake hoses for signs of cracks.
1 - WEAR INDICATOR WIRE
2 - WEAR INDICATOR
(5) Remove the brake hose at the brake caliper
3 - MOUNTING BOLT (Fig. 12).
4 - BRAKE HOSE (6) Remove the brake caliper guide bolt (Fig. 12).
5 - DISC BRAKE CALIPER
6 - ADAPTOR BOLTS (7) Remove the brake caliper (Fig. 12).

REMOVAL - REAR (SRW) INSTALLATION


(1) Unscrew the cap from the brake fluid reservoir.
(2) Raise and support the vehicle. INSTALLATION - FRONT (SRW)
(3) Remove the rear wheels (Refer to 22 - TIRES/
(1) Install the brake caliper to the brake caliper
WHEELS/WHEELS - INSTALLATION).
adapter (Fig. 9). Tighten the guide pins to 25 N·m
(4) Remove the wear indicator cable and the wear
(221 in. lbs.).
indicator (Fig. 11).
NOTE: Do not install the brake hose twisted and
NOTE: Seal off the line ends and connection
ensure freedom of movement.
threads in the brake calipers with plugs. Also check
brake hoses for signs of cracks. (2) Install the brake hose at the brake caliper (Fig.
9). Tighten the bolt to 14 N·m (124 in. lbs.).
(5) Remove the brake hose at the brake caliper
(3) Install the wear indicator cable and the wear
(Fig. 11).
indicator (Fig. 9). Tighten to 10 N·m (89 in. lbs.).
(6) Remove the brake caliper guide bolt (Fig. 11).
(4) Bleed the brake system.
(7) Remove the brake caliper (Fig. 11).
(5) Check the brake system for any leaks.
VA BRAKES - BASE 5 - 13
DISC BRAKE CALIPERS (Continued)
(3) Install the wear indicator cable and the wear
indicator (Fig. 11). Tighten to 10 N·m (89 in. lbs.).
(4) Bleed the brake system.
(5) Check the brake system for any leaks.
(6) Install the rear wheels (Refer to 22 - TIRES/
WHEELS/WHEELS - INSTALLATION).
(7) Lower the vehicle.

INSTALLATION - REAR (DRW)


(1) Install the brake caliper to brake caliper
adapter (Fig. 12). Tighten the guide bolt to 25 N·m
(221 in. lbs.) for M8 bolt or 30 N·m (266 in. lbs.) for
M10 bolt.

NOTE: Do not install the brake hose twisted and


ensure freedom of movement.
Fig. 12 REAR DISC BRAKE CALIPER WITH DUAL
REAR WHEELS (2) Install the brake hose at the brake caliper (Fig.
1 - ADAPTER BOLT
12). Tighten the bolt to 14 N·m (124 in. lbs.).
2 - WEAR INDICATOR MOUNTING BOLT (3) Install the wear indicator cable and the wear
3 - WEAR INDICATOR indicator (Fig. 12). Tighten to 10 N·m (89 in. lbs.).
4 - BRAKE LINE
5 - CLAMP
(4) Bleed the brake system.
6 - BRAKE HOSE (5) Check the brake system for any leaks.
7 - BRAKE CALIPER (6) Install the rear wheels (Refer to 22 - TIRES/
WHEELS/WHEELS - INSTALLATION).
(6) Install the front wheels. (7) Lower the vehicle.
(7) Lower the vehicle.

INSTALLATION - FRONT (DRW) DISC BRAKE CALIPER


(1) Install the brake caliper to the brake caliper
adapter (Fig. 10). Tighten the guide pins to 25 N·m
ADAPTER
(221 in. lbs.)(M8 bolt) or Tighten the guide pins to 30
N·m (265 in. lbs.)(M10 10.9 bolt). REMOVAL
NOTE: Do not install the brake hose twisted and
ensure freedom of movement.
REMOVAL - FRONT
(1) Unscrew the cap from the brake fluid reservoir.
(2) Install the brake hose at the brake caliper (Fig. (2) Raise and support the vehicle.
10). Tighten the bolt to 14 N·m (124 in. lbs.). (3) Remove the front wheels (Refer to 22 - TIRES/
(3) Install the wear indicator cable and the wear WHEELS/WHEELS - REMOVAL).
indicator (Fig. 10). Tighten to 10 N·m (89 in. lbs.). (4) Remove the disc brake caliper from the caliper
(4) Bleed the brake system. adapter (Refer to 5 - BRAKES/HYDRAULIC/ME-
(5) Check the brake system for any leaks. CHANICAL/DISC BRAKE CALIPERS - REMOVAL).
(6) Install the front wheels. (5) Remove the disc brake pads (Refer to 5 -
(7) Lower the vehicle. BRAKES/HYDRAULIC/MECHANICAL/BRAKE
PADS/SHOES - REMOVAL).
INSTALLATION - REAR (SRW) (6) Remove the disc brake caliper adapter.
(1) Install the brake caliper to brake caliper
adapter (Fig. 11). Tighten the guide bolt to 25 N·m REMOVAL - REAR
(221 in. lbs.) for M8 bolt or 30 N·m (266 in. lbs.) for (1) Unscrew the cap from the brake fluid reservoir.
M10 bolt. (2) Raise and support the vehicle.
(3) Remove the rear wheels (Refer to 22 - TIRES/
NOTE: Do not install the brake hose twisted and WHEELS/WHEELS - INSTALLATION).
ensure freedom of movement. (4) Remove the disc brake caliper.
(5) Remove the disc brake pads.
(2) Install the brake hose at the brake caliper (Fig. (6) Remove the disc brake caliper adapter.
11). Tighten the bolt to 14 N·m (124 in. lbs.).
5 - 14 BRAKES - BASE VA
DISC BRAKE CALIPER ADAPTER (Continued)

INSTALLATION STANDARD PROCEDURE - BRAKE FLUID


LEVEL
INSTALLATION - FRONT Always clean the master cylinder reservoir and
(1) Install the brake caliper adapter to the steering caps before checking fluid level. If not cleaned, dirt
knuckle. Tighten to 170 N·m (125 ft. lbs.). could enter the fluid.
(2) Install the disc brake shoes (Refer to 5 - The fluid fill level is indicated on the side of the
BRAKES/HYDRAULIC/MECHANICAL/BRAKE master cylinder reservoir (Fig. 13).
PADS/SHOES - INSTALLATION). The correct fluid level is to the MAX indicator on
the side of the reservoir. If necessary, add fluid to the
NOTE: Do not install the brake hose twisted and proper level.
ensure freedom of movement.

(3) Install the disc brake caliper. Tighten the bolt


to 14 N·m (124 in. lbs.) (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/DISC BRAKE CALIPERS
- INSTALLATION).
(4) Install the front wheels (Refer to 22 - TIRES/
WHEELS/WHEELS - INSTALLATION).
(5) 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

(3) Install the disc brake caliper (Refer to 5 - SPECIFICATIONS


BRAKES/HYDRAULIC/MECHANICAL/DISC
BRAKE CALIPERS - INSTALLATION). BRAKE FLUID
(4) Install the rear wheels (Refer to 22 - TIRES/ The brake fluid used in this vehicle must conform
WHEELS/WHEELS - INSTALLATION). to DOT 4 specifications and SAE standards. No other
(5) Lower the vehicle. type of brake fluid is recommended or approved for
usage in the vehicle brake system. Use only Mopar
brake fluid or an equivalent from a tightly sealed
FLUID container.

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.

Fig. 15 ALB LEVER DEFLECTION


1 - CLIP
2 - SPRING
Fig. 14 FLUID RESERVOIR 3 - LEVER
4 - STRIAGHT EDGE
1 - SUCTION GUN 5 - NUT
2 - BRAKE FLUID CAP 6 - POINT -A
3 - BRAKE FLUID LEVEL INDICATOR 7 - POINT - B
4 - MASTER CYLINDER 8 - SUSPENSION POINT
5 - FLUID RESERVOIR

INSTALLATION ALB CONTROLLER


(1) Install the fluid reservoir and fill with fluid
(Fig. 14). REMOVAL
(2) Bleed the brake system. (1) Install the brake pedal rod to hold the brake
(3) Check the brake system for any leaks. pressure.
(4) Reconnect the electrical connector to the brake (2) Raise and support the vehicle.
fluid level indicator (Fig. 14). (3) Remove the brake lines to the (automatic load-
dependant brake pressure control) ALB controller.
(4) Remove the adjusting nut and the spring from
ALB LEVER the ALB controller.
(5) Remove the mounting bolts.
REMOVAL (6) Remove the ALB controller.
(1) Raise and support the vehicle.
(2) Remove the retaining clip for the ALB lever INSTALLATION
(Fig. 15). (1) Install the ALB controller to the vehicle.
(3) Remove the bolt for the lever at the axle (Fig. (2) Install the mounting bolts for the controller.
15). (3) Install the brake lines. Tighten the lines to 16
(4) Remove the lever. N·m (142 in. lbs.)
(4) Install the adjusting rod, nut and spring to the
INSTALLATION ALB controller.
(1) Install the lever to the vehicle. (5) Lower the vehicle.
(2) Install the lower mounting bolt to the axle (Fig. (6) Remove the brake pedal hold down rod.
15). (7) Fill and bleed the brake system (Refer to 5 -
BRAKES - STANDARD PROCEDURE).
5 - 16 BRAKES - BASE VA
ALB CONTROLLER (Continued)
(8) Raise the vehicle and adjust the ALB controller (11) After adjustment reinstall the brake pedal
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ winch and recheck the pressures and readjust if
ALB CONTROLLER - ADJUSTMENTS). needed.
(9) Lower the vehicle and test drive. (12) Tighten the lock adjusting nut.

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.

Fig. 18 Vacuum Check Valve And Seal


1 - BOOSTER CHECK VALVE
2 - APPLY TEST VACUUM HERE
3 - VALVE SEAL

STANDARD PROCEDURE - MASTER CYLINDER


BLEEDING
A new master cylinder should be bled before instal-
lation on the vehicle. Required bleeding tools include
bleed tubes and a wood dowel to stroke the pistons.
Bleed tubes can be fabricated from brake line.
(1) Mount master cylinder in vise.
(2) Attach bleed tubes to cylinder outlet ports.
Then position each tube end into reservoir (Fig. 19).
(3) Fill reservoir with fresh brake fluid.
(4) Press cylinder pistons inward with wood dowel.
Then release pistons and allow them to return under
spring pressure. Continue bleeding operations until
air bubbles are no longer visible in fluid.

Fig. 17 Typical Booster Vacuum Test Connections


1 - TEE FITTING
2 - SHORT CONNECTING HOSE
3 - CHECK VALVE
4 - CHECK VALVE HOSE
5 - CLAMP TOOL
6 - INTAKE MANIFOLD
7 - VACUUM GAUGE

POWER BOOSTER CHECK VALVE TEST


(1) Disconnect vacuum hose from check valve.
(2) Remove check valve and valve seal from
booster.
(3) Use a hand operated vacuum pump for test.
(4) Apply 15-20 inches vacuum at large end of
check valve (Fig. 18).
(5) Vacuum should hold steady. If gauge on pump Fig. 19 Master Cylinder Bleeding–Typical
indicates vacuum loss, check valve is faulty and 1 - BLEEDING TUBES
should be replaced. 2 - RESERVOIR

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

Fig. 22 BRAKE PEDAL


1 - MOUNTING BOLT
2 - PEDAL BEARING BRACKET
3 - STOP LAMP SWITCH
4 - CLIP
5 - PIVOT BOLT
Fig. 21 MASTER CYLINDER (DRW) 6 - RETURN SPRING
7 - PEDAL
1 - POWER BRAKE BOOSTER 8 - PUSH ROD BOLT
2 - RESERVOIR 9 - PUSH ROD
3 - BRAKE LINES 10 - CLIP
4 - PRESSURE PORTS 11 - BOLT
5 - MASTER CYLINDER 12 - WASHER
VA BRAKES - BASE 5 - 19
PEDAL (Continued)

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).

POWER BRAKE BOOSTER Fig. 23 POWER BRAKE BOOSTER


1 - VACUUM LINE & CHECK VALVE
DESCRIPTION 2
3
-
-
BRAKE BOOSTER
GASKET
All models use a tandem diaphragm, power brake 4 - MOUNTING NUTS (4)
booster. 5 - PUSH ROD PIN
6 - SECURING CLIP
NOTE: The power brake booster is not a repairable
component. The booster must be replaced as an (2) Install the booster mounting nuts (Fig. 23).
assembly if diagnosis indicates a malfunction has Tighten to 25 N·m (221 in.lbs.).
occurred. (3) Install the push rod pin & clip (Fig. 23).
(4) Install the brake booster vacuum line and
check valve (Fig. 23).
OPERATION (5) Install the master cylinder to the brake
The booster unit consists of a single housing booster. Tighten to 28 N·m (248 in.lbs.).
divided into two by a tandem diaphragm. The outer (6) Install the brake lines to the master cylinder.
edge of the diaphragm is secured to the housing. The Tighten to 14 N·m (124 in.lbs.).
booster push rod, which connects the booster to the (7) Install the brake level switch electrical connec-
brake pedal and master cylinder, is attached to the tor.
center of the diaphragm. A check valve is used in the (8) Bleed the base brake system (Refer to 5 -
booster outlet connected to the engine intake mani- BRAKES - STANDARD PROCEDURE).
fold. Power assist is generated by utilizing a combi-
nation of vacuum and atmospheric pressure to boost
brake assist.
ROTORS
REMOVAL REMOVAL
(1) Using a suction gun remove as much brake
fluid from the reservoir as possible. REMOVAL - FRONT (SRW)
(2) Disconnect the brake level switch electrical (1) Raise and support the vehicle.
connector. (2) Remove the front wheels.
(3) Remove the brake lines from the master cylin- (3) Remove the front brake pads (Fig. 24).
der Seal off the ends and bore holes with plugs. (4) Remove the caliper adapter (Fig. 24).
(4) Remove the master cylinder from the booster. (5) Install two lug studs to secure the disc brake
(5) Remove the booster vacuum hose and check rotor when the locking bolt is removed.
valve (Fig. 23). (6) Remove the locking bolt for the disc brake rotor
(6) Remove the pedal push rod clip (Fig. 23). (Fig. 24).
(7) Remove the booster mounting nuts (Fig. 23). (7) Remove the two lug nuts.
(8) Remove the booster from the vehicle. (8) Remove the disc brake rotor (Fig. 24).
INSTALLATION
(1) Install the brake booster to the vehicle.
5 - 20 BRAKES - BASE VA
ROTORS (Continued)

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

DESCRIPTION N·m Ft. Lbs. In. Lbs.


Pressure Transformer Unit 25 — 221
For Brake Cables To
Frame Crossmember
Hand Brake Lever To Seat 25 — 221
Frame
VA BRAKES - BASE 5 - 23
PARKING BRAKE (Continued)

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.

(1) Open the brake control cable lock (Fig. 28).


(2) Press out the safety bolt and remove the brake
control cable lock (Fig. 28).

RETAINING CLIP RELEASE TOOL - 9289

Fig. 28 CONTROL CABLE LOCK


1 - BRAKE CABLE CONTROL LOCK OPEN
2 - BRAKE CABLE CONTROL LOCK CLOSED
RETAINING SPRING TOOL - 9281 3 - BRAKE CONTROL CABLE LOCK
4 - SAFETY BOLT
5 - INSTALLATION POSITION OF BRAKE CONTROL CABLE
LOCK

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).

Fig. 30 REMOVING FRONT PARK BRAKE CABLE AT


THE VEHICLE
1 - UNCLIP CABLE GUIDES
2 - LOCKING CLIP
3 - LOCKING RING PRESSED TOGETHER

(8) Remove the park brake cable from the vehicle.


Compress the locking ring on the pulley unit.

Fig. 29 FRONT PARK BRAKE CABLE AT LEVER


1 - LOCKING CLIP
2 - LOCKING PIN
3 - CABLE STRAP

(4) Unclip the guides at the frame cross members


for the front cable at the vehicle (Fig. 30).
(5) Pull off the locking clips at the floor opening
and pull the front brake cable down and out (Fig.
30).
(6) Press together the locking ring and pull out the
front brake cable to the front (Fig. 30).
(7) Remove the front park brake cable at the vehi-
cle using special tool 9289. Fig. 31 REAR PARK BRAKE CABLE REMOVE /
INSTALL
REMOVAL - REAR 1 - PARK BRAKE ADJUSTER
(1) Raise and support the vehicle. 2 - PARK BRAKE CABLE MOUNTING
(2) Remove the rear tires.
(3) Remove the park brake shoes. INSTALLATION
(4) Remove the park brake cables from the shoe
(Fig. 31). INSTALLATION - FRONT
(5) Remove all the connections on the hand brake (1) Install the front park brake cable to the vehi-
cable (Fig. 31). cle.
(6) Remove the park brake cable lock (Fig. 31). (2) Clip the cable guides at the frame cross mem-
Observe the installed position of the brake bers (Fig. 32).
cable lock for reference on installation. (3) Install the front park brake cable to the hand
(7) Remove the hand brake cable from the anchor brake lever (Fig. 29).
plate (Fig. 31). (4) Reconnect the front park brake cable to the
pulley unit (Fig. 32).
VA BRAKES - BASE 5 - 25
CABLES (Continued)
(5) Adjust the parking park. (5) Remove the 6 mm diameter drill bit or allen
(6) Lower the vehicle. wrench (Fig. 33).
(6) Tighten the hand brake lever one notch (Fig.
33).

Fig. 32 FRONT PARK BRAKE CABLE


1 - RETAINING CLIP
2 - LOCKING PIN Fig. 33 PARK BRAKE ADJUSTER
3 - FRONT PARK BRAKE CABLE
4 - RETAINING CLIP 1 - LOOSEN MOUNTING BOLTS
5 - PARK BRAKE CABLE ADJUSTER 2 - 6 mm ALLEN WRENCH
3 - MOUNTING BOLTS TIGHTENED
4 - FREEPLAY WITH NO TENSION
INSTALLATION - REAR
(7) Clamp the eccentric clockwise until the wheels/
NOTE: Route the park brake cable free of tension disc brake rotors can still be turned with the force of
and the risk of chafing. the hand (Fig. 34).
(8) Tighten the clamp bolt (Fig. 34).
(1) Install the hand brake cable to the anchor
plate (Fig. 31).
(2) Install the park brake cable lock (Fig. 31).
(3) Install all connections on the hardware cable
(Fig. 31).
(4) Install the park brake cables to the shoe (Fig.
31).
(5) Install the park brake shoes.
(6) Install the rear wheels.
(7) Adjust the park brakes.
(8) Lower the vehicle.

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.

Fig. 35 HAND BRAKE LEVER


1 - LOCKING PIN
2 - COVER
3 - HAND BRAKE LEVER
4 - HAND BRAKE CHECK SWITCH
5 - WIRING HARNESS
6 - BOLT Fig. 36 PARK BRAKE SHOES
7 - HAND BRAKE CABLE 1 - PARK BRAKE SHOES
8 - BOLT 2 - PRESSURE SPRING
9 - RETAINING CLIP 3 - RETRACTING SPRING (SHORT HOOK EYE)
10 - CIRCLE COVER 4 - RETRACTING SPRING (LONG HOOK EYE)
5 - CABLE LOCK
INSTALLATION 6 - ADJUSTER
(1) Install the hand brake lever (Fig. 35).
(2) Reconnect the hand brake check switch and the REMOVAL - (DRW)
wiring harness to the hand brake lever (Fig. 35). (1) Raise and support the vehicle.
(3) Install the cover to the hand brake lever (Fig. (2) Remove the rear wheels.
35). (3) Remove the wheel flange ring.
(4) Install the bolts on the hand brake lever. (4) Remove the disc brake rotor.
Tighten to 25 N·m (221 in. lbs.) (Fig. 35). (5) Disconnect the front park brake cable from the
(5) Install the circle cover (Fig. 35). pulley unit. Do not remove the rear park brake
(6) Install the front brake cable to the hand brake cables.
lever. (6) Remove the retracting springs (Fig. 37).
(7) Connect the front brake cable to the pulley unit
(Fig. 35).
VA BRAKES - BASE 5 - 27
SHOES (Continued)
(7) Remove the adjuster (Fig. 37). (2) Install the lower retracting spring using special
(8) Remove the pressure springs (Fig. 37). by tool 9280.
depressing with your fingers and twisting. (3) Install the hold down springs using special tool
(9) Remove the rear park brake shoes (Fig. 37). 9281.
Pull the park brake shoes apart at the bottom (4) Install the upper retracting spring using spe-
and remove them together with the adjuster. cial tool 9280.
(5) Install the adjuster.
(6) Install the front park brake cable to the pulley
unit.
(7) Install the disc brake rotor.
(8) Install the rear wheels.
(9) Adjust the parking brakes.
(10) Lower the vehicle.
(11) Pump the brake pedal several times to check
the operation of the brakes before moving vehicle.

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

(6) Install rear wheels.


(7) Lower the vehicle and test the park brake sys-
tem to hold the vehicle.
VA BRAKES - ABS 5 - 29

BRAKES - ABS

TABLE OF CONTENTS
page page

BRAKES - ABS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 31


SPECIFICATIONS - TORQUE CHART . . . . . . . . 29 TONE WHEEL
ELECTRICAL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 29 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 31
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 HCU (HYDRAULIC CONTROL UNIT)
FRONT WHEEL SPEED SENSOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 31
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 30 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 32
REAR WHEEL SPEED SENSOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

BRAKES - ABS
SPECIFICATIONS - TORQUE CHART
TORQUE SPECIFICATIONS

DESCRIPTION N·m Ft. Lbs. In. Lbs.


Brake Lines To Hydraulic 16 — 12
unit

ELECTRICAL When the ring gear is rotated, the exciter ring


passes the tip of the WSS. As the exciter ring tooth
approaches the tip of the WSS, the magnetic lines of
DESCRIPTION
force expand, causing the magnetic field to cut across
NOTE: Wheel speed sensor should be installed all the sensor’s windings. This, in turn causes current to
the way into the clamping bushings, the wheel flow through the WSS circuit (Fig. 1) in one direc-
speed sensor will self adjust when the vehicle is tion. When the exciter ring tooth moves away from
moved. the sensor tip, the magnetic lines of force collapse
cutting the winding in the opposite direction. This
The ABS brake system uses 4 wheel speed sensors. causes the current to flow in the opposite direction.
A sensor is mounted to each front hub/bearings in Every time a tooth of the exciter ring passes the tip
the front. A rear sensor is mounted to each rear sup- of the WSS, an AC signal is generated. Each AC sig-
port plate. nal (positive to negative signal or sinewave) is inter-
preted by the CAB. It then compares the frequency of
OPERATION the sinewave to a time value to calculate vehicle
The Wheel Speed Sensor consists of a magnet sur- speed. The CAB continues to monitor the frequency
rounded by windings from a single strand of wire. to determine a deceleration rate that would indicate
The sensor sends a small AC signal to the CAB. This a possible wheel-locking tendency.
signal is generated by magnetic induction. The mag- The signal strength of any magnetic induction sen-
netic induction is created when a toothed sensor ring sor is directly affected by:
(exciter ring or tone wheel) passes the stationary • Magnetic field strength; the stronger the mag-
magnetic WSS. netic field, the stronger the signal
5 - 30 BRAKES - ABS VA
ELECTRICAL (Continued)

Fig. 2 FRONT WHEEL SPEED SENSOR


1 - SHRINK-FIT SLEEVE
2 - CLAMPING BUSHING
3 - SPEED SENSOR
4 - SHRINK TUBE
Fig. 1 Operation of the Wheel Speed Sensor
1 - MAGNETIC CORE
(4) Lower the vehicle.
2 - CAB
3 - AIR GAP
4
5
- EXCITER RING
- COIL
REAR WHEEL SPEED SENSOR
• Number of windings in the sensor; more wind- REMOVAL
ings provide a stronger signal (1) Raise and support the vehicle.
• Exciter ring speed; the faster the exciter ring/ (2) Remove the rear wheels.
tone wheel rotates, the stronger the signal will be (3) Pull the wheel speed sensor out of the mount-
• Distance between the exciter ring teeth and ing hole in the axle supporting tube (Fig. 3).
WSS; the closer the WSS is to the exciter ring/tone (4) Only due this step if sensor replacement is
wheel, the stronger the signal will be. necessary. Cut through the wheel speed sensor
cable at an easily accessible point (Fig. 3)

FRONT WHEEL SPEED


SENSOR
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the front wheels.
(3) Pull the wheel speed sensor out of the front
wheel hub (Fig. 2).
(4) Only due this step if sensor replacement is
necessary. Cut through the wheel speed sensor
cable at an easily accessible point (Fig. 2)

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)

INSTALLATION HCU (HYDRAULIC CONTROL


(1) Connect separate wheel speed sensor cables
with shrink-fit sleeves and shrink-fit tubing (Fig.
UNIT)
3).Only due this step if replacing the sensor.
(2) Install the wheel speed sensor all the way into DESCRIPTION
the axle tube, the wheel speed sensor will self adjust The HCU consists of a valve body, pump motor, low
when the vehicle is moved (Fig. 3). pressure accumulators, inlet valves, outlet valves and
(3) Install the rear wheels. noise attenuators.
(4) Lower the vehicle.
REMOVAL
TONE WHEEL NOTE: Store the Hydraulic Control Unit in an
upright position only.
REMOVAL (1) Disconnect the ground cable at the battery.
(1) Remove the hub/bearing assembly (DRW)
The ignition switch must be switched to the off
(Refer to 3 - DIFFERENTIAL & DRIVELINE/REAR
position when disconnecting the battery cable.
AXLE/AXLE BEARINGS - REMOVAL).
(2) Disconnect the multiplug from the control mod-
(2) Insert a hooked prybar between the hub/bear-
ule (Fig. 5).
ing and the inside of the tone wheel and pry upwards
(3) Disconnect the brake lines from the hydraulic
slightly and work your way around the tone wheel
control unit (Fig. 5). Mark the brake lines for
until the wheel is loose (Fig. 4).
reinstallation, also seal off the connections and
(3) Remove the tone wheel.
lines to prevent contamination.
(4) Remove the hydraulic control unit from the
bracket (Fig. 5).
(5) Check the rubber mounts on the bracket.
(Replace if necessary) (Fig. 5).

Fig. 4 TONE WHEEL REMOVAL


1 - HOOKED PRYBAR
2 - TONE WHEEL
3 - HUB/BEARING ASSEMBLY

INSTALLATION Fig. 5 HYDRAULIC CONTROL UNIT (ABS)


(1) Install the tone wheel to the hub/bearing with 1 - BRAKE LINES
a thin bead of silicone around the tone wheel. 2 - HCU WITH CONTROL MODULE
3 - ABS/ABD CONTROL MODULE MULTIPLUG
(2) Tap the tone wheel down with a soft hammer 4 - RUBBER SUPPORT
until seated.
(3) Install the hub/bearing (DRW) (Refer to 3 -
DIFFERENTIAL & DRIVELINE/REAR AXLE/AXLE
BEARINGS - INSTALLATION).
5 - 32 BRAKES - ABS VA
HCU (HYDRAULIC CONTROL UNIT) (Continued)

INSTALLATION (4) Reconnect the ground cable on the battery.


(1) Install the hydraulic control unit into the rub- (5) Bleed the brake system.
ber mounts (Fig. 5). (6) Check the fluid in the reservoir and correct if
(2) Reconnect the brake lines to the hydraulic con- necessary.
trol unit (Fig. 5). Do not mix up the brake lines. (7) Perform function test.
Tighten the lines to 16 N·m (142 in. lbs.)
(3) Reconnect the multiplug to the control module
(Fig. 5).
VA COOLING 7-1

COOLING
TABLE OF CONTENTS

page page

COOLING COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . 2


OPERATION - COOLING SYSTEM . . . . . . . . . . . 1 ACCESSORY DRIVE . . . . . . . . . . . . . . . . . . . . . . . 5
DIAGNOSIS AND TESTING ENGINE ................................9
DIAGNOSIS AND TESTING - PRELIMINARY
CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

COOLING Driving techniques that avoid overheating are:


• Idle with A/C off when temperature gauge is at
end of normal range.
OPERATION - COOLING SYSTEM
• Increasing engine speed for more air flow is rec-
The cooling system regulates engine operating tem-
ommended.
perature. It allows the engine to reach normal oper-
ating temperature as quickly as possible. It also TRAILER TOWING:
maintains normal operating temperature and pre-
Consult Trailer Towing section of owners manual.
vents overheating.
Do not exceed limits.
The cooling system also provides a means of heat-
ing the passenger compartment and cooling the auto- AIR CONDITIONING; ADD-ON OR AFTER MARKET:
matic transmission fluid (if equipped). The cooling A maximum cooling package should have been
system is pressurized and uses a centrifugal water ordered with vehicle if add-on or after market A/C is
pump to circulate coolant throughout the system. installed. If not, maximum cooling system compo-
nents should be installed for model involved per
DIAGNOSIS AND TESTING manufacturer’s specifications.

RECENT SERVICE OR ACCIDENT REPAIR:


DIAGNOSIS AND TESTING - PRELIMINARY
Determine if any recent service has been per-
CHECKS formed on vehicle that may effect cooling system.
This may be:
ENGINE COOLING SYSTEM OVERHEATING • Engine adjustments (incorrect timing)
Establish what driving conditions caused the com- • Slipping engine accessory drive belt(s)
plaint. Abnormal loads on the cooling system such as • Brakes (possibly dragging)
the following may be the cause: • Changed parts. Incorrect water pump or pump
• PROLONGED IDLE rotating in wrong direction due to belt not correctly
• VERY HIGH AMBIENT TEMPERATURE routed
• SLIGHT TAIL WIND AT IDLE • Reconditioned radiator or cooling system refill-
• SLOW TRAFFIC ing (possibly under filled or air trapped in system).
• TRAFFIC JAMS
• HIGH SPEED OR STEEP GRADES NOTE: If investigation reveals none of the previous
items as a cause for an engine overheating com-
plaint, (Refer to 7 - COOLING - DIAGNOSIS AND
TESTING)
7-2 COOLING VA
COOLING (Continued)

COOLING SYSTEM
COOLING SYSTEM DIAGNOSIS - DIESEL ENGINE

CONDITION POSSIBLE CAUSES CORRECTION

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)

CONDITION POSSIBLE CAUSES CORRECTION

13. Brakes dragging. 13. Check brakes. (Refer to 5 -


BRAKES/HYDRAULIC/
MECHANICAL - DIAGNOSIS AND
TESTING)

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.

5. Obstructed air flow through 5. Remove obstruction.


radiator.
7-4 COOLING VA
COOLING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION

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.

HEAT ODOR 1. Damaged or missing drive line 1. Repair or replace damaged or


heat shields. missing heat shields.
2. Thermal viscous fan drive 2. Check thermal viscous fan drive.
damaged. (Refer to 7 - COOLING/ENGINE/
FAN DRIVE VISCOUS CLUTCH -
DIAGNOSIS AND TESTING)
VA ACCESSORY DRIVE 7-5

ACCESSORY DRIVE

TABLE OF CONTENTS
page page

BELT TENSIONERS REMOVAL


DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 5 REMOVAL . . . .........................8
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 REMOVAL . . . .........................8
DRIVE BELTS INSTALLATION
DIAGNOSIS AND TESTING - ACCESSORY INSTALLATION ........................8
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . 6 INSTALLATION ........................8

BELT TENSIONERS Drive belts on all engines are equipped with a


spring loaded automatic belt tensioner. This ten-
sioner maintains constant belt tension at all times
DESCRIPTION
and requires no maintenance or adjustment. (Fig. 1)

OPERATION
WARNING: The automatic belt tensioner assembly
is spring loaded. do not attempt to disassemble the
tensioner assembly.

The automatic belt tensioner maintains correct belt


tension using a coiled spring within the tensioner
housing. The spring applies pressure to the tensioner
arm pressing the arm into the belt, tensioning the
belt.
If a new belt is being installed, the arrow must be
within approximately 3 mm (1/8 in.) of indexing
mark. Belt is considered new if it has been used 15
minutes or less. If this specification cannot be met,
Fig. 1 Accessory Drive Belt check for:
1 - WATER PUMP • The wrong belt being installed (incorrect length/
2 - ACCESSORY DRIVE BELT width)
3 - AUTOMATIC BELT TENSIONER
4 - 3/89 SQUARE BOLT
• Worn bearings on an engine accessory (A/C com-
5 - MOUNT. BOLT pressor, power steering pump, water pump, idler pul-
ley or generator)
CAUTION: Do not attempt to check belt tension with • A pulley on an engine accessory being loose
a belt tension gauge on vehicles equipped with an • Misalignment of an engine accessory
automatic belt tensioner. • Belt incorrectly routed.
7-6 ACCESSORY DRIVE VA

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

ACCESSORY DRIVE BELT DIAGNOSIS CHART

CONDITION POSSIBLE CAUSES CORRECTION

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.

2. Installation damage 2. Replace belt

RIB OR BELT WEAR 1. Pulley misaligned 1. Align pulley(s)

2. Abrasive environment 2. Clean pulley(s). Replace belt if


necessary
3. Rusted pulley(s) 3. Clean rust from pulley(s)
4. Sharp or jagged pulley groove 4. Replace pulley. Inspect belt.
tips
5. Belt rubber deteriorated 5. Replace belt

BELT SLIPS 1. Belt slipping because of 1. Inspect/Replace tensioner if


insufficient tension necessary
2. Belt or pulley exposed to 2. Replace belt and clean pulleys
substance that has reduced friction
(belt dressing, oil, ethylene glycol)
3. Driven component bearing failure 3. Replace faulty component or
(seizure) bearing
4. Belt glazed or hardened from 4. Replace belt.
heat and excessive slippage
VA ACCESSORY DRIVE 7-7
DRIVE BELTS (Continued)

CONDITION POSSIBLE CAUSES CORRECTION

LONGITUDAL BELT CRACKING 1. Belt has mistracked from pulley 1. Replace belt
groove

2. Pulley groove tip has worn away 2. Replace belt


rubber to tensile member

9GROOVE JUMPING9 1. Incorrect belt tension 1. Inspect/Replace tensioner if


(Belt does not maintain correct necessary
position on pulley)
2. Pulley(s) not within design 2. Replace pulley(s)
tolerance
3. Foreign object(s) in grooves 3. Remove foreign objects from
grooves
4. Pulley misalignment 4. Align component
5. Belt cordline is broken 5. Replace belt

BELT BROKEN 1. Incorrect belt tension 1. Replace Inspect/Replace


(Note: Identify and correct problem tensioner if necessary
before new belt is installed)
2. Tensile member damaged during 2. Replace belt
belt installation
3. Severe misalignment 3. Align pulley(s)
4. Bracket, pulley, or bearing failure 4. Replace defective component
and belt

NOISE (Objectional squeal, squeek, 1. Incorrect belt tension 1. Inspect/Replace tensioner if


or rumble is heard or felt while drive necessary
belt is in operation) 2. Bearing noise 2. Locate and repair
3. Belt misalignment 3. Align belt/pulley(s)
4. Belt to pulley mismatch 4. Install correct belt
5. Driven component induced 5. Locate defective driven
vibration component and repair
6. System resonent frequency 6. Vary belt tension within
induced vibration specifications

TENSION SHEETING FABRIC 1. Tension sheeting contacting 1. Correct rubbing condition


FAILURE stationary object
(Woven fabric on outside,
circumference of belt has cracked or 2. Excessive heat causing woven 2. Replace belt
separated from body of belt) fabric to age
3. Tension sheeting splice has 3. Replace belt
fractured

CORD EDGE FAILURE 1. Incorrect belt tension 1. Inspect/Replace tensioner if


(Tensile member exposed at edges necessary
of belt or separated from belt body) 2. Belt contacting stationary object 2. Replace belt
3. Pulley(s) out of tolerance 3. Replace pulley
4. Insufficient adhesion between 4. Replace belt
tensile member and rubber matrix
7-8 ACCESSORY DRIVE VA
DRIVE BELTS (Continued)

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.

(1) Remove A/C compressor drive belt (Refer to 7 -


COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(2) A 3/8 inch square hole is provided in the auto-
matic belt tensioner. Attach a 3/8 inch drive-long
handle ratchet to this hole (Fig. 3).
(3) Rotate ratchet and tensioner assembly counter-
clockwise (as viewed from front) until tension has
been relieved from belt (Fig. 3).
(4) Remove belt from water pump pulley first.

Fig. 4 ACCESSORY DRIVE BELT ROUTING


1 - A/C COMPRESSOR
2 - POWER STEERING
3 - DRIVE BELT TENSIONER
4 - CRANKSHAFT PULLEY
5 - WATER PUMP PULLEY
6 - GENERATOR
7 - IDLER PULLEY

(2) Attach a 3/8 inch ratchet to tensioner.


(3) Rotate ratchet and belt tensioner counterclock-
wise. Place belt over water pump pulley. Let ten-
sioner rotate back into place. Remove ratchet. Be
sure belt is properly seated on all pulleys.
(4) Install A/C compressor drive belt (Refer to 7 -
Fig. 3 DRIVE BELT TENSIONER COOLING/ACCESSORY DRIVE/DRIVE BELTS -
1 - ACCESSORY DRIVE BELT TENSIONER
INSTALLATION).
2 - RATCHET WRENCH
INSTALLATION
(5) Remove belt from vehicle. (1) Position A/C compressor drive belt over crank-
shaft pulley and A/C compressor pulley.
REMOVAL (2) Tighten drive belt tensioner.
(1) Loosen tension adjuster.
(2) Remove A/C compressor drive belt.
VA ENGINE 7-9

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

COOLANT 100 Percent Ethylene-Glycol - Should Not Be Used in


Chrysler Vehicles
Use of 100 percent ethylene-glycol will cause for-
DESCRIPTION mation of additive deposits in the system, as the cor-
Coolant flows through the engine water jackets
rosion inhibitive additives in ethylene-glycol require
and cylinder heads absorbing heat produced by the
the presence of water to dissolve. The deposits act as
engine during operation. The coolant carries heat to
insulation, causing temperatures to rise to as high as
the radiator and heater core. Here it is transferred to
149° C (300° F). This temperature is hot enough to
ambient air passing through the radiator and heater
melt plastic and soften solder. The increased temper-
core fins.
ature can result in engine detonation. In addition,
The required ethylene-glycol (antifreeze) and water
100 percent ethylene-glycol freezes at -22° C (-8° F ).
mixture depends upon the climate and vehicle oper-
ating conditions. The recommended mixture of 50/50 Propylene-glycol Formulations - Should Not Be Used in
ethylene-glycol and water will provide protection Chrysler Vehicles
against freezing to -37° C (-35° F). The antifreeze Propylene-glycol formulations do not meet
concentration must always be a minimum of 44 per- Chrysler coolant specifications. It’s overall effec-
cent, year-round in all climates. If percentage is tive temperature range is smaller than that of ethyl-
lower than 44 percent, engine parts may be ene-glycol. The freeze point of 50/50 propylene-glycol
eroded by cavitation, and cooling system com- and water is -32° C (-26° F). 5° C higher than ethyl-
ponents may be severely damaged by corrosion. ene-glycol’s freeze point. The boiling point (protection
Maximum protection against freezing is provided against summer boil-over) of propylene-glycol is 125°
with a 68 percent antifreeze concentration, which C (257° F ) at 96.5 kPa (14 psi), compared to 128° C
prevents freezing down to -67.7° C (-90° F). A higher (263° F) for ethylene-glycol. Use of propylene-glycol
percentage will freeze at a warmer temperature. can result in boil-over or freeze-up in Chrysler vehi-
Also, a higher percentage of antifreeze can cause the cles, which are designed for ethylene-glycol. Propy-
engine to overheat because the specific heat of anti- lene glycol also has poorer heat transfer
freeze is lower than that of water. characteristics than ethylene glycol. This can
increase cylinder head temperatures under certain
conditions.
7 - 10 ENGINE VA
COOLANT (Continued)
Propylene-glycol/Ethylene-glycol Mixtures - Should Not Be
Used in Chrysler Vehicles
Propylene-glycol/ethylene-glycol Mixtures can
cause the destabilization of various corrosion inhibi-
tors, causing damage to the various cooling system
components. Also, once ethylene-glycol and propy-
lene-glycol based coolants are mixed in the vehicle,
conventional methods of determining freeze point will
not be accurate. Both the refractive index and spe-
cific gravity differ between ethylene glycol and propy-
lene glycol.

CAUTION: Richer antifreeze mixtures cannot be


measured with normal field equipment and can
cause problems associated with 100 percent ethyl-
ene-glycol.

DIAGNOSIS AND TESTING


COOLING SYSTEM LEAKS
ULTRAVIOLET LIGHT METHOD Fig. 1 Leak Detection Using Black Light - Typical
A leak detection additive is available through the 1 - TYPICAL BLACK LIGHT TOOL
parts department that can be added to cooling sys-
tem. The additive is highly visible under ultraviolet Inspect cams on outside of pressure container. If
light (black light). Pour one ounce of additive into cams are damaged, seating of pressure cap valve and
cooling system. Place heater control unit in HEAT tester seal will be affected.
position. Start and operate engine until radiator Attach pressure tester (7700 or an equivalent) to
upper hose is warm to touch. Aim the commercially coolant pressure container (Fig. 2).
available black light tool at components to be
checked. If leaks are present, black light will cause
additive to glow a bright green color.
The black light can be used in conjunction with a
pressure tester to determine if any external leaks
exist (Fig. 1).

PRESSURE TESTER METHOD


The engine should be at normal operating temper-
ature. Recheck the system cold if cause of coolant
loss is not located during the warm engine examina-
tion.

WARNING: Hot, pressurized coolant can cause


injury by scalding.

Carefully remove coolant recovery pressure con-


tainer cap and check coolant level. Push down on cap
to disengage it from stop tabs. Wipe inside of con-
tainer and examine lower inside sealing seat for
nicks, cracks, paint, dirt and solder residue. Inspect
radiator-to- pressure container hose for internal
obstructions. Insert a wire through the hose to be
Fig. 2 PRESSURE TESTING
sure it is not obstructed.
1 - PRESSURE RESERVOIR CAP
2 - PRESSURE RESERVOIR
3 - PRESSURE TESTER
VA ENGINE 7 - 11
COOLANT (Continued)
Operate tester pump to apply 103.4 kPa (15 psi) Because the vehicle is equipped with a catalytic
pressure to system. If hoses enlarge excessively or converter, do not remove spark plug cables or short
bulges while testing, replace as necessary. Observe out cylinders to isolate compression leak.
gauge pointer and determine condition of cooling sys- If the needle on dial of pressure tester does not
tem according to following criteria: fluctuate, race engine a few times to check for an
Holds Steady: If pointer remains steady for two abnormal amount of coolant or steam. This would be
minutes, serious coolant leaks are not present in sys- emitting from exhaust pipe. Coolant or steam from
tem. However, there could be an internal leak that exhaust pipe may indicate a faulty cylinder head gas-
does not appear with normal system test pressure. If ket, cracked engine cylinder block or cylinder head.
it is certain that coolant is being lost and leaks can- A convenient check for exhaust gas leakage into
not be detected, inspect for interior leakage or per- cooling system is provided by a commercially avail-
form Internal Leakage Test. able Block Leak Check tool. Follow manufacturers
Drops Slowly: Indicates a small leak or seepage instructions when using this product.
is occurring. Examine all connections for seepage or
slight leakage with a flashlight. Inspect radiator, COMBUSTION LEAKAGE TEST - WITHOUT
hoses, gasket edges and heater. Seal small leak holes PRESSURE TESTER
with a Sealer Lubricant (or equivalent). Repair leak DO NOT WASTE reusable coolant. If solution is
holes and inspect system again with pressure clean, drain coolant into a clean and suitably marked
applied. container for reuse.
Drops Quickly: Indicates that serious leakage is
occurring. Examine system for external leakage. If WARNING: Do not remove cylinder block drain
leaks are not visible, inspect for internal leakage. plugs or loosen radiator drain with system hot and
Large radiator leak holes should be repaired by a under pressure. serious burns from coolant can
reputable radiator repair shop. occur.

INTERNAL LEAKAGE INSPECTION Drain sufficient coolant to allow thermostat


Remove engine oil pan drain plug and drain a removal.
small amount of engine oil. If coolant is present in Remove accessory drive belt.
the pan, it will drain first because it is heavier than Add coolant to pressure container to bring level to
oil. An alternative method is to operate engine for a within 6.3 mm (1/4 in) of top of thermostat housing.
short period to churn the oil. After this is done,
remove engine dipstick and inspect for water glob- CAUTION: Avoid overheating. Do not operate
ules. Also inspect transmission dipstick for water engine for an excessive period of time. Open drain-
globules and transmission fluid cooler for leakage. cock immediately after test to eliminate boil over.

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.

Fig. 3 DRAINING COOLANT SYSTEM


1 - DRAIN HOSE 3 - RADIATOR DRAIN PLUG
2 - ENGINE DRAIN PLUG 4 - DRAIN HOSE
VA ENGINE 7 - 13
COOLANT (Continued)
(4) After engine has reached normal operating
temperature, shut engine off and allow it to cool.
When engine is cooling down, coolant will be drawn
into the radiator from the pressure container.
(5) Add coolant to pressure container as necessary.
Only add coolant to the container when the
engine is cold. Coolant level in a warm engine
will be higher due to thermal expansion. To
purge the cooling system of all air, this heat up/cool
down cycle (adding coolant to cold engine) must be
performed three times. Add necessary coolant to raise
container level to the COLD MINIMUM mark after
each cool down period.

COOLANT LEVEL SENSOR


REMOVAL
WARNING: Risk of injury to skin and eyes due to
scalding from hot coolant. Do not open the cooling
system unless the temperature is below 194°f
(90°c). Wear protective clothing and eye wear. Risk Fig. 4 COOLANT LEVEL SENSOR
of poisoning if coolant is swallowed. Store coolant 1 - COOLANT LEVEL SENSOR
in proper and appropriately marked containers. 2 - COOLANT RESERVIOR
3 - ELECTRICAL CONNECTOR

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)

Fig. 5 RADIATOR FAN Fig. 6 ENGINE BLOCK HEATER


1 - VISCOUS CLUTCH 1 - ENGINE BLOCK HEATER
2 - COUNTERHOLDER 2 - CORE PLUG
3 - CLUTCH BOLT 3 - ENGINE MOUNT
4 - FAN BOLT 4 - WIRING TIE STRAPS
5 - FAN

(6) Connect negative battery cable.


ENGINE COOLANT TEMP
SENSOR
ENGINE BLOCK HEATER DESCRIPTION
The ECM determines the operating temperature of
REMOVAL the engine by using the signal from the coolant tem-
perature sensor. The coolant temperature sensor has
WARNING: Risk of injury to skin and eyes due to a negative temperature coefficient (NTC) resistor
scalding from hot coolant. Do not open the cooling contained in the plastic housing. NTC means; the
system unless the temperature is below 90°C higher the temperature, then the lower the resis-
(194°F). Wear protective clothing and eye wear. Risk tance. The ECM also uses the coolant temperature
of poisoning if coolant is swallowed. Store coolant sensor signal to calculate glow plug relay triggering.
in proper and appropriately marked containers. If the coolant temperature sensor fails during opera-
tion, the ECM will switch on the cooling fan to pre-
(1) Disconnect the negative battery cable.
vent engine overheating (A/C models only).
(2) Drain the cooling system.
(3) Record the location and snip the wire ties.
(4) Unscrew the engine block heater from the core
REMOVAL
plug hole and remove (Fig. 6). WARNING: Risk of injury to skin and eyes from
scalding with hot coolant. Risk of poisoning from
INSTALLATION swallowing coolant. Do not open cooling system
(1) Screw the block heater into the core hole (Fig. unless coolant temperature is below 90°C. Open
6). cap slowly to release pressure. Store coolant in
(2) Route the heater wiring harness away from suitable and appropriately marked container. Wear
and interference and secure with wiring tie straps. protective gloves, clothes and eye wear.
(3) Refill the cooling system.
(4) Connect the negative battery cable. (1) Disconnect negative battery cable.
(5) Start the engine and inspect for leaks. (2) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
VA ENGINE 7 - 15
ENGINE COOLANT TEMP SENSOR (Continued)
(3) Partailly drain coolant system (Refer to 7 - WARNING: Use extreme caution when engine is
COOLING/ENGINE/COOLANT - STANDARD PRO- operating. Do not stand in a direct line with fan. do
CEDURE). not put your hands near pulleys, belts or fan. Do
(4) Unplug coolant temperature sensor electrical not wear loose clothes.
connector.
(6) Start engine and inspect for leaks.
NOTE: Capture any residual coolant that may flow.

(5) Remove coolant temperature sensor (Fig. 7). ENGINE COOLANT


THERMOSTAT
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 COOL-
ANT IN SUITABLE AND APPROPRIATELY MARKED
CONTAINER. WEAR PROTECTIVE GLOVES,
CLOTHES AND EYE WEAR.

NOTE: Inspect condition of all clamps and hoses,


replace as necessary.

(1) Disconnect negative battery cable.


(2) Partially drain engine coolant (Refer to 7 -
Fig. 7 ENGINE COOLANT TEMPERATURE SENSOR
COOLING/ENGINE/COOLANT - STANDARD PRO-
1 - RETAINING CLAMP
2 - ENGINE COOLANT TEMPERATURE SENSOR
CEDURE).
(3) Unplug connector, pull off locking element and
INSTALLATION pull out coolant temperature sensor.
(4) Detach air intake hose at charge air distribu-
WARNING: Risk of injury to skin and eyes from tion pipe.
scalding with hot coolant. Risk of poisoning from (5) Detach coolant hoses at thermostat housing.
swallowing coolant. Do not open cooling system (6) Unscrew cap at oil filter housing.
unless coolant temperature is below 90°C (194°F). (7) Remove thermostat housing (Fig. 8).
Open cap slowly to release pressure. store coolant (8) Clean all sealing surfaces.
in suitable and appropriately marked container.
Wear protective gloves, clothes and eye wear. INSTALLATION
(1) Clean all sealing surfaces.
(1) Position and install coolant temperature sensor (2) Position and install thermostat housing with
(Fig. 7). new gasket (Fig. 8). Tighten bolts to 9N·m (80
(2) Connect coolant temperature sensor electrical lbs.in.).
connector (Fig. 7).
(3) Refill coolant system to proper level with NOTE: Inspect condition of all clamps and hoses,
proper mixture of coolant (Refer to 7 - COOLING/ replace as necessary.
ENGINE/COOLANT - STANDARD PROCEDURE).
(4) Install engine cover (Refer to 9 - ENGINE - (3) Install cap at oil filter housing.
INSTALLATION). (4) Connect coolant hoses and vent hose (Fig. 8).
(5) Connect negative battery cable. (5) Attach air intake hose at charge air distribu-
tion pipe.
7 - 16 ENGINE VA
ENGINE COOLANT THERMOSTAT (Continued)

FAN DRIVE VISCOUS CLUTCH


REMOVAL
(1) For fan drive viscous clutch removal refer to
(Refer to 7 - COOLING/ENGINE/RADIATOR FAN -
REMOVAL).

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)

Fig. 9 RADIATOR ASSEMBLY


1 - COOLANT HOSE 8 - ATF LINE
2 - SENSOR HARNESS CONNECTOR 9 - LEFT RADIATOR TRIM PANEL
3 - HYDRAULIC HOSE 10 - RIGHT RADIATOR TRIM PANEL
4 - CHARGE AIR HOSE 11 - RADIATOR
5 - HYDRAULIC HOSE 12 - ATF LINE
6 - RUBBER GROMMET 13 - COOLANT HOSE
7 - COOLANT HOSE 14 - COOLANT RESERVOIR

(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)

RADIATOR PRESSURE CAP


DESCRIPTION
All vehicles are equipped with a pressure cap (Fig.
11). This cap releases pressure at some point within
a range of 124-145 kPa (18-21 psi). The pressure
relief point (in pounds) is engraved on top of the cap
The cooling system will operate at pressures
slightly above atmospheric pressure. This results in a
higher coolant boiling point allowing increased radi-
ator cooling capacity. The cap contains a spring-
loaded pressure relief valve. This valve opens when
system pressure reaches the release range of 124-145
kPa (18-21 psi).
A rubber gasket seals the radiator filler neck. This
is done to maintain vacuum during coolant cool-down
and to prevent leakage when system is under pres-
sure.

Fig. 10 RADIATOR AND FAN SHROUD


1 - CLIP
2 - SHROUD
3 - RADIATOR
4 - BOTTOM RADIATOR TRIM PANEL
5 - CHARGE AIR COOLER
6 - TOP RADIATOR TRIM PANEL
7 - POWER STEERING COOLER LOOP

(10) Attach both power steering hydraulic lines


(Fig. 9).
(11) Connect coolant level sensor electrical connec-
tor (Fig. 9).
(12) Connect coolant hoses to the coolant reservoir,
radiator and water pump (Fig. 9).
(13) Attach air intake pipe at the body.
(14) Attach charge air hose at air intake.
(15) Attach charge air hose at turbocharger.
(16) Install A/C condenser.
(17) Install front bumper.
(18) Install front end cross member.
(19) Refill power steering to proper level.
(20) Refill transmission to proper level.
(21) Close radiator drain plug and refill the cooling
system (Refer to 7 - COOLING/ENGINE/COOLANT -
STANDARD PROCEDURE).
(22) Recharge air conditioning (Refer to 24 - Fig. 11 Radiator Pressure Cap - Typical
HEATING & AIR CONDITIONING/PLUMBING -
1 - FILLER NECK SEAL
STANDARD PROCEDURE). 2 - VACUUM VENT VALVE
(23) Run engine until warm and check for leaks. 3 - PRESSURE RATING
4 - PRESSURE VALVE

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.

NOTE: Inspect condition of all clamps and hoses,


replace as necessary.

(1) Disconnect the negative battery cable.


(2) Drain cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(3) Remove viscous fan clutch.
(4) Detach fuel lines from the brackets at the
water pump.
(5) Detach the coolant hoses at the water pump
(Fig. 13).
Fig. 12 Pressure Testing Radiator Pressure Cap - (6) Press off cap at belt guide pulleys.
Typical (7) Remove belt guide pulleys.
1 - PRESSURE CAP (8) Remove water pump retaining bolts and
2 - TYPICAL COOLING SYSTEM PRESSURE TESTER remove water pump.

Operate the tester pump and observe the gauge


pointer at its highest point. The cap release pressure
should be 124-145 kPa (18-21 psi). The cap is satis-
factory when the pressure holds steady. It is also
good if it holds pressure within the 124-145 kPa
(18-21 psi) range for 30 seconds or more. If the
pointer drops quickly, replace the cap.
7 - 20 ENGINE VA
WATER PUMP (Continued)

Fig. 13 WATER PUMP


1 - GASKET 5 - CAP
2 - WASHER 6 - WATER PUMP
3 - GUIDE PULLEY 7 - COOLANT HOSE
4 - BOLT 8 - COOLANT HOSE

INSTALLATION (4) Attach the coolant hoses to the water pump


and tighten clamps (Fig. 13).
NOTE: Clean all mating surfaces. (5) Attach fuel lines to the brackets at the water
pump.
(1) Fit existing accessory drive belt pulley onto the (6) Install accessory drive belt.
water pump. (7) Install viscous fan clutch.
(2) Properly position water pump with new gasket (8) Close radiator and or engine drain plug.
to the engine and tighten bolts to 14 N·m (124 lbs. (9) Refill cooling system to proper level (Refer to 7
in). , M8 (20 N·m (177 lbs. in.) (Fig. 13). - COOLING/ENGINE/COOLANT - STANDARD PRO-
CEDURE). Check for leaks.
NOTE: Be sure to install the washer behind the
guide pulley to assure proper alignment.

(3) Install belt guide pulleys. Tighten bolts to 35


N·m (26 lbs. ft.) (Fig. 13).
VA AUDIO/VIDEO 8A - 1

AUDIO/VIDEO
TABLE OF CONTENTS

page page

AUDIO INSTALLATION ..........................2


SPECIAL TOOLS RADIO
AUDIO . . . . . . . . . . . . . . . . . . . . . . . ........1 REMOVAL .. ...........................2
ANTENNA BODY & CABLE INSTALLATION ..........................2
REMOVAL ..................... ........1 SPEAKER
INSTALLATION . . . . . . . . . . . . . . . . . . ........1 REMOVAL .. ...........................2
INSTRUMENT PANEL ANTENNA CABLE INSTALLATION ..........................2
REMOVAL ..................... ........1

AUDIO

SPECIAL TOOLS
AUDIO
SPECIAL TOOL CROSS REFERENCE CHART

MB MILLER DESCRIPTION
TOOL # TOOL #
000 589 9241 RADIO EXTRACTION
88 63 00 TOOL

ANTENNA BODY & CABLE


Fig. 1 ANTENNA CABLE
REMOVAL 1 - ROOF PANEL
(1) Disconnect and isolate the battery negative 2 - MOUNTING NUT
cable. 3 - ANTENNA CABLE
4 - ELECTRICAL CONNECTOR
(2) Remove the portion of the headliner over the 5 - INSTRUMENT PANEL ANTENNA CABLE
front seat passengers (Refer to 23 - BODY/INTERI-
OR/HEADLINER - REMOVAL).
(3) Disconnect the antenna and electrical connec-
INSTRUMENT PANEL
tions near the windshield (Fig. 1). ANTENNA CABLE
(4) Remove the mounting nut.
(5) Remove the antenna assembly from the roof REMOVAL
and pull wire harness and cable through roof open- (1) Disconnect and isolate the battery negative
ing. cable.
(2) Remove the A-pillar trim (Refer to 23 - BODY/
INSTALLATION INTERIOR/A-PILLAR TRIM - REMOVAL).
(1) Feed wire harness and cable through roof open- (3) Remove the portion of the headliner over the
ing and position antenna to roof panel. front seat passengers (Refer to 23 - BODY/INTERI-
(2) Install and tighten antenna mounting nut. OR/HEADLINER - REMOVAL).
(3) Connect the antenna and electrical connections (4) Disconnect the antenna and electrical connec-
near the windshield. tions near the windshield.
(4) Install the headliner (Refer to 23 - BODY/IN- (5) Remove the glove box (Refer to 23 - BODY/IN-
TERIOR/HEADLINER - INSTALLATION). STRUMENT PANEL/GLOVE BOX - REMOVAL).
(5) Connect the battery negative cable. (6) Remove the radio (Refer to 8 - ELECTRICAL/
AUDIO/RADIO - REMOVAL).
8A - 2 AUDIO/VIDEO VA
INSTRUMENT PANEL ANTENNA CABLE (Continued)
(7) Cut both ends of existing cable close to the
instrument panel (Fig. 2).

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

CHIME/BUZZER DIAGNOSIS AND TESTING - CHIME


DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1 WARNING SYSTEM . . . . . . . . . . . . . . . . . . . . . 2
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

CHIME/BUZZER tion of soldered splices, splice block connectors, and


many different types of wire harness terminal con-
nectors and insulators. Refer to the appropriate wir-
DESCRIPTION
ing information. The wiring information includes
A chime warning system is standard factory-in-
wiring diagrams, proper wire and connector repair
stalled equipment. The chime warning system uses a
procedures, further details on wire harness routing
chime tone generator and a contactless relay that are
and retention, as well as pin-out and location views
soldered onto the electronic circuit board inside the
for the various wire harness connectors, splices and
ElectroMechanical Instrument Cluster (EMIC) to
grounds.
provide audible indications of various vehicle condi-
The EMIC chime tone generator and contactless
tions that may require the attention of the vehicle
relay cannot be adjusted or repaired. If the chime
operator or occupants. The microprocessor-based
tone generator or contactless relay are damaged or
EMIC utilizes electronic messages received from
faulty, the entire EMIC unit must be replaced.
other modules in the vehicle over the Controller Area
Network (CAN) data bus network along with hard
wired inputs to the cluster to monitor many sensors
OPERATION
The chime warning system components operate on
and switches throughout the vehicle. In response to
battery current received through a non-switched
those inputs, the circuitry and internal programming
fused B(+) circuit so that the system may operate
of the EMIC allow it to control audible outputs that
regardless of the ignition switch position. The Elec-
are produced through its on-board chime tone gener-
tro-Mechanical Instrument Cluster (EMIC) also mon-
ator and contactless relay.
itors the ignition switch position so that some chime
The EMIC circuitry and its chime tone generator
features will only occur with ignition switch in the
are capable of producing the following audible out-
On position, while others occur regardless of the igni-
puts:
tion switch position.
• Single Chime Tone - A single, extended “beep-
The chime warning system provides an audible
like” chime tone is issued as a seat belt reminder.
indication to the vehicle operator or occupants under
• Fast Rate Repetitive Chime Tone - Repeated
the following conditions:
“beep-like” tones that are issued at a fast rate as an
• Engine Oil Level Low Warning - Each time
audible alert and to support various visual warnings.
the ignition switch is turned to the On position, the
• Slow Rate Repetitive Click Tone - Repeated
EMIC chime tone generator will generate a fast rate
“click-like” tones that are issued at a slow rate to
repetitive chime tone if electronic messages are
emulate turn signal and hazard flasher operation.
received over the Controller Area Network (CAN)
• Fast Rate Repetitive Click Tone - Repeated
data bus from the Engine Control Module (ECM)
“click-like” tones that are issued at a fast rate to
indicating that the engine level is too low. The ECM
emulate turn signal flasher operation with a bulb
uses internal programming and hard wired inputs
out.
from the engine oil level and temperature sensor to
Hard wired circuitry connects the EMIC and the
determine the engine oil level. This audible warning
various chime warning switch and sensor inputs to
occurs in concert with the visual warning provided by
their respective modules and to each other through
the multi-function indicator in the cluster.
the electrical system of the vehicle. These hard wired
• Fasten Seat Belt Reminder - Each time the
circuits are integral to the vehicle wire harness,
ignition switch is turned to the On position, the
which is routed throughout the vehicle and retained
EMIC chime tone generator will generate a single
by many different methods. These circuits may be
extended chime tone for a duration of about six sec-
connected to each other, to the vehicle electrical sys-
onds, or until the driver side front seat belt is fas-
tem and to the EMIC through the use of a combina-
tened, whichever occurs first. The EMIC uses
8B - 2 CHIME/BUZZER VA
CHIME/BUZZER (Continued)
internal programming and a hard wired input from inputs from the front door ajar switches, the key-in
the driver side front seat belt switch to determine ignition switch, the ignition switch, the seat belt
the status of the driver side front seat belt. This switch, and the turn signal/hazard warning (multi-
audible warning occurs independent of the visual function) switches. The EMIC relies upon electronic
warning provided by the EMIC “Seatbelt” indicator. message inputs received from other electronic mod-
• Lights-On Warning - The EMIC chime tone ules over the CAN data bus network to provide
generator will generate repetitive chime tones at a chime service for the low engine oil level warning.
fast rate when either front door is opened with the Upon receiving the proper inputs, the EMIC acti-
ignition switch in any position except On, and the vates the chime tone generator or the contactless
exterior lights are turned On. The EMIC uses inter- relay to provide the audible warning to the vehicle
nal programming and hard wired inputs from the left operator. The internal programming of the EMIC
(lighting) control stalk of the multi-function switch, determines the priority of each chime request input
the ignition switch, and both front door jamb that is received, as well as the rate and duration of
switches to determine the current status of these each tone that is to be generated. See the owner’s
switches. This chime will continue to sound until the manual in the vehicle glove box for more information
exterior lighting is turned Off, until the ignition on the features provided by the chime warning sys-
switch is turned to the On position, or until both tem.
front doors are closed, whichever occurs first. The hard wired chime warning system inputs to
• Key-In-Ignition Warning - The EMIC chime the EMIC, as well as other hard wired circuits for
tone generator will generate repetitive chime tones at this system may be diagnosed and tested using con-
a fast rate when the key is in the ignition lock cylin- ventional diagnostic tools and procedures. However,
der, the ignition switch is in any position except On, conventional diagnostic methods may not prove con-
and either front door is opened. The EMIC uses clusive in the diagnosis of the EMIC, the CAN data
internal programming and hard wired inputs from bus network, or the electronic message inputs used
the key-in ignition switch, the ignition switch, and by the EMIC to provide chime warning system ser-
both front door jamb switches to determine the cur- vice. The most reliable, efficient, and accurate means
rent status of these switches. The chime will con- to diagnose the EMIC, the CAN data bus network,
tinue to sound until the key is removed from the and the electronic message inputs for the chime
ignition lock cylinder, until the ignition switch is warning system requires the use of a DRBIIIt scan
turned to the On position, or until both front doors tool. Refer to the appropriate diagnostic information.
are closed, whichever occurs first.
• Audible Turn Signal/Hazard Warning Sup- DIAGNOSIS AND TESTING - CHIME WARNING
port - The EMIC contactless relay will generate SYSTEM
repetitive clicks at a slow rate during normal turn
signal/hazard warning operation, or at a fast rate WARNING: To avoid personal injury or death, on
when a turn signal lamp bulb or circuit is inopera- vehicles equipped with airbags, disable the supple-
tive, in concert with the operation of the turn signal mental restraint system before attempting any
indicators in the cluster. These clicks are designed to steering wheel, steering column, airbag, seat belt
emulate the sound of the opening and closing of the tensioner, or instrument panel component diagno-
contact points in a conventional electro-mechanical sis or service. Disconnect and isolate the battery
turn signal or hazard warning flasher. The EMIC negative (ground) cable, then wait two minutes for
uses a hard wired input received from the turn sig- the system capacitor to discharge before perform-
nal relay in the fuse block beneath the steering col- ing further diagnosis or service. This is the only
umn through the turn signal or hazard warning sure way to disable the supplemental restraint sys-
switch circuitry of the multi-function switch to deter- tem. Failure to take the proper precautions could
mine when to flash the turn signal indicators and result in accidental airbag deployment.
activate the contactless relay on the cluster electronic
circuit board. The turn signal clicks will continue to The hard wired chime warning system inputs to
sound until the turn signal switch is turned Off, or the Electro-Mechanical Instrument Cluster (EMIC),
until the ignition switch is turned to the Off position, as well as other hard wired circuits for this system
whichever occurs first. The hazard warning clicks may be diagnosed and tested using conventional
will continue to sound until the hazard warning diagnostic tools and procedures. However, conven-
switch is turned Off. tional diagnostic methods may not prove conclusive
The EMIC provides chime service for all available in the diagnosis of the EMIC, the Controller Area
features in the chime warning system. The EMIC Network (CAN) data bus network, or the electronic
relies upon its internal programming and hard wired message inputs used by the EMIC to provide chime
VA CHIME/BUZZER 8B - 3
CHIME/BUZZER (Continued)
warning system service. The most reliable, efficient, DRBIIIt scan tool. Refer to the appropriate diagnos-
and accurate means to diagnose the EMIC, the CAN tic information.
data bus network, and the electronic message inputs
for the chime warning system requires the use of a
VA ELECTRONIC CONTROL MODULES 8E - 1

ELECTRONIC CONTROL MODULES


TABLE OF CONTENTS

page page

CENTRAL TIMER MODULE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . ..3


DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . ...1 ENGINE CONTROL MODULE
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . ...1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . ..3
DIAGNOSIS AND TESTING - CENTRAL TIMER REMOVAL ........................... ..6
MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . ...2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . ..6
REMOVAL .......................... ...2 TRANSMISSION CONTROL MODULE
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . ...2 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . ..6
CONTROLLER ANTILOCK BRAKE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . ..6
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . ...3 STANDARD PROCEDURE - TCM ADAPTATION .9
REMOVAL .......................... ...3

CENTRAL TIMER MODULE park lamps flash, driver-door-only unlock, and


unlock-all-doors), Panic, and illuminated entry
modes, as well as the ability to be programmed to
DESCRIPTION
recognize up to four RKE transmitters. The RKE
The central timer module (CTM) is located beneath
horn, driver-door-only unlock, and unlock-all-doors
the driver seat. The CTM uses information carried on
features are programmable.
the programmable communications interface (PCI)
• Vehicle Theft Security System - The CTM
data bus network along with many hard wired inputs
provides control of the optional Vehicle Theft Secu-
to monitor many sensor and switch inputs. In
rity System (VTSS) features, including support for
response to those inputs, the circuitry and program-
the central locking/unlocking mode and control of the
ming of the CTM allow it to supply the vehicle occu-
Security indicator in the instrument cluster.
pants with audible and visual information, and to
Hard wired circuitry connects the CTM to the elec-
control and integrate many functions and features of
trical system of the vehicle. Refer to the appropriate
the vehicle through both hard wired outputs and the
wiring information.
transmission of message outputs to other modules in
Many of the features in the vehicle controlled or
the vehicle over the PCI data bus.
supported by the CTM are programmable using the
The features that the CTM supports or controls
DRBIIIt scan tool. However, if any of the CTM hard-
include the following:
ware components are damaged or faulty, the entire
• Central Locking - The CTM on vehicles
CTM unit must be replaced. The hard wired inputs
equipped with the optional Vehicle Theft Security
or outputs of all CTM versions can be diagnosed
System (VTSS) includes a central locking/unlocking
using conventional diagnostic tools and methods;
feature.
however, for diagnosis of the CTM or the PCI data
• Enhanced Accident Response - The CTM pro-
bus, the use of a DRBIIIt scan tool is required. Refer
vides an optional enhanced accident response fea-
to the appropriate diagnostic information.
ture. This is a programmable feature.
• Panic Mode - The CTM provides support for
the optional RKE system panic mode including horn,
OPERATION
The central timer module (CTM) monitors many
headlamp, and park lamp flash features.
hard wired switch and sensor inputs as well as those
• Power Lock Control - The CTM provides the
resources it shares with other modules in the vehicle
optional power lock system features, including sup-
through its communication over the programmable
port for the automatic door lock and door lock inhibit
communications interface (PCI) data bus network.
modes.
The internal programming and all of these inputs
• Programmable Features - The CTM provides
allow the CTM to determine the tasks it needs to
support for certain programmable features.
perform and their priorities, as well as both the stan-
• Remote Keyless Entry - The CTM provides
dard and optional features that it should provide.
the optional Remote Keyless Entry (RKE) system fea-
The CTM then performs those tasks and provides
tures, including support for the RKE Lock (with
those features through both PCI data bus communi-
optional horn and park lamps flash), Unlock (with
cation with other modules and hard wired outputs
8E - 2 ELECTRONIC CONTROL MODULES VA
CENTRAL TIMER MODULE (Continued)
through a number of driver circuits, relays, and ing further diagnosis or service. This is the only
actuators.These outputs allow the CTM the ability to sure way to disable the supplemental restraint sys-
control numerous accessory systems in the vehicle. tem. Failure to take the proper precautions could
The CTM monitors its own internal circuitry as result in accidental airbag deployment.
well as many of its input and output circuits, and The hard wired inputs to and outputs from the
will store a Diagnostic Trouble Code (DTC) in elec- central timer module (CTM) may be diagnosed and
tronic memory for any failure it detects. These DTCs tested using conventional diagnostic tools and meth-
can be retrieved and diagnosed using a DRBIIIt scan ods. Refer to the appropriate wiring information.
tool. Refer to the appropriate diagnostic information. However, conventional diagnostic methods may not
prove conclusive in the diagnosis of the CTM. In
HARD WIRED INPUTS order to obtain conclusive testing of the CTM, the
The hard wired inputs to the CTM include the fol- programmable communications interface (PCI) data
lowing: bus network and all of the modules that provide
• Fused B(+) inputs to or receive outputs from the CTM must also
• Fused ignition switch output (run-acc) be checked. The most reliable, efficient, and accurate
• Fused ignition switch output (run-start) means to diagnose the CTM, the PCI data bus net-
• Ground work, and the modules that provide inputs to, or
• Key-in ignition switch sense receive outputs from, the CTM requires the use of a
• Sliding door switch sense DRBIIIt scan tool. Refer to the appropriate diagnos-
• Passenger door switch sense tic information.
• Driver door switch sense
• PCI bus circuit REMOVAL
(1) Disconnect and isolate the battery negative
HARD WIRED OUTPUTS cable.
The hard wired outputs of the CTM include the fol- (2) Slide the driver seat to the full forward posi-
lowing: tion.
• Door lock relay output (3) Disconnect the wire harness connector for the
• Door unlock relay output seat belt latch. (Fig. 1).
• VTSS indicator driver (4) Remove the screws that secure the closeout
panel beneathe the driver seat cushion and remove
MESSAGING the panel.
The CTM uses the following messages received (5) Remove the screws that secure the central
from other electronic modules over the PCI data bus: timer module to the bracket.
• Airbag Deploy (ACM) (6) Disconnect the wire harness connectors from
• Beep request (CMTC) the central timer module.
• Charging System Failure (PCM) (7) Remove the central timer module from the
• Chime request (EMIC) vehicle.
• Engine RPM (PCM)
• OK to Arm VTSS (PCM) INSTALLATION
• Security indicator request (SKIM) (1) Position the central timer module in the vehicle
• System Voltage (PCM) (2) Connect the wire harness connectors to the
• Valid/Invalid Key (SKIM) central timer module.
• Vehicle Distance (PCM) (3) Install the screws that secure the central timer
• Vehicle Speed (PCM) module. Tighten the screws securely.
(4) Route the seat belt latch wire lead through the
DIAGNOSIS AND TESTING - CENTRAL TIMER hole in the closeout panel and position the panel
MODULE beneath the driver seat cushion
(5) Install the screws that secure the closeout
WARNING: To avoid personal injury or death, on panel beneath the driver seat cushion. Tighten the
vehicles equipped with airbags, disable the supple- screws securely.
mental restraint system before attempting any (6) Connect the wire harness connector to the seat
steering wheel, steering column, airbag, seat belt belt latch connector.
tensioner, or instrument panel component diagno- (7) Slide the driver seat to back to its original posi-
sis or service. Disconnect and isolate the battery tion.
negative (ground) cable, then wait two minutes for (8) Reconnect the negative battery cable.
the system capacitor to discharge before perform-
VA ELECTRONIC CONTROL MODULES 8E - 3
CENTRAL TIMER MODULE (Continued)

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.

ENGINE CONTROL MODULE


DESCRIPTION
The electronic control module (ECM) is mounted to
the left lower dash panel and consists of an electronic
printed circuit board which is designed as a milliliter
board assembly fitted on both sides. The routing of
the wiring harness connector at the ECM connector
are split into interfering cables and sensitive cables
in order to achieve improved electromagnetic compat-
ibility. The smaller wiring harness connector is used
for the vehicle wiring harness and the larger harness
Fig. 1 Central Timer Module is used for the engine wiring harness. The ECM
1 - DRIVER SEAT stores engine specific data, monitors the connected
2 - WIRE HARNESS CONNECTOR
3 - SCREW (2)
sensor and analyzes their measurement (Fig. 2).
4 - CLOSEOUT PANEL Its task consists in controlling the following sys-
5 - CENTRAL TIMER MODULE tems in line with the analysis of the input signals:
6 - WIRE HARNESS CONNECTOR (2)
7 - SCREW (2)
• Fuel Supply System
• Injected Quantity Control
• Emission Control System
CONTROLLER ANTILOCK • Charge Pressure Control
BRAKE • Cruise Control
• A/C Compressor Shut-Off
DESCRIPTION • Pre-Heating Output Relay for the Glow Plugs
The Controler Antilock Brake (CAB) is mounted to • Vehicle Theft
the Hydraulic Control Unit (HCU) and operates the • Air Bag
ABS system. • Monitors inputs/outputs, checks plausibility and
stores faults
REMOVAL • Share information with other control modules
(1) Remove the negative battery cable from the • Diagnosis
battery. If a sensor should fail, provided the fault is not
(2) Pull up on the CAB harness connector release serious, the ECM will continue to operate the engine
and remove connector. in Limp-Home Mode (emergency mode) using a
(3) Remove the CAB mounting bolts. default value for the missing signal. The ECM
(4) Remove the CAB from the HCU. ensures that, continuing to operate the engine will
not cause damage or effect safety, otherwise a Engine
shut-off process will be carried out (Fig. 3).
8E - 4 ELECTRONIC CONTROL MODULES VA
ENGINE CONTROL MODULE (Continued)

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)

Fig. 3 ECM CONTROL


• Heated crankcase ventilation to ensure pressure nals to perform the following functions for optimized
compensation even at low temperatures closed loop control and monitoring of emissions
• Improved boost pressure control using an elec- related components:
tric variable nozzle turbine actuator with position • Injection valve quantity drift compensation in
feed back partial load range: the oxygen content in the exhaust
• Controlled fuel heating using the high pressure is calculated from the air mass and from injection
pump closed-loop control quantity signal and is compared to the air-fuel ratio
• Translation of the drive input received from the as measured by the sensor. If the calculated air-fuel
accelerator pedal module which is equipped with ratio differs from the measured air-fuel ratio, the is
dual hall sensors no correction of the injection quantity but the EGR
• Measurement of the intake air mass using new rate and boost pressure are adjusted to the actual
mass air flow (MAF) sensor with increase precision injection quantity.
and extended measuring range • Injection valve quantity drift compensation in
• O2 sensor for measuring the amount of oxygen full load range: this function is to limit the maximum
in the exhaust in order to calculate the air to fuel injection quantity for engine protection. The injection
ratio. With the intake air mass being known, the quantity signal is compared to the injection quantity
injected fuel quantity can be calculated from the air calculated from the oxygen sensor signal and MAF
to fuel ratio signal. If the comparison shows that the actual injec-
• Activation of the O2 sensor heater to burn off tion quantity is too high, it is limited to the maxi-
deposits mum permissible injection quantity
• Full load EGR with a more precise, model based • Air-fuel ratio controlled smoke limiter (full load):
EGR closed-loop control. The ECM calculates the the smoke limiter limits the injection quantity on the
EGR rate from the various sensor signals. Using the basis of the air-fuel ratio permissible at the smoke
calculate EGR rate in percent instead of the fresh air limit depending on the measure mass air flow and
mass flow as a control parameter enables a more pre- the calculated EGR rate. As a consequence, the gen-
cise control of the EGR rate as well as better correc- eration of smoke due to an excess injection quantity
tion of the target value. is avoided under all operating conditions. At the
The oxygen sensor signal can be used in combina- same time, the oxygen sensor signal is used to
tion with the mass air flow signal, the injection ensure that the air-fuel ratio is adjusted accordingly
quantity signal and pressure and temperature sig-
8E - 6 ELECTRONIC CONTROL MODULES VA
ENGINE CONTROL MODULE (Continued)
A function referred to as air flow sensor drift com- (2) Carefully push the ECM in to the bracket until
pensation detects and corrects the possible drifting of the bracket tensioning springs engage (Fig. 4).
the MAF sensor by comparing the air mass measured (3) Connect the ECM wiring harness connectors
by the MAF with the projected air mass as it is cal- (Fig. 4).
culated by the ECM in consideration of various influ- (4) Connect negative battery cable.
encing conditions. It is the air flow drift
compensation that gives the MAF air mass measure-
ment the precision needed to use it for the function TRANSMISSION CONTROL
mentioned above. The high precision of the MAF MODULE
measurement enables the calculation of the actual
injection quantity from the measured air mass and DESCRIPTION
from the oxygen sensor signal in order to correct The transmission control module (TCM) receives,
injection quantity. The MAF signal can also be used processes and sends various digital and analog sig-
as a input parameter for the smoke limiter. nals related to the automatic transmission. In addi-
tion, it processes information received from other
REMOVAL vehicle systems, such as engine torque and speed,
(1) Disconnect the negative battery cable. accelerator pedal position, wheel speed, kick-down
(2) Disconnect the ECM harness connectors (Fig. switch, traction control information, etc.
4). The TCM is located under the driver’s seat and is
(3) Grasp ECM and pull down firmly to release connected to other control modules via a CAN bus. It
ECM from the retaining bracket tensioning springs controls all shift functions to achieve smooth shift
(Fig. 4). comfort in all driving situations considering:
• Vehicle speed.
• Transmission status.
• Position of selector lever.
• Selected shift range.
• CAN signals.
• Engine Status.
Engine speed limits may be reached in all gears
with full throttle or in kick-down operation. In for-
ward driving, the shift range of the forward gears
can be adjusted by the operator by tipping the selec-
tor lever to the left or right (AutoStick). However, the
TCM features a downshift inhibitor to prevent the
engine from overspeeding.

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 . . . . . . . . . . . . . . . . . . . . . . . . . 1 STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 24


CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 17

BATTERY SYSTEM

TABLE OF CONTENTS
page page

BATTERY SYSTEM REMOVAL


DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1 UNDER HOOD BATTERY REMOVAL . . . . . . . 12
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 AUXILIARY BATTERY REMOVAL . . . . . . . . . . 13
DIAGNOSIS AND TESTING - BATTERY INSTALLATION
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 UNDER HOOD BATTERY INSTALLATION . . . 13
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 AUXILIARY BATTERY INSTALLATION . . . . . . 13
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 BATTERY HOLDDOWN
SPECIAL TOOLS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13
BATTERY SYSTEM SPECIAL TOOLS . . . . . . . 6 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
BATTERY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6 BATTERY CABLES
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 14
DIAGNOSIS AND TESTING - BATTERY . . . . . . . 7 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
STANDARD PROCEDURE DIAGNOSIS AND TESTING - BATTERY
STANDARD PROCEDURE - BATTERY CABLES ........................ . . . . 14
CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
STANDARD PROCEDURE - OPEN-CIRCUIT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16
VOLTAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . 9 BATTERY TRAY
STANDARD PROCEDURE - IGNITION-OFF DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 16
DRAW TEST . . . . . . . . . . . . . . . . . . . . . . . . . 10 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
STANDARD PROCEDURE - USING MICRO REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
420 BATTERY TESTER . . . . . . . . . . . . . . . . . 11 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16
STANDARD PROCEDURE - CHECKING
BATTERY ELECTROLYTE LEVEL . . . . . . . . . 12

BATTERY SYSTEM vehicle covers the following related components,


which are covered in further detail later in this sec-
tion of the service manual:
DESCRIPTION
• Battery - The 12v storage battery(s) provides a
A single 12-volt battery is standard factory-in-
reliable means of storing a renewable source of elec-
stalled equipment on this model. Some vehicles are
trical energy within the vehicle.
equipped with a second auxiliary battery for running
• Battery Cables - The battery cables connect
additional electrical equipment. The standard battery
the battery terminal posts to the vehicle electrical
is located in the engine compartment, while the aux-
system.
iliary battery (if equipped) is located under the pas-
sengers front seat. The battery system for this
8F - 2 BATTERY SYSTEM VA
BATTERY SYSTEM (Continued)
• Battery Holddown - The battery holddown as a complete system. In order for the engine to start
hardware secures the battery in the battery tray in and the battery to maintain its charge properly, all of
the engine compartment. the components that are used in these systems must
• Battery Tray - The battery tray provides a perform within specifications. It is important that
secure mounting location in the vehicle for the bat- the battery, starting, and charging systems be thor-
tery and an anchor point for the battery holddown oughly tested and inspected any time a battery needs
hardware. to be charged or replaced. The cause of abnormal bat-
For battery system maintenance schedules and tery discharge, overcharging or early battery failure
jump starting procedures, see the owner’s manual in must be diagnosed and corrected before a battery is
the vehicle glove box. Optionally, refer to the Lubri- replaced and before a vehicle is returned to service.
cation and Maintenance section of this manual for The service information for these systems has been
the recommended battery maintenance schedules and separated within this service manual to make it eas-
for the proper battery jump starting procedure. While ier to locate the specific information you are seeking.
battery charging can be considered a maintenance However, when attempting to diagnose any of these
procedure, the battery charging procedure and systems, it is important that you keep their interde-
related information are located later in this section of pendency in mind.
this service manual. This was done because the bat- The diagnostic procedures used for the battery,
tery must be fully-charged before any battery system starting, and charging systems include the most
diagnosis or testing procedures can be performed. basic conventional diagnostic methods, to the more
sophisticated On-Board Diagnostics (OBD) built into
OPERATION the Powertrain Control Module (PCM). Use of an
The battery system is designed to provide a safe, induction-type milliampere ammeter, a volt/ohmme-
efficient, reliable and mobile means of delivering and ter, a battery charger, a carbon pile rheostat (load
storing electrical energy. This electrical energy is tester) and a 12-volt test lamp may be required. All
required to operate the engine starting system, as OBD-sensed systems are monitored by the PCM.
well as to operate many of the other vehicle acces- Each monitored circuit is assigned a Diagnostic Trou-
sory systems for limited durations while the engine ble Code (DTC). The PCM will store a DTC in elec-
and/or the charging system are not operating. The tronic memory for any failure it detects. Refer to
battery system is also designed to provide a reserve Charging System for the proper charging system on-
of electrical energy to supplement the charging sys- board diagnostic test procedures.
tem for short durations while the engine is running
and the electrical current demands of the vehicle MICRO 420 BATTERY TESTER
exceed the output of the charging system. In addition The Micro 420 automotive battery tester is
to delivering, and storing electrical energy for the designed to help the dealership technicians diagnose
vehicle, the battery system serves as a capacitor and the cause of a defective battery. Follow the instruc-
voltage stabilizer for the vehicle electrical system. It tion manual supplied with the tester to properly
absorbs most abnormal or transient voltages caused diagnose a vehicle. If the instruction manual is not
by the switching of any of the electrical components available refer to the standard procedure in this sec-
or circuits in the vehicle. tion, which includes the directions for using the
Micro 420 battery tester.
DIAGNOSIS AND TESTING - BATTERY SYSTEM
The battery, starting, and charging systems in the
vehicle operate with one another and must be tested
VA BATTERY SYSTEM 8F - 3
BATTERY SYSTEM (Continued)

BATTERY SYSTEM DIAGNOSIS

CONDITION POSSIBLE CAUSES CORRECTION

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.

2. The charging system is 2. 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.
3. The battery is discharged. 3. Determine the battery state-of-charge using the
Micro 420 battery tester. Refer to the Standard
Procedures in this section for additional test
procedures. Charge the faulty battery, as
required.
4. The battery terminal 4. Refer to Battery Cables for the proper battery
connections are loose or cable diagnosis and testing procedures. Clean
corroded. and tighten the battery terminal connections, as
required.
5. The battery has an 5. Refer to Battery System Specifications for the
incorrect size or rating for proper size and rating. Replace an incorrect
this vehicle. battery, as required.
6. The battery is faulty. 6. Determine the battery cranking capacity using
the Micro 420 battery tester. Refer to the
Standard Procedures in this section for additional
test procedures. Replace the faulty battery, as
required.
7. The starting system is 7. 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.
8. The battery is physically 8. Inspect the battery for loose terminal posts or a
damaged. cracked and leaking case. Replace the damaged
battery, as required.
8F - 4 BATTERY SYSTEM VA
BATTERY SYSTEM (Continued)

BATTERY SYSTEM DIAGNOSIS

CONDITION POSSIBLE CAUSES CORRECTION

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.

installed after manufacture, or repeated short trip


ABNORMAL BATTERY DISCHARGING
use.
Any of the following conditions can result in abnor-
5. A faulty or incorrect starting system component.
mal battery discharging:
Refer to Starting System for the proper starting sys-
1. A faulty or incorrect charging system compo-
tem diagnosis and testing procedures.
nent. Refer to Charging System for additional charg-
6. Corroded or loose battery posts and/or terminal
ing system diagnosis and testing procedures.
clamps.
2. A faulty or incorrect battery. Use Micro 420 bat-
7. Slow driving speeds (heavy traffic conditions) or
tery tester and refer to Battery System for additional
prolonged idling, with high-amperage draw systems
battery diagnosis and testing procedures.
in use.
3. A faulty circuit or component causing excessive
ignition-off draw.
4. Electrical loads that exceed the output of the
CLEANING
The following information details the recommended
charging system. This can be due to equipment
cleaning procedures for the battery and related com-
VA BATTERY SYSTEM 8F - 5
BATTERY SYSTEM (Continued)
ponents. In addition to the maintenance schedules
found in this service manual and the owner’s man-
ual, it is recommended that these procedures be per-
formed any time the battery or related components
must be removed for vehicle service.
(1) Clean the battery cable terminal clamps of all
corrosion. Remove any corrosion using a wire brush
or a post and terminal cleaning tool, and a sodium
bicarbonate (baking soda) and warm water cleaning
solution (Fig. 1).

Fig. 2 Clean Battery - Typical


1 - CLEANING BRUSH
2 - WARM WATER AND BAKING SODA SOLUTION
3 - BATTERY

(5) Clean any corrosion from the battery terminal


posts with a wire brush or a post and terminal
cleaner, and a sodium bicarbonate (baking soda) and
warm water cleaning solution (Fig. 3).

Fig. 1 Clean Battery Cable Terminal Clamp - Typical


1 - TERMINAL BRUSH
2 - BATTERY CABLE

(2) Clean the battery tray and battery hold down


hardware of all corrosion. Remove any corrosion
using a wire brush and a sodium bicarbonate (baking
soda) and warm water cleaning solution. Paint any
exposed bare metal.
(3) If the removed battery is to be reinstalled,
clean the outside of the battery case and the top
cover with a sodium bicarbonate (baking soda) and
warm water cleaning solution using a stiff bristle
parts cleaning brush to remove any acid film (Fig. 2).
Rinse the battery with clean water. Ensure that the
cleaning solution does not enter the battery cells
through the vent holes. If the battery is being
replaced, refer to Battery System Specifications for
the factory-installed battery specifications. Confirm
that the replacement battery is the correct size and
has the correct ratings for the vehicle.
(4) If the vehicle is so equipped, clean the battery Fig. 3 Clean Battery Terminal Post - Typical
thermal guard with a sodium bicarbonate (baking 1 - TERMINAL BRUSH
soda) and warm water cleaning solution using a stiff 2 - BATTERY CABLE
3 - BATTERY
bristle parts cleaning brush to remove any acid film.
8F - 6 BATTERY SYSTEM VA
BATTERY SYSTEM (Continued)

INSPECTION SPECIAL TOOLS


The following information details the recommended
inspection procedures for the battery and related BATTERY SYSTEM SPECIAL TOOLS
components. In addition to the maintenance sched-
ules found in this service manual and the owner’s
manual, it is recommended that these procedures be
performed any time the battery or related compo-
nents must be removed for vehicle service.
(1) Inspect the battery cable terminal clamps for
damage. Replace any battery cable that has a dam-
aged or deformed terminal clamp.
(2) Inspect the battery tray and battery holddown
hardware for damage. Replace any damaged parts.
(3) Slide the thermal guard off of the battery case,
if equipped. Inspect the battery case for cracks or
other damage that could result in electrolyte leaks.
Also, check the battery terminal posts for looseness.
Batteries with damaged cases or loose terminal posts
must be replaced.
(4) Inspect the battery thermal guard for tears,
cracks, deformation or other damage. Replace any
battery thermal guard that has been damaged.
(5) Inspect the battery built-in test indicator sight
glass for an indication of the battery condition. If the
battery is discharged, charge as required. (Refer to 8
- ELECTRICAL/BATTERY SYSTEM/BATTERY - Micro 420 Battery Tester
STANDARD PROCEDURE).
BATTERY
DESCRIPTION
Large capacity, low-maintenance storage batteries
are standard factory-installed equipment on this
model. The primary battery is located in the engine
compartment on all models. A second auxiliary bat-
tery may be installed under the passengers front seat
for running additional electrical equipment.
Male post type terminals made of a soft lead mate-
rial protrude from the top of the molded plastic bat-
tery case to provide the means for connecting the
battery to the vehicle electrical system. The battery
positive terminal post is physically larger in diameter
than the negative terminal post to ensure proper bat-
tery connection. The letters POS and NEG are also
molded into the top of the battery case adjacent to
their respective positive and negative terminal posts
for identification confirmation. Refer to Battery
Cables for more information on the battery cables
that connect the battery to the vehicle electrical sys-
tem.
The battery is made up of six individual cells that
are connected in series. Each cell contains positively
charged plate groups that are connected with lead
straps to the positive terminal post, and negatively
charged plate groups that are connected with lead
straps to the negative terminal post. Each plate con-
sists of a stiff mesh framework or grid coated with
VA BATTERY SYSTEM 8F - 7
BATTERY (Continued)
lead dioxide (positive plate) or sponge lead (negative hydrogen gas can collect in or around the battery. If
plate). Insulators or plate separators made of a non- hydrogen gas is exposed to flame or sparks, it may
conductive material are inserted between the positive ignite. If the electrolyte level is low, the battery may
and negative plates to prevent them from contacting arc internally and explode. If the battery is equipped
or shorting against one another. These dissimilar with removable cell caps, add distilled water when-
metal plates are submerged in a sulfuric acid and ever the electrolyte level is below the top of the
water solution called an electrolyte. plates. If the battery cell caps cannot be removed, the
The factory-installed low-maintenance bat- battery must be replaced if the electrolyte level
tery has removable battery cell caps. Water can becomes low.
be added to this battery. The chemical composition of
the metal coated plates within the low-maintenance DIAGNOSIS AND TESTING - BATTERY
battery reduces battery gassing and water loss, at The battery must be completely charged and the
normal charge and discharge rates. Therefore, the terminals should be properly cleaned and inspected
battery should not require additional water in nor- before diagnostic procedures are performed. Refer to
mal service. Rapid loss of electrolyte can be caused Battery System Cleaning for the proper cleaning pro-
by an overcharging condition. Be certain to diagnose cedures, and Battery System Inspection for the
the charging system before returning the vehicle to proper battery inspection procedures. Refer to Stan-
service. dard Procedures for the proper battery charging pro-
cedures.
OPERATION
The battery is designed to store electrical energy in MICRO 420 BATTERY TESTER
a chemical form. When an electrical load is applied to The Micro 420 automotive battery tester is
the terminals of the battery, an electrochemical reac- designed to help the dealership technicians diagnose
tion occurs. This reaction causes the battery to dis- the cause of a defective battery. Follow the instruc-
charge electrical current from its terminals. As the tion manual supplied with the tester to properly
battery discharges, a gradual chemical change takes diagnose a vehicle. If the instruction manual is not
place within each cell. The sulfuric acid in the elec- available refer to the standard procedure in this sec-
trolyte combines with the plate materials, causing tion, which includes the directions for using the
both plates to slowly change to lead sulfate. At the Micro 420 battery tester.
same time, oxygen from the positive plate material
combines with hydrogen from the sulfuric acid, caus- WARNING: IF THE BATTERY SHOWS SIGNS OF
ing the electrolyte to become mainly water. The FREEZING, LEAKING OR LOOSE POSTS, DO NOT
chemical changes within the battery are caused by TEST, ASSIST-BOOST, OR CHARGE. THE BATTERY
the movement of excess or free electrons between the MAY ARC INTERNALLY AND EXPLODE. PERSONAL
positive and negative plate groups. This movement of INJURY AND/OR VEHICLE DAMAGE MAY RESULT.
electrons produces a flow of electrical current
through the load device attached to the battery ter-
WARNING: EXPLOSIVE HYDROGEN GAS FORMS IN
minals.
AND AROUND THE BATTERY. DO NOT SMOKE,
As the plate materials become more similar chem-
USE FLAME, OR CREATE SPARKS NEAR THE BAT-
ically, and the electrolyte becomes less acid, the volt-
TERY. PERSONAL INJURY AND/OR VEHICLE DAM-
age potential of each cell is reduced. However, by
AGE MAY RESULT.
charging the battery with a voltage higher than that
of the battery itself, the battery discharging process
is reversed. Charging the battery gradually changes WARNING: THE BATTERY CONTAINS SULFURIC
the sulfated lead plates back into sponge lead and ACID, WHICH IS POISONOUS AND CAUSTIC. AVOID
lead dioxide, and the water back into sulfuric acid. CONTACT WITH THE SKIN, EYES, OR CLOTHING.
This action restores the difference in the electron IN THE EVENT OF CONTACT, FLUSH WITH WATER
charges deposited on the plates, and the voltage AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT
potential of the battery cells. For a battery to remain OF THE REACH OF CHILDREN.
useful, it must be able to produce high-amperage cur-
rent over an extended period. A battery must also be A battery that will not accept a charge is faulty,
able to accept a charge, so that its voltage potential and must be replaced. Further testing is not
may be restored. required. A fully-charged battery must be tested to
The battery is vented to release excess hydrogen determine its cranking capacity. A battery that is ful-
gas that is created when the battery is being charged ly-charged, but does not pass the Micro 420 or load
or discharged. However, even with these vents, test, is faulty and must be replaced.
8F - 8 BATTERY SYSTEM VA
BATTERY (Continued)
NOTE: Completely discharged batteries may take Damage to the vehicle electrical system compo-
several hours to accept a charge. Refer to Standard nents may result.
Procedures for the proper battery charging proce-
dures. CAUTION: Battery electrolyte will bubble inside the
battery case during normal battery charging. Elec-
trolyte boiling or being discharged from the battery
vents indicates a battery overcharging condition.
STANDARD PROCEDURE Immediately reduce the charging rate or turn off the
charger to evaluate the battery condition. Damage
STANDARD PROCEDURE - BATTERY to the battery may result from overcharging.
CHARGING
Battery charging is the means by which the bat-
tery can be restored to its full voltage potential. A CAUTION: The battery should not be hot to the
battery is fully-charged when: touch. If the battery feels hot to the touch, turn off
• Micro 420 electrical system tester indicates bat- the charger and let the battery cool before continu-
tery is OK. ing the charging operation. Damage to the battery
• Three hydrometer tests, taken at one-hour inter- may result.
vals, indicate no increase in the temperature-cor-
Some battery chargers are equipped with polarity-
rected specific gravity of the battery electrolyte.
sensing circuitry. This circuitry protects the battery
• Passes Load test.
charger and the battery from being damaged if they
• Open-circuit voltage of the battery is 12.65 volts
are improperly connected. If the battery state-of-
or above.
charge is too low for the polarity-sensing circuitry to
WARNING: IF THE BATTERY SHOWS SIGNS OF detect, the battery charger will not operate. This
FREEZING, LEAKING OR LOOSE POSTS, DO NOT makes it appear that the battery will not accept
TEST, ASSIST-BOOST, OR CHARGE. THE BATTERY charging current. See the instructions provided by
MAY ARC INTERNALLY AND EXPLODE. PERSONAL the manufacturer of the battery charger for details
INJURY AND/OR VEHICLE DAMAGE MAY RESULT. on how to bypass the polarity-sensing circuitry.
After the battery has been charged to 12.4 volts or
greater, retest the battery using the Micro 420 tester
WARNING: EXPLOSIVE HYDROGEN GAS FORMS IN or perform a load test to determine the battery
AND AROUND THE BATTERY. DO NOT SMOKE, cranking capacity. If the battery will endure a load
USE FLAME, OR CREATE SPARKS NEAR THE BAT- test, return the battery to service. If the battery will
TERY. PERSONAL INJURY AND/OR VEHICLE DAM- not endure a load test, it is faulty and must be
AGE MAY RESULT. replaced.
Clean and inspect the battery hold downs, tray,
terminals, posts, and top before completing battery
WARNING: THE BATTERY CONTAINS SULFURIC service. Refer to Battery System Cleaning for the
ACID, WHICH IS POISONOUS AND CAUSTIC. AVOID proper battery system cleaning procedures, and Bat-
CONTACT WITH THE SKIN, EYES, OR CLOTHING. tery System Inspection for the proper battery system
IN THE EVENT OF CONTACT, FLUSH WITH WATER inspection procedures.
AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT
OF THE REACH OF CHILDREN. CHARGING A COMPLETELY DISCHARGED
BATTERY
WARNING: IF THE BATTERY IS EQUIPPED WITH The following procedure should be used to recharge
REMOVABLE CELL CAPS, BE CERTAIN THAT EACH a completely discharged battery. Unless this proce-
OF THE CELL CAPS IS IN PLACE AND TIGHT dure is properly followed, a good battery may be
BEFORE THE BATTERY IS RETURNED TO SER- needlessly replaced.
VICE. PERSONAL INJURY AND/OR VEHICLE DAM- (1) Measure the voltage at the battery posts with a
AGE MAY RESULT FROM LOOSE OR MISSING voltmeter, accurate to 1/10 (0.10) volt (Fig. 4). If the
CELL CAPS. reading is below ten volts, the battery charging cur-
rent will be low. It could take some time before the
battery accepts a current greater than a few milliam-
CAUTION: Always disconnect and isolate the bat- peres. Such low current may not be detectable on the
tery negative cable before charging a battery. Do ammeters built into many battery chargers.
not exceed sixteen volts while charging a battery. (2) Disconnect and isolate the battery negative
cable. Connect the battery charger leads. Some bat-
VA BATTERY SYSTEM 8F - 9
BATTERY (Continued)
• Temperature - A longer time will be needed to
charge a battery at -18° C (0° F) than at 27° C (80°
F). When a fast battery charger is connected to a cold
battery, the current accepted by the battery will be
very low at first. As the battery warms, it will accept
a higher charging current rate (amperage).
• Charger Capacity - A battery charger that
supplies only five amperes will require a longer
charging time. A battery charger that supplies
twenty amperes or more will require a shorter charg-
ing time.
• State-Of-Charge - A completely discharged bat-
tery requires more charging time than a partially
discharged battery. Electrolyte is nearly pure water
in a completely discharged battery. At first, the
charging current (amperage) will be low. As the bat-
tery charges, the specific gravity of the electrolyte
will gradually rise.
The Battery Charging Time Table gives an indica-
Fig. 4 VOLTMETER ACCURATE TO 1/10 VOLT tion of the time required to charge a typical battery
tery chargers are equipped with polarity-sensing cir- at room temperature based upon the battery state-of-
cuitry. This circuitry protects the battery charger and charge and the charger capacity.
the battery from being damaged if they are improp-
erly connected. If the battery state-of-charge is too BATTERY CHARGING TIME TABLE
low for the polarity-sensing circuitry to detect, the Charging 10
battery charger will not operate. This makes it 5 Amps 20 Amps
Amperage Amps
appear that the battery will not accept charging cur-
Open Circuit Hours Charging @ 21° C
rent. See the instructions provided by the manufac-
Voltage (70° F)
turer of the battery charger for details on how to
bypass the polarity-sensing circuitry. 12.25 to 12.49 6 hours 3 hours 1.5
(3) Battery chargers vary in the amount of voltage hours
and current they provide. The amount of time 12.00 to 12.24 10 hours 5 hours 2.5
required for a battery to accept measurable charging hours
current at various voltages is shown in the Charge
10.00 to 11.99 14 hours 7 hours 3.5
Rate Table. If the charging current is still not mea-
hours
surable at the end of the charging time, the battery
is faulty and must be replaced. If the charging cur- Below 10.00 18 hours 9 hours 4.5
rent is measurable during the charging time, the bat- hours
tery may be good and the charging should be
completed in the normal manner. STANDARD PROCEDURE - OPEN-CIRCUIT
VOLTAGE TEST
CHARGE RATE TABLE A battery open-circuit voltage (no load) test will
show the approximate state-of-charge of a battery.
Voltage Hours
This test can be used in place of the hydrometer test
16.0 volts maximum up to 4 hours when a hydrometer is not available, or for mainte-
14.0 to 15.9 volts up to 8 hours nance-free batteries with non-removable cell caps.
13.9 volts or less up to 16 hours Before proceeding with this test, completely charge
the battery (Refer to 8 - ELECTRICAL/BATTERY
SYSTEM/BATTERY - STANDARD PROCEDURE).
CHARGING TIME REQUIRED (1) Before measuring the open-circuit voltage, the
The time required to charge a battery will vary, surface charge must be removed from the battery.
depending upon the following factors: Turn on the headlamps for fifteen seconds, then
• Battery Capacity - A completely discharged allow up to five minutes for the battery voltage to
heavy-duty battery requires twice the charging time stabilize.
of a small capacity battery. (2) Disconnect and isolate both battery cables, neg-
ative cable first.
8F - 10 BATTERY SYSTEM VA
BATTERY (Continued)
(3) Using a voltmeter connected to the battery radio, and other modules which may vary with the
posts (see the instructions provided by the manufac- vehicle equipment.
turer of the voltmeter), measure the open-circuit volt- A vehicle that has not been operated for approxi-
age (Fig. 5). mately twenty days, may discharge the battery to an
inadequate level. When a vehicle will not be used for
twenty days or more (stored), remove the IOD fuse
from the fuseblock. This will reduce battery discharg-
ing.
Excessive IOD can be caused by:
• Electrical items left on.
• Faulty or improperly adjusted switches.
• Faulty or shorted electronic modules and compo-
nents.
• An internally shorted generator.
• Intermittent shorts in the wiring.
If the IOD is over thirty-five milliamperes, the
problem must be found and corrected before replac-
ing a battery. In most cases, the battery can be
charged and returned to service after the excessive
IOD condition has been corrected.
(1) Verify that all electrical accessories are off.
Turn off all lamps, remove the ignition key, and close
all doors. If the vehicle is equipped with an illumi-
Fig. 5 Testing Open Circuit Voltage nated entry system or an electronically tuned radio,
allow the electronic timer function of these systems
See the Open-Circuit Voltage Table. This voltage to automatically shut off (time out). This may take
reading will indicate the battery state-of-charge, but up to three minutes.
will not reveal its cranking capacity. If a battery has (2) Determine that the underhood lamp is operat-
an open-circuit voltage reading of 12.4 volts or ing properly, then disconnect the lamp wire harness
greater, it may be load tested to reveal its cranking connector or remove the lamp bulb.
capacity (Refer to 8 - ELECTRICAL/BATTERY SYS- (3) Disconnect the battery negative cable.
TEM/BATTERY - STANDARD PROCEDURE). (4) Set an electronic digital multi-meter to its
highest amperage scale. Connect the multi-meter
OPEN CIRCUIT VOLTAGE TABLE between the disconnected battery negative cable ter-
Open Circuit Voltage Charge Percentage minal clamp and the battery negative terminal post.
Make sure that the doors remain closed so that the
11.7 volts or less 0% illuminated entry system is not activated. The multi-
12.0 volts 25% meter amperage reading may remain high for up to
12.2 volts 50% three minutes, or may not give any reading at all
while set in the highest amperage scale, depending
12.4 volts 75%
upon the electrical equipment in the vehicle. The
12.6 volts or more 100% multi-meter leads must be securely clamped to the
battery negative cable terminal clamp and the bat-
STANDARD PROCEDURE - IGNITION-OFF tery negative terminal post. If continuity between the
DRAW TEST battery negative terminal post and the negative cable
The term Ignition-Off Draw (IOD) identifies a nor- terminal clamp is lost during any part of the IOD
mal condition where power is being drained from the test, the electronic timer function will be activated
battery with the ignition switch in the Off position. A and all of the tests will have to be repeated.
normal vehicle electrical system will draw from five (5) After about three minutes, the high-amperage
to thirty-five milliamperes (0.005 to 0.035 ampere) IOD reading on the multi-meter should become very
with the ignition switch in the Off position, and all low or nonexistent, depending upon the electrical
non-ignition controlled circuits in proper working equipment in the vehicle. If the amperage reading
order. Up to thirty-five milliamperes are needed to remains high, remove and replace each fuse or circuit
enable the memory functions for the Powertrain Con- breaker in the Fuse Blocks, one at a time until the
trol Module (PCM), digital clock, electronically tuned amperage reading becomes very low, or nonexistent.
Refer to the appropriate wiring information in this
VA BATTERY SYSTEM 8F - 11
BATTERY (Continued)
service manual for complete fuseblock fuse, circuit
breaker, and circuit identification. This will isolate
each circuit and identify the circuit that is the source
of the high-amperage IOD. If the amperage reading
remains high after removing and replacing each fuse
and circuit breaker, disconnect the wire harness from
the generator. If the amperage reading now becomes
very low or nonexistent, refer to Charging System for
the proper charging system diagnosis and testing
procedures. After the high-amperage IOD has been
corrected, switch the multi-meter to progressively
lower amperage scales and, if necessary, repeat the
fuse and circuit breaker remove-and-replace process
to identify and correct all sources of excessive IOD. It
is now safe to select the lowest milliampere scale of
the multi-meter to check the low-amperage IOD.

CAUTION: Do not open any doors, or turn on any


electrical accessories with the lowest milliampere
scale selected, or the multi-meter may be damaged.

(6) Observe the multi-meter reading. The low-am-


perage IOD should not exceed thirty-five milliam- Fig. 6 Micro 420 Battery Tester
peres (0.035 ampere). If the current draw exceeds
thirty-five milliamperes, isolate each circuit using the accessible, you may test using both the positive and
fuse and circuit breaker remove-and-replace process negative jumper posts. Select TESTING AT JUMPER
in Step 5. The multi-meter reading will drop to POST when connecting to that location.
within the acceptable limit when the source of the (3) Connect the tester (Fig. 6) to the battery or
excessive current draw is disconnected. Repair this jumper posts, the red clamp to positive (+) and the
circuit as required; whether a wiring short, incorrect black clamp to negative (–).
switch adjustment, or a component failure is at fault.
NOTE: Multiple batteries connected in parallel must
have the ground cable disconnected to perform a
STANDARD PROCEDURE - USING MICRO 420 battery test. Failure to disconnect may result in
BATTERY TESTER false battery test readings.
Always use the Micro 420 Instruction Manual that
was supplied with the tester as a reference. If the (4) Using the ARROW key select in or out of vehi-
Instruction Manual is not available the following pro- cle testing and press ENTER to make a selection.
cedure can be used: (5) If not selected, choose the Cold Cranking Amp
(CCA) battery rating. Or select the appropriate bat-
WARNING: ALWAYS WEAR APPROPRIATE EYE tery rating for your area (see menu). The tester will
PROTECTION AND USE EXTREME CAUTION WHEN then run its self programmed test of the battery and
WORKING WITH BATTERIES. display the results. Refer to the test result table
noted below.
BATTERY TESTING CAUTION: If REPLACE BATTERY is the result of the
(1) If testing the battery OUT-OF-VEHICLE, clean test, this may mean a poor connection between the
the battery terminals with a wire brush before test- vehicle’s cables and battery exists. After discon-
ing. If the battery is equipped with side post termi- necting the vehicle’s battery cables from the bat-
nals, install and tighten the supplied lead terminal tery, retest the battery using the OUT-OF-VEHICLE
stud adapters. Do not use steel bolts. Failure to prop- test before replacing.
erly install the stud adapters, or using stud adapters
that are dirty or worn-out may result in false test (6) While viewing the battery test result, press the
readings. CODE button and the tester will prompt you for the
(2) If testing the battery IN-THE-VEHICLE, make last 4 digits of the VIN. Use the UP/DOWN arrow
certain all of the vehicle accessory loads are OFF, buttons to scroll to the correct character; then press
including the ignition. The preferred test position ENTER to select and move to the next digit. Then
is at the battery terminal. If the battery is not press the ENTER button to view the SERVICE
8F - 12 BATTERY SYSTEM VA
BATTERY (Continued)
CODE. Pressing the CODE button a second time will
return you to the test results.

BATTERY TEST RESULTS


GOOD BATTERY Return to service
GOOD - RECHARGE Fully charge battery and
return to service
CHARGE & RETEST Fully charge battery and
retest battery
REPLACE BATTERY Replace the battery and
retest complete system
BAD-CELL REPLACE Replace the battery and
retest complete system

NOTE: The SERVICE CODE is required on every


warranty claim submitted for battery replacement.

STANDARD PROCEDURE - CHECKING BATTERY


ELECTROLYTE LEVEL Fig. 8 Hook Inside Battery Cap Holes
(1) Remove the battery cell caps (Fig. 7).
1 - BATTERY SURFACE COVER
2 - HOOK

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.

The following operation will require a voltmeter


accurate to 1/10 (0.10) volt. Before performing this
test, be certain that the following procedures are
accomplished:
• The battery is fully-charged and tested. (Refer to
8 - ELECTRICAL/BATTERY SYSTEM/BATTERY -
STANDARD PROCEDURE).
• Fully engage the parking brake.
• Place the automatic transmission gearshift selec-
tor lever in the Park position.
• Verify that all lamps and accessories are turned Fig. 10 Test Battery Positive Connection Resistance
off. - Typical
• Prevent the engine from starting. 1 - VOLTMETER
(1) Connect the positive lead of the voltmeter to 2 - BATTERY
the battery negative terminal post. Connect the neg-
ative lead of the voltmeter to the battery negative (3) Connect the voltmeter to measure between the
cable terminal clamp (Fig. 9). Rotate and hold the battery positive cable terminal clamp and the starter
ignition switch in the Start position. Observe the solenoid B(+) terminal stud (Fig. 11). Rotate and hold
voltmeter. If voltage is detected, correct the poor con- the ignition switch in the Start position. Observe the
nection between the battery negative cable terminal voltmeter. If the reading is above 0.2 volt, clean and
clamp and the battery negative terminal post. tighten the battery positive cable eyelet terminal con-
nection at the starter solenoid B(+) terminal stud.
Repeat the test. If the reading is still above 0.2 volt,
replace the faulty battery positive cable.

Fig. 9 Test Battery Negative Connection Resistance


- Typical
1 - VOLTMETER
2 - BATTERY

(2) Connect the positive lead of the voltmeter to


the battery positive terminal post. Connect the nega-
Fig. 11 Test Battery Positive Cable Resistance -
tive lead of the voltmeter to the battery positive cable
Typical
terminal clamp (Fig. 10). Rotate and hold the ignition
switch in the Start position. Observe the voltmeter. If 1 - BATTERY
2 - VOLTMETER
voltage is detected, correct the poor connection 3 - STARTER MOTOR
8F - 16 BATTERY SYSTEM VA
BATTERY CABLES (Continued)
(4) Connect the voltmeter to measure between the BATTERY TRAY
battery negative cable terminal clamp and a good
clean ground on the engine block (Fig. 12). Rotate
DESCRIPTION
and hold the ignition switch in the Start position.
The battery is mounted in a stamped steel battery
Observe the voltmeter. If the reading is above 0.2
tray located in the left front corner of the engine
volt, clean and tighten the battery negative cable
compartment. The battery tray is secured with bolts
eyelet terminal connection to the engine block.
to the left front wheelhouse inner steel panel. A hole
Repeat the test. If the reading is still above 0.2 volt,
in the bottom of the battery tray is fitted with a
replace the faulty battery negative cable.
formed drain tube. A second hole in the bottom of the
tray is fitted with a battery temperature sensor.

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 GENERATOR DECOUPLER PULLEY


SPECIFICATIONS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 19
TORQUE – 2.7L DIESEL . . . . . . . . . . . . . . . . 17 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SPECIAL TOOLS ...... . . . . . . . . . . . . . . . . . 18 DIAGNOSIS AND TESTING - GENERATOR
GENERATOR DECOUPLER . . . . . . . . . . . . . . . . . . . . . . . . . 20
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 18 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 22
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 VOLTAGE REGULATOR
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 23

CHARGING SYSTEM

SPECIFICATIONS
TORQUE – 2.7L DIESEL

DESCRIPTION N-m Ft. Lbs. In. Lbs.


B+ Terminal Nut at Top of 13 - 115
Generator
Generator Mounting 54 40 -
Bolts/Nut
Rear Generator Support 28 - 250
Bracket Bolts (to engine)
Generator Decoupler 110 81 -
8F - 18 CHARGING SYSTEM VA
CHARGING SYSTEM (Continued)

SPECIAL TOOLS delivered to the vehicle electrical system through the


generator battery terminal.
Although the generators appear the same exter-
nally, different generators with different output rat-
ings are used on this vehicle. Be certain that the
replacement generator has the same output rating
and part number as the original unit. Refer to Spec-
ifications and see Generator Ratings for amperage
ratings and part numbers.
Noise emitting from the generator may be caused
by: worn, loose or defective bearings; a loose or defec-
tive drive pulley (decoupler pulley); incorrect, worn,
damaged or misadjusted fan drive belt; loose mount-
ing bolts; a misaligned drive pulley or a defective sta-
tor or diode.
GENERATOR DECOUPLER TOOL #8433 An instrument panel mounted, battery charge indi-
cator lamp is used. When the key is in the on posi-
tion, the lamp will be illuminated. This is done as a
bulb check. If this lamp remains illuminated while
the engine is running, a Diagnostic Trouble Code
(DTC) has been detected for the charging system.

REMOVAL
CAUTION: DISCONNECT NEGATIVE CABLE FROM
BATTERY BEFORE REMOVING BATTERY OUTPUT
WIRE FROM GENERATOR. FAILURE TO DO SO
CAN RESULT IN INJURY.

CAUTION: Never force a belt over a pulley rim


using a screwdriver. The synthetic fiber of the belt
can be damaged.

CAUTION: When installing a serpentine accessory


GENERATOR DECOUPLER TOOL #8823 drive belt, the belt MUST be routed correctly. The
water pump will be rotating in the wrong direction if
GENERATOR the belt is installed incorrectly, causing the engine
to overheat. Refer to belt routing label in engine
DESCRIPTION compartment, or refer to Belt Schematics in Cooling
The generator is belt-driven by the engine using a System.
serpentine-type drive belt. It is serviced only as a
complete assembly. If the generator fails for any rea- (1) Disconnect and isolate negative battery cable.
son, the entire assembly must be replaced. (2) Remove generator drive belt. Refer to Cooling
On certain engines, the decoupler pulley may be System for procedure.
replaced separately. (3) Raise and support vehicle.
(4) Remove protective plastic cover from B+ stud
OPERATION at top of generator.
As the energized rotor begins to rotate within the (5) Remove nut securing battery output cable to
generator, the spinning magnetic field induces a cur- B+ terminal at top of generator.
rent into the windings of the stator coil. Once the (6) Unplug field terminal connector at rear of gen-
generator begins producing sufficient current, it also erator.
provides the current needed to energize the rotor. (7) Remove 4 generator mounting bolts (Torx-style
The stator winding connections deliver the induced #12 bit) (Fig. 1).
AC current to 3 positive and 3 negative diodes for (8) Remove generator from lower side of vehicle.
rectification. From the diodes, rectified DC current is
VA CHARGING SYSTEM 8F - 19
GENERATOR (Continued)
CAUTION: When installing a serpentine accessory
drive belt, the belt MUST be routed correctly. The
water pump will be rotating in the wrong direction if
the belt is installed incorrectly, causing the engine
to overheat. Refer to belt routing label in engine
compartment, or refer to Belt Schematics in Cooling
System.

(8) Install generator drive belt. Refer to Cooling


System for procedure.
(9) Connect negative battery cable.
(10) Check charging system for proper operation.

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).

Fig. 1 GENERATOR MOUNTING - 2.7L DIESEL


1 - GENERATOR
2 - DRIVE BELT
3 - MOUNTING BOLTS (4)
4 - GENERATOR WIRING HARNESS

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)

DIAGNOSIS AND TESTING - GENERATOR


DECOUPLER

CONDITION POSSIBLE CAUSES CORRECTION


Does not drive generator Internal failure Replace decoupler
(generator not charging)

Noise coming from Internal failure Replace decoupler


decoupler

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.

Fig. 4 GENERATOR DECOUPLER PULLEY (LITENS)


1 - DECOUPLER (LITENS)
2 - HEX OPENING

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)

Fig. 7 END OF GENERATOR SHAFT (SPLINED)


1 - GENERATOR SHAFT
2 - SPLINES
Fig. 5 #8823 TOOL AND INA DECOUPLER
1 - INA DECOUPLER
2 - TOOL #8823 (VM.1048)

Fig. 8 DECOUPLER REMOVAL (INA-HEX)


1 - DEEP 10 MM SOCKET
2 - TOOL #8823 (VM.1048)
Fig. 6 END OF GENERATOR SHAFT (HEX)
1 - GENERATOR SHAFT
2 - HEX
8F - 22 CHARGING SYSTEM VA
GENERATOR DECOUPLER PULLEY (Continued)

Fig. 10 # 8433 TOOL AND LITENS DECOUPLER

Fig. 9 DECOUPLER REMOVAL (INA-SPLINED)


1 - DRIVER
2 - TOOL #8823 (VM.1048)
3 - 17 MM WRENCH

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.

Fig. 13 DECOUPLER INSTALLATION (INA SPLINED)


1 - DRIVER
2 - TOOL # 8823 (VM.1048)
3 - BACKUP WRENCH

Fig. 12 DECOUPLER INSTALLATION (INA-HEX)


1 - 10MM DEEP SOCKET
2 - TOOL # 8823 (VM.1048)

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.

VOLTAGE REGULATOR Fig. 14 DECOUPLER INSTALLATION (Litens)

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

STARTING SYSTEM STARTER MOTOR


DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 24 DIAGNOSIS AND TESTING - STARTER
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
DIAGNOSIS AND TESTING - STARTING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 30
SPECIFICATIONS STARTER MOTOR RELAY
TORQUE - STARTER - DIESEL . . . . . . . . . . . 29 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 30
SPECIFICATIONS - STARTER MOTOR - REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
DIESEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 32

STARTING SYSTEM starter motor high-amperage, and a low-amperage


control circuit that operates on less than 20 amperes.
The high-amperage feed circuit components include
DESCRIPTION
the battery, the battery cables, the contact disc por-
The starting system consists of:
tion of the starter solenoid, and the starter motor
• Starter relay
itself. The low-amperage control circuit components
• Starter motor (including an integral starter sole-
include the ignition switch, the park/neutral position
noid)
switch (automatic transmission), the starter relay,
Other components to be considered as part of start-
the electromagnetic windings of the starter solenoid,
ing system are:
and the connecting wire harness components.
• Battery
If the vehicle is equipped with an automatic trans-
• Battery cables
mission, battery voltage is supplied through the low-
• Ignition switch and key lock cylinder
amperage control circuit to the coil battery terminal
• Park/neutral position switch (automatic trans-
of the starter relay when the ignition switch is
mission)
turned to the momentary Start position. The park/
• Wire harnesses and connections.
neutral position switch is installed in series between
The Battery, Starting, and Charging systems oper-
the starter relay coil ground terminal and ground.
ate in conjunction with one another, and must be
This normally open switch prevents the starter relay
tested as a complete system. For correct operation of
from being energized and the starter motor from
starting/charging systems, all components used in
operating unless the automatic transmission gear
these 3 systems must perform within specifications.
selector is in the Neutral or Park positions.
When attempting to diagnose any of these systems, it
When the starter relay coil is energized, the nor-
is important that you keep their interdependency in
mally open relay contacts close. The relay contacts
mind.
connect the relay common feed terminal to the relay
The diagnostic procedures used in each of these
normally open terminal. The closed relay contacts
groups include the most basic conventional diagnostic
energize the starter solenoid coil windings.
methods, to the more sophisticated On-Board Diag-
The energized solenoid pull-in coil pulls in the sole-
nostics (OBD) built into the Engine Control Module
noid plunger. The solenoid plunger pulls the shift
(ECM). Use of an induction-type milliampere amme-
lever in the starter motor. This engages the starter
ter, volt/ohmmeter, battery charger, carbon pile rheo-
overrunning clutch and pinion gear with the starter
stat (load tester), and 12-volt test lamp may be
ring gear on the manual transmission flywheel or on
required.
the automatic transmission torque converter or
Certain starting system components are monitored
torque converter drive plate.
by the ECM and may produce a Diagnostic Trouble
As the solenoid plunger reaches the end of its
Code (DTC).
travel, the solenoid contact disc completes the high-
amperage starter feed circuit and energizes the sole-
OPERATION noid plunger hold-in coil. Current now flows between
The starting system components form two separate
the solenoid battery terminal and the starter motor,
circuits. A high-amperage feed circuit that feeds the
energizing the starter.
VA STARTING SYSTEM 8F - 25
STARTING SYSTEM (Continued)
Once the engine starts, the overrunning clutch pro- lever to disengage the overrunning clutch and pinion
tects the starter motor from damage by allowing the gear from the starter ring gear.
starter pinion gear to spin faster than the pinion
shaft. When the driver releases the ignition switch to DIAGNOSIS AND TESTING - STARTING
the On position, the starter relay coil is de-energized. SYSTEM
This causes the relay contacts to open. When the The battery, starting, and charging systems oper-
relay contacts open, the starter solenoid plunger ate in conjunction with one another, and must be
hold-in coil is de-energized. tested as a complete system. For correct starting/
When the solenoid plunger hold-in coil is de-ener- charging system operation, all of the components
gized, the solenoid plunger return spring returns the involved in these 3 systems must perform within
plunger to its relaxed position. This causes the con- specifications.
tact disc to open the starter feed circuit, and the shift

Starting System Diagnosis


CONDITION POSSIBLE CAUSE CORRECTION
STARTER FAILS TO 1. Battery discharged or 1. Refer to Battery. Charge or replace battery, if required.
OPERATE. faulty.
2. Starting circuit wiring 2. Refer to 8, Wiring Diagrams. Test and repair starter
faulty. feed and/or control circuits, if required.
3. Starter relay faulty. 3. Refer to Starter Relay in Diagnosis and Testing.
Replace starter relay if required.
4. Ignition switch faulty. 4. Refer to Ignition Switch and Key Lock Cylinder.
Replace ignition switch if required.
5. Clutch pedal position 5. Refer to Clutch Pedal Position Switch.
switch faulty.
6. Park/Neutral position 6. Refer to Park/Neutral Position Switch. Replace
switch faulty or park/neutral position switch if required.
misadjusted.
7. Starter solenoid faulty. 7. Refer to Starter Motor. Replace starter motor assembly
if required.
8. Starter motor faulty. 8. If all other starting system components and circuits test
OK, replace starter motor.
STARTER ENGAGES, 1. Battery discharged or 1. Refer to Battery. Charge or replace battery if required.
FAILS TO TURN faulty.
ENGINE. 2. Starting circuit wiring 2. Refer to 8, Wiring Diagrams. Test and repair starter
faulty. feed and/or control circuits if required.
3. Starter motor faulty. 3. If all other starting system components and circuits test
OK, replace starter motor assembly.
4. Engine seized. 4. Refer to Engine Diagnosis in the Diagnosis and Testing
section of 9, Engine.
STARTER ENGAGES, 1. Starter ring gear faulty. 1. Refer to Starter Motor Removal and Installation.
SPINS OUT BEFORE Remove starter motor to inspect starter ring gear.
ENGINE STARTS. Replace starter ring gear if required.
2. Starter motor faulty. 2. If all other starting system components and circuits test
OK, replace starter motor assembly.
8F - 26 STARTING SYSTEM VA
STARTING SYSTEM (Continued)

Starting System Diagnosis


CONDITION POSSIBLE CAUSE CORRECTION
STARTER DOES NOT 1. Starter motor 1. Refer to Starter Motor Removal and Installation.
DISENGAGE. improperly installed. Tighten starter mounting hardware to correct torque
specifications.
2. Starter relay faulty. 2. Refer to Starter Relay Diagnosis and Testing. Replace
starter relay if required.
3. Ignition switch faulty. 3. Refer to Ignition Switch and Key Lock Cylinder.
Replace ignition switch if required.
4. Starter motor faulty. 4. If all other starting system components and circuits test
OK, replace starter motor.

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.

• Battery - Visually inspect battery for indica-


tions of physical damage and loose or corroded cable
connections. Determine state-of-charge and cranking
capacity of battery. Charge or replace battery if
required. Refer to Battery in 8, Battery.
• Ignition Switch - Visually inspect ignition
switch for indications of physical damage and loose
or corroded wire harness connections. Refer to Igni-
tion Switch and Key Lock Cylinder.
• Park/Neutral Position Switch - Visually
inspect park/neutral position switch for indications of Fig. 1 VOLTS-AMPS TESTER CONNECTIONS -
physical damage and loose or corroded wire harness TYPICAL
connections. Refer to Park/Neutral Position 1 - POSITIVE CLAMP
Switch in 21, Transmission. 2 - NEGATIVE CLAMP
• Starter Relay - Visually inspect starter relay 3 - INDUCTION AMMETER CLAMP
for indications of physical damage and loose or cor-
(2) Fully engage parking brake.
roded wire harness connections.
(3) Place gearshift selector lever in Park position.
• Starter Motor - Visually inspect starter motor
(4) Verify that all lamps and accessories are
for indications of physical damage and loose or cor-
turned off.
roded wire harness connections.
(5) To prevent engine from starting, remove Fuel
• Starter Solenoid - Visually inspect starter sole-
Pump Relay. This relay is located in Power Distribu-
noid for indications of physical damage and loose or
tion Center (PDC). Refer to label on PDC cover for
corroded wire harness connections.
relay location.
• Wiring - Visually inspect wire harnesses for
damage or corrosion. Repair or replace any faulty
wiring, as required. Refer to 8, Wiring Diagrams.
VA STARTING SYSTEM 8F - 27
STARTING SYSTEM (Continued)
WARNING: IF EQUIPPED WITH DIESEL ENGINE, (1) Connect positive lead of voltmeter to negative
ATTEMPT TO START ENGINE A FEW TIMES battery cable terminal post. Connect negative lead of
BEFORE PROCEEDING WITH FOLLOWING STEP. voltmeter to negative battery cable clamp (Fig. 2).
Rotate and hold ignition switch in Start position.
(6) Rotate and hold ignition switch in Start posi- Observe voltmeter. If voltage is detected, correct poor
tion. Note cranking voltage and current (amperage) contact between cable clamp and terminal post.
draw readings shown on volt-ampere tester.
(a) If voltage reads below 9.6 volts, refer to
Starter Motor in Diagnosis and Testing. If starter
motor is OK, refer to Engine Diagnosis in 9,
Engine for further testing of engine. If starter
motor is not OK, replace faulty starter motor.
(b) If voltage reads above 9.6 volts and current
(amperage) draw reads below specifications, refer
to Feed Circuit Test in this section.
(c) If voltage reads 12.5 volts or greater and
starter motor does not turn, refer to Control Cir-
cuit Testing in this section.
(d) If voltage reads 12.5 volts or greater and
starter motor turns very slowly, refer to Feed Cir-
cuit Test in this section.

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

FEED CIRCUIT TEST (2) Connect positive lead of voltmeter to positive


The starter feed circuit test (voltage drop method) battery terminal post. Connect negative lead of volt-
will determine if there is excessive resistance in meter to battery positive cable clamp (Fig. 3). Rotate
high-amperage feed circuit. For complete starter wir- and hold ignition switch in Start position. Observe
ing circuit diagrams, refer 8, Wiring Diagrams. voltmeter. If voltage is detected, correct poor contact
When performing these tests, it is important to between cable clamp and terminal post.
remember that voltage drop is giving an indication of
resistance between two points at which voltmeter
probes are attached.
Example: When testing resistance of positive bat-
tery cable, touch voltmeter leads to positive battery
cable clamp and cable connector at starter solenoid.
If you probe positive battery terminal post and cable
connector at starter solenoid, you are reading com-
bined voltage drop in positive battery cable clamp-to-
terminal post connection and positive battery cable.
The following operation will require a voltmeter
accurate to 1/10 (0.10) volt. Before performing tests,
be certain that following procedures are accom-
plished:
• Battery is fully-charged and load-tested. Refer to
Battery in 8, Battery.
• Fully engage parking brake. Fig. 3 TEST POSITIVE BATTERY CABLE
• Place gearshift selector lever in Park position. CONNECTION RESISTANCE - TYPICAL
• Verify that all lamps and accessories are turned 1 - VOLTMETER
off. 2 - BATTERY
• To prevent engine from starting, remove Fuel
(3) Connect voltmeter to measure between battery
Pump Relay. This relay is located in Power Distribu-
positive terminal post and starter solenoid battery
tion Center (PDC). Refer to label on PDC cover for
terminal stud (Fig. 4). Rotate and hold ignition
relay location.
8F - 28 STARTING SYSTEM VA
STARTING SYSTEM (Continued)
switch in Start position. Observe voltmeter. If read-
ing is above 0.2 volt, clean and tighten battery cable
connection at solenoid. Repeat test. If reading is still
above 0.2 volt, replace faulty positive battery cable.

Fig. 5 TEST GROUND CIRCUIT RESISTANCE -


TYPICAL
1 - VOLTMETER
2 - BATTERY
3 - ENGINE GROUND
Fig. 4 TEST POSITIVE BATTERY CABLE
1 - BATTERY
2 - VOLTMETER
3 - STARTER MOTOR

(4) Connect voltmeter to measure between nega-


tive battery terminal post and a good clean ground
on engine block (Fig. 5). Rotate and hold ignition
switch in Start position. Observe voltmeter. If read-
ing is above 0.2 volt, clean and tighten negative bat-
tery cable attachment on engine block. Repeat test. If
reading is still above 0.2 volt, replace faulty negative
battery cable.
(5) Connect positive lead of voltmeter to starter
housing. Connect negative lead of voltmeter to nega-
tive battery terminal post (Fig. 6). Rotate and hold
ignition switch in Start position. Observe voltmeter.
If reading is above 0.2 volt, correct poor starter to Fig. 6 TEST STARTER GROUND - TYPICAL
engine block ground contact. 1 - STARTER MOTOR
If resistance tests detect no feed circuit problems, 2 - BATTERY
3 - VOLTMETER
refer to Starter Motor in the Diagnosis and Testing.
• Park/Neutral Position Switch - If equipped
CONTROL CIRCUIT TESTING
with automatic transmission, refer to Park/Neutral
The starter control circuit components should be Position Switch in 21, Transmission.
tested in the order in which they are listed, as fol- • Wire harnesses and connections - Refer to 8,
lows: Wiring Diagrams.
• Starter Relay - Refer to Starter Relay Diag-
nosis and Testing.
• Starter Solenoid - Refer to Starter Motor
Diagnosis and Testing.
• Ignition Switch - Refer to Ignition Switch
and Key Lock Cylinder
VA STARTING SYSTEM 8F - 29
STARTING SYSTEM (Continued)

SPECIFICATIONS
TORQUE - STARTER - DIESEL

DESCRIPTION N-m Ft. Lbs. In. Lbs.


Battery Cable Nut at 14 - 124
Starter Solenoid (larger
nut)
Starter Mounting Bolts 40 30 -
Starter Solenoid (smaller 6 - 52
nut)

SPECIFICATIONS - STARTER MOTOR - DIESEL

ITEM SPECIFICATION

ENGINE 2.7L TURBO DIESEL


RATED VOLTAGE 12 VOLTS
NUMBER OF FIELDS 4
NUMBER OF POLES 4
NUMBER OF BRUSHES 4
DRIVE TYPE GEAR REDUCTION
FREE RUNNING TEST VOLTAGE 11.5 VOLTS
FREE RUNNING TEST MAXIMUM 160 AMPS
AMPERAGE DRAW
FREE RUNNING TEST MINIMUM SPEED 5500 RPM
SOLENOID CLOSING MAXIMUM VOLTAGE 7.8 VOLTS
MAXIMUM CRANKING AMPERAGE DRAW * 500 AMPS
* A COLD OR NEW ENGINE WILL INCREASE STARTER AMPERAGE DRAW. THE USE OF HEAVY WEIGHT
ENGINE OIL WILL ALSO INCREASE STARTER AMPERAGE DRAW.

STARTER MOTOR vided by manufacturer of volt-ampere tester being


used.
(4) Install jumper wire from solenoid terminal to
DIAGNOSIS AND TESTING - STARTER MOTOR
solenoid battery terminal. The starter motor should
Correct starter motor operation can be confirmed
operate. If starter motor fails to operate, replace
by performing the following free running bench test.
faulty starter motor assembly.
This test can only be performed with starter motor
(5) Adjust carbon pile load of tester to obtain free
removed from vehicle. Refer to Starter Specifications
running test voltage. Refer to Specifications for
for specifications.
starter motor free running test voltage specifications.
(1) Remove starter motor from vehicle. Refer to
(6) Note reading on ammeter and compare reading
Starter Motor Removal and Installation.
to free running test maximum amperage draw. Refer
(2) Mount starter motor securely in a soft-jawed
to Specifications for starter motor free running test
bench vise. The vise jaws should be clamped on the
maximum amperage draw specifications.
mounting flange of starter motor. Never clamp on
(7) If ammeter reading exceeds maximum amper-
starter motor by field frame.
age draw specification, replace faulty starter motor
(3) Connect a suitable volt-ampere tester and a
assembly.
12-volt battery to starter motor in series, and set
ammeter to 100 ampere scale. See instructions pro-
8F - 30 STARTING SYSTEM VA
STARTER MOTOR (Continued)
STARTER SOLENOID (4) Working from under vehicle hood, remove 2
This test can only be performed with starter motor starter solenoid wiring harness nuts (Fig. 10).
removed from vehicle. (5) Remove solenoid wire connector from solenoid
(1) Remove starter motor from vehicle. Refer to stud, and battery cable from solenoid stud.
Starter Motor Removal and Installation. (6) Raise and support vehicle.
(2) Disconnect wire from solenoid field coil termi- (7) Remove 2 starter mounting bolts (E14Torx)
nal. (Fig. 10).
(3) Check for continuity between solenoid terminal (8) Remove starter from transmission bellhousing.
and solenoid field coil terminal with a continuity
tester (Fig. 7). There should be continuity. If OK, go
to Step 4. If not OK, replace faulty starter motor
assembly.

Fig. 7 CONTINUITY BETWEEN SOLENOID AND


FIELD COIL TERMINALS - TYPICAL
1 - OHMMETER
2 - SOLENOID TERMINAL
3 - FIELD COIL TERMINAL

(4) Check for continuity between solenoid terminal


and solenoid case (Fig. 8). There should be continuity.
If not OK, replace faulty starter motor assembly.
Fig. 9 STARTER AND SOLENOID LOCATION
1 - STARTER SOLENOID LOCATION
2 - STARTER MOTOR LOCATION

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)

Fig. 10 STARTER REMOVAL/INSTALLATION


1 - WIRING HARNESS
2 - STARTER SOLENOID
3 - STARTER MOTOR
4 - MOUNTING BOLTS (2)
Fig. 11 WIRING TROUGH - FOR STARTER REMOVAL
5 - SOLENOID NUTS (2) (VIEW FROM REAR)
1 - WIRING TROUGH
under, and to the left side of the drivers seat. See 2 - REAR/LEFT END OF TRANS. BELLHOUSING (VIEW FROM
REAR)
Fuse/Relay Block cover for relay identification and
location.
The starter relay is an International Standards
Organization (ISO) relay. Relays conforming to ISO
specifications have common physical dimensions, cur-
rent capacities, terminal patterns, and terminal func-
tions.
The starter relay cannot be repaired or adjusted
and, if faulty or damaged, it must be replaced.

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).

Fig. 13 FUSE / RELAY BLOCK COVER


1 - LEFT SIDE OF DRIVERS SEAT
2 - FUSE / RELAY BLOCK
3 - RELEASE TABS (2)
4 - COVER (ACCESS PANEL)
VA HEATED SYSTEMS 8G - 1

HEATED SYSTEMS
TABLE OF CONTENTS

page page

HEATED GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 HEATED SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9


HEATED MIRRORS . . . . . . . . . . . . . . . . . . . . . . . . . 8

HEATED GLASS

TABLE OF CONTENTS
page page

HEATED GLASS REAR WINDOW DEFOGGER SWITCH


DESCRIPTION . . . . . . . . . . . . . . . . . . . .......1 DESCRIPTION . . . . . . . . . . . . . . . . . . . .......4
OPERATION . . . . . . . . . . . . . . . . . . . . . .......2 OPERATION . . . . . . . . . . . . . . . . . . . . . .......4
DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING
ELECTRIC BACKLIGHT (EBL) SYSTEM .....2 REAR WINDOW DEFOGGER SWITCH ......5
REAR WINDOW DEFOGGER RELAY REMOVAL ...................... .......6
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . .3 INSTALLATION . . . . . . . . . . . . . . . . . . . .......6
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 REAR WINDOW DEFOGGER GRID
REMOVAL ...................... . . . . . . .4 STANDARD PROCEDURE
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . .4 GRID LINE AND TERMINAL REPAIR . .......6

HEATED GLASS
DESCRIPTION
CAUTION: Grid lines can be damaged or scraped
off with sharp instruments. Care should be taken in
cleaning glass or removing foreign materials,
decals or stickers. Normal glass cleaning solvents
or hot water used with rags or toweling is recom-
mended.

The rear window defogger system, also known as


the electric backlight (EBL), consists of a backglass
with two vertical bus bars linked by a series of grid
lines fired onto the inside surface of the rear window.
The EBL system is turned On or Off by a control
switch (Fig. 1) located in the instrument panel near
the right side of the steering wheel, which sends a
request signal to the rear window defogger module
that operates the left and right rear window defogger Fig. 1 Rear Window Defogger Switch
relays located in the fuse/relay block under the driv- 1 - REAR WINDOW DEFOGGER SWITCH
ers seat. 2 - INSTRUMENT PANEL
Circuit protection is provided by a 30 amp fuse
also located in the fuse/relay block.
8G - 2 HEATED GLASS VA
HEATED GLASS (Continued)

OPERATION cent clear glass should be detected within three to


When the rear window defogger switch is pressed four minutes of operation.
to the On position, current is directed through the (2) If a temperature difference is not detected, use
switch to the rear window defogger module. The rear a 12-volt DC voltmeter and contact the rear glass
window defogger module then grounds the control heating grid terminal B with the negative lead, and
side of the left and right rear window defogger (EBL) terminal A with the positive lead (Fig. 2). The volt-
relays which allows battery current to flow to the meter should read battery voltage. If the voltmeter
rear window defogger grid lines. The heated grid does not read battery voltage, check the following:
lines heat the rear glass to help clear the rear win- • Confirm that the ignition switch is in the On
dow surfaces of fog or frost. position.
The electric backlight (EBL) system is controlled • Make sure that the rear glass heating grid feed
by the EBL timing circuity, which is integral to the wires and ground wires are connected to the window
rear window defogger module. A yellow indicator in terminals. Confirm that the ground wires have conti-
the switch will illuminate to indicate when the EBL nuity to ground.
system is turned on. • Check that fuse 7 (15 amp) in fuse block #1 and
fuse 10 (30 amp) in the fuse/relay block are OK. The
NOTE: The EBL system turns off automatically after fuses must be tight in there receptacles and all elec-
approximately 10 minutes of initial operation. Each trical connections must be secure.
following activation cycle of the EBL system will (3) When the above steps have been completed and
last approximately five minutes. the rear glass heating grid is still inoperative, one or
more of the following is faulty.
The EBL system will be automatically turned off • Rear window defogger switch in the instrument
after a programmed time interval of about ten min- panel.
utes. After the initial time interval has expired, if the • Rear window defogger (EBL) relays in the fuse/
rear window defogger switch is pressed to the On relay block.
position again during the same ignition cycle, the • Rear window defogger (EBL) relay control circu-
EBL system will automatically turn off after about ity in the rear window defogger module.
five minutes. • Check for a loose wire connector or a wire
The EBL system will automatically shut off if the pushed out of a connector.
ignition switch is turned to the Off position, or it can • Rear window grid lines (all grid lines would
be turned off manually by pressing the defogger have to be broken, or the power feed or ground wire
switch a second time. not connected, for the entire heating grid to be inop-
erative).
(4) If the system operation has been verified but
DIAGNOSIS AND TESTING the defogger switch indicator does not illuminate,
check for voltage at the defogger indicator from the
ELECTRIC BACKLIGHT (EBL) SYSTEM rear window defogger module when the defogger
switch is activated. If power is present, replace the
NOTE: Illumination of the defogger switch indicator
rear window defogger switch.
lamp means that there is electrical current available
(5) If broken defogger grid lines are suspected, use
at the output of the rear window defogger logic cir-
a 12-volt DC voltmeter and contact terminal B with
cuitry, but does not confirm that the electrical cur-
the negative lead and each rear glass heating grid
rent is reaching the rear glass heating grid lines.
line at it’s mid-point with the positive lead. The volt-
meter should read approximately 6 volts at each grid
NOTE: For circuit descriptions and diagrams of the line mid-point C. If the voltmeter does not read
EBL system, refer to 8W - WIRING DIAGRAM approximately 6 volts, repair the open grid line(s)
INFORMATION. (Refer to 8 - ELECTRICAL/HEATED GLASS/REAR
WINDOW DEFOGGER GRID - STANDARD PROCE-
Operation of the electrical backlight (EBL) system DURE).
can be confirmed by the following:
(1) Turn the ignition switch to the On position. Set
the rear window defogger switch in the On position.
The rear window defogger operation can be checked
by feeling the rear window glass. A distinct difference
in temperature between the grid lines and the adja-
VA HEATED GLASS 8G - 3
HEATED GLASS (Continued)

Fig. 2 Grid Line Test


1 - VOLTMETER
2 - VOLTAGE FEED (A)
3 - FEED WIRE
4 - MID-POINT (C) Fig. 3 Rear Window Defogger (EBL) Relays
5 - HEATED WINDOW GRID 1 - REAR WINDOW DEFOGGER (EBL) RELAY (2)
6 - GROUND WIRE 2 - TERMINAL PATTERN
7 - GROUND (B)

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.

Fig. 5 Rear Window Defogger Switch


Fig. 4 Rear Window Defogger (EBL) Relays 1 - REAR WINDOW DEFOGGER SWITCH
2 - INSTRUMENT PANEL
1 - DRIVERS SEAT
2 - FUSE/RELAY BLOCK
OPERATION
INSTALLATION A yellow indicator lamp will illuminate when the
rear window defogger switch is activated. The switch
NOTE: Refer to the fuse and relay map located on energizes the timing circuit of the rear window defog-
the inner surface of the fuse/relay block cover for ger module which then activates the rear window
the left and right rear window defogger (EBL) relay defogger (EBL) relays. The EBL relays controls the
locations. current flow to the rear window defogger grids. The
EBL system will operate for approximately five min-
VA HEATED GLASS 8G - 5
REAR WINDOW DEFOGGER SWITCH (Continued)
utes or until the rear window defogger switch or igni- (5) Press the defogger switch to the On position.
tion switch is turned off. Refer to 8 - ELECTRICAL/ The indicator lamp should come on and remain on
HEATED GLASS - DIAGNOSIS AND TESTING for for approximately 5 minutes.
diagnosis and testing of the rear window defogger (a) If OK, install the rear window defogger
switch. switch (Refer to 8 - ELECTRICAL/HEATED
The rear window defogger switch cannot be GLASS/REAR WINDOW DEFOGGER SWITCH -
repaired and, if faulty or damaged, it must be INSTALLATION).
replaced. (b) If NOT OK, go to Step 6.
(6) Check Pin 9, with defogger switch in the On
position there should be battery voltage.
DIAGNOSIS AND TESTING (a) If OK, go to Step 7.
(b) If NOT OK, check the wiring circuits. Refer
REAR WINDOW DEFOGGER SWITCH to 8W - WIRING DIAGRAM INFORMATION.
(7) Check Pin 10 for a good ground.
WARNING: On vehicles equipped with airbags, dis- (a) If OK, replace the rear window defogger
able the airbag system before attempting any steer- switch.
ing wheel, steering column, or instrument panel (b) If NOT OK, check the wiring circuits. Refer
component diagnosis or service. Disconnect and to 8W - WIRING DIAGRAM INFORMATION.
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 air-
bag system. Failure to take the proper precautions
could result in an accidental airbag deployment and
possible personal injury.

NOTE: The rear window defogger switch may be


tested in the vehicle or out of the vehicle, on a
bench.

NOTE: For circuit descriptions and diagrams of the


rear window defogger system, refer to 8W - WIRING
DIAGRAM INFORMATION.

(1) Remove the rear window defogger switch from


the instrument panel, but leave the switch connected
(Refer to 8 - ELECTRICAL/HEATED GLASS/REAR
Fig. 6 Rear Window Defogger Switch Connector
WINDOW DEFOGGER SWITCH - REMOVAL).
(2) Turn the ignition switch ON.
(3) Using a voltmeter, check for battery voltage at DEFOGGER SWITCH CONNECTOR PIN
Pin 3 of the rear window defogger switch (Fig. 6). CALL-OUT
(a) If OK, go to Step 4.
(b) If NOT OK, check fuse 7 (15 amp) in fuse PIN FUNCTION
block #1. If fuse is OK, check the wiring circuits.
1 FUSED B+ (DRL RELAY)
Refer to 8W - WIRING DIAGRAM INFORMA-
TION. 3 IGNITION SWITCH OUTPUT (START-
(4) Check Pin 7, with defogger switch in the On RUN)
position there should be battery voltage and, no volt- 5 PANEL LAMPS DRIVER
age with the switch in the Off position. 7 DEFOGGER SWITCH OUTPUT
(a) If OK, go to Step 5.
(b) If NOT OK, no voltage in the On position or 9 PANEL LAMPS DRIVER
voltage in the Off position, replace the rear window 10 GROUND
defogger switch.
8G - 6 HEATED GLASS VA
REAR WINDOW DEFOGGER SWITCH (Continued)

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.

(1) Disconnect and isolate the negative battery


cable. Fig. 8 Headlamp Leveling Switch Remove/Install
(2) Remove the cluster bezel from the instrument 1 - SWITCH
panel (Fig. 7) (Refer to 23 - BODY/INSTRUMENT 2 - LATCH (2)
PANEL/CLUSTER BEZEL - REMOVAL). 3 - CLUSTER BEZEL

(2) Using hand pressure, push the rear window


defogger switch firmly and evenly into the switch
mounting hole of the cluster bezel until both of the
latches on the switch body are fully engaged.
(3) Install the cluster bezel (Refer to 23 - BODY/
INSTRUMENT PANEL/CLUSTER BEZEL -
INSTALLATION).
(4) Reconnect the negative battery cable.

REAR WINDOW DEFOGGER


GRID

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.

(4) Properly orient the new terminal(s) with the


attaching clip facing outboard in the original loca-
tion(s) on the grid bus bar and hold the terminal(s)
with a metal pick or other suitable pointed tool.

CAUTION: Do not allow the glass surface to exceed


204° C (400° F), glass may fracture.

NOTE: New rear window defogger terminals are pre-


soldered and fluxed. Do not reuse a terminal if it
Fig. 9 Grid Line Repair has been previously heated.
1 - BREAK
2 - GRID LINE Place the solder gun onto the new terminal(s) and
3 - MASKING TAPE heat the terminal until the solder flows. Remove the
solder gun and continue to hold the terminal in the
REAR WINDOW DEFOGGER GRID TERMINAL REPAIR correct position for an additional five seconds.
(5) Allow the solder to cool for ten minutes.
CAUTION: Do not use a flame type solder gun or an
electric solder gun rated greater than 500 watts or NOTE: To ensure proper installation, do not attach
damage to the glass may occur. the wire harness connector(s) to the terminal(s)
until the solder is completely cooled.
If the rear window defogger grid terminal(s) is
damaged or separated from the rear window, the new (6) After the solder has cooled, reconnect the wire
grid terminal(s) must be securely fastened to the rear harness connector(s) and verify operation of the rear
window defogger bus bar by soldering. window defogger.
(1) If the grid terminal(s) is broken and a portion
of the terminal is still attached to the heating grid,
8G - 8 HEATED MIRRORS VA

HEATED MIRRORS

TABLE OF CONTENTS
page page

HEATED MIRRORS OPERATION ............................8


DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8

HEATED MIRRORS OPERATION


The electric heater grid located behind the glass of
DESCRIPTION each of the outside rear view mirrors is energized
The available heated outside rear view mirror sys- when the ignition switch is turned to the Run posi-
tem is operational anytime the ignition switch is in tion. The heater grids heat the glass surface of the
the Run position (Fig. 1). When energized, each of outside rear view mirrors.
these heater grids produce heat to help clear the out- If the outside mirror heating grids are inoperative,
side mirrors of ice, snow, or fog. refer to 8W - WIRING DIAGRAM INFORMATION.
The heating grid behind each outside mirror glass
cannot be repaired and, if faulty or damaged, the
mirror glass must be replaced (Refer to 23 - BODY/
EXTERIOR/MIRROR-SIDE VIEW - GLASS -
REMOVAL).

Fig. 1 SIDE VIEW MIRROR - GLASS


1 - MIRROR GLASS
2 - ELECTRICAL CONNECTORS
3 - GUIDES
VA HEATED SEATS 8G - 9

HEATED SEATS

TABLE OF CONTENTS
page page

HEATED SEATS OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 12


DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9 DIAGNOSIS AND TESTING - HEATED SEAT
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DIAGNOSIS AND TESTING - HEATED SEATS . 10 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DRIVER HEATED SEAT SWITCH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10 HEATED SEAT SENSOR
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 12
DIAGNOSIS AND TESTING - DRIVER HEATED DIAGNOSIS AND TESTING - HEATED SEAT
SEAT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . 10 SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 PASSENGER HEATED SEAT SWITCH
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 12
HEATED SEAT ELEMENT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11 DIAGNOSIS AND TESTING - PASSENGER
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 HEATED SEAT SWITCH . . . . . . . . . . . . . . . . . 13
DIAGNOSIS AND TESTING - HEATED SEAT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13
HEATED SEAT RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11

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

HEATED SEAT SYSTEM DIAGNOSIS

CONDITION POSSIBLE CAUSES CORRECTION

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.

HEATED SEAT ELEMENT DIAGNOSIS AND TESTING - HEATED SEAT


ELEMENT
DESCRIPTION For complete circuit diagrams, refer to Wiring.
The heated seat system includes two seat heating
elements in each front seat, one for the seat cushion NOTE: When checking heated seat elements for
(Fig. 1) and the other for the seat back. All models continuity, be certain to move the heating element
use two resistor wire heating elements for each seat being checked. Moving the element, such as sitting
that are connected in series with the Heated Seat in the seat will eliminate the possibility of an inter-
Relay. The temperature sensor is a Negative Temper- mittent open in the element which would only be
ature Coefficient (NTC) thermistor. One temperature evident if the element was in a certain position.
sensor is used for each seat, and it is located in the Failure to check the element in various positions
seat cushion heating element for all models. could result in an incomplete test.

(1) Disconnect and isolate the battery negative


cable. Disconnect the heated seat element wire har-
ness connector from under the seat cushion. Check
for continuity between the seat heater driver circuit
and ground. There should be continuity, less than 7
ohms. If OK, go to Step 2. If not OK, replace the seat
assembly.
(2) Check for continuity between the seat heater
B+ driver circuit cavity and the seat back frame.
There should be no continuity. If OK, heating ele-
ment is OK at this time. If not OK, replace the seat
assembly.

HEATED SEAT RELAY


DESCRIPTION
The heated seat relay is an electromechanical
device that switches 12v battery current to the
heated seat elements when the relay control coil is
energized. The heated seat relay is located in the
Fig. 1 Heated Seat Element - Typical Fuse Block, under the drivers seat. The heated seat
relay is a International Standards Organization
1 - Seat Back Wire Harness
2 - Heated Seat Wire Harness Connector (ISO) relay. Relays conforming to the ISO specifica-
3 - Heated Seat Cushion Element
8G - 12 HEATED SEATS VA
HEATED SEAT RELAY (Continued)
tions have common physical dimensions, current HEATED SEAT SENSOR
capacities, terminal patterns, and terminal functions.
The heated seat relay cannot be repaired or
DESCRIPTION
adjusted and, if faulty or damaged, it must be
The heated seat temperature sensor is a Negative
replaced.
Temperature Coefficient (NTC) thermistor. One tem-
perature sensor is used for each seat. The sensor is
OPERATION located in the seat cushion heating element for all
The ISO relay consists of an electromagnetic coil, a
models.
resistor or diode, and three (two fixed and one mov-
The heated seat sensor cannot be adjusted or
able) electrical contacts. The movable (common feed)
repaired and if it is found to be faulty, the complete
relay contact is held against one of the fixed contacts
heated seat element must be replaced.
(normally closed) by spring pressure. When the elec-
tromagnetic coil is energized, it draws the movable
DIAGNOSIS AND TESTING - HEATED SEAT
contact away from the normally closed fixed contact,
and holds it against the other (normally open) fixed SENSOR
contact. When the electromagnetic coil is de-ener- For complete circuit diagrams, refer to Wiring.
gized, spring pressure returns the movable contact to
NOTE: Any resistance values (ohms V) given in the
the normally closed position. The resistor or diode is
following text are supplied using the automatic
connected in parallel with the electromagnetic coil in
range generated by a FLUKET automotive meter. If
the relay, and helps to dissipate voltage spikes that
another type of measuring device is used the val-
are produced when the coil is de-energized.
ues generated may not be the same as the results
shown here, or may have to be converted to the
DIAGNOSIS AND TESTING - HEATED SEAT
range used here.
RELAY
The heated seat relay is located in the Fuse Block, (1) Backprobe the heated seat relay wire harness
under the drivers seat. Refer to Wiring for the loca- connector, do not disconnect. Using an voltmeter,
tion of complete heated seat system wiring diagrams. check the voltage of the seat temperature sensor
(1) Remove the heated seat relay from the fuse input cavity of the heated seat relay wire harness
block. connector. The seat sensor input voltage should be
(2) A relay in the de-energized position should between 1.7 volts and 3.0 volts with the system ON.
have continuity between terminals 87A and 30, and If OK, sensor is OK at this time. If not OK, replace
no continuity between terminals 87 and 30. If OK, go the faulty seat cushion heating element and sensor
to Step 3. If not OK, replace the faulty relay. assembly.
(3) Resistance between terminals 85 and 86 (elec-
tromagnet) should be 75 ± 5 ohms. If OK, go to Step
4. If not OK, replace the faulty relay. PASSENGER HEATED SEAT
(4) Connect a battery to terminals 85 and 86. SWITCH
There should now be continuity between terminals
30 and 87, and no continuity between terminals 87A
DESCRIPTION
and 30. If OK, check the relay supply circuits. If not
The heated seat switches are located on the instru-
OK, replace the faulty relay.
ment panel, in the accessory switch bezel. The two,
momentary rocker type switches provide a signal to
REMOVAL the Heated Seat Relay through separate hard wired
(1) Disconnect and isolate the battery negative
circuits. Each switch contains two light emitting
cable.
diodes (LED), one for each High and Low setting to
(2) The heated seat relay is located in the fuse
let the occupant know that the seat heater system is
block, under the drivers seat. Refer to wiring for
on.
detailed location.
The heated seat switches and their LED’s cannot
(3) Grasp the heated seat relay firmly and pull it
be repaired. If either switch is faulty or damaged the
straight out from the fuse block. A slight rocking
entire switch must be replaced.
motion will aid in removal.
OPERATION
INSTALLATION There are three modes that can be selected with
(1) Grasp the heated seat relay firmly and push it each of the heated seat switches: Off, Low, and High.
straight in the fuse block. When the top of the switch rocker is depressed, the
(2) Reconnect the battery negative cable.
VA HEATED SEATS 8G - 13
PASSENGER HEATED SEAT SWITCH (Continued)
low mode is selected and the low mode LED indicator (2) Remove the gear selector bezel trim. Refer to
illuminates. Depressing the top of the switch rocker a the Body section for the procedure.
second time will turn the heated seat to Off. This (3) Remove the storage bin. Refer to the Body sec-
same process is repeated for High heat setting. The tion for the procedure.
heated seats will automatically return to the Off (4) Remove the switch bezel retaining screw and
mode anytime the vehicle ignition switch is turned remove the switch bezel from the instrument panel.
Off. Refer to the Body section for the procedure.
Both switches provide separate hard wire inputs to (5) Disconnect electrical connections.
the Heated Seat Relay to indicate the selected mode. (6) Working from the underside of the switch, gen-
The Heated Seat Relay responds to the heated seat tly rock the switch back and forth out of its mounting
switch messages by controlling the output to the seat location in the switch bezel.
heater elements of the selected seat.
INSTALLATION
DIAGNOSIS AND TESTING - PASSENGER (1) Install the heated seat switch in its mounting
HEATED SEAT SWITCH location in the switch bezel.
For circuit description and diagrams, refer to Wir- (2) Connect electrical connections.
ing. (3) Position the switch bezel and install the retain-
(1) Inspect the Heated Seat Switches for apparent ing screw. Refer to the Body section for the proce-
damage or sticking/binding and replace if required. dure.
Refer to Heated Seat Switch Removal and Installa- (4) Install the storage bin. Refer to the Body sec-
tion in this section. tion for the procedure.
(2) Replace the heated seat switch with a known (5) Install the gear selector bezel trim. Refer to the
good unit and retest the heated seat system. Body section for the procedure.
(6) Connect the negative battery cable.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
VA HORN 8H - 1

HORN
TABLE OF CONTENTS

page page

HORN HORN SWITCH


REMOVAL .............................1 REMOVAL .............................1
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 1 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 1

HORN HORN SWITCH


REMOVAL REMOVAL
(1) Disconnect and isolate the battery negative (1) Disconnect and isolate the battery negative
cable. cable.
(2) Disconnect the wire harness connectors. (2) Remove the drivers side airbag (Refer to 8 -
(3) Remove the mounting fastener and horns. ELECTRICAL/RESTRAINTS/DRIVER AIRBAG -
REMOVAL).
INSTALLATION (3) Remove the electrical harness connector.
(1) Position horns and install mounting fasteners. (4) Remove the mounting fasteners and horn
(2) Connect wire harness connector. switch.
(3) Connect battery negative cable.
INSTALLATION
(1) Connect the wire harness connector.
(2) Position the horn switch and install the mount-
ing fasteners.
(3) Install the drivers side airbag (Refer to 8 -
ELECTRICAL/RESTRAINTS/DRIVER AIRBAG -
INSTALLATION).
(4) Connect the battery negative cable.
VA IGNITION CONTROL 8I - 1

IGNITION CONTROL
TABLE OF CONTENTS

page page

IGNITION CONTROL GLOW PLUG RELAY


OPERATION - GLOW PLUG ................1 DESCRIPTION . . . . . . . . . .................2
SPECIAL TOOLS ....... .................1 OPERATION . . . . . . . . . . . .................2
GLOW PLUG DIAGNOSIS AND TESTING - GLOW PLUG
REMOVAL ............ .................2 RELAYS . . . . . . . . . . . . . .................3
INSTALLATION . . . . . . . . . .................2

IGNITION CONTROL If a failure in the glow plug system occurs, the


glow plug indicator lamp will be illuminated only as
long as the fault is current. If the failure is no longer
OPERATION - GLOW PLUG
present, the glow plug indicator lamp will be
switched off but a code will be stored in the ECM.
Pre-Glowing
With the key in the On position, the glow plug out-
After Glow
put stage and the indicator lamp are actuated by the
Once the engine has started, the ECM determines
ECM. The pre-heating time is calculated by the ECM
the after glow time depending on cooling tempera-
in line with the coolant temperature. The glow plug
ture. During this time the glow plugs continue to be
output stage switches the current through the glow
actuated by the glow plug output stage. This results
plugs. The glow plug indicator lamp goes out after a
in improved smooth running after a cold start and
pre-glow period has elapsed. Component or cable fail-
improved warming up properties, elimination of blue
ures in the pre-glow system are indicated by the glow
exhaust after a cold start up and a more stable cold
plug lamp and stored in the ECM.
starting speed.
If no signal is received from the coolant tempera-
Glow Output Stage
ture sensor the signal from the oil sensor is used as a
With the ignition key in the On position a signal is
substitute.
transmitted from the ECM to the glow plug output
stager. If no data is exchanged with the ECM the
glow plug stage is terminated after two seconds. The
SPECIAL TOOLS
glow plug out put stage constantly signals the cur-
rent operating state (ON/OFF) and any system
faults. The following faults are recognized by the out
put stage and transmitted to the ECM:
• Open circuit in one or more of the glow plug
leads
• Short circuit in the glow plug circuit
• Out put stage fault or temperature related shut-
off GLOW PLUG PLIERS
8I - 2 IGNITION CONTROL VA

GLOW PLUG is to improve combustion for low emissions and to


achieve easy starting at low temperatures.
REMOVAL
(1) Disconnect the negative battery cable.
OPERATION
When the ignition key is turned to the ON posi-
(2) Remove the engine cover.
tion, the glow plug output stage and pre-glow indica-
(3) Use special tool #9286 pliers to unplug the
tor lamp are actuated by the ECM. The duration of
glow plug wiring harness connector(s) at the glow
the signal depends on the coolant temperature. The
plug.
glow plug relay has processing that communicates
(4) Remove the glow plug(s) (Fig. 1).
with the ECM. If no data exchange occurs at the trig-
gering stage, the preheating is switched off after 2
INSTALLATION
seconds.
(1) Screw glow plug(s) into cylinder head and
Start glowing is initiated when the key is in the
tighten to 12 N·m (115 lbs. in) (Fig. 1).
start position. The glow plugs (R13–R17) continue to
(2) Connect the glow plug wiring harness connec-
be supplied with voltage. This makes it possible to
tor(s)
stabilize the cold starting speed. (After glowing is ini-
(3) Install the engine cover.
tiated when the starter reject speed is reached).
(4) Connect negative battery cable.
After the engine starts, the ECM determines the
afterglow period in line with coolant temperature. If
GLOW PLUG RELAY no signal is received from the coolant temperature
sensor, afterglow is maintained for thirty seconds.
The following aims are reached by the afterglow :
DESCRIPTION
• Improvement in warming-up properties
The glow plug relay supplies battery voltage to the
• Prevention of white exhaust smoke after cold
glow plug through a timed cycle that is related to
start
coolant temperature. The glow plug relay is located
• Stabilizing of the cold starting speed
under the battery. The purpose of a glow plug system

Fig. 1 GLOW PLUG (S)


1 - GLOW PLUG 3 - INTAKE MANIFOLD
2 - WIRING HARNESS CONNECTOR 4 - ENGINE COVER
VA IGNITION CONTROL 8I - 3
GLOW PLUG RELAY (Continued)
The glow plug output stage constantly signals the coming on. Once the fault is no longer current, the
current operating state and faults. The following are indicator is immediately switched off, but the fault is
faults detected and transmitted to the ECM : stored in the ECM. If the fault is constantly current,
• Open circuit at one or several glow plugs the preglow indicator lamp remains on until the igni-
• Short circuit in the glow plug circuit tion is switched off.
• Relay fault
If the Glow plug relay detects an open circuit at a DIAGNOSIS AND TESTING - GLOW PLUG
glow plug, it is stored and indicated only once the RELAYS
engine is running by the preglow indicator lamp com- Refer to the appropriate Diesel Powertrain Diagno-
ing on for about one minute and a fault is stored in sis Manual for information on diagnosing the glow
the ECM. If a short circuit, a glow plug output stage plug relays.
faulty or a temperature related switching off of out-
put stages is detected, the fault is stored and indi-
cated immediately by the preglow indicator lamp
VA INSTRUMENT CLUSTER 8J - 1

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

Fig. 2 Instrument Cluster Components


1 - LENS
2 - HOOD
3 - CLUSTER HOUSING
4 - REAR COVER
Fig. 1 Instrument Cluster
1 - COVER integral latches to the molded black plastic cluster
2 - BEZEL
3 - INSTRUMENT CLUSTER hood. Four, black plastic multi-function indicator
4 - STEERING WHEEL switch push buttons protrude through dedicated
5 - MULTI-FUNCTION SWITCH holes in a rectangular black plastic switch bezel that
6 - SPEED CONTROL SWITCH
is integral to the cluster lens and located near the
The instrument cluster for this model is an Elec- lower edge of the cluster directly below the multi-
troMechanical Instrument Cluster (EMIC) that is function indicator LCD unit. The cluster hood serves
located above the steering column opening in the as a visor and shields the face of the cluster from
instrument panel, directly in front of the driver (Fig. ambient light and reflections to reduce glare. The
1). The remainder of the EMIC, including the mounts cluster hood has eight integral latches that engage
and the electrical connections, are concealed within eight integral latch tabs on the cluster rear cover,
the instrument panel behind the cluster bezel and sandwiching the cluster housing unit between the
beneath the instrument panel top cover for the clus- hood and the rear cover. The cluster hood also has
ter. The instrument cluster includes analog gauges, two integral pivot loops molded into its underside
meters, indicators, and acoustic signal transmitters. that engage two pairs of molded pivot hooks that are
The EMIC module also incorporates a multi-func- integral to the top of the instrument panel base
tion indicator that consists of a digital Liquid Crystal structure. These pivots allow the cluster to be rolled
Display (LCD) unit for displaying odometer/trip rearward to ease service access to the wire harness
odometer information, an electronic digital clock, connectors at the back of the cluster.
engine oil level information, automatic transmission The rear of the cluster housing and the EMIC elec-
gear selector position (PRNDL), and certain diagnos- tronic circuitry are protected by the molded plastic
tic information. The multi-function indicator also has rear cover. A mounting ear at each upper corner of
four push button switches, which provide the vehicle the rear cover are used to secure the EMIC to the
operator with an interface to adjust certain inputs to molded plastic instrument panel base unit with two
the instrument cluster and to select from multiple screws. The rear cover includes clearance holes for
display options. If the vehicle is equipped with the the two cluster connector receptacles on the cluster
appropriate options, the multi-function indicator also electronic circuit board. The connector receptacles on
provides an outside ambient temperature indicator the back of the cluster electronic circuit board con-
display and an Active Service SYStem (ASSYST) nect the EMIC to the vehicle electrical system
engine oil maintenance indicator to display engine oil through two take outs with connectors from the vehi-
level and maintenance reminders. cle wire harness. The EMIC rear cover includes a
The EMIC gauges and indicators are visible molded mounting tab and a latch feature that
through a dedicated opening in the cluster bezel on secures the RKE/immobilizer module to the back of
the instrument panel and are protected by a clear the cluster. The RKE/immobilizer module is con-
plastic cluster lens (Fig. 2) that is secured by eight nected to the vehicle electrical system through a sep-
VA INSTRUMENT CLUSTER 8J - 3
INSTRUMENT CLUSTER (Continued)
arate take out and connector of the vehicle wire maintenance indicator option, the EMIC electronic
harness. circuit board includes a second dedicated micropro-
Located between the rear cover and the cluster cessor. This second microprocessor evaluates various
hood is the cluster housing. The molded plastic clus- data including time, mileage, and driving conditions
ter housing serves as the carrier for the cluster elec- to calculate the required engine oil service intervals,
tronic circuit board and circuitry, the cluster and provides both visual and audible alerts to the
connector receptacles, the gauges, a Light Emitting vehicle operator when certain engine oil maintenance
Diode (LED) for each cluster indicator and general services are required.
illumination lamp, the multi-function indicator LCD • Audible Warnings - The EMIC electronic cir-
unit, electronic tone generators, the cluster overlay, cuit board is equipped with an audible tone generator
the gauge pointers, the multi-function indicator and programming that allows it to provide various
switches and the four switch push buttons. audible alerts to the vehicle operator, including buzz-
The cluster overlay is a laminated plastic unit. The ing and chime tones. An audible contactless elec-
dark, visible, outer surface of the overlay is marked tronic relay is also soldered onto the circuit board to
with all of the gauge dial faces and graduations, but produce audible clicks that is synchronized with turn
this layer is also translucent. The darkness of this signal indicator flashing to emulate the sounds of a
outer layer prevents the cluster from appearing clut- conventional turn signal or hazard warning flasher.
tered or busy by concealing the cluster indicators These audible clicks can occur at one of two rates to
that are not illuminated, while the translucence of emulate both normal and bulb-out turn or hazard
this layer allows those indicators and icons that are flasher operation. (Refer to 8 - ELECTRICAL/
illuminated to be readily visible. The underlying CHIME/BUZZER - DESCRIPTION).
layer of the overlay is opaque and allows light from • Panel Lamps Dimming Control - The EMIC
the LED for each of the various indicators and illu- provides a hard wired 12-volt Pulse-Width Modulated
mination lamps behind it to be visible through the (PWM) output that synchronizes the dimming level
outer layer of the overlay only through predeter- of all panel lamps dimmer controlled lamps with that
mined cutouts. A rectangular opening in the overlay of the cluster general illumination lamps and multi-
at the base of the speedometer provides a window function indicator.
through which the illuminated multi-function indica- The EMIC houses four analog gauges and has pro-
tor LCD unit can be viewed. visions for up to nineteen indicators (Fig. 3). The
Several versions of the EMIC module are offered EMIC includes the following analog gauges:
on this model. These versions accommodate all of the • Coolant Temperature Gauge
variations of optional equipment and regulatory • Fuel Gauge
requirements for the various markets in which the • Speedometer
vehicle will be offered. The microprocessor-based • Tachometer
EMIC utilizes integrated circuitry, Electrically Eras- The EMIC includes provisions for the following
able Programmable Read Only Memory (EEPROM) indicators (Fig. 3):
type memory storage, information carried on the • Airbag (SRS) Indicator
Controller Area Network (CAN) data bus, along with • Antilock Brake System (ABS) Indicator
several hard wired analog and multiplexed inputs to • Brake Indicator
monitor systems, sensors and switches throughout • Brake Wear Indicator
the vehicle. • Charging Indicator
In response to those inputs, the hardware and soft- • Clogged Fuel Filter Indicator
ware of the EMIC allow it to control and integrate • Constant Engine Speed (ADR) Indicator
many electronic functions and features of the vehicle • Coolant Low Indicator
through both hard wired outputs and the transmis- • Electronic Stability Program (ESP) Indica-
sion of electronic message outputs to other electronic tor
modules in the vehicle over the CAN data bus. (Refer • High Beam Indicator
to 8 - ELECTRICAL/ELECTRONIC CONTROL • Low Fuel Indicator
MODULES/COMMUNICATION - DESCRIPTION - • Malfunction Indicator Lamp (MIL)
CAN BUS). • Multi-Function Indicator (LCD)
Besides typical instrument cluster gauge and indi- • Park Brake Indicator
cator support, the electronic functions and features • Seatbelt Indicator
that the EMIC supports or controls include the fol- • Traction Control (ASR) Indicator
lowing: • Traction Control (ASR) Malfunction Indica-
• Active Service System - In vehicles equipped tor
with the Active Service SYSTem (ASSYST) engine oil • Turn Signal (Right and Left) Indicators
8J - 4 INSTRUMENT CLUSTER VA
INSTRUMENT CLUSTER (Continued)

Fig. 3 Gauges & Indicators


1 - AIRBAG INDICATOR 16 - SEATBELT INDICATOR
2 - TACHOMETER 17 - ABS INDICATOR
3 - LEFT TURN INDICATOR 18 - MULTI-FUNCTION INDICATOR PLUS/MINUS SWITCH PUSH
BUTTONS
4 - SPEEDOMETER 19 - MULTI-FUNCTION INDICATOR (INCLUDES: CLOCK, GEAR
SELECTOR INDICATOR, ODOMETER, TRIP ODOMETER,
ENGINE OIL LEVEL DATA, AMBIENT TEMPERATURE
INDICATOR [OPTIONAL], & ACTIVE SERVICE SYSTEM
[ASSYST] ENGINE OIL MAINTENANCE INDICATOR [OPTIONAL])
5 - TRACTION CONTROL INDICATOR 20 - MULTI-FUNCTION INDICATOR MODE (MILES
[KILOMETERS]/TIME) SWITCH PUSH BUTTONS
6 - RIGHT TURN INDICATOR 21 - COOLANT LOW INDICATOR
7 - ENGINE TEMPERATURE GAUGE 22 - BRAKE INDICATOR
8 - FUEL GAUGE 23 - OIL LEVEL INDICATOR
9 - WAIT-TO-START INDICATOR 24 - BRAKE WEAR INDICATOR
10 - WASHER FLUID INDICATOR (OPTIONAL) 25 - WATER-IN-FUEL INDICATOR
11 - CONSTANT ENGINE SPEED (ADR) INDICATOR (OPTIONAL) 26 - CHARGING INDICATOR
12 - LOW FUEL INDICATOR 27 - HIGH BEAM INDICATOR
13 - TRACTION CONTROL MALFUNCTION INDICATOR 28 - PARK BRAKE INDICATOR
14 - MALFUNCTION INDICATOR LAMP 29 - FUEL FILTER CLOGGED INDICATOR
15 - ELECTRONIC STABILITY PROGRAM (ESP) INDICATOR
(OPTIONAL)

• 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)

Fig. 4 Instrument Cluster Remove/Install Fig. 6 Cluster Connectors


1 - SCREW (2) 1 - STEERING WHEEL
2 - COVER 2 - INSTRUMENT CLUSTER
3 - SCREW (2) 3 - CONNECTOR (2)
4 - INSTRUMENT CLUSTER
5 - LOOP (2)
pairs of molded plastic pivot hooks that are integral
to the top of the instrument panel base structure.
(8) Remove the instrument cluster from the instru-
ment panel.

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.

OPERATION AIRBAG INDICATOR


The constant engine speed (ADR) indicator gives
an indication to the vehicle operator concerning the DESCRIPTION
operating status of the constant engine speed (ADR) An airbag indicator is standard equipment on all
feature. The ADR indicator is controlled by a transis- instrument clusters. The airbag indicator is located
tor on the instrument cluster circuit board based near the left edge of the instrument cluster, next to
upon cluster programming and electronic messages the tachometer. The airbag indicator consists of a
received by the cluster from the Engine Control Mod- stencil-like cutout of the letters “SRS” in the opaque
ule (ECM) over the Controller Area Network (CAN) layer of the instrument cluster overlay. The dark
data bus. The ADR indicator Light Emitting Diode outer layer of the overlay prevents the indicator from
(LED) is completely controlled by the instrument being clearly visible when it is not illuminated. A red
cluster logic circuit, and that logic will only allow Light Emitting Diode (LED) behind the cutout in the
this indicator to operate when the instrument cluster opaque layer of the overlay causes the “SRS” text to
detects that the ignition switch is in the On position. appear in red through the translucent outer layer of
Therefore, the LED will always be off when the igni- the overlay when the indicator is illuminated from
tion switch is in any position except On. The LED behind by the LED, which is soldered onto the
only illuminates when it is provided a path to ground instrument cluster electronic circuit board. The air-
by the instrument cluster transistor. The instrument bag indicator is serviced as a unit with the instru-
cluster will turn on the traction control indicator for ment cluster.
the following reasons:
• Constant Engine Speed (ADR) Indicator OPERATION
Lamp-On Message - Each time the cluster receives The airbag (SRS) indicator gives an indication to
an ADR indicator lamp-on message from the ECM, the vehicle operator when the Airbag Control Module
the indicator will be illuminated. The indicator is (ACM) has recorded a Diagnostic Trouble Code (DTC)
illuminated when the ADR feature has been acti- for a Supplemental Restraint System (SRS) circuit or
vated with the ADR switch, and is turned off when component malfunction. Such a DTC may indicate
the ADR feature is deactivated with the ADR switch. that the SRS is faulty or inoperative. The airbag
The ADR indicator will be extinguished if the ADR indicator is controlled by a transistor on the instru-
feature is turned off because the park brake has been ment cluster circuit board based upon cluster pro-
released or the vehicle is in motion. The ADR indica- gramming and a hard wired input received by the
tor will also be extinguished if the service brake cluster from the ACM. The airbag indicator Light
pedal is depressed, but the ADR feature will auto- Emitting Diode (LED) is completely controlled by the
matically be restored and the indicator illuminated instrument cluster logic circuit, and that logic will
when the brake pedal is released. The indicator only allow this indicator to operate when the instru-
remains illuminated until the cluster receives a ment cluster detects that the ignition switch is in the
lamp-off message from the ECM, or until the ignition On position. Therefore, the LED will always be off
switch is turned to the Off position, whichever occurs when the ignition switch is in any position except
first. On. The LED only illuminates when it is provided a
The ECM continually monitors the constant engine path to ground by the instrument cluster transistor.
speed (ADR) switch and electronic messages from the The instrument cluster will turn on the airbag indi-
Controller Antilock Brake (CAB) concerning the sta- cator for the following reasons:
tus of the four wheel speed sensors, the park brake • Bulb Test - Each time the ignition switch is
switch and the brake lamp switch to determine the turned to the On position the airbag indicator is illu-
correct operating mode for the ADR feature. The minated for about four seconds. The entire four sec-
ECM then sends the proper lamp-on or lamp-off mes- ond bulb test is a function of the ACM.
sages to the instrument cluster. See the owner’s man- • Airbag Lamp-On Input - Each time the cluster
ual in the vehicle glove box for more information on receives a lamp-on input from the ACM, the airbag
the features, use, activation and deactivation of the indicator will be illuminated. The indicator can be
constant engine speed (ADR) feature. For proper flashed on and off, or illuminated solid, as dictated
diagnosis of the ADR feature, the ECM, the CAB, the by the ACM input. For some DTC’s, if the problem
CAN data bus, or the electronic message inputs to does not recur, the ACM will send a lamp-off input
the instrument cluster that control the ADR indica- automatically. Other DTC’s may require that a fault
VA INSTRUMENT CLUSTER 8J - 11
AIRBAG INDICATOR (Continued)
be repaired and the ACM be reset before a lamp-off turned Off, the display is illuminated at maximum
input will be sent. For more information on the ACM brightness. When the exterior lighting is turned On
and the DTC set and reset parameters, refer to 8 - the display illumination level can be adjusted in con-
ELECTRICAL/RESTRAINTS/AIRBAG CONTROL cert with the cluster general illumination lighting
MODULE - OPERATION). The indicator remains using the “+” (plus) and “2” (minus) multi-function
illuminated until the cluster receives a lamp-off indicator push buttons. The ambient temperature
input from the ACM, or until the ignition switch is indicator is serviced as a unit with the instrument
turned to the Off position, whichever occurs first. cluster.
• Airbag Indicator Malfunction - Following the
seatbelt reminder function, each time the cluster OPERATION
detects a malfunction in the airbag (SRS) indicator or The optional ambient temperature indicator gives
the airbag indicator circuit, the cluster will flash the an indication to the vehicle operator of the outside
seatbelt indicator on and off. The cluster will con- air temperature. This indicator is controlled by the
tinue to flash the seatbelt indicator until the airbag instrument cluster microprocessor based upon cluster
indicator circuit fault is resolved, or until the ignition programming and a hard wired input received by the
switch is turned to the Off position, whichever occurs cluster from the ambient temperature sensor. The
first. ambient temperature indicator is completely con-
The ACM continually monitors the SRS circuits trolled by the instrument cluster logic circuit, and
and sensors to decide whether the system is in good that logic will allow this indicator to operate when-
operating condition. The ACM then provides the ever the multi-function indicator Liquid Crystal Dis-
proper lamp-on or lamp-off inputs to the instrument play (LCD) is activated. Therefore, the ambient
cluster. If the ACM provides a lamp-on input after temperature indicator remains functional regardless
the bulb test, it indicates that the ACM has detected of the ignition switch position.
a system malfunction and/or that the airbags and The vehicle operator can choose to have the ambi-
seat belt tensioners may not deploy when required, ent temperature indicator displayed instead of the
or may deploy when not required. The ACM will clock information, but the clock and ambient temper-
store a DTC for any malfunction it detects. The ACM ature indicator cannot be displayed at the same time.
input circuit to the instrument cluster can be diag- The clock or ambient temperature indicator display
nosed using conventional diagnostic tools and meth- option is selected using the multi-function indicator
ods. For proper diagnosis of the SRS, the ACM, or clock switch on the instrument cluster circuit board.
the instrument cluster circuitry that controls the air- This switch is actuated manually by depressing the
bag indicator, a DRBIIIt scan tool is required. Refer clock switch push button that extends through the
to the appropriate diagnostic information. lower edge of the cluster lens below the left end of
the multi-function indicator. Actuating this switch
momentarily will toggle the display between the
AMBIENT TEMPERATURE clock and ambient temperature indicator modes.
INDICATOR Actuating this switch twice within about one second
will cause the display to toggle, but then automati-
DESCRIPTION cally revert to the originally selected mode after
An ambient temperature indicator is optional about twenty seconds.
equipment on all instrument clusters. In vehicles so The ambient temperature sensor located below the
equipped, the ambient temperature indication can be front bumper is a Negative Temperature Coefficient
toggled with the clock indication on the right side of (NTC) thermistor. The internal resistance of the sen-
the multi-function indicator Liquid Crystal Display sor is reduced as the ambient temperature rises. The
(LCD) located near the lower edge of the instrument instrument cluster continually monitors the resis-
cluster, directly below the speedometer. The ambient tance through the sensor to determine the tempera-
temperature indication consists of a numeric value ture value to be displayed. The current value is
with a “+” (plus) or “2” (minus) prefix, and the unit displayed immediately after the LCD is activated.
of measure is identified with the characters “°C” The display value will remain static regardless of
(Canadian vehicles only) or “°F” (United States vehi- decreases in the sensor resistance (temperature ris-
cles only) located directly above the temperature ing) below vehicle speeds of 10 to 15 kilometers-per-
indication. The indications of the ambient tempera- hour (6 to 9 miles-per-hour). Decreases in the sensor
ture indicator are not visible when the LCD is not resistance above 15 kilometers-per-hour (9 miles-per-
illuminated. When illuminated the indications hour) and increases the sensor resistance (tempera-
appear as dark characters and icons silhouetted ture falling) regardless of vehicle speed are displayed
against an amber field. When the exterior lighting is subject to a sixty second delay.
8J - 12 INSTRUMENT CLUSTER VA
AMBIENT TEMPERATURE INDICATOR (Continued)
The ambient temperature sensor is connected to On position. Therefore, the LED will always be off
the instrument cluster in series between the ambient when the ignition switch is in any position except
temperature sensor return and sense circuits. The On. The LED only illuminates when it is provided a
ambient temperature sensor and the return and path to ground by the instrument cluster transistor.
sense circuits to the instrument cluster can be diag- The instrument cluster will turn on the brake indica-
nosed using conventional diagnostic tools and meth- tor for the following reasons:
ods. For proper diagnosis of the instrument cluster • Bulb Test - Each time the ignition switch is
circuitry that controls the ambient temperature indi- turned to the On position the brake indicator is illu-
cator, a DRBIIIt scan tool is required. Refer to the minated by the instrument cluster for about two sec-
appropriate diagnostic information. onds as a bulb test.
• Brake Fluid Level Switch Input - Each time
the cluster detects ground on the brake indicator sig-
BRAKE INDICATOR nal circuit (brake fluid level switch closed = brake
fluid level low) while the ignition switch is in the On
DESCRIPTION position, the brake indicator is illuminated. The indi-
A brake indicator is standard equipment on all cator remains illuminated until the brake signal indi-
instrument clusters. The brake indicator is located cator input to the cluster is an open circuit (brake
near the lower edge of the instrument cluster, to the fluid level switch open = brake fluid level okay), or
left of the multi-function indicator display. In vehi- until the ignition switch is turned to the Off position,
cles built for the United States market, the brake whichever occurs first.
indicator consists of a stencil-like cutout of the word • Electronic Brake Force Distribution (EBV)
“BRAKE” in the opaque layer of the instrument clus- Indicator Lamp-On Message - Each time the clus-
ter overlay. In vehicles built for the Canadian mar- ter receives a EBV indicator lamp-on message from
ket, the brake indicator consists of the International the CAB, the indicator will be illuminated. The indi-
Control and Display Symbol icon for “Brake Failure” cator remains illuminated until the cluster receives a
imprinted within a rectangular cutout in the opaque lamp-off message from the CAB, or until the ignition
layer of the instrument cluster overlay. In either switch is turned to the Off position, whichever occurs
case, the dark outer layer of the overlay prevents the first.
indicator from being clearly visible when it is not The CAB continually monitors the EBV system cir-
illuminated. A red Light Emitting Diode (LED) cuits and sensors to decide whether the system is in
behind the cutout in the opaque layer of the overlay good operating condition. The CAB then sends the
causes the “BRAKE” text to appear in red, or the proper lamp-on or lamp-off messages to the instru-
icon to appear silhouetted against a red field through ment cluster. If the CAB sends a lamp-on message
the translucent outer layer of the overlay when the after the bulb test, it indicates that the CAB has
indicator is illuminated from behind by the LED, detected a system malfunction and that the EBV sys-
which is soldered onto the instrument cluster elec- tem has become inoperative. The CAB will store a
tronic circuit board. The brake indicator is serviced Diagnostic Trouble Code (DTC) for any malfunction it
as a unit with the instrument cluster. detects.
The brake fluid level switch in the brake master
OPERATION cylinder provides a hard wired ground input to the
The brake indicator gives an indication to the vehi- instrument cluster circuitry through the brake indi-
cle operator when there are certain brake hydraulic cator signal circuit whenever the fluid level in the
system malfunctions as indicated by a low brake brake master cylinder is low. The switch is connected
hydraulic fluid level condition, or when there is a in parallel between ground and the instrument clus-
problem in the electronic brake force distribution ter. The brake fluid level switch and the input circuit
(EBV) system. This indicator is controlled by a tran- to the instrument cluster can be diagnosed using con-
sistor on the instrument cluster circuit board based ventional diagnostic tools and methods. For proper
upon cluster programming, electronic messages diagnosis of the instrument cluster circuitry that con-
received by the cluster from the Controller Antilock trols the brake indicator, a DRBIIIt scan tool is
Brake (CAB) over the Controller Area Network required. Refer to the appropriate diagnostic infor-
(CAN) data bus, and a hard wired input from the mation.
brake fluid level switch. The brake indicator Light
Emitting Diode (LED) is completely controlled by the
instrument cluster logic circuit, and that logic will
only allow this indicator to operate when the instru-
ment cluster detects that the ignition switch is in the
VA INSTRUMENT CLUSTER 8J - 13

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 . . . . . . . . . . . . . . . 1 LAMPS/LIGHTING - INTERIOR . . . . . . . . . . . . . . . 27

LAMPS/LIGHTING - EXTERIOR

TABLE OF CONTENTS
page page

LAMPS/LIGHTING - EXTERIOR FOG LAMP SWITCH


DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13
SPECIFICATIONS - LAMPS/LIGHTING - FRONT LAMP UNIT
EXTERIOR ...........................5 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
BACKUP LAMP BULB INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13
REMOVAL .............................5 ADJUSTMENTS
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 5 ADJUSTMENT - FRONT LAMP UNIT . . . . . . . 13
BRAKE LAMP SWITCH FRONT POSITION LAMP BULB
REMOVAL .............................6 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
ADJUSTMENTS FRONT TURN/PARK/SIDE MARKER LAMP
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . 7 BULB
BRAKE/PARK LAMP BULB REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
REMOVAL .............................7 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7 HEADLAMP LEVELING MOTOR
CENTER HIGH MOUNTED STOP LAMP BULB REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
REMOVAL .............................8 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8 HEADLAMP LEVELING SWITCH
CENTER HIGH MOUNTED STOP LAMP UN REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
REMOVAL .............................8 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8 HIGH BEAM HEADLAMP BULB
CLEARANCE LAMP BULB REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
REMOVAL .............................9 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9 LICENSE PLATE LAMP BULB
CLEARANCE LAMP UNIT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
REMOVAL .............................9 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9 LICENSE PLATE LAMP UNIT
DAYTIME RUNNING LAMP RELAY REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
REMOVAL .............................9 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10 LOW BEAM HEADLAMP BULB
FOG LAMP BULB REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11 MULTI-FUNCTION SWITCH
FOG LAMP RELAY REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11
8L - 2 LAMPS/LIGHTING - EXTERIOR VA

PARK BRAKE SWITCH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23


REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 REPEATER LAMP UNIT
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
REAR SIDE MARKER LAMP BULB INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 TAIL LAMP UNIT
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 22 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
REAR TURN LAMP BULB INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 TURN SIGNAL RELAY
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 22 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
REPEATER LAMP BULB INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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.

FRONT FOG LAMPS


Vehicles equipped with optional front fog lamps
have a front fog lamp relay installed in a relay
bracket located below the forward edge of the driver
side front seat cushion within the driver side front
seat riser, a fog lamp switch installed in the cluster
bezel on the instrument panel outboard of the steer-
ing column, and a fog lamp bulb installed in each of
the two front lamp units. The front fog lamps have a
path to ground at all times through their connection
to the vehicle wire harness. The headlamp switch cir-
cuitry of the left (lighting) control stalk of the multi-
function switch controls front fog lamp operation by Fig. 1 Lighting Switch
providing battery current to the front fog lamp relay 1 - LEFT TURN SIGNAL
only when the low beam headlamps are selected. The 2 - RIGHT TURN SIGNAL
fog lamp switch controls front fog lamp operation by 3 -EXTERIOR LIGHTING
4 - BEAM SELECT (DIMMER)
energizing or de-energizing the front fog lamp relay 5 - OPTICAL HORN
control coil.
a rotary thumbwheel actuated headlamp leveling
HAZARD WARNING LAMPS switch in the cluster bezel on the instrument panel
With the hazard switch in the On position, the outboard of the steering column. The headlamp lev-
hazard switch button illuminates and the right and eling system allows the headlamp beam reflectors to
left turn signal indicators as well as the right and be adjusted to one of four vertical positions to com-
left turn signal lamps begin to flash on and off. When pensate for changes in inclination caused by the load-
the hazard warning system is activated, the hazard ing of the vehicle suspension. The actuator motors
switch circuitry within the multi-function switch and are mechanically connected through an integral
the wipers, turn signals and engine start control pushrod to an adjustable headlamp reflector. The
module electronic circuitry within the fuse block will headlamp leveling switch is a resistor multiplexed
repeatedly energize and de-energize the turn signal unit that provides one of four voltage outputs to the
relay located in the fuse block. The turn signal relay headlamp leveling motors. The headlamp leveling
switches battery current from a fused B(+) fuse in motors will move the headlamps to the selected posi-
the fuse block to the turn signal indicators and the tion based upon the voltage input received from the
turn signal lamps. The flashing of the hazard switch switch. The headlamp leveling motors and switch
button illumination lamp is also controlled by the have a path to ground at all times. The headlamp
output from the turn signal relay. leveling components operate on battery current
received through the park lamps circuit so that the
HEADLAMPS system will only operate when the exterior lighting is
The headlamp system includes the exterior lighting turned on.
switches integral to the left (lighting) control stalk of
the multi-function switch as well as the low and high PARK LAMPS
beam bulbs installed in the right and left front lamp The park lamps system includes the exterior light-
units (Fig. 1). The headlamp bulbs have a path to ing switches integral to the left (lighting) control
ground at all times through the vehicle wire harness. stalk of the multi-function switch (Fig. 1), the front
The exterior lighting switches control headlamp oper- park/side marker lamps, the front position lamps, the
ation by providing battery current to the selected low rear park lamps, the rear side marker lamps, the
or high beam bulbs. Each front lamp unit includes optional clearance lamps, and the license plate
two integral adjustment screws to be used for static lamps. Each of these lamps are provided with a path
horizontal and vertical aiming of the headlamp beam to ground at all times through the vehicle wire har-
reflectors. ness. The exterior lighting switches control the park
lamp operation by providing battery current through
HEADLAMP LEVELING the park lamps circuit to the appropriate lamp bulbs.
The headlamp leveling system includes a leveling
actuator motor integral to each front lamp unit, and
VA LAMPS/LIGHTING - EXTERIOR 8L - 5
LAMPS/LIGHTING - EXTERIOR (Continued)
TURN SIGNAL LAMPS BACKUP LAMP BULB
When the left (lighting) control stalk of the multi-
function switch is activated (Fig. 1), the turn signal REMOVAL
system illuminates the selected right or left turn sig- (1) Disconnect and isolate the battery negative
nal indicator and the turn signal lamps begin to cable.
flash. The turn signal lamps include a bulb integral (2) If the vehicle is so equipped, remove the trim
to each front lamp unit and each tail lamp unit, as from the inside of the right or left rear corner pillar.
well as a repeater lamp bulb located on each front (3) From inside the vehicle, use hand pressure to
fender above the front wheels. When the turn signal push the two latch tabs toward the center of the tail
system is activated, the turn signal switch circuitry lamp unit socket plate and pull the socket plate
within the multi-function switch and the electronic straight out from the inner rear pillar (Fig. 2).
circuitry of the wipers, turn signals and engine start
control module within the fuse block will repeatedly
energize and de-energize the turn signal relay
located in the fuse block. The turn signal relay
switches battery current from a fused ignition switch
output fuse in the fuse block to the appropriate turn
signal indicator and turn signal lamps.
The ElectroMechanical Instrument Cluster (EMIC)
contactless relay will generate repetitive, audible
turn signal “click” sounds to emulate the sounds of a
conventional electro-mechanical turn signal flasher
at one of two rates to coincide with the flashing of
the turn signals. The slow rate emulates normal turn
signal operation, while the fast rate emulates “bulb
out” turn signal operation.

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)

Fig. 3 Tail Lamp Bulb Remove/Install


1 - BRAKE/PARK LAMP BULB
2 - BACKUP LAMP BULB
3 - TURN SIGNAL LAMP BULB
4 - SIDE MARKER LAMP BULB
Fig. 4 Brake Lamp Switch Location
5 - TAIL LAMP SOCKET PLATE 1 - PEDAL BRACKET
2 - BRAKE LAMP SWITCH
(5) Reconnect the battery negative cable. 3 - BRAKE PEDAL

BRAKE LAMP 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 Fig. 5 Brake Lamp Switch Remove/Install
negative (ground) cable, then wait two minutes for 1 - PEDAL BRACKET
2 - PLUNGER
the system capacitor to discharge before perform- 3 - BRAKE LAMP SWITCH
ing further diagnosis or service. This is the only 4 - CONNECTOR RECEPTACLE
sure way to disable the supplemental restraint sys- 5 - LOCKING TAB
tem. Failure to take the proper precautions could
result in accidental airbag deployment. INSTALLATION
(1) Disconnect and isolate the battery negative WARNING: To avoid personal injury or death, on
cable. vehicles equipped with airbags, disable the supple-
(2) Locate the brake lamp switch on the pedal mental restraint system before attempting any
bracket underneath the instrument panel (Fig. 4). steering wheel, steering column, airbag, seat belt
(3) Depress the locking tab on the brake lamp tensioner, or instrument panel component diagno-
switch body behind the pedal bracket and rotate the sis or service. Disconnect and isolate the battery
switch counterclockwise about 30 degrees (Fig. 5). negative (ground) cable, then wait two minutes for
(4) Pull the switch forward in the vehicle far the system capacitor to discharge before perform-
enough to disengage the switch plunger from the ing further diagnosis or service. This is the only
mounting hole in the pedal bracket. sure way to disable the supplemental restraint sys-
(5) Disconnect the vehicle wire harness from the tem. Failure to take the proper precautions could
brake lamp switch connector receptacle. result in accidental airbag deployment.
(6) Remove the brake lamp switch from the vehi-
cle. (1) Pull the plunger of the brake lamp switch out-
ward from the switch body to its travel limit (Fig. 5).
(2) Reconnect the vehicle wire harness to the
brake lamp switch connector receptacle.
VA LAMPS/LIGHTING - EXTERIOR 8L - 7
BRAKE LAMP SWITCH (Continued)
(3) Depress and hold the brake pedal in the (4) Release the brake pedal from its depressed
depressed position until the brake lamp switch position to automatically adjust the brake lamp
installation is completed (Fig. 4). switch plunger.
(4) Insert the brake lamp switch plunger through
the mounting hole from behind until the switch lock-
ing collar is fully seated against the pedal bracket. BRAKE/PARK LAMP BULB
(5) Rotate the brake lamp switch clockwise until
the locking tab on the switch body fully engages the REMOVAL
pedal bracket. Full locking tab engagement will be (1) Disconnect and isolate the battery negative
accompanied by an audible click. cable.
(2) If the vehicle is so equipped, remove the trim
NOTE: Do not pull the brake pedal upwards as this from the inside of the right or left rear corner pillar.
will adjust the switch plunger to an incorrect posi- (3) From inside the vehicle, use hand pressure to
tion. The switch is properly adjusted when the push the two latch tabs toward the center of the tail
switch plunger is just contacting (no gap) the brake lamp unit socket plate and pull the socket plate
pedal arm with the pedal in the relaxed (released) straight out from the inner rear pillar (Fig. 6).
position.

(6) Release the brake pedal from its depressed


position to automatically adjust the brake lamp
switch plunger.
(7) Reconnect the battery negative cable.

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.

CENTER HIGH MOUNTED


STOP LAMP UN
Fig. 7 Tail Lamp Bulb Remove/Install
REMOVAL
1 - BRAKE/PARK LAMP BULB
2 - BACKUP LAMP BULB (1) Disconnect and isolate the battery negative
3 - TURN SIGNAL LAMP BULB cable.
4 - SIDE MARKER LAMP BULB (2) Remove the two screws that secure the
5 - TAIL LAMP SOCKET PLATE
CHMSL unit to the vehicle (Fig. 9).
(3) Using hand pressure, push the socket plate
gently and evenly into the inner rear pillar mounting
hole until both latch tabs are fully engaged (Fig. 6).
(4) If the vehicle is so equipped, reinstall the trim
onto the inside of the right or left rear corner pillar.
(5) Reconnect the battery negative cable.

CENTER HIGH MOUNTED


STOP LAMP BULB
Fig. 9 Center High Mounted Stop Lamp Remove/
REMOVAL Install
(1) Disconnect and isolate the battery negative 1 - LAMP
2 - SCREW (2)
cable. 3 - LENS
(2) Remove the two screws that secure the
CHMSL lamp to the vehicle, then remove the lens (3) Pull the CHMSL unit away from the vehicle far
from the lamp housing (Fig. 8). enough to access and disconnect the vehicle wire har-
ness from the lamp pigtail wire connector.
(4) Remove the CHMSL unit from the vehicle.

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

(3) Push straight in on the CHMSL bulb and


rotate it counterclockwise about 30 degrees to remove
it from the lamp socket.
VA LAMPS/LIGHTING - EXTERIOR 8L - 9

CLEARANCE LAMP BULB


REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the clearance lamp unit from the vehi-
cle, but do not disconnect it from the vehicle wire
harness. (Refer to 8 - ELECTRICAL/LAMPS/LIGHT-
ING - EXTERIOR/CLEARANCE LAMP -
REMOVAL).
Fig. 11 Clearance Lamp Unit Remove/Install
(3) Pull the clearance lamp away from the vehicle
1 - LAMP
far enough to access the bulb holder on the back of 2 - BULB HOLDER
the lamp housing (Fig. 10). 3 - WIRE HARNESS
4 - SCREW (2)

cle wire harness from the bulb holder connector


receptacle.
(4) Remove the clearance lamp unit from the vehi-
cle.

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.

(4) Rotate the bulb holder counterclockwise about


30 degrees and pull it straight out from the lamp DAYTIME RUNNING LAMP
housing.
(5) Remove the bulb from the clearance lamp bulb
RELAY
holder.
REMOVAL
INSTALLATION Daytime Running Lamps (DRL) are only used in
vehicles manufactured for the Canadian market,
(1) Install the bulb into the clearance lamp bulb
where this is required equipment. On vehicles
holder (Fig. 10).
equipped with DRL, a right and a left DRL relay are
(2) Insert the bulb holder into the back of the
each located in a dedicated connector of the vehicle
clearance lamp housing and rotate it clockwise about
wire harness. Each connector is snapped into an
30 degrees to lock it into place.
opening in a stamped sheet metal bracket which is
(3) Reinstall the clearance lamp onto the vehicle.
secured with screws within the driver side front seat
(Refer to 8 - ELECTRICAL/LAMPS/LIGHTING -
riser just beneath the seat riser cover panel.
EXTERIOR/CLEARANCE LAMP - INSTALLATION).
(4) Reconnect the battery negative cable. WARNING: To avoid personal injury or death, on
vehicles equipped with airbags, disable the supple-
mental restraint system before attempting any
CLEARANCE LAMP UNIT steering wheel, steering column, airbag, seat belt
tensioner, or instrument panel component diagno-
REMOVAL sis or service. Disconnect and isolate the battery
(1) Disconnect and isolate the battery negative negative (ground) cable, then wait two minutes for
cable. the system capacitor to discharge before perform-
(2) Remove the two screws that secure the clear- ing further diagnosis or service. This is the only
ance lamp unit to the vehicle (Fig. 11). sure way to disable the supplemental restraint sys-
(3) Pull the clearance lamp unit away from the tem. Failure to take the proper precautions could
vehicle far enough to access and disconnect the vehi- result in accidental airbag deployment.
8L - 10 LAMPS/LIGHTING - EXTERIOR VA
DAYTIME RUNNING LAMP RELAY (Continued)
(1) Disconnect and isolate the battery negative (2) Align the DRL relay terminals with the termi-
cable. nal cavities in the relay connector.
(2) Move the driver side front seat to its most for- (3) Using hand pressure, push firmly and evenly
ward position for easiest access to the seat riser on the top of the DRL relay until the terminals are
cover panel (Fig. 12). fully seated in the relay connector.
(4) Position the cover panel onto the top of the
driver side seat riser (Fig. 12).
(5) Install and tighten the two screws that secure
the cover panel to the top of the seat riser under the
driver side front seat.
(6) Move the driver side front seat back to its driv-
ing position.
(7) Reconnect the battery negative cable.

FOG LAMP BULB


REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Disengage and swing the retainers that secure
Fig. 12 Seat Riser Cover the front lamp unit rear cover to each side of the
lamp housing and remove the cover (Fig. 13).
1 - DRIVER SEAT BACK
2 - COVER PANEL
3 - SCREW (2)
4 - SEAT RISER

(3) Remove the cover panel from the top of the


driver side seat riser.
(4) Remove the DRL relay by grasping it firmly
and pulling it straight out of the relay connector.

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.

(1) Disconnect and isolate the battery negative


cable.
(2) Move the driver side front seat to its most for-
Fig. 14 Fog Lamp Bulb Remove/Install ward position for easiest access to the seat riser
1 - LAMP HOUSING cover panel (Fig. 15).
2 - BULB RETAINER
3 - CONNECTOR
4 - BULB BASE

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.

(1) Position the fog lamp relay to the relay connec-


tor.
(2) Align the fog lamp relay terminals with the
terminal cavities in the relay connector.
(3) Using hand pressure, push firmly and evenly
on the top of the fog lamp relay until the terminals
are fully seated in the relay connector.
Fig. 16 Fog Lamp Switch
(4) Position the cover panel onto the top of the
driver side seat riser (Fig. 15). 1 - FOG LAMP SWITCH
2 - SCREW (2)
(5) Install and tighten the two screws that secure 3 - CLUSTER BEZEL
the cover panel to the top of the seat riser under the 4 - TO REAR WINDOW DEFOGGER SWITCH (OPTION AL)
driver side front seat. 5 - TO HEADLAMP LEVELING SWITCH
6 - TO FOG LAMP SWITCH (OPTIONAL)
(6) Move the driver side front seat back to its driv-
ing position. (3) From the back of the cluster bezel, squeeze the
(7) Reconnect the battery negative cable. two latches on the fog lamp switch body and push
the switch out through the face of the bezel (Fig. 17).
FOG LAMP 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
result in accidental airbag deployment.
Fig. 17 Fog Lamp Switch Remove/Install
(1) Disconnect and isolate the battery negative 1 - FOG LAMP SWITCH
cable. 2 - LATCH (2)
3 - CLUSTER BEZEL

(4) Remove the fog lamp switch from the face of


the cluster bezel.
VA LAMPS/LIGHTING - EXTERIOR 8L - 13
FOG LAMP SWITCH (Continued)

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. 21 Fog Lamp Cut-Off Pattern


FRONT POSITION LAMP BULB
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Disengage and swing the retainers that secure
the front lamp unit rear cover to each side of the
lamp housing and remove the cover (Fig. 22).
Fig. 19 Front Lamp Unit Adjusting Screws
1 - HORIZONTAL ADJUSTMENT
2 - VERTICAL ADJUSTMENT

(6) When properly aligned, the low beam head-


lamps and, if equipped, fog lamps should provide a
cut-off pattern as shown in (Fig. 20) and (Fig. 21).
Repeat the adjustment procedure as necessary to
obtain the recommended cut-off patterns.

Fig. 22 Front Lamp Unit Bulbs Remove/Install


1 - COVER RETAINER (2)
2 - BULB RETAINER (3)
3 - FOG LAMP BULB (OPTIONAL)
4 - COVER
5 - LOW BEAM BULB
6 - POSITION BULB
7 - HIGH BEAM BULB
8 - TURN/PARK/SIDE MARKER BULB
9 - FRONT LAMP UNIT

(3) Pull the position lamp bulb holder straight out


Fig. 20 Low Beam Headlamp Cut-Off Pattern
to remove it from the front lamp unit reflector (Fig.
23).
(4) Remove the position lamp bulb from the bulb
holder.
VA LAMPS/LIGHTING - EXTERIOR 8L - 15
FRONT POSITION LAMP BULB (Continued)

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 MOTOR


REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Disengage and swing the retainers that secure
the front lamp unit rear cover to each side of the
lamp housing and remove the cover (Fig. 26).

Fig. 27 Headlamp Leveling Motor


1 - HOUSING
2 - REFLECTOR
3 - CONNECTOR
4 - MOTOR
5 - MOUNT

Fig. 26 Front Lamp Unit Bulbs Remove/Install


1 - COVER RETAINER (2)
2 - BULB RETAINER (3)
3 - FOG LAMP BULB (OPTIONAL)
4 - COVER
5 - LOW BEAM BULB
6 - POSITION BULB
7 - HIGH BEAM BULB
8 - TURN/PARK/SIDE MARKER BULB
9 - FRONT LAMP UNIT

(3) Disconnect the front lamp unit wire harness


connector from the connector receptacle for the head-
lamp leveling motor (Fig. 27).
(4) Rotate the headlamp leveling motor counter-
clockwise about 30 degrees and pull it straight out Fig. 28 Headlamp Leveling Motor Remove/Install
from the mount integral to the front lamp unit hous- 1 - PUSHROD
ing (Fig. 28). 2 - MOTOR
(5) Stabilize the front lamp unit reflector with one 3 - MOUNT
4 - BRACKET
hand, then use the other hand to pull the headlamp 5 - REFLECTOR
leveling motor away from the reflector until the ball
on the end of the motor pushrod unsnaps from the (3) Push the headlamp leveling motor into the
bracket on the reflector. mount integral to the front lamp unit housing until it
(6) Remove the headlamp leveling motor from the is fully seated, then rotate the motor clockwise about
mount on the front lamp unit housing. 30 degrees to lock it into place (Fig. 27).
(4) Reconnect the front lamp unit wire harness
INSTALLATION connector to the connector receptacle for the head-
(1) Position the headlamp leveling motor to the lamp leveling motor.
mount on the front lamp unit housing (Fig. 28). (5) Position the front lamp unit rear cover onto the
(2) Snap the ball on the end of the headlamp lev- lamp housing and engage the retainers over each
eling motor into the bracket on the front lamp unit side of the cover to secure it (Fig. 26).
reflector. (6) Reconnect the battery negative cable.
VA LAMPS/LIGHTING - EXTERIOR 8L - 17

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.

(1) Position the headlamp leveling switch to the


proper mounting hole on the face of the cluster bezel
(Fig. 29).
(2) Using hand pressure, push the headlamp level-
ing switch firmly and evenly into the switch mount-
Fig. 29 Headlamp Leveling Switch
ing hole of the cluster bezel until both of the latches
1 - HEADLAMP LEVELING SWITCH on the switch body are fully engaged.
2 - SCREW (2)
3 - CLUSTER BEZEL (3) Reinstall the cluster bezel onto the instrument
4 - TO REAR WINDOW DEFOGGER SWITCH (OPTIONAL) panel. (Refer to 23 - BODY/INSTRUMENT PANEL/
5 - TO HEADLAMP LEVELING SWITCH CLUSTER BEZEL - INSTALLATION).
6 - TO FOG LAMP SWITCH (OPTIONAL)
(4) Reconnect the battery negative cable.
(3) From the back of the cluster bezel, squeeze the
two latches on the headlamp leveling switch body
and push the switch out through the face of the bezel
HIGH BEAM HEADLAMP BULB
(Fig. 30).
(4) Remove the headlamp leveling switch from the REMOVAL
face of the cluster bezel. (1) Disconnect and isolate the battery negative
cable.
(2) Disengage and swing the retainers that secure
the front lamp unit rear cover to each side of the
lamp housing and remove the cover (Fig. 31).
8L - 18 LAMPS/LIGHTING - EXTERIOR VA
HIGH BEAM HEADLAMP BULB (Continued)

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).

Fig. 32 High Beam Headlamp Bulb Remove/Install


1 - LAMP HOUSING
2 - BULB RETAINER
3 - CONNECTOR
4 - BULB BASE

(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).

Fig. 35 Front Lamp Unit Bulbs Remove/Install


1 - COVER RETAINER (2)
2 - BULB RETAINER (3)
3 - FOG LAMP BULB (OPTIONAL)
Fig. 34 License Plate Lamp Unit Remove/Install 4 - COVER
1 - LAMP HOUSING 5 - LOW BEAM BULB
2 - LENS 6 - POSITION BULB
7 - HIGH BEAM BULB
8 - TURN/PARK/SIDE MARKER BULB
(3) Pull the license plate lamp housing slightly to 9 - FRONT LAMP UNIT
the right to disengage the left side of the unit from
the mounting hole. (3) Disconnect the front lamp unit wire harness
(4) Disconnect the one or two vehicle wire harness connector from the low beam headlamp bulb base
connections from the terminals on the back of the (Fig. 36).
license plate lamp unit. (4) Disengage the low beam headlamp bulb
(5) Remove the license plate lamp unit from the retainer by pushing it slightly toward the front lamp
vehicle. unit housing and downward from the bulb base, then
pivot the retainer off of the bulb base.
INSTALLATION (5) Remove the low beam headlamp bulb from the
(1) Position the license plate lamp unit to the integral bulb holder on the front lamp unit reflector.
mounting hole on the vehicle (Fig. 34).
(2) Reconnect the one or two vehicle wire harness INSTALLATION
connections to the terminals on the back of the (1) Position the low beam headlamp bulb into the
license plate lamp unit. integral bulb holder on the front lamp unit reflector.
8L - 20 LAMPS/LIGHTING - EXTERIOR VA
LOW BEAM HEADLAMP BULB (Continued)
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the fuse block from the underside of
the steering column. (Refer to 8 - ELECTRICAL/
POWER DISTRIBUTION/FUSE BLOCK -
REMOVAL).
(3) Remove the clockspring from the steering col-
umn. (Refer to 8 - ELECTRICAL/RESTRAINTS/
CLOCKSPRING - REMOVAL).
(4) If the vehicle is so equipped, remove the steer-
ing angle sensor from the steering column. (Refer to
5 - BRAKES/ELECTRICAL/STEERING ANGLE
SENSOR - REMOVAL).
(5) Remove the two screws that secure the upper
shroud to the top of the multi-function switch (Fig.
37).
Fig. 36 Low Beam Headlamp Bulb Remove/Install
1 - LAMP HOUSING
2 - BULB BASE
3 - CONNECTOR
4 - BULB RETAINER

Be certain that the lugs on the bulb base are


engaged in the recesses of the bulb holder (Fig. 36).
(2) Engage the low beam headlamp bulb retainer
by pivoting it over the bulb base, pressing it slightly
toward the front lamp unit housing and upward
toward the side of the bulb base.
(3) Reconnect the front lamp unit wire harness
connector to the low 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. 35).
(5) Reconnect the battery negative cable. Fig. 37 Multi-Function Switch Remove/Install
1 - SCREW (2)
2 - UPPER SHROUD
MULTI-FUNCTION SWITCH 3 - SWITCH
4 - SCREW (2)

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.

(1) Reinstall the speed control switch onto the


back of the multi-function switch. (Refer to 8 - ELEC- Fig. 38 Park Brake Switch Remove/Install
TRICAL/SPEED CONTROL/SWITCH - INSTALLA- 1 - LEVER
TION). 2 - SWITCH
(2) Position the multi-function switch onto the 3 - WIRE HARNESS
4 - SCREW
steering column (Fig. 37).
(3) Install and tighten the two screws that secure (5) Remove the park brake switch from the park
the multi-function switch to the steering column. brake lever.
(4) Position the upper shroud onto the top of the
multi-function switch. INSTALLATION
(5) Install and tighten the two screws that secure (1) Position the park brake switch near the park
the upper shroud to the top of the multi-function brake lever (Fig. 38).
switch. (2) Reconnect the vehicle wire harness connector
(6) If the vehicle is so equipped, reinstall the steer- for the park brake switch to the switch terminal.
ing angle sensor onto the steering column. (Refer to 5 (3) Engage the park brake switch into the park
- BRAKES/ELECTRICAL/STEERING ANGLE SEN- brake lever.
SOR - INSTALLATION). (4) Install and tighten the screw that secures the
(7) Reinstall the clockspring onto the steering col- park brake switch and the ground eyelet terminal to
umn. (Refer to 8 - ELECTRICAL/RESTRAINTS/ the park brake lever.
CLOCKSPRING - INSTALLATION). (5) Reinstall the trim cover onto the park brake
(8) Reinstall the fuse block onto the underside of lever. (Refer to 5 - BRAKES/PARKING BRAKE/LE-
the steering column. (Refer to 8 - ELECTRICAL/ VER - INSTALLATION).
POWER DISTRIBUTION/FUSE BLOCK - INSTAL-
LATION).
(9) Reconnect the battery negative cable. REAR SIDE MARKER LAMP
BULB
PARK BRAKE SWITCH
REMOVAL
REMOVAL (1) Disconnect and isolate the battery negative
(1) Remove the trim cover from the park brake cable.
lever (Fig. 38). (Refer to 5 - BRAKES/PARKING (2) If the vehicle is so equipped, remove the trim
BRAKE/LEVER - REMOVAL). from the inside of the right or left rear corner pillar.
(2) Remove the screw that secures the park brake (3) From inside the vehicle, use hand pressure to
switch and the ground eyelet terminal to the park push the two latch tabs toward the center of the tail
brake lever. lamp unit socket plate and pull the socket plate
(3) Disengage the park brake switch from the park straight out from the inner rear pillar (Fig. 39).
brake lever. (4) Pull the socket plate away from the inner rear
(4) Disconnect the vehicle wire harness connector pillar far enough to access the side marker lamp bulb
for the park brake switch from the switch terminal. (Fig. 40).
(5) Remove the side marker lamp bulb from the
tail lamp socket plate.
8L - 22 LAMPS/LIGHTING - EXTERIOR VA
REAR SIDE MARKER LAMP BULB (Continued)

REAR TURN LAMP BULB


REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) If the vehicle is so equipped, remove the trim
from the inside of the right or left rear corner pillar.
(3) From inside the vehicle, use hand pressure to
push the two latch tabs toward the center of the tail
lamp unit socket plate and pull the socket plate
straight out from the inner rear pillar (Fig. 41).

Fig. 39 Tail Lamp Socket Plate Remove/Install


1 - SOCKET PLATE
2 - INNER REAR PILLAR
3 - LATCH TAB (2)

Fig. 41 Tail Lamp Socket Plate Remove/Install


1 - SOCKET PLATE
2 - INNER REAR PILLAR
3 - LATCH TAB (2)

(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. 42 Tail Lamp Bulb Remove/Install


1 - BRAKE/PARK LAMP BULB
2 - BACKUP LAMP BULB
3 - TURN SIGNAL LAMP BULB
4 - SIDE MARKER LAMP BULB
5 - TAIL LAMP SOCKET PLATE

REPEATER LAMP BULB Fig. 44 Large Repeater Lamp Bulb Remove/Install


1 - LAMP HOUSING
2 - BULB
REMOVAL 3 - LENS
(1) Disconnect and isolate the battery negative 4 - SCREW
cable.
(2) Remove the small or large style repeater lamp (4) Remove the repeater lamp bulb from the bulb
unit from its mounting location, but do not discon- holder.
nect it from the vehicle wire harness. (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/RE- INSTALLATION
PEATER LAMP - REMOVAL). (1) Install the repeater lamp bulb into the bulb
(3) Remove the bulb holder from the lens (small holder (Fig. 43) or (Fig. 44).
type) (Fig. 43), or the lens from the lamp housing (2) Reinstall the bulb holder into the lens (small
(large type) (Fig. 44). type), or the lens onto the lamp housing (large type).
(3) Reinstall the repeater lamp unit into its
mounting location. (Refer to 8 - ELECTRICAL/
LAMPS/LIGHTING - EXTERIOR/REPEATER LAMP
- INSTALLATION).
(4) Reconnect the battery negative cable.

REPEATER LAMP UNIT


REMOVAL
SMALL
(1) Disconnect and isolate the battery negative
cable.
(2) Using hand pressure, press the rear edge of the
repeater lamp lens/housing toward the front of the
vehicle against the spring pressure of the retaining
clip, then pull the rear edge of the lamp outward to
disengage it from the mounting hole (Fig. 45).
(3) Pull the repeater lamp housing slightly to the
Fig. 43 Small Repeater Lamp Bulb Remove/Install
rear to disengage the front edge of the unit from the
1 - LAMP HOUSING mounting hole.
2 - BULB HOLDER
3 - BULB
8L - 24 LAMPS/LIGHTING - EXTERIOR VA
REPEATER LAMP UNIT (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.

TURN SIGNAL RELAY


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-
Fig. 47 Tail Lamp Socket Plate Remove/Install sis or service. Disconnect and isolate the battery
1 - SOCKET PLATE negative (ground) cable, then wait two minutes for
2 - INNER REAR PILLAR the system capacitor to discharge before perform-
3 - LATCH TAB (2) 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.

(1) Disconnect and isolate the battery negative


cable.
(2) Remove the fuse access panel from the steering
column opening cover below the steering column on
the instrument panel.
(3) Reach through and below the inboard side of
the fuse access opening to access the turn signal
relay (Fig. 49).
(4) Remove the turn signal relay by grasping it
firmly, releasing the latches and pulling it straight
down from the receptacle on the bottom of the fuse
block.

Fig. 48 Tail Lamp Unit Remove/Install INSTALLATION


1 - SOCKET PLATE
2 - NUT (4) WARNING: To avoid personal injury or death, on
3 - LAMP HOUSING
4 - GASKET vehicles equipped with airbags, disable the supple-
mental restraint system before attempting any
(5) From the inside of the vehicle, remove the four steering wheel, steering column, airbag, seat belt
nuts that secure the tail lamp unit housing to the tensioner, or instrument panel component diagno-
vehicle. sis or service. Disconnect and isolate the battery
(6) Remove the tail lamp unit housing and gasket negative (ground) cable, then wait two minutes for
from the outside of the vehicle. the system capacitor to discharge before perform-
ing further diagnosis or service. This is the only
INSTALLATION sure way to disable the supplemental restraint sys-
(1) Position the tail lamp unit housing and gasket tem. Failure to take the proper precautions could
to the outside of the vehicle (Fig. 48). result in accidental airbag deployment.
8L - 26 LAMPS/LIGHTING - EXTERIOR VA
TURN SIGNAL RELAY (Continued)

Fig. 49 Turn Signal Relay


1 - STEERING COLUMN OPENING COVER
2 - FUSE BLOCK
3 - LOWER INSTRUMENT PANEL
4 - TURN SIGNAL RELAY
5 - ENGINE CONTROL MODULE RELAY
6 - WIPER RELAY

(1) Position the turn signal relay to the receptacle


on the bottom of the fuse block (Fig. 49).
(2) Align the turn signal relay terminals with the
terminal cavities in the fuse block receptacle.
(3) Push firmly and evenly on the top of the turn
signal relay until the terminals are fully seated in
the terminal cavities in the receptacle of the fuse
block and both latches are fully engaged.
(4) Reinstall the fuse access panel onto the steer-
ing column opening cover below the steering column
on the instrument panel.
(5) Reconnect the battery negative cable.
VA LAMPS/LIGHTING - INTERIOR 8L - 27

LAMPS/LIGHTING - INTERIOR

TABLE OF CONTENTS
page page

LAMPS/LIGHTING - INTERIOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 31


DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 27 DOME/READING LAMP UNIT
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
SPECIFICATIONS - INTERIOR LIGHTING . . . . . 28 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 32
ASH RECEIVER/CIGAR LIGHTER LAMP UNIT DOME LAMP/INTRUSION SENSOR BULB
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 29 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 32
CARGO/DOME LAMP BULB DOME LAMP/INTRUSION SENSOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 29 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 32
CARGO/DOME LAMP UNIT DOOR JAMB SWITCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 30 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 33
CARGO LAMP SWITCH ENTRY/EXIT LAMP BULB
REMOVAL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
REMOVAL - INSTRUMENT PANEL ..... . . . 30 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 33
REMOVAL - BULKHEAD . . . . . . . . . . . . . . . . 30 ENTRY/EXIT LAMP UNIT
REMOVAL - REAR PILLAR . . . . . . . . . . . . . . 30 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSTALLATION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSTALLATION - INSTRUMENT PANEL . . . . . 31 TIME DELAY RELAY
INSTALLATION - BULKHEAD . . . . . . . . . . . . . 31 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSTALLATION - REAR PILLAR . . . . . . . . . . . 31 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 35
DOME/READING LAMP BULB
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

LAMPS/LIGHTING - INTERIOR switch has two Light-Emitting Diode (LED) units,


one for illumination and a second that provides an
indication. The switches mounted in the cargo com-
DESCRIPTION
partment also have two LED units, but only the indi-
The interior lighting for this model includes the
cation LED unit is functional in this application.
following standard and optional incandescent interior
• Dome/Reading Lamp - An optional equipment
lamps and controls:
dome/reading lamp unit is located in the windshield
• Ash Receiver/Cigar Lighter Lamp - An avail-
header area between the driver and passenger sun
able ash receiver/cigar lighter lamp is secured by an
visors. This lamp features two incandescent bulbs,
integral mount to the outside of the cigar lighter halo
one dome lamp bulb and a second, dedicated reading
ring. A single lamp serves to illuminate both the
lamp bulb. An integral four-position switch protrudes
translucent halo ring and the ash receiver.
through the lamp lens.
• Cargo/Dome Lamp - Several cargo/dome lamp
• Dome Lamp/Intrusion Sensor - An optional
units located overhead in both the front and rear of
equipment dome lamp/intrusion sensor unit is
the vehicle interior are standard equipment. These
located overhead in the vehicle interior. This lamp
lamps feature a single incandescent bulb. An optional
features four incandescent bulbs, two for dome lamps
version of these lamps includes an integral three-po-
and two for dedicated right and left reading lamps.
sition switch that protrudes through the lamp lens.
This lamp has two integral three-position switches,
• Cargo Lamp Switch - Toggle-type remote
one to control interior lamp operation and one to con-
cargo lamp switches located in the accessory switch
trol reading lamp operation. This lamp also houses
bezel in the center of the instrument panel, on the
three intrusion sensors that are part of an optional
back side of the cargo compartment bulkhead panel,
vehicle theft security system.
and on the rear cargo door pillar are an available
• Door Jamb Switch - A door jamb switch for
option on all van models. The instrument panel
each front door is standard equipment on all models.
8L - 28 LAMPS/LIGHTING - INTERIOR VA
LAMPS/LIGHTING - INTERIOR (Continued)
A door jamb switch for each sliding side door and the ground path independent of the door jamb switches
right rear door is standard equipment on wagon mod- to turn the lamp On. The second, or center position
els. The sliding and rear door jamb switches are not allows the door jamb switches to control the lamp.
available for van models. The third position segregates that lamp from the
• Entry/Exit Lamp - An entry/exit lamp to illu- door jamb switch input, turning the lamp Off. In the
minate each front and sliding side door step well is case of the optional dome/reading lamp, the integral
optional equipment on wagon models. lamp switch has a fourth position which will illumi-
• Time Delay Relay - Vehicles equipped with the nate only the reading lamp bulb.
optional remote cargo lamp switches also have a time
delay relay located in the electrical center within the VAN MODELS
driver side front seat riser. Unless a van model is equipped with an optional
Hard wired circuitry connects the interior lighting remote cargo lamp switch, all of the lamps in the
system components to the electrical system of the interior lighting circuit operate the same way as the
vehicle. These hard wired circuits are integral to sev- wagon models except that there are only two door
eral wire harnesses, which are routed throughout the jamb switches, one for each front door. If the vehicle
vehicle and retained by many different methods. is equipped with an optional remote cargo lamp
These circuits may be connected to each other, to the switch, the lamps in the rear of the vehicle on the
vehicle electrical system and to the interior lighting interior lighting circuit are provided with battery
system components through the use of a combination current by the time delay relay. The time delay relay
of soldered splices, splice block connectors, and many is a smart relay containing active electronic elements
different types of wire harness terminal connectors that comprise an electronic timer logic circuit. When
and insulators. Refer to the appropriate wiring infor- the remote cargo lamp switches provide the proper
mation. The wiring information includes wiring dia- input to the time delay relay, the relay logic responds
grams, proper wire and connector repair procedures, by energizing the relay control coil. The energized
further details on wire harness routing and reten- relay control coil provides battery current to all of
tion, as well as pin-out and location views for the the lamps on the rear interior lighting circuit and to
various wire harness connectors, splices and grounds. the indicator Light-Emitting Diode (LED) units in
the remote cargo switches causing each to illuminate.
OPERATION If a remote cargo lamp switch remains On for more
The interior lighting systems can be divided into than about fifteen minutes, the time delay relay will
two general classifications based upon the circuit then automatically de-energize the rear interior
that controls their operation: The interior lighting lighting circuits until the remote cargo lamp switch
circuit, or the exterior lighting circuit. The hard is cycled Off and then back On.
wired circuits and components of the interior lighting
systems may be diagnosed and tested using conven- EXTERIOR LIGHTING CIRCUIT
tional diagnostic tools and procedures. The exterior lighting circuit provides battery cur-
rent to the optional ash receiver/cigar lighter lamp
INTERIOR LIGHTING CIRCUIT and to the illumination Light-Emitting Diode (LED)
Depending upon the vehicle model (van or wagon) unit within the remote cargo lamp switch in the
and the selected vehicle options the interior lighting instrument panel accessory switch bezel whenever
circuit may include dome/cargo lamps located over- the exterior lamps are turned On.
head in the front and rear of the vehicle, a dome/
reading lamp located in the header area above the SPECIFICATIONS - INTERIOR LIGHTING
windshield between the sun visors, and entry/exit BULB SPECIFICATIONS
lamps located in the front and sliding side door step
wells. LAMP BULB
WAGON MODELS Cargo/Dome Lamp K - 12V 18W
In all wagon models, the lamps in the interior Dome/Reading Lamp K - 12V 10W
lighting circuit are provided with battery current at Dome Lamp w/Intrusion K - 12V 6W
all times by a fuse in the fuse block beneath the Sensor
steering column. The front, side, and rear door jamb
Entry/Exit Lamp W5W - 12V 5W
switches control a ground path for each of these
lamps, except for the optional reading lamp. If the
lamp has an optional integral switch, that switch has
three separate positions. The first position provides a
VA LAMPS/LIGHTING - INTERIOR 8L - 29

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).

Fig. 1 Ash Receiver/Cigar Lighter Lamp Unit


1 - CIGAR LIGHTER
2 - HALO RING
3 - LENS
4 - LAMP UNIT (BIN REMOVED)
5 - ASH RECEIVER BIN
6 - ASH RECEIVER

An ash receiver/cigar lighter lamp unit is optional


equipment on this model (Fig. 1). The bulb and bulb
holder are secured by an integral mount to the out-
side of the cigar lighter halo ring, and serves to illu-
minate both the translucent halo ring and the ash
receiver. A small lens that is snap-fit into the inboard Fig. 2 Cargo/Dome Lamp Bulb Remove/Install
side of the ash receiver bin allows light from the
1 - LAMP HOUSING
lamp on the halo ring to also illuminate the ash 2 - BULB
receiver. The ash receiver/cigar lighter lamp is ser- 3 - CONNECTOR RECEPTACLE
viced only as a unit with the ash receiver housing
and cigar lighter receptacle. If the lamp is faulty or INSTALLATION
damaged, the entire ash receiver housing and cigar (1) Grasp the cargo/dome lamp housing in one
lighter receptacle unit must be replaced. (Refer to 23 hand and carefully insert the bulb into the bulb
- BODY/INSTRUMENT PANEL/ASH RECEIVER - holder with the other hand (Fig. 2).
REMOVAL). (2) Reinstall the cargo/dome lamp unit into its
mounting location. (Refer to 8 - ELECTRICAL/
INSTALLATION LAMPS/LIGHTING - INTERIOR/CARGO/DOME
An ash receiver/cigar lighter lamp unit is optional LAMP UNIT - INSTALLATION).
equipment on this model (Fig. 1). The bulb and bulb (3) Reconnect the battery negative cable.
holder are secured by an integral mount to the out-
side of the cigar lighter halo ring, and serves to illu-
minate both the translucent halo ring and the ash CARGO/DOME LAMP UNIT
receiver. A small lens that is snap-fit into the inboard
side of the ash receiver bin allows light from the REMOVAL
lamp on the halo ring to also illuminate the ash (1) Disconnect and isolate the battery negative
receiver. The ash receiver/cigar lighter lamp is ser- cable.
viced only as a unit with the ash receiver housing (2) Insert the tip of a small flat-bladed screwdriver
and cigar lighter receptacle. If the lamp is faulty or into the notch on one edge of the cargo/dome lamp
8L - 30 LAMPS/LIGHTING - INTERIOR VA
CARGO/DOME LAMP UNIT (Continued)
housing to depress the retainer clip and pull that cargo lamp switch from the receptacle on the back of
edge of the lamp away from its mounting location the switch (Fig. 4).
(Fig. 3).

Fig. 3 Cargo/Dome Lamp Unit Remove/Install


1 - LAMP HOUSING
2 - SWITCH BUTTON Fig. 4 Cargo Lamp Switch - Accessory Switch Bezel
3 - NOTCH
Mounted Remove/Install
(3) Pull the cargo/dome lamp unit from its mount- 1 - SWITCH (TYPICAL)
2 - ACCESSORY SWITCH BEZEL
ing location far enough to access and disconnect the 3 - BLOCK-OUT PLATE
vehicle wire harness from the lamp connector recep- 4 - LATCH (2)
tacle.
(4) Remove the cargo/dome lamp unit from its (4) From the back of the accessory switch bezel,
mounting location. depress the two latches on the outside of the switch
body and push the switch out through the front of
INSTALLATION the bezel.
(1) Position the cargo/dome lamp unit to its
mounting location. REMOVAL - BULKHEAD
(2) Reconnect the vehicle wire harness connector (1) Disconnect and isolate the battery negative
to the cargo/dome lamp connector receptacle (Fig. 3). cable.
(3) Position the edge of the cargo/dome lamp hous- (2) Carefully pry the cargo lamp switch and switch
ing opposite from the retainer clip into the mounting bezel out of the switch box on the back of the cargo
hole. compartment bulkhead panel.
(4) Push firmly and evenly on the notched edge of (3) Pull the cargo lamp switch and bezel away
the cargo/dome lamp housing until the retainer clip from the switch box far enough to access and discon-
latches into place. nect the vehicle wire harness connector for the
(5) Reconnect the battery negative cable. switch from the receptacle on the back of the switch.
(4) From the back of the switch bezel, depress the
two latches on the outside of the cargo lamp switch
CARGO LAMP SWITCH body and push the switch out through the top of the
switch bezel.

REMOVAL REMOVAL - REAR PILLAR


(1) Disconnect and isolate the battery negative
REMOVAL - INSTRUMENT PANEL cable.
(1) Disconnect and isolate the battery negative (2) Carefully pry the cargo lamp switch and switch
cable. bezel out of the switch mounting hole on the inside of
(2) Remove the accessory switch bezel from the the rear door opening pillar.
instrument panel. (Refer to 23 - BODY/INSTRU- (3) Pull the cargo lamp switch and bezel away
MENT PANEL/ACCESSORY SWITCH BEZEL - from the pillar far enough to access and disconnect
REMOVAL). the vehicle wire harness connector for the switch
(3) From the back of the accessory switch bezel, from the receptacle on the back of the switch.
disconnect the vehicle wire harness connector for the
VA LAMPS/LIGHTING - INTERIOR 8L - 31
CARGO LAMP SWITCH (Continued)
(4) From the back of the switch bezel, depress the DOME/READING LAMP BULB
two latches on the outside of the cargo lamp switch
body and push the switch out through the top of the
REMOVAL
switch bezel.
(1) Disconnect and isolate the battery negative
cable.
INSTALLATION (2) Remove the dome/reading lamp unit from its
mounting location, but do not disconnect the vehicle
INSTALLATION - INSTRUMENT PANEL wire harness from the lamp connector receptacle.
(1) From the front of the accessory switch bezel, (Refer to 8 - ELECTRICAL/LAMPS/LIGHTING -
align the cargo lamp switch body with the opening in INTERIOR/DOME/READING LAMP UNIT -
the bezel and push the switch into the bezel until the REMOVAL).
two latches on the outside of the switch body snap (3) Grasp the lamp housing in one hand and care-
into place (Fig. 4). fully pull the bulb out of the bulb holder with the
(2) From the back of the accessory switch bezel, other hand (Fig. 5).
reconnect the vehicle wire harness connector for the
cargo lamp switch to the receptacle on the back of
the switch.
(3) Reinstall the accessory switch bezel onto the
instrument panel. (Refer to 23 - BODY/INSTRU-
MENT PANEL/ACCESSORY SWITCH BEZEL -
INSTALLATION).
(4) Reconnect the battery negative cable.

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)

Fig. 7 Dome Lamp/Intrusion Sensor Bulb Remove/


Install
Fig. 6 Dome/Reading Lamp Unit Remove/Install 1 - BULB HOLDER/BULB (4)
1 - LAMP HOUSING 2 - LAMP HOUSING
2 - SWITCH BUTTON
3
4
-
-
NOTCH
SUN VISOR (2)
INSTALLATION
5 - HEADLINER (1) Grasp the dome lamp/intrusion sensor unit
housing in one hand and align the bulb holder and
(3) Pull the dome/reading lamp unit from its bulb unit with the bulb mounting hole in the circuit
mounting location far enough to access and discon- board with the other hand (Fig. 7).
nect the vehicle wire harness from the lamp connec- (2) Insert the bulb holder and bulb unit straight
tor receptacle. into the circuit board bulb mounting hole until it is
(4) Remove the dome/reading lamp unit from its firmly seated.
mounting location. (3) Rotate the bulb holder and bulb unit clockwise
about 30 degrees on the circuit board.
INSTALLATION (4) Reinstall the dome lamp/intrusion sensor unit
(1) Position the dome/reading lamp unit to its into its mounting location. (Refer to 8 - ELECTRI-
mounting location. CAL/LAMPS/LIGHTING - INTERIOR/DOME LAMP/
(2) Reconnect the vehicle wire harness connector to INTRUSION SENSOR UNIT - INSTALLATION).
the dome/reading lamp connector receptacle (Fig. 6). (5) Reconnect the battery negative cable.
(3) Position the edge of the dome/reading lamp
housing opposite from the retainer clip into the
mounting hole. DOME LAMP/INTRUSION
(4) Push firmly and evenly on the notched edge of SENSOR
the dome/reading lamp housing until the retainer
clip latches into place. REMOVAL
(5) Reconnect the battery negative cable. (1) Disconnect and isolate the battery negative
cable.
(2) Insert the tip of a small flat-bladed screwdriver
DOME LAMP/INTRUSION into the notch on one edge of the dome lamp/intru-
SENSOR BULB sion sensor unit housing to depress the retainer clip
and pull that edge of the lamp away from its mount-
REMOVAL ing location (Fig. 8).
(1) Disconnect and isolate the battery negative (3) Pull the dome lamp/intrusion sensor unit from
cable. its mounting location far enough to access and dis-
(2) Remove the dome lamp/intrusion sensor unit connect the vehicle wire harness from the lamp con-
from its mounting location, but do not disconnect the nector receptacle.
vehicle wire harness from the lamp connector recep- (4) Remove the dome lamp/intrusion sensor unit
tacle. (Refer to 8 - ELECTRICAL/LAMPS/LIGHTING from its mounting location.
- INTERIOR/DOME LAMP/INTRUSION SENSOR
UNIT - REMOVAL). INSTALLATION
(3) Grasp the lamp housing in one hand and rotate (1) Position the dome lamp/intrusion sensor unit to
the bulb holder and bulb unit counterclockwise about its mounting location (Fig. 8).
30 degrees on the circuit board (Fig. 7). (2) Reconnect the vehicle wire harness connector
(4) Pull the bulb holder and bulb unit straight out to the dome lamp/intrusion sensor unit connector
from the mounting hole in the circuit board. receptacle.
VA LAMPS/LIGHTING - INTERIOR 8L - 33
DOME LAMP/INTRUSION SENSOR (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).

Fig. 10 Entry/Exit Lamp Bulb Remove/Install


1 - LAMP HOUSING
2 - BULB HOLDER
3 - CONNECTOR

(4) Remove the bulb from the bulb holder.

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

ENTRY/EXIT LAMP UNIT TIME DELAY RELAY


REMOVAL REMOVAL
(1) Disconnect and isolate the battery negative
cable. WARNING: To avoid personal injury or death, on
(2) Insert the tip of a small flat-bladed screwdriver vehicles equipped with airbags, disable the supple-
into the notch on one edge of the entry/exit lamp mental restraint system before attempting any
housing to depress the retainer clip and pull that steering wheel, steering column, airbag, seat belt
edge of the lamp away from its mounting location tensioner, or instrument panel component diagno-
(Fig. 11). 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.

(1) Disconnect and isolate the battery negative


cable.
(2) Move the driver side front seat to its most for-
ward position for easiest access to the seat riser
Fig. 11 Entry/Exit Lamp Unit Remove/Install cover panel.
1 - STEP WELL SCUFF PAD (3) Remove the two screws that secure the cover
2 - NOTCH
3 - ENTRY/EXIT LAMP UNIT
panel to the top of the seat riser under the driver
side front seat (Fig. 12).
(3) Pull the entry/exit lamp unit from its mounting
location far enough to access and disconnect the vehi-
cle wire harness from the lamp connector receptacle.
(4) Remove the entry/exit lamp unit from its
mounting location.

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

(4) Remove the cover panel from the top of the


driver side seat riser.
(5) Remove the time delay relay from its vehicle
wire harness connector by grasping it firmly and
pulling it straight out from the connector within the
driver side seat riser.
VA LAMPS/LIGHTING - INTERIOR 8L - 35
TIME DELAY RELAY (Continued)

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.

(1) Position the time delay relay to its vehicle wire


harness connector within the driver side seat riser.
(2) Align the time delay relay terminals with the
terminal cavities in the vehicle wire harness connec-
tor.
VA POWER SYSTEMS 8N - 1

POWER SYSTEMS
TABLE OF CONTENTS

page page

POWER LOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 POWER WINDOWS. . . . . . . . . . . . . . . . . . . . . . . . . 5


POWER MIRRORS . . . . . . . . . . . . . . . . . . . . . . . . . 3

POWER LOCKS

TABLE OF CONTENTS
page page

DOOR LOCK MOTOR DIAGNOSIS AND TESTING - MASTER LOCK


REMOVAL .......... ...................1 SWITCH ............ .................1
INSTALLATION . . . . . . . ...................1 REMOVAL ............ .................2
REMOTE KEYLESS ENTRY TRANSMITTER INSTALLATION . . . . . . . . . .................2
DESCRIPTION . . . . . . . ...................1
MASTER LOCK SWITCH
DESCRIPTION . . . . . . . ...................1

DOOR LOCK MOTOR When a transmitter is lost, it is necessary to dis-


able the affected transmitter so that it can no longer
be used to operate the vehicle. It will then be neces-
REMOVAL
sary to program a new transmitter to the vehicle.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the door trim panel. MASTER LOCK SWITCH
(3) Remove the door lock.
(4) Remove the door lock motor from the door lock.
DESCRIPTION
The master lock switch is a momentary contact
INSTALLATION switch. Pressing the once in the up direction unlocks
(1) Install the door lock motor to the door lock.
the driver door. Pressing it again in the same direc-
(2) Install the door lock.
tion unlocks all doors. Pressing the button in the
(3) Install the door trim panel.
down direction locks all doors.
(4) Connect the battery negative cable.
DIAGNOSIS AND TESTING - MASTER LOCK
REMOTE KEYLESS ENTRY SWITCH
(1) Disconnect and isolate the battery negative
TRANSMITTER cable.
(2) Remove the switch to be tested.
DESCRIPTION (3) Using an ohmmeter, test switch for continuity
Pressing the unlock button on the transmitter will (Fig. 1).
unlock the drivers door, pressing it a second time (4) If test results are not obtained as shown in the
within 2.5 seconds will unlock all other doors. The test table, replace the switch.
transmitter has a range of 10 meters. A key is inte-
gral to the transmitter.
8N - 2 POWER LOCKS VA
MASTER LOCK SWITCH (Continued)

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).

Fig. 1 POWER LOCK SWITCH

MASTER LOCK SWITCH

SWITCH POSITION CONTINUITY BETWEEN


OPEN 4 AND 7
Fig. 2 POWER LOCK SWITCH
4 AND 10
1 - CENTRAL LOCKING SWITCH
7 AND 10 2 - INSTRUMENT PANEL
LOCK/UNLOCK 3 AND 4
(3) Remove the central locking switch from the
3 AND 7 bezel (Fig. 2).
3 AND 10
4 AND 7 INSTALLATION
(1) Install switch to bezel.
4 AND 10
(2) Install instrument panel center bezel (Refer to
4 AND 8 23 - BODY/INSTRUMENT PANEL/INSTRUMENT
7 AND 8 PANEL CENTER BEZEL - INSTALLATION).
(3) Connect battery negative cable.
7 AND 10
VA POWER MIRRORS 8N - 3

POWER MIRRORS

TABLE OF CONTENTS
page page

POWER MIRRORS REMOVAL .............................3


DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 3 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 4
POWER MIRROR SWITCH
DIAGNOSIS AND TESTING - POWER MIRROR
SWITCH .............................3

POWER MIRRORS MIRROR SWITCH TEST

DESCRIPTION MIRROR SELECT SWITCH IN “LEFT”


The power operated outside rear view mirrors POSITION
allow the driver to adjust both outside mirrors elec- BUTTON CONTINUITY BETWEEN
trically from the driver side front seat position by POSITION
operating a switch on the driver side front door trim UP PIN 6 AND 9
panel. The power mirrors receive a non-switched bat- PIN 6 AND 8
tery feed through a fuse so that the system will
remain operational, regardless of the ignition switch DOWN PIN 2 AND 4
position. PIN 6 AND 10
LEFT PIN 2 AND 3
PIN 6 AND 10
POWER MIRROR SWITCH RIGHT PIN 2 AND 3
PIN 6 AND 2
DIAGNOSIS AND TESTING - POWER MIRROR
MIRROR SELECT SWITCH IN “RIGHT”
SWITCH POSITION
(1) Disconnect and isolate the battery negative
cable. BUTTON CONTINUITY BETWEEN
(2) Remove power mirror switch (Refer to 8 - POSITION
ELECTRICAL/POWER MIRRORS/POWER MIRROR UP PIN 6 AND 8
SWITCH - REMOVAL). PIN 6 AND 9
(3) Using an ohmmeter, test for continuity between DOWN PIN 6 AND 3
the terminals of the switch (Fig. 1).
LEFT PIN 1 AND 7
RIGHT PIN 1 AND 8

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.

Fig. 1 POWER MIRROR SWITCH


8N - 4 POWER MIRRORS VA
POWER MIRROR SWITCH (Continued)

Fig. 2 POWER MIRROR SWITCH


INSTALLATION
(1) Connect electrical harness connector to switch.
(2) install the mirror switch/power window switch
trim.
(3) Install the door handle trim.
(4) Connect the battery negative cable.
VA POWER WINDOWS 8N - 5

POWER WINDOWS

TABLE OF CONTENTS
page page

POWER WINDOWS POWER WINDOW SWITCH


DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 5 DIAGNOSIS AND TESTING - POWER
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 WINDOW SWITCH . . . . . .................5
WINDOW MOTOR REMOVAL ............ .................6
REMOVAL .............................5 INSTALLATION . . . . . . . . . .................6

POWER WINDOWS POWER WINDOW SWITCH


DESCRIPTION DIAGNOSIS AND TESTING - POWER WINDOW
The power window system allows each of the door SWITCH
windows to be raised and lowered electrically by Test the power window switch continuity. Refer to
actuating a switch on each door panel. A master the Power Window Switch Continuity chart to deter-
switch on the drivers door allows the driver to raise mine if the continuity is correct in the Off, Up and
or lower each door window. The power window sys- Down switch positions (Fig. 1).
tem operates only when the ignition switch is in the
RUN or ACCESSORY position.

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

RESTRAINTS and passive types. Active restraints are those which


require the vehicle occupants to take some action to
employ, such as fastening a seat belt; while passive
DESCRIPTION
restraints require no action by the vehicle occupants
An occupant restraint system is standard factory-
to be employed (Fig. 1).
installed safety equipment on this model. Available
occupant restraints for this model include both active
8O - 2 RESTRAINTS VA
RESTRAINTS (Continued)

Fig. 1 Supplemental Restraint System


1 - PASSENGER AIRBAG (OPTIONAL) 5 - SEAT BELT TENSIONER (DRIVER SIDE - STANDARD,
2 - SIDE IMPACT SENSOR (2 - WITH OPTIONAL SIDE CURTAIN PASSENGER SIDE - OPTIONAL WITH PASSENGER AIRBAG
AIRBAGS ONLY) ONLY)
3 - DRIVER AIRBAG 6 - SIDE CURTAIN AIRBAG (2 - OPTIONAL)
4 - AIRBAG CONTROL MODULE

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)

OPERATION During a frontal vehicle impact, the knee blockers


work in concert with properly fastened and adjusted
ACTIVE RESTRAINTS seat belts to restrain both the driver and the front
The primary passenger restraints in this or any seat passenger in the proper position for an airbag
other vehicle are the standard equipment factory-in- deployment. The knee blockers also absorb and dis-
stalled seat belts. Seat belts are referred to as an tribute the crash energy from the driver and the
active restraint because the vehicle occupants are front seat passenger to the structure of the instru-
required to physically fasten and properly adjust ment panel. The seat belt tensioners remove the
these restraints in order to benefit from them. See slack from the front seat belts to provide further
the owner’s manual in the vehicle glove box for more assurance that the driver and front seat passenger
information on the features, use and operation of all are properly positioned and restrained for an airbag
of the factory-installed active restraints. deployment.
Typically, the vehicle occupants recall more about
PASSIVE RESTRAINTS the events preceding and following a collision than
The passive restraints are referred to as a supple- they do of an airbag deployment itself. This is
mental restraint system because they were designed because the airbag deployment and deflation occur so
and are intended to enhance the protection for the rapidly. In a typical 48 kilometer-per-hour (30 mile-
occupants of the vehicle only when used in conjunc- per-hour) barrier impact, from the moment of impact
tion with the seat belts. They are referred to as pas- until the airbags are fully inflated takes only a few
sive restraints because the vehicle occupants are not milliseconds. Within one to two seconds from the
required to do anything to make them operate; how- moment of impact, the airbags are almost entirely
ever, the vehicle occupants must be wearing their deflated. The times cited for these events are approx-
seat belts in order to obtain the maximum safety imations, which apply only to a barrier impact at the
benefit from the factory-installed supplemental given speed. Actual times will vary somewhat,
restraint system. depending upon the vehicle speed, impact angle,
The supplemental restraint system electrical cir- severity of the impact, and the type of collision.
cuits are continuously monitored and controlled by a When the ACM monitors a problem in any of the
microprocessor and software contained within the airbag system circuits or components, including the
Airbag Control Module (ACM). An airbag indicator in seat belt tensioners, it stores a fault code or Diagnos-
the ElectroMechanical Instrument Cluster (EMIC) tic Trouble Code (DTC) in its memory circuit and
illuminates for about four seconds as a bulb test each sends a hard wired output to the EMIC to turn on
time the ignition switch is turned to the On or Start the airbag indicator. If the EMIC detects a problem
positions. Following the bulb test, the airbag indica- in the airbag indicator or airbag indicator circuit, the
tor is turned on or off by the ACM to indicate the cluster will flash the seatbelt indicator on and off.
status of the supplemental restraint system. If the Proper testing of the supplemental restraint system
airbag indicator comes on either solid or flashing at components as well as the retrieval or erasure of a
any time other than during the bulb test, it indicates DTC from the ACM requires the use of a DRBIIIt
that there is a problem in the supplemental restraint scan tool. Refer to the appropriate diagnostic infor-
system electrical circuits. Such a problem may cause mation.
airbags not to deploy when required, or to deploy See the owner’s manual in the vehicle glove box for
when not required. more information on the features, use and operation
Deployment of the supplemental restraints of all of the factory-installed passive restraints.
depends upon the angle and severity of an impact.
Deployment is not based upon vehicle speed; rather,
deployment is based upon the rate of deceleration as
measured by the forces of gravity (G force) upon the
impact sensor(s). When an impact is severe enough,
the microprocessor in the ACM signals the inflator of
the appropriate airbag units to deploy their airbag
cushions. The front seat belt tensioners are provided
with a deployment signal by the ACM in conjunction
with the driver and passenger airbags.
VA RESTRAINTS 8O - 5
RESTRAINTS (Continued)

WARNING WARNING: To avoid personal injury or death, when


handling a seat belt tensioner retractor, proper care
WARNINGS - RESTRAINT SYSTEM should be exercised to keep fingers out from under
the retractor cover and away from the seat belt
WARNING: To avoid personal injury or death, during webbing where it exits from the retractor cover.
and following any seat belt service, carefully
inspect all seat belts, buckles, mounting hardware,
WARNING: To avoid personal injury or death,
retractors, tether straps, and anchors for proper
replace all restraint system components only with
installation, operation, or damage. Replace any belt
parts specified in the DaimlerChrysler Mopar Parts
that is cut, frayed, or torn. Straighten any belt that
Catalog. Substitute parts may appear interchange-
is twisted. Tighten any loose fasteners. Replace any
able, but internal differences may result in inferior
belt that has a damaged or inoperative buckle or
occupant protection.
retractor. Replace any belt that has a bent or dam-
aged latch plate or anchor plate. Never attempt to
repair a seat belt component. Always replace dam- WARNING: To avoid personal injury or death, the
aged or faulty seat belt components with the cor- fasteners, screws, and bolts originally used for the
rect, new and unused replacement parts listed in restraint system components must never be
the DaimlerChrysler Mopar Parts Catalog. replaced with any substitutes. These fasteners have
special coatings and are specifically designed for
the restraint system. Any time a new fastener is
WARNING: To avoid personal injury or death, on
needed, replace it with the correct fasteners pro-
vehicles equipped with airbags, disable the supple-
vided in the service package or specified in the
mental restraint system before attempting any
DaimlerChrysler Mopar Parts Catalog.
steering wheel, steering column, airbag, seat belt
tensioner, impact sensor, or instrument panel com-
ponent diagnosis or service. Disconnect and isolate WARNING: To avoid personal injury or death, when
the battery negative (ground) cable, then wait two a steering column has an airbag unit attached,
minutes for the system capacitor to discharge never place the column on the floor or any other
before performing further diagnosis or service. This surface with the steering wheel or airbag unit face
is the only sure way to disable the supplemental down.
restraint system. Failure to take the proper precau-
tions could result in accidental airbag deployment.
DIAGNOSIS AND TESTING - SUPPLEMENTAL
WARNING: To avoid personal injury or death on RESTRAINT SYSTEM
vehicles equipped with airbags, before performing Proper diagnosis and testing of the supplemental
any welding operations disconnect and isolate the restraint system components or the Airbag Control
battery negative (ground) cable and disconnect all Module (ACM), initialization of the ACM, as well as
wire harness connectors from the Airbag Control the retrieval or erasure of a Diagnostic Trouble Code
Module (ACM). Failure to take the proper precau- (DTC) from the ACM requires the use of a DRBIIIt
tions could result in accidental airbag deployment scan tool. Refer to the appropriate diagnostic infor-
and other possible damage to the supplemental mation.
restraint system circuits and components.
WARNING: To avoid personal injury or death, on
vehicles equipped with airbags, disable the supple-
WARNING: To avoid personal injury or death, do not mental restraint system before attempting any
attempt to dismantle an airbag unit or tamper with steering wheel, steering column, airbag, seat belt
its inflator. Do not puncture, incinerate, or bring tensioner, impact sensor, or instrument panel com-
into contact with electricity. Do not store at temper- ponent diagnosis or service. Disconnect and isolate
atures exceeding 93° C (200° F). An airbag inflator the battery negative (ground) cable, then wait two
unit may contain sodium azide and potassium minutes for the system capacitor to discharge
nitrate. These materials are poisonous and before performing further diagnosis or service. This
extremely flammable. Contact with acid, water, or is the only sure way to disable the supplemental
heavy metals may produce harmful and irritating restraint system. Failure to take the proper precau-
gases (sodium hydroxide is formed in the presence tions could result in accidental airbag deployment.
of moisture) or combustible compounds. An airbag
inflator unit may also contain a gas canister pres-
surized to over 2500 psi.
8O - 6 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.

STANDARD PROCEDURE - SERVICE AFTER A


SUPPLEMENTAL RESTRAINT DEPLOYMENT
Any vehicle which is to be returned to use follow-
ing a supplemental restraint deployment, must have
the deployed restraints replaced. In addition, if the
driver airbag has been deployed, the clockspring and
the steering wheel must be replaced. If the passenger Fig. 3 Wear Safety Glasses and Rubber Gloves -
airbag has been deployed, the instrument panel must Typical
be replaced. The seat belt tensioners are deployed by
the same signal that deploys the driver and passen-
VA RESTRAINTS 8O - 7
RESTRAINTS (Continued)
WARNING: To avoid personal injury or death, if you STANDARD PROCEDURE - VERIFICATION TEST
experience skin irritation during cleanup, run cool The following procedure should be performed using
water over the affected area. Also, if you experience a DRBIIIt scan tool to verify proper supplemental
irritation of the nose or throat, exit the vehicle for restraint system operation following the service or
fresh air until the irritation ceases. If irritation con- replacement of any supplemental restraint system
tinues, see a physician. component.
(1) Begin the cleanup by using a vacuum cleaner WARNING: To avoid personal injury or death, on
to remove any residual powder from the vehicle inte- vehicles equipped with airbags, disable the supple-
rior. Clean from outside the vehicle and work your mental restraint system before attempting any
way inside, so that you avoid kneeling or sitting on a steering wheel, steering column, airbag, seat belt
non-cleaned area. tensioner, impact sensor, or instrument panel com-
(2) Be certain to vacuum the heater and air condi- ponent diagnosis or service. Disconnect and isolate
tioning outlets as well (Fig. 4). Run the heater and the battery negative (ground) cable, then wait two
air conditioner blower on the lowest speed setting minutes for the system capacitor to discharge
and vacuum any powder expelled from the outlets. 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) During the following test, the battery negative


cable remains disconnected and isolated, as it was
during the supplemental restraint system component
removal and installation procedures.
(2) Be certain that the DRBIIIt scan tool contains
the latest version of the proper DRBIIIt software.
Connect the DRBIIIt to the 16-way Data Link Con-
nector (DLC). The DLC is located on the dash panel
beneath the driver side lower edge of the instrument
panel, outboard of the steering column (Fig. 5).

Fig. 4 Vacuum Heater and A/C Outlets - Typical


CAUTION: All damaged, faulty, or non-deployed
supplemental restraints which are replaced on vehi-
cles are to be handled and disposed of properly. If
an airbag unit or seat belt tensioner unit is faulty or
damaged and non-deployed, refer to the Hazardous
Substance Control System for proper disposal. Be
certain to dispose of all non-deployed and deployed
supplemental restraints in a manner consistent with
state, provincial, local and federal regulations.

(3) Next, remove the deployed supplemental


restraints from the vehicle. Refer to the appropriate
service removal procedures. Fig. 5 16-Way Data Link Connector
(4) You may need to vacuum the interior of the
1 - BOTTOM OF INSTRUMENT PANEL
vehicle a second time to recover all of the powder. 2 - CONNECTOR COVER
3 - 16-WAY DATA LINK CONNECTOR
4 - DASH PANEL
5 - INSIDE HOOD RELEASE LEVER

(3) Turn the ignition switch to the On position and


exit the vehicle with the DRBIIIt scan tool.
(4) Check to be certain that nobody is in the vehi-
cle, then reconnect the battery negative cable.
8O - 8 RESTRAINTS VA
RESTRAINTS (Continued)
(5) Using the DRBIIIt, read and record the active
(current) Diagnostic Trouble Code (DTC) data.
(6) Next, use the DRBIIIt to read and record any
stored (historical) DTC data.
(7) If any DTC is found in Step 5 or Step 6, refer
to the appropriate diagnostic information.
(8) Use the DRBIIIt to erase the stored DTC data.
If any problems remain, the stored DTC data will not
erase. Refer to the appropriate diagnostic informa-
tion to diagnose any stored DTC that will not erase.
If the stored DTC information is successfully erased,
go to Step 9.
(9) Turn the ignition switch to the Off position for
about fifteen seconds, and then back to the On posi-
tion. Observe the airbag indicator in the instrument
cluster. It should illuminate for four seconds, and
then go out. This indicates that the supplemental
Fig. 6 Airbag Control Module
restraint system is functioning normally and that the 1 - AIRBAG CONTROL MODULE
2 - LABEL
repairs are complete. If the airbag indicator fails to 3 - ORIENTATION ARROW
light, or lights and stays on, there is still an active 4 - CONNECTOR RECEPTACLE
supplemental restraint system fault or malfunction.
Refer to the appropriate diagnostic information to
diagnose the problem.

NOTE: If the Airbag Control Module (ACM) has been


replaced with a new unit, it will be necessary to ini-
tialize the new ACM. In order to function properly,
the ACM must be programmed for the correct stan-
dard and optional supplemental restraint system
components installed in the vehicle. To initialize the
ACM, a DRBIIIT scan tool is required. Refer to the
appropriate diagnostic information.

AIRBAG CONTROL MODULE


DESCRIPTION Fig. 7 ACM Bracket
The Airbag Control Module (ACM) is secured with 1 - ACM BRACKET
three screws to the top mounting surface of a 2 - SEAT RISER
stamped steel bracket that is welded onto the floor 3 - EYELET TERMINAL
4 - ACM CONNECTOR
panel within the seat riser underneath the driver 5 - FLOOR PANEL
side front seat in the passenger compartment of the
vehicle (Fig. 6). A molded plastic protective cover is sor, and an energy storage capacitor. A stamped
installed over the ACM and secured with integral metal cover plate is permanently secured to the bot-
snap features to a flat metal base plate sandwiched tom of the ACM housing to enclose and protect the
between the bottom of the ACM and the mounting internal electronic circuitry and components.
bracket on the floor panel (Fig. 7). This cover is An arrow printed on a label on the top of the ACM
designed to shield the ACM and its wire harness con- housing near the rear provides a visual verification
nection from other electrical components and wiring of the proper orientation of the unit, and should
located within the seat riser area beneath the driver always be pointed toward the front of the vehicle.
seat, and must always be reinstalled following ser- The ACM housing has integral mounting flanges on
vice removal. three corners. A molded plastic electrical connector
Concealed within a hollow in the center of the die receptacle containing numerous terminal pins is inte-
cast aluminum ACM housing is the electronic cir- gral to the left facing side of the ACM housing. These
cuitry of the ACM which includes a microprocessor, terminal pins connect the ACM to the vehicle electri-
an electronic impact sensor, an electronic safing sen-
VA RESTRAINTS 8O - 9
AIRBAG CONTROL MODULE (Continued)
cal system through a dedicated take out and connec- driver side seat riser. A case ground is also provided
tor of the vehicle wire harness. for the ACM through a ground circuit and eyelet ter-
The impact sensor internal to the ACM are cali- minal connector secured under the left rear ACM
brated for the specific vehicle, and are only serviced mounting screw. These connections allow the ACM to
as a unit with the ACM. In addition, the ACM must be operational whenever the ignition switch is in the
be electronically programmed for the correct stan- On position.
dard and optional supplemental restraint system The ACM also contains an energy-storage capaci-
components installed in the vehicle. The ACM cannot tor. When the ignition switch is in the On position,
be repaired or adjusted and, if damaged or faulty, it this capacitor is continually being charged with
must be replaced. enough electrical energy to deploy the supplemental
restraint components for up to one second following a
OPERATION battery disconnect or failure. The purpose of the
The microprocessor in the Airbag Control Module capacitor is to provide backup supplemental restraint
(ACM) contains the supplemental restraint system system protection in case there is a loss of battery
logic circuits and controls all of the supplemental current supply to the ACM during an impact.
restraint system components. The ACM uses Two sensors are contained within the ACM, an
On-Board Diagnostics (OBD) and can communicate electronic impact sensor and a safing sensor. These
with the DRBIIIt scan tool using a diagnostic Serial electronic sensors are accelerometers that sense the
Communication Interface (SCI) data bus line for sup- rate of vehicle deceleration, which provide verifica-
plemental restraint system programming or diagno- tion of the direction and severity of an impact. On
sis and testing through the 16-way Data Link models equipped with optional side curtain airbags,
Connector (DLC) located on the dash panel below the the ACM also monitors inputs from two remote side
driver side end of the instrument panel. A hard wired impact sensors located within the left and right front
output from the ACM is used for control of the airbag door step wells to control deployment of the side cur-
indicator in the ElectroMechanical Instrument Clus- tain airbag units.
ter (EMIC). (Refer to 8 - ELECTRICAL/INSTRU- The safing sensor is an electronic accelerometer
MENT CLUSTER/AIRBAG INDICATOR - sensor within the ACM that provides an additional
OPERATION). logic input to the ACM microprocessor. The safing
The ACM microprocessor continuously monitors all sensor is used to verify the need for a supplemental
of the supplemental restraint system electrical cir- restraint deployment by detecting impact energy of a
cuits to determine the system readiness. If the ACM lesser magnitude than that of the primary electronic
detects a monitored system fault, it sets an appropri- impact sensors, and must exceed a safing threshold
ate Diagnostic Trouble Code (DTC) and sends an out- in order for the airbags to deploy. Vehicles equipped
put to the EMIC to turn on the airbag indicator. The with optional side curtain airbags feature a second
ACM illuminates the indicator for about four seconds safing sensor within the ACM to provide confirma-
each time the ignition switch is turned to the On tion to the ACM microprocessor of side impact forces.
position as a bulb test. If the indicator remains illu- This second safing sensor is a bi-directional unit that
minated for about ten seconds after the ignition detects impact forces from either side of the vehicle.
switch is turned to the On position, the ACM has Pre-programmed decision algorithms in the ACM
detected a non-critical fault that poses no danger to microprocessor determine when the deceleration rate
the vehicle occupants. If the airbag indicator illumi- as signaled by the impact sensors and the safing sen-
nates solid (not flashing) while driving or stays on sors indicate an impact that is severe enough to
longer than ten seconds following the bulb test, the require supplemental restraint system protection.
ACM has detected a critical fault that may cause the When the programmed conditions are met, the ACM
airbags not to deploy when required or to deploy sends the proper electrical signals to deploy the front
when not required. An active fault only remains for airbags and seat belt tensioners and, if the vehicle is
the duration of the fault, or in some cases, for the so equipped, either side curtain airbag unit.
duration of the current ignition switch cycle, while a The ACM also provides a hard wired electrical
stored fault causes a DTC to be stored in memory by crash signal output following a supplemental
the ACM. restraint deployment event. This output is used to
The ACM receives battery current through a fused signal other electronic modules in the vehicle to pro-
ignition switch output circuit. The ACM receives vide their enhanced accident response features,
ground through a ground circuit and take out of the which include automatically disabling the engine
vehicle wire harness. This take out has an eyelet ter- from running and unlocking all of the doors. How-
minal connector secured by a nut to a ground stud on ever, these responses are each dependent upon the
the floor panel directly below the ACM within the circuits, components, and modules controlling these
8O - 10 RESTRAINTS VA
AIRBAG CONTROL MODULE (Continued)
features remaining intact from collateral damage
incurred during the vehicle impact.
A single ACM is used for all variations of the sup-
plemental restraint system available in this vehicle.
This ACM is programmable and in order to function
properly it must be programmed for the correct vehi-
cle supplemental restraint system equipment using
an initialization procedure. The initialization proce-
dure requires the use of a DRBIIIt scan tool. Refer to
the appropriate diagnostic information. The hard
wired inputs and outputs for the ACM may be diag-
nosed and tested using conventional diagnostic tools
and procedures. However, conventional diagnostic
methods will not prove conclusive in the diagnosis of
the ACM or the supplemental restraint system. The
most reliable, efficient, and accurate means to diag-
nose the ACM or the supplemental restraint system
requires the use of a DRBIIIt scan tool. Refer to the
appropriate diagnostic information.

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.

WARNING: To avoid personal injury or death, never


strike or drop the airbag control module as it can
damage the impact sensor or affect its calibration.
The airbag control module contains the impact sen-
sor, which enables the system to deploy the supple-
mental restraints. If an airbag control module is
accidentally dropped during service, the module
must be scrapped and replaced with a new unit. Fig. 9 Seat Riser Cover
Failure to observe this warning could result in acci- 1 - DRIVER SEAT BACK
dental, incomplete, or improper supplemental 2 - COVER PANEL
3 - SCREW (2)
restraint deployment. 4 - SEAT RISER

(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)

Fig. 12 Airbag Control Module Remove/Install


Fig. 10 Control Module Bracket
1 - ACM LABEL
1 - SEAT RISER 2 - ACM
2 - SCREW (2) 3 - SCREW (3)
3 - CONTROL MODULE BRACKET 4 - GROUND EYELET
5 - CONNECTOR
(7) Locate the Airbag Control Module (ACM) in the
right rear corner of the area within the driver side (10) Remove the ACM from within the driver side
seat riser. Firmly grasp and pull upward on the front seat riser.
molded plastic cover to unsnap it from over the ACM
(Fig. 11). 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, 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.

WARNING: To avoid personal injury or death, never


strike or drop the airbag control module as it can
Fig. 11 ACM Cover damage the impact sensor or affect its calibration.
1 - SEAT RISER The airbag control module contains the impact sen-
2 - COVER sor, which enables the system to deploy the supple-
3 - ACM
mental restraints. If an airbag control module is
(8) Remove the three screws that secure the ACM accidentally dropped during service, the module
to the bracket that is welded onto the floor panel must be scrapped and replaced with a new unit.
under the driver side front seat (Fig. 12). Failure to observe this warning could result in acci-
(9) Lift the ACM upward far enough to access the dental, incomplete, or improper supplemental
ACM wiring connection. Depress the release and lift restraint deployment.
the lever arm to disconnect the vehicle wire harness
(1) Reconnect and latch the vehicle wire harness
connector for the ACM from the ACM connector
connector for the ACM to the ACM connector recep-
receptacle located on the left facing side of the mod-
tacle located on the left facing side of the module
ule.
(Fig. 12).
8O - 12 RESTRAINTS VA
AIRBAG CONTROL MODULE (Continued)
(2) Carefully position the ACM cover base plate cation test procedure should be performed following
onto the mounting bracket that is welded onto the service of any supplemental restraint system compo-
floor panel under the driver side front seat (Fig. 13). nent. (Refer to 8 - ELECTRICAL/RESTRAINTS -
STANDARD PROCEDURE - VERIFICATION TEST).

NOTE: If the Airbag Control Module (ACM) has been


replaced with a new unit, it will be necessary to ini-
tialize the new ACM. In order to function properly,
the ACM must be programmed for the correct stan-
dard and optional supplemental restraint system
components installed in the vehicle. To initialize the
ACM, a DRBIIIT scan tool is required. Refer to the
appropriate diagnostic information.

CLOCKSPRING
DESCRIPTION
Fig. 13 ACM Cover Base Plate
1 - BASE PLATE
2 - SEAT RISER
3 - GROUND EYELET TERMINAL
4 - ACM CONNECTOR
5 - FLOOR PANEL

(3) Carefully position the ACM onto the ACM cover


base plate. When the ACM is correctly positioned, the
three ACM mounting tabs will be aligned with the
holes in the cover base plate and the mounting
bracket, and the orientation arrow on the ACM label
will be pointed forward in the vehicle.
(4) Install and tighten the three screws that secure
the ACM to the mounting bracket that is welded onto
the floor panel within the driver side front seat riser.
Be certain that the ground eyelet terminal is
installed under the screw for the left rear mounting Fig. 14 Clockspring
tab. Tighten the screws to 12 N·m (105 in. lbs.). 1 - PIGTAIL WIRE CONNECTOR (2)
2 - CASE
(5) Position the ACM cover over the ACM and 3 - CANCEL CAM
press it down firmly and evenly until it snaps into 4 - ROTOR
position over the ACM cover base plate (Fig. 11). 5 - SCREW (2)
6 - HORN SWITCH CONNECTOR (2)
(6) Position the control module bracket onto the 7 - AIRBAG CONNECTOR
top of the driver side seat riser (Fig. 10).
(7) Install and tighten the two screws that secure The clockspring assembly is secured with two
the control module bracket to the top of the seat riser screws onto the multi-function switch housing near
under the driver side front seat. Tighten the screws the top of the steering column directly below the
to 2 N·m (18 in. lbs.). steering wheel (Fig. 14). The clockspring consists of a
(8) Position the cover panel onto the top of the flat, round molded plastic case that contains a spool-
driver side seat riser (Fig. 9). like molded plastic rotor with a large exposed hub
(9) Install and tighten the two screws that secure covering the entire upper surface of the case. The
the cover panel to the top of the seat riser under the rotor hub has a large center hole that is internally
driver side front seat. Tighten the screws to 2 N·m ribbed to engage splines on the upper steering col-
(18 in. lbs.). umn shaft, and two small clearance holes that pro-
(10) Move the driver side front seat back to its vide access to the case mounting screws. The lower
driving position. side of the rotor hub also serves as an integral
(11) Do not reconnect the battery negative cable at molded plastic turn signal cancel cam.
this time. The supplemental restraint system verifi-
VA RESTRAINTS 8O - 13
CLOCKSPRING (Continued)
A single connector receptacle on the upper surface the horn switch located within the hub cavity of the
of the rotor has pigtail wires that connect to the horn steering wheel.
switch and the driver airbag on the steering wheel, Like the clockspring in a timepiece, the clockspring
while a single connector receptacle on the lower sur- tape has travel limits and can be damaged by being
face of the case has pigtail wires that connect the wound too tightly during full stop-to-stop steering
clockspring to the vehicle wire harness on the steer- wheel rotation. To prevent this from occurring, the
ing column. Within the plastic case and wound clockspring is centered when it is installed on the
around the rotor spool is a long ribbon-like tape that steering column. Centering the clockspring indexes
consists of several thin copper wire leads sandwiched the clockspring tape to the movable steering compo-
between two thin plastic membranes. The outer end nents so that the tape can operate within its
of the tape terminates at the connector receptacle designed travel limits. However, if the clockspring is
that faces the steering column, while the inner end of removed from the steering column or if the steering
the tape terminates at the connector receptacle on shaft is disconnected from the steering gear, the
the hub of the clockspring rotor that faces the steer- clockspring spool can change position relative to the
ing wheel. movable steering components. The clockspring must
Service replacement clocksprings are shipped pre- be re-centered following completion of this service or
centered and with the mounting screws backed out the tape may be damaged.
from the case far enough to engage the access holes Service replacement clocksprings are shipped pre-
in the upper surface of the rotor. The mounting centered and with the mounting screws backed out
screws secure the centered clockspring rotor to the from the case far enough to engage the access holes
clockspring case during shipment, but allow free in the upper surface of the rotor. The mounting
rotation of the rotor once the clockspring is properly screws secure the centered clockspring rotor to the
installed on the steering column. (Refer to 8 - ELEC- clockspring case during shipment, but allow free
TRICAL/RESTRAINTS/CLOCKSPRING - STAN- rotation of the rotor once the clockspring is properly
DARD PROCEDURE - CLOCKSPRING installed on the steering column. The clockspring
CENTERING). mounting screws should not be tightened into the
The clockspring cannot be repaired. If the clock- clockspring case until the clockspring has been
spring is faulty, damaged, or if the driver airbag has installed on the steering column. If the screws are
been deployed, the clockspring must be replaced. tightened into or removed from the case before the
clockspring is installed on a steering column, the
OPERATION clockspring centering procedure must be performed.
The clockspring is a mechanical electrical circuit (Refer to 8 - ELECTRICAL/RESTRAINTS/CLOCK-
component that is used to provide continuous electri- SPRING - STANDARD PROCEDURE - CLOCK-
cal continuity between the fixed vehicle wire harness SPRING CENTERING).
and the electrical components mounted on or in the
rotating steering wheel. On this model the rotating STANDARD PROCEDURE - CLOCKSPRING
electrical components include the driver airbag and CENTERING
the horn switch. The clockspring case is positioned The clockspring is designed to wind and unwind
and secured to the multi-function switch housing when the steering wheel is rotated, but is only
near the top of the steering column. The connector designed to rotate the same number of turns (about
receptacle on the underside of the fixed clockspring six to seven complete rotations) as the steering wheel
case connects the clockspring to the vehicle electrical can be turned from stop to stop. Centering the clock-
system through two take outs with connectors from spring indexes the clockspring tape to other steering
the vehicle wire harness. components so that it can operate within its designed
The clockspring rotor is movable and is keyed by travel limits. The rotor of a centered clockspring can
integral molded ribs on the inner circumference of be rotated three to three and one-half turns in either
the rotor hub to the splines on the external circum- direction from the centered position, without damag-
ference of the upper steering column shaft. The two ing the clockspring tape.
integral lobes of the turn signal cancel cam formation However, if the clockspring is removed for service
on the lower surface of the clockspring rotor hub con- or if the steering column is disconnected from the
tact the turn signal cancel actuator of the multi-func- steering gear, the clockspring tape can change posi-
tion switch to provide automatic turn signal tion relative to the other steering components. The
cancellation. The yellow sleeved pigtail wire on the clockspring must then be re-centered following com-
upper surface of the clockspring rotor connects the pletion of such service or the clockspring tape may be
clockspring to the driver airbag, while two single pig- damaged. Service replacement clocksprings are
tail wires connect to the feed and ground terminals of shipped pre-centered and with the mounting screws
8O - 14 RESTRAINTS VA
CLOCKSPRING (Continued)
backed out from the case far enough to engage the (4) Rotate the clockspring rotor counterclockwise
access holes in the upper surface of the rotor (Fig. to the end of its travel. Do not apply excessive
15). The clockspring mounting screws should not be torque.
tightened into the clockspring case until the clock- (5) From the end of the counterclockwise travel,
spring has been installed on the steering column. If rotate the rotor about three to three and one-half
the screws are tightened into or removed from the turns clockwise, until the clearance holes in the
case before the clockspring is installed on a steering clockspring rotor are aligned with the two mounting
column, the clockspring centering procedure must be screws in the clockspring case. The clockspring is
performed. now centered.
(6) Loosen the two clockspring mounting screws
WARNING: To avoid personal injury or death, on far enough so that they extend into the clearance
vehicles equipped with airbags, disable the supple- holes in the upper surface of the clockspring rotor,
mental restraint system before attempting any preventing the rotor from changing position relative
steering wheel, steering column, airbag, seat belt to the clockspring case.
tensioner, impact sensor, or instrument panel com- (7) The front wheels should still be in the straight-
ponent diagnosis or service. Disconnect and isolate ahead position. Reinstall the clockspring onto the
the battery negative (ground) cable, then wait two steering column. (Refer to 8 - ELECTRICAL/RE-
minutes for the system capacitor to discharge STRAINTS/CLOCKSPRING - INSTALLATION).
before performing further diagnosis or service. This
is the only sure way to disable the supplemental REMOVAL
restraint system. Failure to take the proper precau- The clockspring cannot be repaired. It must be
tions could result in accidental airbag deployment. replaced if faulty or damaged, or if the driver airbag
has been deployed.

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, 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.

NOTE: Before starting this procedure, be certain to


Fig. 15 Clockspring Centering turn the steering wheel until the front wheels are in
1 - CLOCKSPRING ROTOR the straight-ahead position.
2 - SCREW (2)
3 - HORN SWITCH CONNECTOR (2)
4 - AIRBAG CONNECTOR (1) Place the front wheels in the straight ahead
position.
(2) Remove the driver airbag from the steering
NOTE: Before starting this procedure, be certain to wheel. (Refer to 8 - ELECTRICAL/RESTRAINTS/
turn the steering wheel until the front wheels are in DRIVER AIRBAG - REMOVAL).
the straight-ahead position. (3) Disconnect the clockspring upper pigtail wire
connectors from the terminals of the horn switch
(1) Place the front wheels in the straight-ahead located in the hub cavity of the steering wheel.
position. (4) Remove the steering wheel from the steering
(2) Remove the clockspring from the steering col- column. (Refer to 19 - STEERING/COLUMN/STEER-
umn. (Refer to 8 - ELECTRICAL/RESTRAINTS/ ING WHEEL - REMOVAL).
CLOCKSPRING - REMOVAL). (5) Remove the steering column opening cover
(3) Tighten the two clockspring mounting screws from the instrument panel. (Refer to 23 - BODY/IN-
all the way into the clockspring case. STRUMENT PANEL/STEERING COLUMN OPEN-
ING COVER - REMOVAL).
VA RESTRAINTS 8O - 15
CLOCKSPRING (Continued)
(6) Disconnect the two clockspring lower pigtail backed out from the case far enough to engage the
connectors from the vehicle wire harness connectors access holes in the upper surface of the rotor. The
located between the steering column and the back of clockspring mounting screws should not be tightened
the fuse block underneath the steering column (Fig. into the clockspring case until the clockspring has
16). been installed on the steering column. If the screws
are tightened into or removed from the case before
the clockspring is installed on a steering column, the
clockspring centering procedure must be performed.

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, 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.
Fig. 16 Clockspring Remove/Install
1 - CLOCKSPRING NOTE: Before starting this procedure, be certain
2 - SHROUD that the front wheels are still in the straight-ahead
3 - LOWER PIGTAIL CONNECTOR (2)
position.
(7) Loosen the two screws that secure the clock-
(1) Carefully slide the centered clockspring down
spring to the multi-function switch housing far
over the steering column upper shaft until the screws
enough to engage the clearance holes in the clock-
in the clockspring case are aligned with the mount-
spring rotor and to disengage the clockspring case
ing holes on the multi-function switch housing.
from the switch housing.
(2) Tighten the two screws that secure the clock-
(8) Remove the clockspring from the multi-function
spring to the multi-function switch mounting hous-
switch housing. The clockspring cannot be repaired.
ing. Tighten the screws to 2 N·m (18 in. lbs.).
It must be replaced if faulty or damaged, or if the
(3) Reconnect the two clockspring lower pigtail
driver airbag has been deployed.
connectors to the vehicle wire harness connectors
(9) If the removed clockspring is to be reused, be
located between the steering column and the back of
certain that the clockspring rotor is secured to the
the fuse block underneath the steering column (Fig.
clockspring case to maintain clockspring centering
16).
until it is reinstalled on the steering column. If clock-
(4) Route the clockspring lower pigtail wires
spring centering is not maintained, the clockspring
around the lug on the bottom of the multi-function
must be centered again before it is reinstalled. (Refer
switch housing and behind the fuse block underneath
to 8 - ELECTRICAL/RESTRAINTS/CLOCKSPRING -
the steering column (Fig. 17).
STANDARD PROCEDURE - CLOCKSPRING CEN-
(5) Reinstall the steering column opening cover
TERING).
onto the instrument panel. (Refer to 23 - BODY/IN-
STRUMENT PANEL/STEERING COLUMN OPEN-
INSTALLATION ING COVER - INSTALLATION).
The clockspring cannot be repaired. It must be (6) Reinstall the steering wheel onto the steering
replaced if faulty or damaged, or if the driver airbag column. (Refer to 19 - STEERING/COLUMN/STEER-
has been deployed. ING WHEEL - INSTALLATION).
If the clockspring is not properly centered in rela- (7) Reconnect the clockspring upper pigtail wire
tion to the steering wheel, steering shaft and steer- connectors to the terminals of the horn switch
ing gear, it may be damaged. (Refer to 8 - located in the hub cavity of the steering wheel.
ELECTRICAL/RESTRAINTS/CLOCKSPRING - (8) Reinstall the driver airbag onto the steering
STANDARD PROCEDURE - CLOCKSPRING CEN- wheel. (Refer to 8 - ELECTRICAL/RESTRAINTS/
TERING). Service replacement clocksprings are DRIVER AIRBAG - INSTALLATION).
shipped pre-centered and with the mounting screws
8O - 16 RESTRAINTS VA
CLOCKSPRING (Continued)
tor, and the retainers that secure the inflator to the
airbag housing (Fig. 19). The airbag cushion, hous-
ing, and inflator are secured within an integral
receptacle molded into the back of the trim cover.

Fig. 17 Clockspring Pigtail Routing


1 - MULTI-FUNCTION SWITCH
2 - FUSE BLOCK
3 - CLOCKSPRING LOWER PIGTAILS (2)

Fig. 19 Driver Airbag Housing


DRIVER AIRBAG
1 - HOUSING
2 - INFLATOR
DESCRIPTION 3 - CONNECTOR RECEPTACLE
4 - TRIM COVER

The airbag used in this model is a Next Genera-


tion-type that complies with revised federal airbag
standards to deploy with less force than those used
in some prior models. A radial deploying fabric cush-
ion with internal tethers is used. The airbag inflator
is a solid fuel, pyrotechnic-type unit with four studs
and is secured by four hex nuts to four studs on the
airbag cushion retainer ring to the back of the
stamped metal airbag housing. A keyed connector
receptacle on the driver airbag inflator connects the
inflator initiator to the vehicle electrical system
through a yellow-jacketed, two-wire pigtail harness of
the clockspring.
The driver airbag and trim cover unit cannot be
repaired, and must be replaced if deployed, faulty, or
in any way damaged.

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).

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, 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.
Fig. 20 Driver Airbag Operation
1 - TRIM COVER
2 - INFLATOR WARNING: To avoid personal injury or death, when
3 - INITIATOR removing a deployed airbag, rubber gloves, eye
4 - CUSHION (FOLDED) protection, and a long-sleeved shirt should be
5 - STEERING WHEEL
worn. There may be deposits on the airbag cushion
ion inflates, the driver airbag trim cover will split at and other interior surfaces. In large doses, these
predetermined breakout lines, then fold back out of deposits may cause irritation to the skin and eyes.
the way. Following an airbag deployment, the airbag
(1) Disconnect and isolate the battery negative
cushion quickly deflates by venting the inert gas
cable. Wait two minutes for the system capacitor to
towards the instrument panel through filtered vents
discharge before further service.
within the fabric used to construct the back (steering
(2) From the underside of the steering wheel,
wheel side) panel of the airbag cushion.
remove the two screws that secure the driver airbag
Some of the chemicals used to create the inert gas
to the horn switch armature within the hub cavity of
may be considered hazardous while in their solid
the steering wheel (Fig. 21).
state before they are burned, but they are securely
(3) Pull the driver airbag away from the steering
sealed within the airbag inflator. Typically, all poten-
wheel far enough to access the electrical connection
tially hazardous chemicals are burned during an air-
at the back of the airbag housing.
bag deployment event. The inert gas that is produced
when the chemicals are burned is harmless. How- CAUTION: Do not pull on the clockspring pigtail
ever, a small amount of residue from the burned wires to disengage the connector from the driver
chemicals may cause some temporary discomfort if it airbag inflator connector receptacle. Improper
contacts the skin, eyes, or breathing passages. If skin removal of these pigtail wires and their connector
or eye irritation is noted, rinse the affected area with insulator can result in damage to the airbag circuits
plenty of cool, clean water. If breathing passages are or the connector insulator.
irritated, move to another area where there is plenty
of clean, fresh air to breath. If the irritation is not
alleviated by these actions, contact a physician.
8O - 18 RESTRAINTS VA
DRIVER AIRBAG (Continued)

Fig. 21 Driver Airbag Remove/Install


1 - AIRBAG CONNECTOR 3 - SCREW (2)
2 - DRIVER AIRBAG 4 - STEERING WHEEL

(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).

Fig. 24 Front Seat Belt Turning Loop


1 - HEIGHT ADJUSTER
2 - NUT
3 - FRONT SEAT BELT
Fig. 23 Turning Loop Height Adjuster
1 - HEIGHT ADJUSTER TRIM
2 - LUG
3 - HEIGHT ADJUSTER
4 - DRIVER

(8) Pull the front seat belt and lower anchor


through the back of the height adjuster trim.
(9) Remove the nut that secures the front seat belt
turning loop to the height adjuster (Fig. 24).
(10) Remove the front seat belt turning loop from
the height adjuster.

CAUTION: Do not pull on the wires to disengage


the connector from the seat belt tensioner initiator
connector receptacle. Improper removal of the con-
nector insulator can result in damage to the seat
belt tensioner circuits or the connector insulator.

(11) If so equipped, disconnect the vehicle wire


harness connector for the seat belt tensioner from the
initiator receptacle of the retractor located on the
lower inner B-pillar (Fig. 25). The connector is a
tight snap-fit into the initiator receptacle. Firmly
grasp and pull or gently pry on the connector insula- Fig. 25 Front Seat Belt Retractor
tor and pull the connector straight out from the ini-
1 - RETRACTOR
tiator to disconnect it from the receptacle. 2 - CONNECTOR
(12) Remove the screw that secures the front seat 3 - SCREW
belt retractor to the lower inner B-pillar. 4 - GUIDE
(13) Remove the front seat belt and retractor unit
from the B-pillar.
VA RESTRAINTS 8O - 21
FRONT SEAT BELT & RETRACTOR (Continued)

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.

Fig. 26 Front Seat Belt Buckle Remove/Install PASSENGER AIRBAG


1 - SEAT RISER COVER PANEL
2 - SEAT BELT SWITCH PIGTAIL WIRE (DRIVER SIDE ONLY) DESCRIPTION
3 - BUCKLE
4 - SCREW AND/OR COVER The rearward facing surface of the injection
molded, thermoplastic passenger airbag door is the
(3) On the driver side only, pull the seat belt most visible part of the optional passenger airbag
switch pigtail wire out through the clearance hole in (Fig. 27). The passenger airbag door is located above
the seat riser cover far enough to access and discon- the glove box opening in front of the front seat pas-
nect the pigtail wire from the vehicle wire harness. senger seating position on the instrument panel. The
(4) If the vehicle is so equipped, unsnap and upper and lower edges of the airbag door are secured
remove the plastic cover from the screw that secures by a snap-fit to molded plastic clips. The two clips at
the front seat belt buckle lower anchor to the inboard the top are each secured by a screw to the instru-
side of the seat frame. ment panel base trim, while the clips at the bottom
are integral to the panel that surrounds the passen-
ger airbag door opening in the instrument panel base
VA RESTRAINTS 8O - 23
PASSENGER AIRBAG (Continued)

Fig. 27 Passenger Airbag Door Fig. 28 Passenger Airbag Unit


1 - INSTRUMENT PANEL TRAY 1 - DOOR
2 - PASSENGER AIRBAG DOOR 2 - CLIP (2)
3 - GLOVE BOX DOOR 3 - HOUSING
4 - CONNECTOR RECEPTACLE
5 - END PLATE (2)
trim. The airbag door is also secured to the airbag
housing by two wide woven straps that serve as
the initiator in the airbag inflator. When the ACM
hinges for the door upon an airbag deployment.
sends the proper electrical signal to the initiator the
Located behind the passenger airbag door is the
electrical energy generates enough heat to initiate a
passenger airbag unit (Fig. 28). The airbag housing
small pyrotechnic charge which, in turn, ignites
is constructed of a long U-shaped aluminum extru-
chemical pellets within the inflator. Once ignited,
sion with two stamped steel end plates. A stepped
these chemical pellets burn rapidly and produce a
flange that extends from the back of the extrusion
large quantity of inert gas. The inflator is sealed to
serves as the airbag mounting flange. This mounting
the back of the airbag housing and a diffuser in the
flange is secured with screws to a stamped steel air-
inflator directs all of the inert gas into the airbag
bag mounting bracket that is secured with screws to
cushion, causing the cushion to inflate.
the tubular steel instrument panel structural support
As the airbag cushion inflates, the passenger air-
above the glove box opening. The end plates are
bag door will unsnap from the clips that retain it to
secured to each side of the passenger airbag housing
the instrument panel at the top and bottom, then
with screws.
pivot towards the top of the instrument panel and
The passenger airbag unit used in this model is a
out of the way on the woven straps. Following a pas-
Next Generation-type that complies with revised fed-
senger airbag deployment, the airbag cushion quickly
eral airbag standards to deploy with less force than
deflates by venting the inert gas through the loose
those used in some prior models. The airbag housing
weave of the fabric used to construct the back
contains the folded airbag cushion, the airbag
(instrument panel side) of the airbag cushion.
retainer, and the airbag inflator. The airbag is a rect-
Some of the chemicals used to create the inert gas
angular fabric cushion. The airbag inflator is a solid
may be considered hazardous while in their solid
fuel, pyrotechnic-type unit that is secured to and
state before they are burned, but they are securely
sealed within the airbag housing along with the
sealed within the airbag inflator. However, the gas
folded airbag cushion. The inflator initiator connector
that is produced when the chemicals are burned is
receptacle is connected to the vehicle electrical sys-
harmless. A small amount of residue from the burned
tem through a dedicated take out of the vehicle wire
chemicals may cause some temporary discomfort if it
harness with a yellow connector insulator.
contacts the skin, eyes, or breathing passages. If skin
The passenger airbag and airbag door unit cannot
or eye irritation is noticed, rinse the affected area
be repaired, and must be replaced if deployed, faulty
with plenty of cool, clean water. If breathing pas-
or in any way damaged.
sages are irritated, move to another area where there
is plenty of clean, fresh air to breath. If the irritation
OPERATION is not alleviated by these actions, contact a physician
The passenger airbag is deployed by an electrical immediately.
signal generated by the Airbag Control Module
(ACM) through the passenger airbag squib circuits to
8O - 24 RESTRAINTS VA
PASSENGER AIRBAG (Continued)

REMOVAL CAUTION: Do not pull on the wires to disengage


The following procedure is for replacement of a the connector from the passenger airbag inflator
faulty or damaged passenger airbag. If the airbag is connector receptacle. Improper removal of the con-
faulty or damaged, but not deployed, review the rec- nector insulator can result in damage to the airbag
ommended procedures for handling non-deployed circuits or the connector insulator.
supplemental restraints. (Refer to 8 - ELECTRICAL/
RESTRAINTS - STANDARD PROCEDURE - HAN- (6) The vehicle wire harness connector is a tight
DLING NON-DEPLOYED SUPPLEMENTAL snap-fit into the airbag inflator connector receptacle,
RESTRAINTS). If the passenger airbag has been which is located on the right end of the passenger
deployed, review the recommended procedures for airbag housing. Firmly grasp and pull or gently pry
service after a supplemental restraint deployment on the connector insulator and pull the connector
before removing the airbag from the vehicle. (Refer to straight out from the inflator to disconnect it from
8 - ELECTRICAL/RESTRAINTS - STANDARD PRO- the receptacle.
CEDURE - SERVICE AFTER A SUPPLEMENTAL (7) Remove the passenger airbag and airbag door
RESTRAINT DEPLOYMENT). from the instrument panel as a unit.

WARNING: To avoid personal injury or death, on INSTALLATION


vehicles equipped with airbags, disable the supple- The following procedure is for replacement of a
mental restraint system before attempting any faulty or damaged passenger airbag. If the airbag is
steering wheel, steering column, airbag, seat belt faulty or damaged, but not deployed, review the rec-
tensioner, impact sensor, or instrument panel com- ommended procedures for handling non-deployed
ponent diagnosis or service. Disconnect and isolate supplemental restraints. (Refer to 8 - ELECTRICAL/
the battery negative (ground) cable, then wait two RESTRAINTS - STANDARD PROCEDURE - HAN-
minutes for the system capacitor to discharge DLING NON-DEPLOYED SUPPLEMENTAL
before performing further diagnosis or service. This RESTRAINTS). If the passenger airbag has been
is the only sure way to disable the supplemental deployed, review the recommended procedures for
restraint system. Failure to take the proper precau- service after a supplemental restraint deployment
tions could result in accidental airbag deployment. before removing the airbag from the vehicle. (Refer to
8 - ELECTRICAL/RESTRAINTS - STANDARD PRO-
CEDURE - SERVICE AFTER A SUPPLEMENTAL
WARNING: To avoid personal injury or death, when RESTRAINT DEPLOYMENT).
removing a deployed airbag, rubber gloves, eye
protection, and a long-sleeved shirt should be WARNING: To avoid personal injury or death, on
worn. There may be deposits on the airbag unit and vehicles equipped with airbags, disable the supple-
other interior surfaces. In large doses, these depos- mental restraint system before attempting any
its may cause irritation to the skin and eyes. steering wheel, steering column, airbag, seat belt
tensioner, impact sensor, or instrument panel com-
(1) Disconnect and isolate the battery negative ponent diagnosis or service. Disconnect and isolate
cable. Wait two minutes for the system capacitor to the battery negative (ground) cable, then wait two
discharge before further service. minutes for the system capacitor to discharge
(2) Remove the instrument panel top cover tray before performing further diagnosis or service. This
from over the passenger airbag (Fig. 29). (Refer to 23 is the only sure way to disable the supplemental
- BODY/INSTRUMENT PANEL/INSTRUMENT restraint system. Failure to take the proper precau-
PANEL TOP COVER - TRAY - REMOVAL). tions could result in accidental airbag deployment.
(3) Remove the two screws that secure the passen-
ger airbag door upper clips to the instrument panel
base trim. WARNING: To avoid personal injury or death, use
(4) Remove the three screws that secure the flange extreme care to prevent any foreign material from
of the passenger airbag housing to the bracket on the entering the passenger airbag, or becoming
instrument panel structural support. entrapped between the passenger airbag cushion
(5) Pull the passenger airbag unit rearward to dis- and the passenger airbag door. Failure to observe
engage the airbag door from the lower clips and far this warning could result in occupant injuries upon
enough to access the electrical connection on the airbag deployment.
right end of the unit.
VA RESTRAINTS 8O - 25
PASSENGER AIRBAG (Continued)

Fig. 29 Passenger Airbag Remove/Install


1 - TRAY 5 - CONNECTOR
2 - SCREW (2) 6 - PASSENGER AIRBAG
3 - UPPER CLIP (2) 7 - SCREW (3)
4 - LOWER CLIP (2)

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).

Fig. 32 Rear Seat Belt Turning Loop


1 - TURNING LOOP (2) Fig. 34 Right Outboard or Center Rear Seat Belt
2 - PUSH NUT Lower Anchor
3 - BRACKET
4 - PIN 1 - REAR SEAT CUSHION FRAME
5 - REAR SEAT BACK 2 - SCREW
6 - SEAT BELT 3 - REAR SEAT BELT LOWER ANCHOR

(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 REAR SEAT BELT BUCKLE


WARNING: To avoid personal injury or death, during
and following any seat belt service, carefully REMOVAL
inspect all seat belts, buckles, mounting hardware,
retractors, and anchors for proper installation, oper- REMOVAL - INBOARD
ation, or damage. Replace any belt that is cut,
frayed, or torn. Straighten any belt that is twisted. WARNING: To avoid personal injury or death, during
Tighten any loose fasteners. Replace any belt that and following any seat belt service, carefully
has a damaged or inoperative buckle or retractor. inspect all seat belts, buckles, mounting hardware,
Replace any belt that has a bent or damaged latch retractors, and anchors for proper installation, oper-
plate or anchor plate. Never attempt to repair a seat ation, or damage. Replace any belt that is cut,
belt component. Always replace damaged or faulty frayed, or torn. Straighten any belt that is twisted.
seat belt components with the correct, new and Tighten any loose fasteners. Replace any belt that
unused replacement parts listed in the has a damaged or inoperative buckle or retractor.
DaimlerChrysler Mopar Parts Catalog. Replace any belt that has a bent or damaged latch
plate or anchor plate. Never attempt to repair a seat
(1) Position the rear seat belt and retractor unit belt component. Always replace damaged or faulty
onto the bracket of the rear seat cushion frame (Fig. seat belt components with the correct, new and
35). Be certain to engage the guide on the retractor unused replacement parts listed in the
into the locating notch on the bracket. DaimlerChrysler Mopar Parts Catalog.
(2) Install and tighten the screw that secures the
rear seat belt retractor to the bracket on the rear (1) Remove the rear bench seat containing the
seat cushion frame. Tighten the screw to 35 N·m (26 inboard rear seat belt buckle unit to be serviced from
ft. lbs.). the vehicle.
(3) Route the rear seat belt and lower anchor (2) Remove the plastic shield from the back of the
through the turning loop bracket and the turning rear seat. (Refer to 23 - BODY/SEATS/REAR SEAT
loop trim cover. BACK SHIELD - REMOVAL).
(4) Position the rear seat belt lower anchor to the
rear seat cushion frame (Fig. 33) or (Fig. 34).
VA RESTRAINTS 8O - 29
REAR SEAT BELT BUCKLE (Continued)
(3) Remove the screw that secures either the
inboard rear seat belt buckle to the rear seat cushion
frame (Fig. 36).

Fig. 37 Outboard Rear Seat Belt Buckle


1 - REAR SEAT BACK TRIM
2 - REAR SEAT BELT BUCKLE
3 - REAR SEAT CUSHION TRIM
Fig. 36 Inboard Rear Seat Belt Buckle 4 - SCREW & COVER
1 - REAR SEAT CUSHION FRAME
2 - INBOARD REAR SEAT BELT LOWER ANCHOR INSTALLATION
3 - SCREW
4 - INBOARD REAR SEAT BELT BUCKLE
INSTALLATION - INBOARD
(4) Remove the inboard rear seat belt buckle from
the rear seat cushion frame. WARNING: To avoid personal injury or death, during
and following any seat belt service, carefully
REMOVAL - OUTBOARD inspect all seat belts, buckles, mounting hardware,
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
seat belt components with the correct, new and (1) Position the inboard rear seat belt buckle to
unused replacement parts listed in the the rear seat cushion frame (Fig. 36).
DaimlerChrysler Mopar Parts Catalog. (2) Install and tighten the screw that secures
either the inboard rear seat belt buckle to the rear
(1) Unsnap and remove the plastic cover from the seat cushion frame. Tighten the screw to 35 N·m (26
screw that secures the outboard rear seat belt buckle ft. lbs.).
to the right side of the seat cushion frame (Fig. 37). (3) Reinstall the plastic shield onto the back of the
(2) Remove the screw that secures the outboard rear seat. (Refer to 23 - BODY/SEATS/REAR SEAT
rear seat belt buckle to the rear seat cushion frame. BACK SHIELD - INSTALLATION).
(3) Remove the outboard rear seat belt buckle from (4) Reinstall the rear bench seat into the vehicle.
the right side of the rear seat cushion frame.
8O - 30 RESTRAINTS VA
REAR SEAT BELT BUCKLE (Continued)

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.

SEAT BELT SWITCH


DESCRIPTION
The seat belt switch is a small, normally closed,
single pole, single throw, leaf contact, momentary
switch. Only one seat belt switch is installed in the
vehicle, and it is integral to the driver side front seat
belt buckle unit. The seat belt switch is connected to
the vehicle electrical system through a two-wire pig-
tail wire harness and connector to a dedicated take
out and connector of the vehicle wire harness located
within the driver side front seat riser.
The seat belt switch cannot be adjusted or repaired
Fig. 38 Seat Belt Tensioner
and, if faulty or damaged, the entire driver side seat
1 - TURNING LOOP
belt buckle unit must be replaced. 2 - LATCH PLATE
3 - LOWER ANCHOR
OPERATION 4 - RETRACTOR
5 - TENSIONER
The seat belt switch is designed to control a path
to ground for the seat belt switch sense input of the Front seating position seat belt tensioners supple-
Electro-Mechanical Instrument Cluster (EMIC). The ment the standard driver and optional passenger air-
seat belt switch contact is actuated by the seat belt bags for all versions of this model. When equipped,
latch plate being inserted in to the buckle. When the the seat belt tensioner is integral to the front seat
seat belt latch plate is inserted into the buckle far belt and retractor units, which are secured to the
enough to be engaged by the seat belt buckle latch, inner B-pillars of the vehicle (Fig. 38). Each retractor
the switch leaf contact opens the seat belt switch is concealed beneath the molded plastic B-pillar trim.
sense circuit ground path; and, when the seat belt The seat belt tensioner consists primarily of a tubu-
latch plate is released and extracted from the seat lar steel housing, a piston, a cable, a torsion bar, and
a small pyrotechnically activated gas generator. All of
VA RESTRAINTS 8O - 31
SEAT BELT TENSIONER (Continued)
these components are located on one side of the
retractor spool on the outside of the retractor housing
except for the torsion bar, which serves as the spin-
dle upon which the retractor spool rotates. The seat
belt tensioner is controlled by the Airbag Control
Module (ACM) and is connected to the vehicle elec-
trical system through a dedicated take out of the
vehicle wire harness by a keyed, snap-fit molded
plastic connector insulator to ensure a secure connec-
tion.
The seat belt tensioner cannot be repaired and, if
faulty or damaged, the entire front seat belt and
retractor unit must be replaced. If the front airbags
have been deployed, the seat belt tensioners have
also been deployed. The seat belt tensioner is not
intended for reuse and must be replaced following a
deployment. A growling or grinding sound while
attempting to operate the seat belt retractor is a sure
indication that the seat belt tensioner has been
deployed and requires replacement. (Refer to 8 -
ELECTRICAL/RESTRAINTS/FRONT SEAT BELT &
RETRACTOR - REMOVAL).

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

SEAT BELT TURNING LOOP


ADJUSTER
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.

WARNING: To avoid personal injury or death, during


and following any seat belt service, carefully
inspect all seat belts, buckles, mounting hardware,
retractors, and anchors for proper installation, oper- Fig. 40 Turning Loop Height Adjuster
ation, or damage. Replace any belt that is cut, 1 - HEIGHT ADJUSTER TRIM
2 - LUG
frayed, or torn. Straighten any belt that is twisted. 3 - HEIGHT ADJUSTER
Tighten any loose fasteners. Replace any belt that 4 - DRIVER
has a damaged or inoperative buckle or retractor.
Replace any belt that has a bent or damaged latch
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.

(1) Move the front seat to its most forward position


for easiest access to the B-pillar trim.
(2) Disconnect and isolate the battery negative
cable. Wait two minutes for the system capacitor to
discharge before further service.
(3) Remove the trim panel from the inside of the
B-pillar. (Refer to 23 - BODY/INTERIOR/B-PILLAR
TRIM - REMOVAL).
(4) Pull the height adjuster trim away from the
upper B-pillar to disengage the driver from the lug of
the height adjuster (Fig. 40).
(5) Remove the nut that secures the front seat belt
turning loop to the height adjuster (Fig. 41).
(6) Remove the front seat belt turning loop from
the height adjuster.
(7) Remove the two screws that secure the seat Fig. 41 Front Seat Belt Turning Loop
belt turning loop height adjuster to the upper inner 1 - HEIGHT ADJUSTER
B-pillar (Fig. 42). 2 - NUT
(8) Remove the seat belt turning loop height 3 - FRONT SEAT BELT
adjuster from the inner B-pillar.
VA RESTRAINTS 8O - 33
SEAT BELT TURNING LOOP ADJUSTER (Continued)
unused replacement parts listed in the
DaimlerChrysler Mopar Parts Catalog.
(1) Position the seat belt turning loop height
adjuster onto the inner B-pillar (Fig. 42).
(2) Install and tighten the two screws that secure
the seat belt turning loop height adjuster to the
upper inner B-pillar. Tighten the screws to 35 N·m
(26 ft. lbs.).
(3) Position the front seat belt turning loop onto
the height adjuster on the upper B-pillar (Fig. 41).
(4) Install and tighten the nut that secures the
front seat belt turning loop to the height adjuster.
Tighten the nut to 35 N·m (26 ft. lbs.).
(5) Position the height adjuster trim to the upper
B-pillar so that the driver on the back of the trim
engages the lug of the height adjuster (Fig. 40).
(6) Reinstall the trim panel onto the inside of the
B-pillar. (Refer to 23 - BODY/INTERIOR/B-PILLAR
TRIM - INSTALLATION).
(7) Reconnect the battery negative cable.

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.

WARNING: To avoid personal injury or death, during


and following any seat belt service, carefully Fig. 43 Side Curtain Airbag
inspect all seat belts, buckles, mounting hardware, 1 - GRAB HANDLE
retractors, and anchors for proper installation, oper- 2 - B-PILLAR TRIM
3 - SIDE CURTAIN AIRBAG
ation, or damage. Replace any belt that is cut,
frayed, or torn. Straighten any belt that is twisted.
Optional side curtain airbags are available for this
Tighten any loose fasteners. Replace any belt that
model when it is also equipped with dual front air-
has a damaged or inoperative buckle or retractor.
bags. These airbags are passive, inflatable, Supple-
Replace any belt that has a bent or damaged latch
mental Restraint System (SRS) components (Fig. 43).
plate or anchor plate. Never attempt to repair a seat
This system is designed to reduce injuries to the
belt component. Always replace damaged or faulty
vehicle occupants in the event of a side impact colli-
seat belt components with the correct, new and
sion.
8O - 34 RESTRAINTS VA
SIDE CURTAIN AIRBAG (Continued)
Vehicles equipped with side curtain airbags have cushion fabric, and the deflated cushion hangs down
two individually controlled curtain airbag units. loosely from the roof rail.
These airbag units are concealed and mounted above
the front door openings where they are each secured REMOVAL
to one of the roof side rails. Each folded airbag cush- The following procedure is for replacement of a
ion is contained within a channel in the molded plas- faulty or damaged side curtain airbag. If the airbag
tic garnish molding that extends along the roof rail is faulty or damaged, but not deployed, review the
from the A-pillar at the front of the vehicle to just recommended procedures for handling non-deployed
behind the B-pillar. A tether extends down the A-pil- supplemental restraints. (Refer to 8 - ELECTRICAL/
lar from the front of the airbag cushion, where it is RESTRAINTS - STANDARD PROCEDURE - HAN-
secured to the base of the pillar near the belt line DLING NON-DEPLOYED SUPPLEMENTAL
with a screw. RESTRAINTS). If the side curtain airbag has been
The hybrid-type inflator for each airbag is con- deployed, review the recommended procedures for
nected to the airbag cushion by a tubular manifold. service after a supplemental restraint deployment
The inflator bracket and the airbag cushion channel before removing the airbag from the vehicle. (Refer to
are located with a stamped metal lug to a bore in the 8 - ELECTRICAL/RESTRAINTS - STANDARD PRO-
roof rail, then secured with screws at the A-pillar in CEDURE - SERVICE AFTER A SUPPLEMENTAL
the front and the B-pillar in the rear. A two-wire pig- RESTRAINT DEPLOYMENT).
tail wire is routed from the airbag inflator down the
B-pillar where it connects the unit to a take out of WARNING: To avoid personal injury or death, on
the vehicle body wire harness with a keyed and vehicles equipped with airbags, disable the supple-
latched connector insulator. mental restraint system before attempting any
The side curtain airbag unit cannot be adjusted or steering wheel, steering column, airbag, seat belt
repaired and must be replaced if deployed, faulty, or tensioner, impact sensor, or instrument panel com-
in any way damaged. Once a side curtain airbag has ponent diagnosis or service. Disconnect and isolate
been deployed, the complete airbag unit and all other the battery negative (ground) cable, then wait two
visibly damaged components must be replaced. minutes for the system capacitor to discharge
before performing further diagnosis or service. This
OPERATION is the only sure way to disable the supplemental
Each side curtain airbag is deployed individually restraint system. Failure to take the proper precau-
by an electrical signal generated by the Airbag Con- tions could result in accidental airbag deployment.
trol Module (ACM) to which it is connected through
left or right curtain airbag line 1 and line 2 (or
WARNING: To avoid personal injury or death, when
squib) circuits. The hybrid-type inflator assembly for
removing a deployed airbag, rubber gloves, eye
each airbag contains a small canister of highly com-
protection, and a long-sleeved shirt should be
pressed inert gas. When the ACM sends the proper
worn. There may be deposits on the airbag unit and
electrical signal to the airbag inflator, the electrical
other interior surfaces. In large doses, these depos-
energy creates enough heat to ignite chemical pellets
its may cause irritation to the skin and eyes.
within the inflator. Once ignited, these chemicals
burn rapidly and produce the pressure necessary to
rupture a containment disk in the inert gas canister. WARNING: To avoid personal injury or death, use
The inflator and inert gas canister are sealed and extreme care to prevent any foreign material from
connected to a tubular manifold so that all of the entering the side curtain airbag, or becoming
released gas is directed into the folded side curtain entrapped between the side curtain airbag cushion
airbag cushion, causing the cushion to inflate. and the roof rail garnish molding. Failure to
As the airbag cushion inflates it will split the gar- observe this warning could result in occupant inju-
nish molding at a pre-determined breakout line and ries upon airbag deployment.
drop down from the roof rail along the side glass and
body pillars to form a curtain-like cushion to protect (1) Disconnect and isolate the battery negative
the vehicle occupants during a side impact collision. cable. Wait two minutes for the system capacitor to
The front tether keeps the front portion of the side discharge before further service.
curtain bag taut, thus ensuring that the bag will (2) Remove the pinch welt from the front door
deploy in the proper position. Following the airbag opening of the vehicle as needed to access the side
deployment, the airbag cushion quickly deflates by curtain airbag (Fig. 44).
venting the inert gas through the loose weave of the
VA RESTRAINTS 8O - 35
SIDE CURTAIN AIRBAG (Continued)
(6) Disconnect the pigtail wire connector for the
side curtain airbag from the vehicle wire harness
connector on the B-pillar (Fig. 46).

Fig. 44 Pinch Welt


1 - GRAB HANDLE
2 - B-PILLAR TRIM
3 - PINCH WELT
Fig. 46 Side Curtain Airbag Connector
(3) Remove the trim from the inside of the B-pillar. 1 - TIE WRAP
(Refer to 23 - BODY/INTERIOR/B-PILLAR TRIM - 2 - B-PILLAR
3 - CONNECTOR
REMOVAL).
(4) Remove the grab handle from the headliner. (7) Cut the tie wrap that secures the side curtain
(Refer to 23 - BODY/INTERIOR/ASSIST HANDLE - airbag pigtail wire to the inside of the B-pillar.
REMOVAL). (8) Remove the screw that secures the side curtain
(5) Carefully remove the trim from the A-pillar airbag tether retainer to the base of the A-pillar near
that conceals the side curtain airbag front tether the belt line (Fig. 47).
(Fig. 45).

Fig. 47 Tether Anchor Screw


Fig. 45 A-Pillar Front Tether
1 - A-PILLAR
1 - A-PILLAR 2 - TETHER
2 - FRONT TETHER 3 - SCREW
8O - 36 RESTRAINTS VA
SIDE CURTAIN AIRBAG (Continued)
(9) Remove the screw that secures the front of the INSTALLATION
side curtain airbag to the A-pillar (Fig. 48). The following procedure is for replacement of a
faulty or damaged side curtain airbag. If the airbag
is faulty or damaged, but not deployed, review the
recommended procedures for handling non-deployed
supplemental restraints. (Refer to 8 - ELECTRICAL/
RESTRAINTS - STANDARD PROCEDURE - HAN-
DLING NON-DEPLOYED SUPPLEMENTAL
RESTRAINTS). If the side curtain 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).

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, impact sensor, or instrument panel com-
Fig. 48 Side Curtain Airbag Screws ponent diagnosis or service. Disconnect and isolate
the battery negative (ground) cable, then wait two
1 - SIDE CURTAIN AIRBAG
2 - REAR SCREW minutes for the system capacitor to discharge
3 - FRONT SCREW before performing further diagnosis or service. This
is the only sure way to disable the supplemental
(10) Remove the screw that secures the rear of the restraint system. Failure to take the proper precau-
side curtain airbag to the B-pillar. tions could result in accidental airbag deployment.
(11) Disengage the lug that secures the side cur-
tain airbag bracket from within the bore in the roof
side rail and remove the unit from the vehicle (Fig. WARNING: To avoid personal injury or death, when
49). removing a deployed airbag, rubber gloves, eye
protection, and a long-sleeved shirt should be
worn. There may be deposits on the airbag unit and
other interior surfaces. In large doses, these depos-
its may cause irritation to the skin and eyes.

WARNING: To avoid personal injury or death, use


extreme care to prevent any foreign material from
entering the side curtain airbag, or becoming
entrapped between the side curtain airbag cushion
and the roof rail garnish molding. Failure to
observe this warning could result in occupant inju-
ries upon airbag deployment.

(1) Position the side curtain airbag into the vehicle


as a unit.
(2) Engage the lug that secures the side curtain
airbag bracket into the bore in the roof side rail (Fig.
50).
(3) Install and tighten the screw that secures the
Fig. 49 Side Curtain Airbag Remove rear of the side curtain airbag to the B-pillar (Fig.
1 - ROOF SIDE RAIL 48). Tighten the screw to 23 N·m (17 ft. lbs.).
2 - SIDE CURTAIN AIRBAG (4) Install and tighten the screw that secures the
front of the side curtain airbag to the A-pillar.
Tighten the screw to 9 N·m (80 in. lbs.).
VA RESTRAINTS 8O - 37
SIDE CURTAIN AIRBAG (Continued)

SIDE IMPACT SENSOR


DESCRIPTION

Fig. 50 Side Curtain Airbag Install


1 - ROOF SIDE RAIL
2 - BORE
3 - SIDE CURTAIN AIRBAG BRACKET
4 - LUG
Fig. 51 Side Impact Sensor
(5) Install and tighten the screw that secures the 1 - MOUNTING FLANGE (2)
2 - IMPACT SENSOR
side curtain airbag front tether retainer to the base 3 - CONNECTOR RECEPTACLE
of the A-pillar near the belt line (Fig. 47). Tighten
the screw to 5 N·m (44 in. lbs.). On vehicles equipped with the optional side curtain
(6) Install a new tie wrap to secure the side cur- airbags, two side impact sensors are used, one each
tain airbag pigtail wire to the inside of the B-pillar for the left and right sides of the vehicle (Fig. 51).
(Fig. 46). These sensors are mounted remotely from the bi-di-
(7) Reconnect the pigtail wire connector for the rectional safing sensor that is internal to the Airbag
side curtain airbag to the vehicle wire harness con- Control Module (ACM). The side impact sensors are
nector on the B-pillar. Be certain the connector is each secured with two screws to the forward vertical
fully engaged and latched. surface of the right and left front door step wells and
(8) Reinstall the trim onto the A-pillar that con- concealed behind the step well trim paneling within
ceals the side curtain airbag front tether (Fig. 45). the passenger compartment.
(9) Reinstall the grab handle onto the headliner. The impact sensor housing has an integral connec-
(Refer to 23 - BODY/INTERIOR/ASSIST HANDLE - tor receptacle and two integral mounting flanges, one
INSTALLATION). at the top and one at the bottom. An arrow on the
(10) Reinstall the trim onto the inside of the B-pil- sensor housing provides a visual verification of the
lar. (Refer to 23 - BODY/INTERIOR/B-PILLAR TRIM proper orientation of the unit, and should always be
- INSTALLATION). pointed toward the outboard side of the vehicle. A
(11) Reinstall the pinch welt to the front door cavity in the center of the molded plastic impact sen-
opening (Fig. 44). sor housing contains the electronic circuitry of the
(12) Do not reconnect the battery negative cable at sensor, which includes an electronic communication
this time. The supplemental restraint system verifi- chip and an electronic impact sensor. Potting mate-
cation test procedure should be performed following rial fills the cavity to seal and protect the internal
service of any supplemental restraint system compo- electronic circuitry and components. The side impact
nent. (Refer to 8 - ELECTRICAL/RESTRAINTS - sensors are each connected to the vehicle electrical
STANDARD PROCEDURE - VERIFICATION TEST). system through a dedicated take out and connector of
the vehicle wire harness.
The side impact sensors cannot be repaired or
adjusted and, if damaged or faulty, they must be
replaced.
8O - 38 RESTRAINTS VA
SIDE IMPACT SENSOR (Continued)

OPERATION (1) Disconnect and isolate the battery negative


The side impact sensors are electronic accelerome- cable. Wait two minutes for the system capacitor to
ters that sense the rate of vehicle deceleration, which discharge before further service.
provides verification of the direction and severity of (2) Remove the trim paneling from the interior of
an impact. Each sensor also contains an electronic the front door step well. (Refer to 23 - BODY/INTE-
communication chip that allows the unit to commu- RIOR/STEPWELL SCUFF PADS - REMOVAL).
nicate the sensor status as well as sensor fault infor- (3) Disconnect the vehicle wire harness connector
mation to the microprocessor in the Airbag Control from the side impact sensor connector receptacle
Module (ACM). The ACM microprocessor continu- (Fig. 52).
ously monitors all of the passive restraint system
electrical circuits to determine the system readiness.
If the ACM detects a monitored system fault, it sets
a Diagnostic Trouble Code (DTC) and controls the
airbag indicator operation accordingly.
The impact sensors each receive battery current
and ground through dedicated left and right sensor
plus and minus circuits from the ACM. The impact
sensors and the ACM communicate by modulating
the voltage in the sensor plus circuit. The hard wired
circuits between the side impact sensors and the
ACM may be diagnosed and tested using conven-
tional diagnostic tools and procedures. However, con-
ventional diagnostic methods will not prove
conclusive in the diagnosis of the ACM or the impact
sensors. The most reliable, efficient, and accurate
means to diagnose the impact sensors, the ACM, and
the electronic message communication between the
sensors and the ACM requires the use of a DRBIIIt
scan tool. Refer to the appropriate diagnostic infor- Fig. 52 Side Impact Sensor Remove/Install
mation. 1 - SCREW (2)
2 - IMPACT SENSOR
REMOVAL 3
4
-
-
CONNECTOR
STEP WELL

WARNING: To avoid personal injury or death, on


(4) Remove the two screws that secure the side
vehicles equipped with airbags, disable the supple-
impact sensor to the forward vertical surface of the
mental restraint system before attempting any
step well.
steering wheel, steering column, airbag, seat belt
(5) Remove the side impact sensor from the step
tensioner, impact sensor, or instrument panel com-
well.
ponent diagnosis or service. Disconnect and isolate
the battery negative (ground) cable, then wait two
minutes for the system capacitor to discharge
INSTALLATION
before performing further diagnosis or service. This WARNING: To avoid personal injury or death, on
is the only sure way to disable the supplemental vehicles equipped with airbags, disable the supple-
restraint system. Failure to take the proper precau- mental restraint system before attempting any
tions could result in accidental airbag deployment. steering wheel, steering column, airbag, seat belt
tensioner, impact sensor, or instrument panel com-
WARNING: To avoid personal injury or death, never ponent diagnosis or service. Disconnect and isolate
strike or drop the side impact sensor, as it can the battery negative (ground) cable, then wait two
damage the impact sensor or affect its calibration. minutes for the system capacitor to discharge
The side impact sensor enables the system to before performing further diagnosis or service. This
deploy the side curtain airbags. If an impact sensor is the only sure way to disable the supplemental
is accidentally dropped during service, the sensor restraint system. Failure to take the proper precau-
must be scrapped and replaced with a new unit. tions could result in accidental airbag deployment.
Failure to observe this warning could result in acci-
dental, incomplete, or improper supplemental
restraint deployment.
VA RESTRAINTS 8O - 39
SIDE IMPACT SENSOR (Continued)
WARNING: To avoid personal injury or death, never (3) Reconnect the vehicle wire harness connector
strike or drop the side impact sensor, as it can for the side impact sensor to the sensor connector
damage the impact sensor or affect its calibration. receptacle.
The side impact sensor enables the system to (4) Reinstall the trim paneling to the interior of
deploy the side curtain airbags. If an impact sensor the front door step well. (Refer to 23 - BODY/INTE-
is accidentally dropped during service, the sensor RIOR/STEPWELL SCUFF PADS - INSTALLATION).
must be scrapped and replaced with a new unit. (5) Do not reconnect the battery negative cable at
Failure to observe this warning could result in acci- this time. The supplemental restraint system verifi-
dental, incomplete, or improper supplemental cation test procedure should be performed following
restraint deployment. service of any supplemental restraint system compo-
nent. (Refer to 8 - ELECTRICAL/RESTRAINTS -
(1) Position the side impact sensor to the forward STANDARD PROCEDURE - VERIFICATION TEST).
vertical surface of the step well (Fig. 52). Be certain
that the arrow on the sensor housing is pointed
toward the outboard side of the vehicle.
(2) Install and tighten the two screws that secure
the side impact sensor to the step well.
VA SPEED CONTROL 8P - 1

SPEED CONTROL
TABLE OF CONTENTS

page page

SPEED CONTROL SERVO


DESCRIPTION . .........................1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2
OPERATION . . . .........................1 SWITCH
SPECIFICATIONS REMOVAL .............................3
TORQUE . . . . .........................2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CABLE
DESCRIPTION . .........................2

SPEED CONTROL WARNING: THE USE OF SPEED CONTROL IS NOT


RECOMMENDED WHEN DRIVING CONDITIONS DO
NOT PERMIT MAINTAINING A CONSTANT SPEED,
DESCRIPTION
SUCH AS IN HEAVY TRAFFIC OR ON ROADS THAT
The speed control system is electronically con-
ARE WINDING, ICY, SNOW COVERED, OR SLIP-
trolled by the Engine Control Module (ECM). A
PERY.
cable and a vacuum controlled servo are not
used. This is a servo-less system. Control of the
system is accomplished by a 4-position, instrument
panel mounted switch (Fig. 1).
Switch settings (Fig. 2) are:
• 1. Set / Accelerate
• 2. Resume Set Speed
• 3. Set / Decelerate
• 4. Off
The system is designed to operate at speeds above
25 mph (40 km/h).

Fig. 2 SPEED CONTROL SWITCH FUNCTIONS


1 - SET / ACCELERATE
2 - RESUME SET SPEED
3 - SET / DECELERATE
4 - OFF
5 - SWITCH HANDLE

Fig. 1 INSTRUMENT CLUSTER OPERATION


When speed control operation is selected by the
1 - COVER
2 - BEZEL speed control switch, the ECM (Engine Control Mod-
3 - INSTRUMENT CLUSTER ule) allows a set speed to be stored in its RAM for
4 - STEERING WHEEL speed control. To store a set speed, press either of the
5 - MULTI-FUNCTION SWITCH
6 - SPEED CONTROL SWITCH SET switch functions while the vehicle is moving,
8P - 2 SPEED CONTROL VA
SPEED CONTROL (Continued)
and above 25 mph (40 km/h). In order for the speed • The speed signal decreases at a rate of 10 mph
control to engage, the brakes cannot be applied, nor per second (indicates that the vehicle may have
can the gear selector be indicating the transmission decelerated at an extremely high rate)
is in Park or Neutral. Once the speed control has been disengaged,
The speed control can be disengaged manually by: depressing the RES/ACCEL switch (when speed is
• Stepping on the brake pedal greater than 30 mph) restores the vehicle to the tar-
• Pressing the speed control switch to OFF get speed that was stored in the ECM.
• Depressing the clutch pedal (if equipped). While the speed control is engaged, the driver can
increase the vehicle speed by depressing the RES/AC-
NOTE: Depressing the OFF switch or turning off the CEL switch. The new target speed is stored in the
ignition switch will erase the set speed stored in ECM when the RES/ACCEL is released. The PCM
the ECM. also has a 9tap-up9 feature in which vehicle speed
increases at a rate of approximately 2 mph for each
For added safety, the speed control system is pro- momentary switch activation of the RES/ACCEL
grammed to disengage for any of the following condi- switch.
tions: A “tap down” feature is used to decelerate without
• An indication of Park or Neutral disengaging the speed control system. To decelerate
• A rapid increase rpm (indicates that the clutch from an existing recorded target speed, momentarily
has been disengaged) depress the COAST switch. For each switch activa-
• Excessive engine rpm (indicates that the trans- tion, speed will be lowered approximately 1 mph.
mission may be in a low gear)
• The speed signal increases at a rate of 10 mph
per second (indicates that the coefficient of friction
between the road surface and tires is extremely low)

SPECIFICATIONS

TORQUE

DESCRIPTION N-m Ft. Lbs. In. Lbs.


Switch Mounting Screw .9-1.1 - 8-10

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.

Fig. 4 SPEED CONTROL SWITCH REMOVAL /


INSTALLATION
1 - SWITCH MOUNTING SCREW (1)
2 - SPEED CONTROL SWITCH
3 - SWITCH HANDLE
4 - MULTI-FUNCTION SWITCH

(1) Position speed control switch to back of multi-


function switch.
(2) Install switch mounting screw (Fig. 4). Refer to
Torque Specifications.
Install multi-function switch. Refer to Multi-Func-
tion Switch Removal/Installation.
(3) Plug pigtail electrical connector (Fig. 3) into
instrument panel wiring harness. Be sure wires are
not pinched.
(4) Install negative battery cable to battery.
Fig. 3 SPEED CONTROL SWITCH LOCATION
1 - SWITCH HANDLE
2 - PIGTAIL ELECTRICAL CONNECTOR
3 - MULTI-FUNCTION SWITCH

INSTALLATION
The speed control switch is mounted to the back of
the multi-function switch (Fig. 3).
VA VEHICLE THEFT SECURITY 8Q - 1

VEHICLE THEFT SECURITY


TABLE OF CONTENTS

page page

VEHICLE THEFT SECURITY SENTRY KEY REMOTE ENTRY MODULE


DESCRIPTION . . . . . . . . . .................1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . .2
OPERATION . . . . . . . . . . . .................1 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
DIAGNOSIS AND TESTING - VEHICLE THEFT REMOVAL ..................... . . . . . . . .3
SECURITY . . . . . . . . . . . .................1 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . .4
INTRUSION SENSOR SIREN
REMOVAL ............ .................2 REMOVAL ..................... ........4
INSTALLATION . . . . . . . . . .................2 INSTALLATION . . . . . . . . . . . . . . . . . . ........4
SECURITY SYSTEM MODULE TRANSPONDER KEY
REMOVAL ............ .................2 DESCRIPTION . . . . . . . . . . . . . . . . . . ........4
INSTALLATION . . . . . . . . . .................2 OPERATION . . . . . . . . . . . . . . . . . . . . ........4

VEHICLE THEFT SECURITY The interior monitoring system included in the


anti-theft alarm is based on ultrasonics and triggers
an alarm if an object intrudes the interior of the
DESCRIPTION
vehicle or if any movement is detected inside the
An anti-theft alarm with battery powered horn is
vehicle. For proper and effective protection, all win-
available as an option and includes interior monitor-
dows and the sunroof must be closed.
ing, anti-tow away protection and rear window mon-
To switch off the interior monitoring system and /
itoring based on the heater wires. The alarm is
or the anti-tow away protection, a switch with LED
automatically activated when the central locking sys-
indicator light is provided in the switch panel. An
tem is operated.
alarm button enables the operator to trigger an
The alarm will sound when any of the following
alarm manually and to lock all doors if they are
occur:
closed. Triggering an alarm makes the horn sound
• A door is opened
and the turn signals flash until the alarm is switched
• A door is unlocked from inside the vehicle
off.
• The hood is opened
The anti-theft alarm control unit includes a gradi-
• The vehicle is raised at the front or rear
ent indicator as anti-tow away protection. The gradi-
• The trailer wire harness is disconnected
ent indicator triggers an audible and visual alarm if
• Movements inside the vehicle
the vehicle is lifted (to tow away or to remove the
• The central locking is unlocked by a key at any
wheels). The alarm remains effective even if the bat-
other door than the driver’s door
tery is disconnected as the horn is powered by its
The alarm is functional about 30 seconds after the
own battery. The interior monitoring system should
vehicle is locked using the RKE transmitter or the
be switched off if people and/or animals are left in
key in the driver’s door. Activation is indicated by the
the vehicle.
indicator lights flashing three times and the warning
lamp flashing in the switch. If persons or animals
remain in the locked vehicle, the operator should
DIAGNOSIS AND TESTING - VEHICLE THEFT
switch off the interior monitor to avoid a false alarm. SECURITY
Any diagnosis of the Vehicle Theft Security
OPERATION system should begin with the use of the DRB
The anti-theft alarm is activated/deactivated by IIIt diagnostic tool. For information on the use
locking/unlocking the vehicle with the remote trans- of the DRB IIIt, refer to the appropriate Diag-
mitter or with the key at the driver’s door. The key nostic Service Manual.
must be held in the locking position for more than
two seconds. Activation is indicated by the turn sig-
nal lights flashing once. Unlocking the vehicle at one
of the other doors will trigger an alarm.
8Q - 2 VEHICLE THEFT SECURITY VA

INTRUSION SENSOR INSTALLATION


(1) Connect wire harness connector.
REMOVAL (2) Position module. Install and tighten mounting
(1) Disconnect and isolate the battery negative fasteners.
cable. (3) Install driver seat cushion.
(2) Insert the tip of a small flat-bladed screwdriver (4) Connect battery negative cable.
into the notch on one edge of the dome lamp/intru-
sion sensor unit housing to depress the retainer clip
and pull that edge of the lamp away from its mount-
SENTRY KEY REMOTE ENTRY
ing location (Fig. 1). MODULE
DESCRIPTION
The Sentry Key Remote Entry Module (SKREEM)
(Fig. 2) performs the functions of the Sentry Key
Immobilizer Module (SKIM) and the Remote Keyless
Entry (RKE) module.

Fig. 1 DOME LAMP/INTRUSION SENSOR


1 - NOTCH
2 - SENSOR (3)
3 - HOUSING
4 - SWITCH (2)

(3) Pull the dome lamp/intrusion sensor unit from


its mounting location far enough to access and dis-
connect the vehicle wire harness from the lamp con-
nector receptacle.
(4) Remove the dome lamp/intrusion sensor unit
from its mounting location.
Fig. 2 SENTRY KEY REMOTE ENTRY MODULE
(SKREEM)
INSTALLATION
(1) Position the dome lamp/intrusion sensor unit to SENTRY KEY IMMOBILIZER
its mounting location. The Sentry Key Immobilizer System (SKIS)
(2) Reconnect the vehicle wire harness connector authenticates an electronically coded Transponder
to the dome lamp/intrusion sensor unit connector Key placed into the ignition and sends a valid/invalid
receptacle. key message to the Engine Control Module (ECM)
(3) Position the edge of the dome lamp/intrusion based upon the results. The “VALID/INVALID KEY”
sensor unit housing opposite from the retainer clip message communication is performed using a rolling
into the mounting hole. code algorithm. A “VALID KEY” message must be
(4) Push firmly and evenly on the notched edge of sent to the ECM within two seconds of ignition ON
the dome lamp/intrusion sensor unit housing until to free the engine from immobilization. This Control-
the retainer clip latches into place. ler Area Network (CAN) data bus message is sent to
(5) Connect the battery negative cable. the ECM after first going through the SKREEM. The
SKREEM is located behind the instrument cluster
and has a separately mounted antenna ring mounted
SECURITY SYSTEM MODULE around the ignition cylinder (Fig. 3) which picks up
the transponder key signal.
REMOVAL
(1) Disconnect and isolate the battery negative REMOTE KEYLESS ENTRY (RKE)
cable. The RKE transmitter uses radio frequency signals
(2) Remove driver seat cushion. to communicate with the Sentry Key Remote Entry
(3) Remove mounting fasteners. Module (SKREEM). The SKREEM is hardwired to
(4) Disconnect wire harness connector. the Central Timer Module (CTM). When the operator
VA VEHICLE THEFT SECURITY 8Q - 3
SENTRY KEY REMOTE ENTRY MODULE (Continued)
the unlock button, on the RKE transmitter, one time,
the driver door lock will unlock, the illuminated
entry will turn on the courtesy lamps, and the VTSS
(if equipped) will disarm. After pressing the unlock
button a second time, the remaining door locks will
unlock.
The SKREEM is capable of retaining up to 8 indi-
vidual access codes (8 transmitters). If the PRNDL is
in any position except park, the SKREEM will dis-
able the RKE. Use the DRBIIIt or the customer pro-
gramming method to program the RKE system.
However, the SKREEM will only allow RKE pro-
gramming when the ignition is in the ON position,
the PRNDL is in park position, and the VTSS (if
equipped) is disarmed.

Fig. 3 TRANSPONDER RING REMOVAL


presses a button on the transmitter, it sends a spe-
cific request to the SKREEM. In turn, the SKREEM SENTRY KEY REMOTE ENTRY MODULE
sends the appropriate request to the CTM to unlock (1) Open hood, disconnect and isolate the battery
the vehicle doors. negative cable.
(2) Wait two minutes for the system reserve capac-
OPERATION itor to discharge before beginning any system or com-
ponent service.
SENTRY KEY IMMOBILIZER (3) Remove top cover - cluster (Refer to 23 -
The Sentry Key Remote Entry Module (SKREEM) BODY/INSTRUMENT PANEL/TOP COVER - CLUS-
receives an encrypted Radio Frequency (RF) signal TER - REMOVAL).
from the transponder key which is read by the (4) Disconnect the one electrical connector to the
remotely mounted antenna ring at the ignition cylin- SKREEM (Fig. 4) which is the transponder ring con-
der. The SKREEM then decrypts the signal and nector.
broadcasts the requested remote commands to the
appropriate modules in the vehicle over the Control-
ler Area Network (CAN) data bus. A valid transpon-
der key ID must be incorporated into the RF signal
in order for the SKREEM to pass the message on to
the appropriate modules.
Automatic transponder key synchronization is done
by the SKREEM if a valid transponder key is
inserted into the ignition cylinder, and the ignition is
turned ON. This provides a maximum operation win-
dow for RKE functions.
Each Sentry Key Remote Entry System (SKREES)
consists of a SKREEM, an antenna ring mounted
around the ignition cylinder, and a transponder key.
Each system has a secret key code unique to that
system. The secret key is electronically coded in the
SKREEM and in all programmed transponder keys.
It is used for immobilization and RKE functions for
data security. In addition, each transponder key will
have a unique identification. Fig. 4 SENTRY KEY REMOTE ENTRY MODULE
(SKREEM) - REMOVE/INSTALL
REMOTE KEYLESS ENTRY 1 - SENTRY KEY REMOTE ENTRY MODULE (SKREEM)
After pressing the lock button on the RKE trans- 2 - INSTRUMENT CLUSTER (REAR)
3 - INSTRUMENT PANEL
mitter, all of the door locks will lock, the illuminated
entry will turn off (providing all doors are closed),
and the VTSS (if equipped) will arm. After pressing
8Q - 4 VEHICLE THEFT SECURITY VA
SENTRY KEY REMOTE ENTRY MODULE (Continued)
(5) Pull SKREEM straight out of rear of instru- SENTRY KEY REMOTE ENTRY MODULE
ment cluster (Fig. 4) and remove from vehicle. TRANSPONDER RING
(1) Maneuver wiring through instrument panel
SENTRY KEY REMOTE ENTRY MODULE (Fig. 5).
TRANSPONDER RING (2) Connect the transponder electrical connect or
(1) Open hood, disconnect and isolate the battery to the SKREEM (Fig. 4).
negative cable. (3) Install the top cover - cluster (Refer to 23 -
(2) Wait two minutes for the system reserve capac- BODY/INSTRUMENT PANEL/TOP COVER - CLUS-
itor to discharge before beginning any system or com- TER - INSTALLATION)
ponent service. (4) Snap the SKREEM transponder in place
(3) Remove the steering column shrouds. around the ignition cylinder (Fig. 5).
(4) Unsnap the SKREEM transponder from the (5) Install the steering column shrouds.
ignition cylinder (Fig. 5). (6) Connect the battery negative cable.
(7) Verify vehicle and system operation.
(8) Close hood.

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.

SENTRY KEY REMOTE ENTRY MODULE OPERATION


(1) Push SKREEM straight into the rear of instru- Each Sentry Key has a unique transponder identi-
ment cluster (Fig. 4). fication code permanently programmed into it by the
(2) Connect the one electrical connector to the manufacturer. Likewise, the Sentry Key Remote
SKREEM (Fig. 4). Entry Module (SKREEM) has a unique 9Secret Key9
(3) Install the top cover - cluster (Refer to 23 - code programmed into it by the manufacturer as
BODY/INSTRUMENT PANEL/TOP COVER - CLUS- well. When a Sentry Key is programmed into the
TER - INSTALLATION) memory of the SKREEM, the SKREEM stores the
(4) Connect the battery negative cable. transponder identification code from the Sentry Key,
(5) Verify vehicle and system operation. and the Sentry Key learns the 9Secret Key9 code from
(6) Close hood. the SKREEM. Once the Sentry Key learns the
9Secret Key9 code of the SKREEM, it is also perma-
nently programmed into the transponder’s memory.
VA VEHICLE THEFT SECURITY 8Q - 5
TRANSPONDER KEY (Continued)
inserted into the ignition lock cylinder. When the
ignition switch is turned to the ON position, the
SKREEM communicates with the Sentry Key via a
radio frequency (RF) signal. The SKREEM deter-
mines if a valid key is present based on the informa-
tion it receives from the Sentry Key. If a valid key is
detected, that fact is communicated to the Engine
Control Module (ECM) via the Controller Area Net-
work (CAN) data bus and the vehicle is allowed to
continue running. If an invalid key is received by the
ECM or no status at all is communicated, the vehicle
will stall after two (2) seconds of running. The indi-
cator light will be flashing at this point. The Sentry
Key’s transponder can not be repaired. If it is faulty
or damaged, it must be replaced.
Common communication problems:
Fig. 6 TRANSPONDER KEY • Two transponder keys too close together.
1 - TRANSPONDER KEY FOB • Speed Pass too close to transponder key.
2 - RKE BUTTONS Solid indicator that there is a system failure.
3 - INDICATOR LIGHT
4 - KEY BLADE RELEASE BUTTON
• Loss of ECM communication.
5 - KEY BLADE • Failed transponder ring circuit.

The Sentry Key’s transponder is within the range


of the SKREEM’s transponder ring when it is
VA WIPERS/WASHERS 8R - 1

WIPERS/WASHERS
TABLE OF CONTENTS

page page

WIPERS/WASHERS WASHER PUMP/MOTOR


DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 18
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
DIAGNOSIS AND TESTING - WIPER & REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
WASHER SYSTEM . . . . . . . . . . . . . . . . . . . . . 5 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19
CLEANING - WIPER & WASHER SYSTEM . . . . . 9 WASHER RESERVOIR
INSPECTION - WIPER & WASHER SYSTEM . . 10 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 20
CHECK VALVE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 WIPER ARM
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 22
RAIN SENSOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23
STANDARD PROCEDURE WIPER BLADE
RAIN SENSOR BRACKET REPLACEMENT . . 12 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 24
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
RAIN SENSOR CONTROL MODULE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 14 WIPER LINKAGE
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 25
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
WASHER FLUID LEVEL SWITCH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 27
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 16 WIPER MOTOR
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 28
WASHER HOSES/TUBES OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 17 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 28
WASHER NOZZLE WIPER RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 18 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 29
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 31

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)

Fig. 1 Wiper & Washer System


1 - WASHER RESERVOIR, PUMP/MOTOR, FLUID LEVEL SWITCH 4 - MULTI-FUNCTION (WIPER, WASHER, & LIGHTING) SWITCH
2 - WIPER MOTOR, LINKAGE & PIVOTS MODULE 5 - RAIN SENSOR (W/AUTOMATIC WIPERS ONLY)
3 - WIPER RELAY 6 - RAIN SENSOR CONTROL MODULE (W/AUTOMATIC WIPERS
ONLY)

• 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.

INTERMITTENT WIPER SYSTEM

CONDITION POSSIBLE CAUSES CORRECTION

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)

CONDITION POSSIBLE CAUSES CORRECTION

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.

AUTOMATIC WIPER SYSTEM

CONDITION POSSIBLE CAUSES CORRECTION

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)

CONDITION POSSIBLE CAUSES CORRECTION

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)

CONDITION POSSIBLE CAUSES CORRECTION

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.

CLEANING - WIPER & WASHER SYSTEM WASHER SYSTEM


If the washer system is contaminated with foreign
WIPER SYSTEM material, drain the washer reservoir by removing the
The squeegees of wiper blades exposed to the ele- washer pump/motor from the reservoir. Clean foreign
ments for a long time tend to lose their wiping effec- material from the inside of the washer pump/motor
tiveness. Periodic cleaning of the squeegees is inlet nipple and the washer reservoir using clean
suggested to remove any deposits of salt or road film. washer fluid, a mild detergent, or a non-abrasive
The wiper blades, arms, and windshield glass should cleaner. Flush foreign material from the washer sys-
only be cleaned using a sponge or soft cloth and tem plumbing by first disconnecting the washer
windshield washer fluid, a mild detergent, or a non- hoses from the washer nozzles, then running the
abrasive cleaner. If the wiper blades continue to washer pump/motor to run clean washer fluid or
leave streaks, smears, hazing, or beading on the water through the system. Plugged or restricted
glass after thorough cleaning of the squeegees and washer nozzles should be carefully back-flushed
the glass, the entire wiper blade assembly must be using compressed air. If the washer nozzle obstruc-
replaced. tion cannot be cleared, replace the washer nozzle.

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.

INSPECTION - WIPER & WASHER SYSTEM


WIPER SYSTEM
The wiper blades and wiper arms should be
inspected periodically, not just when wiper perfor-
mance problems are experienced. This inspection
should include the following points:
(1) Inspect the wiper arms for any indications of
damage, or contamination. If the wiper arms are con-
taminated with any foreign material, clean them as
required. (Refer to 8 - ELECTRICAL/WIPERS/
WASHERS - CLEANING). If a wiper arm is damaged
or corrosion is evident, replace the wiper arm with a
new unit. Do not attempt to repair a wiper arm that
is damaged or corroded.
(2) Carefully lift the wiper blade off of the glass.
Note the action of the wiper arm hinge. The wiper Fig. 3 Wiper Blade Inspection
arm should pivot freely at the hinge, but with no lat- 1 - WORN OR UNEVEN EDGES
eral looseness evident. If there is any binding evident 2 - ROAD FILM OR FOREIGN MATERIAL DEPOSITS
in the wiper arm hinge, or there is evident lateral 3 - HARD, BRITTLE, OR CRACKED
4 - DEFORMED OR FATIGUED
play in the wiper arm hinge, replace the wiper arm. 5 - SPLIT
6 - DAMAGED SUPPORT COMPONENTS
CAUTION: Do not allow the wiper arm to spring
back against the glass without the wiper blade in
WASHER SYSTEM
place or the glass may be damaged.
The washer system components should be
(3) Once proper hinge action of the wiper arm is inspected periodically, not just when washer perfor-
confirmed, check the hinge for proper spring tension. mance problems are experienced. This inspection
Remove the wiper blade from the wiper arm. Either should include the following points:
place a small postal scale between the blade end of (1) Check for ice or other foreign material in the
the wiper arm and the glass, or carefully lift the washer reservoir. If contaminated, clean and flush
blade end of the arm away from the glass using a the washer system. (Refer to 8 - ELECTRICAL/WIP-
small fish scale. Compare the scale readings between ERS/WASHERS - CLEANING).
the right and left wiper arms. Replace a wiper arm if (2) Inspect the washer plumbing for pinched, leak-
it has comparatively lower spring tension, as evi- ing, deteriorated, or incorrectly routed hoses and
denced by a lower scale reading. damaged or disconnected hose fittings. Replace dam-
(4) Inspect the wiper blades and squeegees for any aged or deteriorated hoses and hose fittings. Leaking
indications of damage, contamination, or rubber dete- washer hoses can sometimes be repaired by cutting
rioration (Fig. 3). If the wiper blades or squeegees the hose at the leak and splicing it back together
are contaminated with any foreign material, clean using an in-line connector fitting. Similarly, sections
them and the glass as required. (Refer to 8 - ELEC- of deteriorated hose can be cut out and replaced by
TRICAL/WIPERS/WASHERS - CLEANING). After splicing in new sections of hose using in-line connec-
cleaning the wiper blade and the glass, if the wiper tor fittings. Whenever routing a washer hose or a
blade still fails to clear the glass without smearing, wire harness containing a washer hose, it must be
streaking, chattering, hazing, or beading, replace the routed away from hot, sharp, or moving parts. Also,
wiper blade. Also, if a wiper blade is damaged or the sharp bends that might pinch the washer hose must
squeegee rubber is damaged or deteriorated, replace be avoided.
the wiper blade with a new unit. Do not attempt to
repair a wiper blade that is damaged.
VA WIPERS/WASHERS 8R - 11

CHECK VALVE plumbing, the fluid pressure unseats a diaphragm


from over a sump well within the valve by overriding
the spring pressure applied to it by a piston. With
DESCRIPTION
the diaphragm unseated, washer fluid is allowed to
flow toward the two washer nozzles. When the
washer pump stops operating, the spring pressure on
the piston seats the diaphragm over the sump well in
the valve and fluid flow in either direction within the
washer plumbing is prevented. The check valve can-
not be adjusted or repaired and, if faulty or damaged,
it must be replaced.

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).

Fig. 4 Check Valve


1 - INLET NIPPLE
2 - CHECK VALVE
3 - OUTLET NIPPLE (2)

A single washer system check valve is standard


equipment on this model, and is installed in the
washer system plumbing (Fig. 4). The check valve is
integral to the washer plumbing fitting located on
the underside of the cowl top panel behind the rear
of the hood panel opening in the engine compart-
ment. The check valve consists of a molded plastic
body with three barbed hose nipples, one at the inlet
side of the valve body and two at the outlet side. The
check valve cannot be adjusted or repaired and, if
faulty or damaged, it must be replaced.
Fig. 5 Check Valve Remove/Install
OPERATION 1 - COWL HOOD SEAL
The check valve provides more than one function 2 - CHECK VALVE
in this application. It serves as a plumbing connector 3 - HOSE TO WASHER NOZZLE (2)
4 - HOSE FROM WASHER PUMP
fitting between the engine compartment and washer
nozzle sections of the washer supply hose. It prevents (3) Remove the check valve unit from the under-
washer fluid from draining out of the washer supply side of the cowl top panel.
hoses back to the washer reservoir. This drain-back
would result in a lengthy delay from when the INSTALLATION
washer switch is actuated until washer fluid was dis- (1) Position the check valve unit to the underside
pensed through the washer nozzles, because the of the cowl top panel (Fig. 5).
washer pump would have to refill the washer plumb- (2) Reconnect the three washer hoses to the
ing from the reservoir to the nozzles. Such a drain- barbed nipples of the check valve unit.
back condition could also result in water, dirt, or (3) Close and latch the hood.
other outside contaminants being siphoned into the
washer system through the washer nozzle orifice.
This water could subsequently freeze and plug the RAIN SENSOR
nozzle, while other contaminants could interfere with
proper nozzle operation and cause improper nozzle DESCRIPTION
spray patterns. In addition, the check valve prevents The rain sensor provides the primary input for the
washer fluid from siphoning through the washer noz- optional automatic wiper system (Fig. 6). The rain
zles after the washer system is turned Off. sensor is located on the inside of the windshield,
When the washer pump pressurizes and pumps where it is concealed within the molded plastic trim
washer fluid from the reservoir through the washer cover that snaps over the base of the rear view mir-
8R - 12 WIPERS/WASHERS VA
RAIN SENSOR (Continued)
module. The rain sensor contains InfraRed (IR)
diodes that direct IR light beams at the windshield
at an angle. When the windshield glass is dry, most
of this IR light is reflected back to the sensor, which
uses photocell receivers to measure the intensity of
the light. When moisture accumulates on the wind-
shield glass, much of the IR light is refracted away
from the photocell receivers. This causes changes in
the signal output of the rain sensor. The rain sensor
control module monitors the signal output from the
sensor and then controls the wiper motor speed and
wipe intervals accordingly.
It is important to note that the default condition
for the wiper system is automatic wipers Off; there-
fore, if no message is received from the rain sensor
by the rain sensor control module, the automatic wip-
ers will be disabled. If automatic wipers are disabled,
normal low and high speed continuous wiper opera-
tion are unaffected. Also, due to the low voltage
Fig. 6 Rain Sensor nature of the rain sensor signal and the impact that
1 - HEADLINER minor fluctuations in this signal strength can have
2 - TROUGH on wiper operation, grounded shielding circuits are
3 - WINDSHIELD
4 - RAIN SENSOR
provided at the roof and control module connectors to
5 - MIRROR control electrical induction into the sensor signal cir-
cuit.
ror arm. The sensor fits within the center of a ring- The hard wired rain sensor circuits may be diag-
like molded plastic bracket that is glued to the inside nosed using conventional diagnostic tools and meth-
of the windshield glass and that also serves as the ods. However, conventional diagnostic methods may
support for the rear view mirror. not prove conclusive in the diagnosis of the internal
The rain sensor is contained within a circular circuitry or the optics of the rain sensor. Refer to the
molded black plastic housing with a short pigtail appropriate wiring information.
wire and a connector insulator containing three ter-
minal cavities that exits one side of the housing. This
pigtail connects the rain sensor to the vehicle electri- STANDARD PROCEDURE
cal system through a dedicated take out and connec-
tor of the overhead wire harness that extends from RAIN SENSOR BRACKET REPLACEMENT
above the headliner. A molded plastic trough routes The rain sensor fits within the center of a ring-like
and conceals the pigtail wires on the inside of the molded plastic bracket that is glued to the inside of
windshield between the rear view mirror base and the windshield glass and that also serves as the sup-
the headliner. port for the rear view mirror arm. If the bracket
The windshield side of the rain sensor housing is should come loose from the windshield, it must be
open, but covered with a clear gelatin-like material reinstalled using a rear view mirror adhesive kit and
that protects the internal electronic sensor circuitry the procedure that follows.
and serves as the lens for the InfraRed (IR) diodes
and photocells within the sensor housing. This gel WARNING: To avoid personal injury or death, on
coating must never be touched or the rain sensor vehicles equipped with airbags, disable the supple-
function may be impaired and the unit rendered mental restraint system before attempting any
unusable. The rain sensor cannot be adjusted or steering wheel, steering column, airbag, seat belt
repaired and, if damaged or faulty, the entire sensor tensioner, or instrument panel component diagno-
must be replaced. The sensor bracket and a rear view sis or service. Disconnect and isolate the battery
mirror adhesive kit are available for separate service negative (ground) cable, then wait two minutes for
replacement. the system capacitor to discharge before perform-
ing further diagnosis or service. This is the only
OPERATION sure way to disable the supplemental restraint sys-
The rain sensor operates on battery current and a tem. Failure to take the proper precautions could
clean ground received from the rain sensor control result in accidental airbag deployment.
VA WIPERS/WASHERS 8R - 13
RAIN SENSOR (Continued)
CAUTION: Do not touch the gel-like surface of the
rain sensor or the sensor function may be impaired
and the sensor rendered unusable.

(1) Disconnect and isolate the battery negative


cable.
(2) Remove the rear view mirror and the rain sen-
sor from the rain sensor bracket. (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/RAIN SENSOR -
REMOVAL).
(3) Cut diagonally through the nylon mesh fabric
from the rear view mirror adhesive kit (Fig. 7).

Fig. 8 Trim Nylon Mesh Fabric


1 - FABRIC
2 - BRACKET

Fig. 7 Cut Nylon Mesh Fabric


1 - FABRIC
2 - DIAGONAL CUT

(4) Place the rain sensor bracket onto the nylon


mesh fabric (Fig. 8).
(5) Cut the two sections of nylon mesh fabric to
the contours of the rain sensor.

NOTE: If the early version of the rain sensor


bracket is used, the nylon mesh material must be
cut so as not to lie over the bracket collar (Fig. 9). Fig. 9 Rain Sensor Brackets
1 - COLLAR
(6) Complete the bracket installation following the 2 - EARLY TYPE BRACKET
instructions provided with the rear view mirror adhe- 3 - LATE TYPE BRACKET
sive kit.
(7) Reinstall the rain sensor and the rear view mental restraint system before attempting any
mirror onto the rain sensor bracket. (Refer to 8 - steering wheel, steering column, airbag, seat belt
ELECTRICAL/WIPERS/WASHERS/RAIN SENSOR - tensioner, or instrument panel component diagno-
INSTALLATION). sis or service. Disconnect and isolate the battery
(8) Reconnect the battery negative cable. negative (ground) cable, then wait two minutes for
the system capacitor to discharge before perform-
REMOVAL ing further diagnosis or service. This is the only
sure way to disable the supplemental restraint sys-
WARNING: To avoid personal injury or death, on tem. Failure to take the proper precautions could
vehicles equipped with airbags, disable the supple- result in accidental airbag deployment.
8R - 14 WIPERS/WASHERS VA
RAIN SENSOR (Continued)
(1) Disconnect and isolate the battery negative INSTALLATION
cable.
(2) Unsnap the base covers from each other and WARNING: To avoid personal injury or death, on
remove them from the rear view mirror arm at the vehicles equipped with airbags, disable the supple-
windshield (Fig. 10). 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.

CAUTION: Do not touch the gel-like surface of the


rain sensor or the sensor function may be impaired
and the sensor rendered unusable.

(1) Position the rain sensor into the center of the


bracket on the windshield (Fig. 10).
(2) Reconnect the sensor pigtail wire connector to
the roof wire harness connector.
(3) Reinstall the anti-rattle felt over the wire con-
Fig. 10 Rain Sensor Remove/Install nector insulators.
1 - FELT (4) Pull the headliner down from the windshield
2 - CONNECTOR header far enough to tuck the rain sensor pigtail
3 - INNER VISOR HINGE (2)
4 - WIRE COVER wire connector under the headliner.
5 - BRACKET (5) Tighten the screws securing both inner sun
6 - SENSOR visor hinges to the windshield header.
7 - RETAINING COLLAR
8 - BASE COVER (6) Align and install the two halves of the wire
9 - MIRROR cover over the rain sensor pigtail wires.
10 - ARM
(7) Press the rear view mirror arm upward paral-
lel to the windshield until the mirror arm snaps onto
(3) Using a small thin-bladed screwdriver, gently
the bracket.
pry the retaining collar slightly upward while press-
(8) Align and position the base covers to each
ing the mirror arm downward parallel to the wind-
other and snap them over the rear view mirror arm
shield until the mirror arm unsnaps from the
at the windshield.
bracket.
(9) Reconnect the battery negative cable.
(4) Separate and remove the two halves of the
wire cover from the rain sensor pigtail wires.
(5) Loosen the screws securing both inner sun RAIN SENSOR CONTROL
visor hinges to the windshield header.
(6) Pull the headliner down from the windshield MODULE
header far enough to pull the rain sensor pigtail wire
connector out from under the headliner. DESCRIPTION
(7) Remove the anti-rattle felt from the wire con- The Rain Sensor Control Module (RSCM) is the
nector insulators. primary component of the automatic wiper system
(8) Disconnect the sensor pigtail wire connector (Fig. 11). The RSCM is secured with two screws and
from the roof wire harness connector. nuts to a bracket located under the instrument panel
above the throttle pedal within the passenger com-
CAUTION: Do not touch the gel-like surface of the partment. The rectangular molded plastic housing of
rain sensor or the sensor function may be impaired the RSCM has an integral mounting tab on each side
and the sensor rendered unusable. and an integral connector receptacle on one end,
which contains the module terminal pins. These ter-
(9) Remove the rain sensor from the center of the minal pins connect the RSCM to the vehicle electrical
bracket.
VA WIPERS/WASHERS 8R - 15
RAIN SENSOR CONTROL MODULE (Continued)
The hard wired RSCM circuits may be diagnosed
using conventional diagnostic tools and methods.
However, conventional diagnostic methods may not
prove conclusive in the diagnosis of the internal cir-
cuitry of the RSCM. Refer to the appropriate wiring
information.

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 FLUID LEVEL


SWITCH
DESCRIPTION
The optional washer fluid level switch is a single
pole, single throw switch that is integral to a unique
version of the washer pump/motor unit, located rear-
ward facing side of the washer reservoir, which is
located in a dedicated hole on the top of the sump
area near the back of the windshield washer reser-
voir on the right front fender wheel house in the
engine compartment. Only a molded plastic nipple
with a clear vent tube are visible near the top of the
washer pump/motor unit that is equipped with the
Fig. 13 Rain Sensor Control Module Remove/Install
optional fluid level switch when it is installed in the
1 - SCREW (2) reservoir. The vent tube is routed to and retained in
2 - CONNECTOR
3 - NUT (2) an integral clip located behind the reservoir filler cap
4 - TIE WRAP near the top of the reservoir. This version of the
5 - MODULE washer pump/motor unit also has a third terminal
pin in its integral connector receptacle. The washer
(4) Unlock and disconnect the wire harness con-
fluid level switch cannot be adjusted or repaired. If
nector from the module connector receptacle.
faulty or damaged, the entire washer pump/motor
(5) Remove the two screws and nuts that secure
unit must be replaced.
the module to the bracket.
(6) Remove the module from the bracket.
OPERATION
The washer fluid level switch monitors the level of
INSTALLATION the washer fluid in the washer reservoir. When the
WARNING: TO AVOID PERSONAL INJURY OR fluid level in the washer reservoir is at or above the
DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, predetermined minimum, the switch contacts are
DISABLE THE SUPPLEMENTAL RESTRAINT SYS- open. When the fluid level in the washer reservoir
TEM BEFORE ATTEMPTING ANY STEERING falls below the predetermined minimum, the switch
WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT contacts of the normally open switch close. The
TENSIONER, OR INSTRUMENT PANEL COMPO- washer fluid level switch is connected to the vehicle
NENT DIAGNOSIS OR SERVICE. DISCONNECT AND electrical system through the washer pump/motor
ISOLATE THE BATTERY NEGATIVE (GROUND) unit take out and connector of the vehicle wire har-
CABLE, THEN WAIT TWO MINUTES FOR THE SYS- ness. The switch receives a path to ground at all
TEM CAPACITOR TO DISCHARGE BEFORE PER- times through another take out of the vehicle wire
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS harness with a single eyelet terminal connector that
IS THE ONLY SURE WAY TO DISABLE THE SUP- is secured under a ground screw located near the
PLEMENTAL RESTRAINT SYSTEM. FAILURE TO right headlamp in the engine compartment.
TAKE THE PROPER PRECAUTIONS COULD The switch is connected in series between ground
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. and the washer fluid switch sense input to the Elec-
troMechanical Instrument Cluster (EMIC). When the
(1) Position the rain sensor control module to the switch closes, the EMIC senses the ground on the
bracket under the instrument panel above the throt- washer fluid switch sense circuit. The EMIC is pro-
tle pedal (Fig. 12). grammed to respond to this input by illuminating the
(2) Install and tighten the two screws and nuts washer fluid indicator. The washer fluid level switch
that secure the module to the bracket (Fig. 13). input to the EMIC may be diagnosed using conven-
(3) Reconnect and lock the wire harness connector tional diagnostic tools and methods.
to the module connector receptacle.
VA WIPERS/WASHERS 8R - 17

WASHER HOSES/TUBES
DESCRIPTION

Fig. 14 Washer Plumbing


1 - WASHER SUPPLY HOSE 4 - ELBOW FITTING (2)
2 - CHECK VALVE 5 - WIPER ARM WASHER HOSE (2)
3 - WASHER NOZZLE HOSE (2) 6 - WASHER RESERVOIR

The washer plumbing consists of a small diameter OPERATION


rubber hose that is routed from the barbed outlet Washer fluid in the washer reservoir is pressurized
nipple of the washer pump/motor on the washer res- and fed by the washer pump/motor through the
ervoir to the check valve just below the cowl top washer system plumbing and fittings to the two
panel behind the rear of the hood opening in the washer nozzles. Whenever routing the washer hose
engine compartment (Fig. 14). The other two barbed or a wire harness containing a washer hose, it must
nipples of the check valve are connected to two short be routed away from hot, sharp, or moving parts;
lengths of hose that each terminate at a molded plas- and, sharp bends that might pinch the hose must be
tic elbow that passes through a rubber grommet from avoided.
the engine compartment to the outside of the cowl
top panel near each wiper pivot. The two washer noz-
zle hoses are then connected from the elbow fittings
on the outside of the cowl top panel along the under-
side of the wiper arms to the two washer nozzles.
Washer hose is available for service only as roll
stock, which must then be cut to length. The molded
plastic washer hose fittings cannot be repaired. If
these fittings are faulty or damaged, they must be
replaced.
8R - 18 WIPERS/WASHERS VA

WASHER NOZZLE
DESCRIPTION

Fig. 16 Washer Nozzle Remove/Install


Fig. 15 Washer Nozzle 1 - WIPER ARM
1 - WASHER NOZZLE 2 - WASHER NOZZLE
2 - NIPPLE 3 - HOSE GUARD
3 - ORIFICE (3) 4 - WASHER HOSE
5 - WIPER BLADE
The two washer nozzles have integral mounts with
snap features that secure them near the tops of the (2) Using hand pressure, slide the washer nozzle
two wiper arms on the windshield. The lower surface onto the wiper arm until it snaps into place. Be cer-
of the washer nozzle has an integral barbed nipple tain the nozzle snap feature is engaged in the locator
that connects to the washer hose, and three nozzle hole on the wiper arm.
orifices are oriented to dispense the washer fluid on
the windshield glass throughout the wiped area of
the glass (Fig. 15). The washer nozzles are con-
WASHER PUMP/MOTOR
structed entirely of molded plastic. The washer noz-
zles cannot be adjusted or repaired and, if faulty or DESCRIPTION
damaged, they must be replaced.

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

(1) Reconnect the hose to the barbed nipple of the


The washer pump/motor unit is located in a dedi-
washer nozzle (Fig. 16).
cated hole on the top of the sump area near the back
VA WIPERS/WASHERS 8R - 19
WASHER PUMP/MOTOR (Continued)
of the windshield washer reservoir on the right front
fender wheel house in the engine compartment (Fig.
17). A small permanently lubricated and sealed elec-
tric motor is coupled to the rotor-type washer pump.
An inlet nipple on the bottom of the pump housing
passes through a rubber grommet seal installed in
the dedicated mounting hole in the washer reservoir.
A small barbed outlet nipple near the bottom of the
pump housing connects the unit to the washer hose.
The washer pump/motor unit is retained on the res-
ervoir by the interference fit between the inlet nipple
and the grommet seal, which is a light press fit. An
integral electrical connector receptacle is located on
the top of the motor housing.
An optional version of the washer pump/motor unit
incorporates an integral washer fluid level switch.
This version can be distinguished from models with-
out the switch by a vent nipple at the top of the
switch housing that is connected to a vent hose that
is retained in an integral clip behind the filler cap
near the top of the reservoir, and by a third terminal
pin in the washer pump/motor connector receptacle.
The washer pump/motor unit cannot be repaired. If
faulty or damaged, the entire washer pump/motor
unit must be replaced.
Fig. 18 Washer Pump/Motor Remove/Install
OPERATION 1 - WASHER RESERVOIR
The washer pump/motor unit is connected to the 2 - WASHER SUPPLY HOSE
3 - VENT HOSE (W/FLUID LEVEL SWITCH ONLY)
vehicle electrical system through a single take out 4 - WIRE HARNESS CONNECTOR
and connector of the vehicle wire harness. The 5 - WASHER PUMP/MOTOR
washer pump/motor is grounded at all times through
a take out of the vehicle wire harness with a single vent nipple near the top of the washer pump/motor
eyelet terminal connector that is secured under a unit.
ground screw located near the right headlamp in the (4) Using hand pressure, firmly grasp and pull the
engine compartment. The washer pump/motor washer pump out of the rubber grommet seal in the
receives battery current on a washer switch sense reservoir. Care must be taken not to damage the res-
circuit through the closed contacts of the momentary ervoir.
washer switch circuitry within the multi-function (5) Remove the rubber grommet seal from the
switch. When the pump motor is energized, the rotor- washer pump mounting hole in the washer reservoir
type pump pressurizes the washer fluid and forces it and discard.
through the pump outlet nipple, the washer plumb-
ing, and the washer nozzles onto the windshield INSTALLATION
glass. The washer pump/motor unit can be diagnosed (1) Install a new rubber grommet seal into the
using conventional diagnostic tools and methods. washer pump mounting hole in the washer reservoir.
Always use a new rubber grommet seal on the reser-
REMOVAL voir.
(1) Disconnect the vehicle wire harness connector (2) Position the inlet nipple of the washer pump to
for the washer pump/motor from the motor connector the rubber grommet seal in the reservoir.
receptacle (Fig. 18). (3) Using hand pressure, press firmly and evenly
(2) Disconnect the washer supply hose from the on the washer pump until the inlet nipple is fully
barbed outlet nipple of the washer pump/motor and seated in the rubber grommet seal in the washer res-
allow the washer fluid to drain into a clean container ervoir mounting hole (Fig. 18).
for reuse. (4) If the vehicle is so equipped, reconnect the
(3) If the vehicle is so equipped, disconnect the washer fluid level switch vent hose to the barbed
washer fluid level switch vent hose from the barbed vent nipple at the top of the washer pump/motor
housing.
8R - 20 WIPERS/WASHERS VA
WASHER PUMP/MOTOR (Continued)
(5) Reconnect the washer hose to the barbed outlet the bottom inboard side of the reservoir with a dedi-
nipple of the washer pump. cated hole provided for the mounting of the washer/
(6) Reconnect the vehicle wire harness connector pump motor unit and rubber grommet seal.
for the washer pump/motor unit to the motor connec- The washer reservoir cannot be repaired and, if
tor receptacle. faulty or damaged, it must be replaced. The washer
(7) Refill the washer reservoir with the washer reservoir, the mounting grommets, the grommet seal
fluid drained from the reservoir during the removal for the washer pump/motor unit, and the filler cap
procedure. are each available for service replacement.

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

The molded plastic washer fluid reservoir is


located in the right rear corner of the engine com-
partment (Fig. 19). Two integral mounting posts, one
on the bottom and one at the rear of the reservoir,
each are engaged in rubber mounting grommets, one
in the dash panel and one in the top of the right
front wheel house. A single nut and washer secures
an integral mounting hole near the top of the reser-
voir to a stud nut on the right inner fender shield.
Also near the upper inboard side of the reservoir are
two integral hose routing troughs, one for the stan-
Fig. 20 Heat Shield & Air Cleaner Housing
dard washer supply hose and the second for the
1 - UPPER AIR CLEANER HOUSING
optional vent hose used when the washer pump/mo- 2 - VEHICLE WIRE HARNESS CONNECTOR
tor is equipped with an integral washer fluid level 3 - CLAMP
switch. 4 - UPPER TURBO HEAT SHIELD
5 - SCREW
A molded blue plastic filler cap with an integral 6 - NUT (2)
retainer ring and tether strap snaps over the open
end of the filler neck, and hangs from the tether (3) Disconnect the vehicle wire harness connector
when it is removed for inspecting or adjusting the for the washer pump/motor unit from the motor con-
fluid level in the reservoir. There is a sump area near nector receptacle.
VA WIPERS/WASHERS 8R - 21
WASHER RESERVOIR (Continued)
(4) Disengage the vehicle wire harness from the
routing clip integral to the front of the washer reser-
voir (Fig. 21).

Fig. 21 Washer Reservoir Remove/Install


1 - RIGHT INNER FENDER
2 - WASHER RESERVOIR
3 - NUT & WASHER
4 - ROUTING CLIP

(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

Fig. 23 Wiper Arm


1 - HOOK 7 - CHANNEL
2 - STRAP 8 - COVER
3 - WASHER HOSE 9 - PIVOT END
4 - BRACKET (2) 10 - GUARD
5 - HINGE PIN 11 - WASHER NOZZLE
6 - TENSION SPRING

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

(5) Remove the wiper arm pivot end from the


wiper pivot shaft.

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

(1) The wiper arms must be indexed to the wiper


CAUTION: The use of a screwdriver or other prying
pivot shafts with the wiper motor in the park posi-
tool to remove a wiper arm may distort it. This dis-
tion to be properly installed. Position the wiper arm
tortion could allow the arm to come off of the wiper
pivot ends onto the wiper pivots so that the lower
pivot during wiper operation, regardless of how
edge of the wiper arm tip is aligned with the black
carefully it is reinstalled.
wiper alignment line located near the lower edge of
the windshield glass (Fig. 24).
8R - 24 WIPERS/WASHERS VA
WIPER ARM (Continued)
(2) Once the wiper blade is aligned, lift the wiper • Element - The wiper element or squeegee is the
arm away from the windshield slightly to relieve the resilient rubber member of the wiper blade that con-
spring tension on the pivot end and push the pivot tacts the glass.
hole in the pivot end of the arm down firmly and • Flexor - The flexor is a rigid metal component
evenly over the wiper pivot shaft. Gently lower the running along the length of the wiper element on
wiper arm until the wiper blade rests on the glass. each side, where it is gripped by the claws of the
(3) Install and tighten the nut that secures the superstructure.
wiper arm to the wiper pivot shaft. Tighten the nut All Sprinter models have unequal length wiper
to 24 N·m (18 ft. lbs.). blades with non-replaceable rubber elements (squee-
(4) Wet the windshield glass, then operate the wip- gees). The left (driver) side wiper blade is 60.0 centi-
ers. Move the right (wiper) control stalk of the multi- meters (23.5 inches), and the right (passenger) side
function switch to the Off position, then check for the wiper blade is 55.0 centimeter (21.5 inches). These
correct wiper arm position and readjust as required. wiper blades also include an anti-lift feature. The
(5) Engage the pivot cover with the wiper arm wiper blades cannot be adjusted or repaired. If faulty,
hinge pin, then push the pivot end of the cover down worn, or damaged the entire wiper blade unit must
firmly and evenly until it snaps over the wiper blade be replaced.
pivot end.
(6) Reconnect the washer nozzle hose to the elbow OPERATION
fitting on the cowl top panel near the pivot end of the The wiper blades are moved back and forth across
wiper arm. the glass by the wiper arms when the wipers are
being operated. The wiper blade superstructure is
the flexible frame that grips the wiper blade element
WIPER BLADE and evenly distributes the force of the spring-loaded
wiper arm along the length of the element. The com-
DESCRIPTION bination of the wiper arm force and the flexibility of
Each wiper blade is secured by an integral latching the superstructure makes the element conform to
pivot block to the hook formation on the tip of the and maintain proper contact with the glass, even as
wiper arm, and rests on the glass near the base of the blade is moved over the varied curvature that
the windshield when the wipers are not in operation may be encountered across the glass surface. The
(Fig. 26). The wiper blade consists of the following wiper element flexor provides the claws of the blade
components: superstructure with a rigid, yet flexible component
• Superstructure - The superstructure includes on the element which can be gripped. The rubber ele-
several stamped steel bridges and links with claw ment is designed to be stiff enough to maintain an
formations that grip the wiper blade element. Also even cleaning edge as it is drawn across the glass,
included in this unit is the latching, molded plastic but resilient enough to conform to the glass surface
pivot block that secures the superstructure to the and flip from one cleaning edge to the other each
wiper arm. All of the metal components of the wiper time the wiper blade changes directions.
blade have a satin black finish applied.

Fig. 26 Wiper Blade


1 - PIVOT BLOCK 4 - FLEXOR
2 - SUPERSTRUCTURE 5 - ELEMENT
3 - CLAWS 6 - PIVOT PIN
VA WIPERS/WASHERS 8R - 25
WIPER BLADE (Continued)

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)

Fig. 28 Wiper Linkage Module


1 - PIVOT SHAFT (2) 4 - PIVOT CRANK ARM (2)
2 - PIVOT SHAFT HOUSING (2) 5 - DRIVE LINK (2)
3 - MODULE BRACKET 6 - MOTOR CRANK ARM

then secured with screws to the underside of the cowl REMOVAL


top panel. (1) Disconnect and isolate the battery negative
• Motor Crank Arm - The wiper motor crank cable.
arm is a stamped steel unit with a round hole on the (2) Remove the wiper arms from the wiper pivots.
driven end that is secured to the wiper motor output (Refer to 8 - ELECTRICAL/WIPERS/WASHERS/
shaft with a nut, and a long ball stud secured to the WIPER ARM - REMOVAL).
drive end. (3) Remove the five nuts that secure the ventila-
• Pivot - The two molded plastic wiper pivot tion housing to the dash panel and the underside of
brackets are secured to the ends of the linkage mod- the cowl top panel (Fig. 29).
ule bracket tubular member. The crank arms that (4) Pull the ventilation housing forward far enough
extend from the bottom of the pivot shafts each have to disengage the housing from the studs on the dash
a ball stud on their end. The upper end of each pivot panel, then lower the housing until it rests on the
shaft where the wiper arms will be fastened each is top of the engine.
tapered and externally serrated with a threaded stud (5) Disconnect the wiper motor pigtail wire connec-
at the top where the wiper arms are secured by a tor from the vehicle wire harness connector.
nut. Each pivot shaft operates within a housing (6) Remove the nut and washer that secures each
formed in the pivot bracket featuring a large external wiper pivot housing to the outside of the cowl top
flange near its center and external threads near the panel (Fig. 30).
top. The pivot housings are secured to the outer sur- (7) Remove the two screws that secure the wiper
face of the cowl top panel by a large washer and a linkage module motor bracket to the flange on the
nut threaded onto the outside of the housing where it underside of the cowl top panel.
protrudes through the cowl top. (8) Remove the wiper linkage module and wiper
The wiper linkage module cannot be adjusted or motor from the underside of the cowl top panel as a
repaired. If any component of the linkage module is unit.
faulty or damaged, the entire wiper linkage module (9) Remove the wiper motor from the wiper link-
unit must be replaced. age module. (Refer to 8 - ELECTRICAL/WIPERS/
WASHERS/WIPER MOTOR - REMOVAL).
OPERATION
The wiper linkage operation is controlled by the
output of the wiper motor through the wiper motor
crank arm. The wiper motor crank arm, the two
wiper drive links, and the two wiper pivots mechan-
ically convert the rotary output of the wiper motor to
the back and forth wiping motion of the wiper arms
and blades on the glass.
VA WIPERS/WASHERS 8R - 27
WIPER LINKAGE (Continued)

Fig. 29 Ventilation Housing


1 - NUT (5) 3 - CABIN FILTER HOUSING
2 - WASHER (5) 4 - VENTILATION HOUSING

Fig. 30 Wiper Linkage Module Remove/Install


1 - NUT & WASHER (2) 4 - COWL TOP PANEL
2 - PIVOT (2) 5 - MOTOR BRACKET
3 - SCREW (2)

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

WIPER MOTOR ground or to battery current, depending upon the


position of the wipers on the glass. This feature
allows the intermittent wipe logic circuit to monitor
DESCRIPTION
the position and the cycles of the wiper motor to pro-
vide the intermittent wipe and wipe-after-wash
modes, as well as allowing the motor to complete its
current wipe cycle after the wiper system has been
turned Off and park the wiper blades in the lowest
portion of the wipe pattern.
The wiper motor may be diagnosed using conven-
tional diagnostic tools and methods.

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)

Fig. 32 Wiper Motor Remove/Install


1 - NUT 4 - PIGTAIL WIRE CONNECTOR
2 - LINK (2) 5 - WIPER MOTOR
3 - MOTOR CRANK ARM 6 - SCREW (3)

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.

(1) Position the wiper relay to the receptacle on


Fig. 34 Wiper Relay Remove/Install the bottom of the fuse block (Fig. 34).
1 - FUSE BLOCK (2) Align the wiper relay terminals with the termi-
2 - LOWER INSTRUMENT PANEL nal cavities in the fuse block receptacle.
3 - STEERING COLUMN COVER (3) Push firmly and evenly on the top of the wiper
4 - LATCH (2)
5 - WIPER RELAY relay until the terminals are fully seated in the ter-
minal cavities in the receptacle of the fuse block and
both latches are fully engaged.
(4) Reinstall the fuse access panel onto the steer-
ing column opening cover below the steering column
on the instrument panel.
(5) Reconnect the battery negative cable.
VA WIRING 8W - 1

WIRING
TABLE OF CONTENTS

page page

WIRING DIAGRAM INFORMATION. . . . . . . 8W-01-1 CENTRAL TIMER MODULE. . . . . . . . . . . . . 8W-45-1


COMPONENT INDEX . . . . . . . . . . . . . . . . . . 8W-02-1 AUDIO SYSTEM . . . . . . . . . . . . . . . . . . . . . 8W-47-1
POWER DISTRIBUTION . . . . . . . . . . . . . . . 8W-10-1 REAR WINDOW DEFOGGER. . . . . . . . . . . . 8W-48-1
FUSE BLOCK. . . . . . . . . . . . . . . . . . . . . . . . 8W-11-1 FRONT LIGHTING . . . . . . . . . . . . . . . . . . . . 8W-50-1
GROUND DISTRIBUTION . . . . . . . . . . . . . . 8W-15-1 REAR LIGHTING . . . . . . . . . . . . . . . . . . . . . 8W-51-1
BUS COMMUNICATIONS . . . . . . . . . . . . . . 8W-18-1 TURN SIGNALS. . . . . . . . . . . . . . . . . . . . . . 8W-52-1
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . 8W-20-1 WIPERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-1
STARTING SYSTEM . . . . . . . . . . . . . . . . . . 8W-21-1 TRAILER TOW. . . . . . . . . . . . . . . . . . . . . . . 8W-54-1
FUEL/IGNITION SYSTEM . . . . . . . . . . . . . . 8W-30-1 NAVIGATION/TELECOMMUNICATIONS . . . . 8W-55-1
TRANSMISSION CONTROL SYSTEM . . . . . 8W-31-1 POWER WINDOWS. . . . . . . . . . . . . . . . . . . 8W-60-1
VEHICLE SPEED CONTROL . . . . . . . . . . . . 8W-33-1 POWER DOOR LOCKS . . . . . . . . . . . . . . . . 8W-61-1
ANTILOCK BRAKES. . . . . . . . . . . . . . . . . . . 8W-35-1 POWER MIRRORS . . . . . . . . . . . . . . . . . . . 8W-62-1
VEHICLE THEFT SECURITY SYSTEM . . . . . 8W-39-1 POWER SEATS . . . . . . . . . . . . . . . . . . . . . . 8W-63-1
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . 8W-40-1 SPLICE INFORMATION . . . . . . . . . . . . . . . . 8W-70-1
HORN/CIGAR LIGHTER. . . . . . . . . . . . . . . . 8W-41-1 CONNECTOR PIN-OUTS . . . . . . . . . . . . . . . 8W-80-1
AIR CONDITIONING-HEATER . . . . . . . . . . . 8W-42-1 CONNECTOR/GROUND/
AIRBAG SYSTEM . . . . . . . . . . . . . . . . . . . . 8W-43-1 SPLICE LOCATION . . . . . . . . . . . . . . . . . . 8W-91-1
INTERIOR LIGHTING. . . . . . . . . . . . . . . . . . 8W-44-1 POWER DISTRIBUTION . . . . . . . . . . . . . . . 8W-97-1
VA 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 1

8W-01 WIRING DIAGRAM INFORMATION

TABLE OF CONTENTS
page page

WIRING DIAGRAM INFORMATION TESTING COMPONENTS FOR A SHORT TO


DESCRIPTION GROUND ON A FUSE POWERING
HOW TO USE WIRING DIAGRAMS . . .......1 SEVERAL LOADS . . . . . . . . . . . . . . . . . . . . . . 8
CIRCUIT INFORMATION . . . . . . . . . . .......5 TESTING FOR A VOLTAGE DROP .........9
SECTION IDENTIFICATION AND CONNECTOR
INFORMATION . . . . . . . . . . . . . . . . . .......5 REMOVAL .............................9
CONNECTOR, GROUND, AND SPLICE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INFORMATION . . . . . . . . . . . . . . . . . .......5 DIODE
WARNINGS - GENERAL . . . . . . . . . . . . .......6 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
DIAGNOSIS AND TESTING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10
WIRING HARNESS . . . . . . . . . . . . . . .......6 TERMINAL
STANDARD PROCEDURE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ELECTROSTATIC DISCHARGE (ESD) INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10
SENSITIVE DEVICES . . . . . . . . . . . . .... . . .7 WIRE
TESTING FOR VOLTAGE POTENTIAL .... . . .8 STANDARD PROCEDURE
TESTING FOR CONTINUITY . . . . . . . .... . . .8 WIRE SPLICING . . . . . . . . . . . . . . . . . . . . . . 11
TESTING FOR A SHORT TO GROUND ... . . .8

WIRING DIAGRAM Components are shown two ways. A solid line


around a component indicates that the component is
INFORMATION complete. A dashed line around the component indi-
cates that the component is being shown is not com-
plete. Incomplete components have a reference
DESCRIPTION number to indicate the page where the component is
shown complete.
HOW TO USE WIRING DIAGRAMS It is important to realize that no attempt is made
DaimlerChrysler Corporation wiring diagrams are on the diagrams to represent components and wiring
designed to provide information regarding the vehi- as they appear on the vehicle. For example, a short
cles wiring content. In order to effectively use the piece of wire is treated the same as a long one. In
wiring diagrams to diagnose and repair addition, switches and other components are shown
DaimlerChrysler Corporation vehicles, it is important as simply as possible, with regard to function only.
to understand all of their features and characteris-
tics. SYMBOLS
Diagrams are arranged such that the power (B+) International symbols are used throughout the wir-
side of the circuit is placed near the top of the page, ing diagrams. These symbols are consistent with
and the ground (B-) side of the circuit is placed near those being used around the world (Fig. 3).
the bottom of the page (Fig. 1).
All switches, components, and modules are shown
in the at rest position with the doors closed and the
key removed from the ignition (Fig. 2).
8W - 01 - 2 8W-01 WIRING DIAGRAM INFORMATION VA
WIRING DIAGRAM INFORMATION (Continued)

Fig. 1 WIRING DIAGRAM EXAMPLE 1


VA 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 3
WIRING DIAGRAM INFORMATION (Continued)

Fig. 2 WIRING DIAGRAM EXAMPLE 2


8W - 01 - 4 8W-01 WIRING DIAGRAM INFORMATION VA
WIRING DIAGRAM INFORMATION (Continued)

Fig. 3 Wiring Diagram Symbols


VA 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 5
WIRING DIAGRAM INFORMATION (Continued)
TERMINOLOGY Splice diagrams in Section 8W-70 show the entire
This is a list of terms and definitions used in the splice and provide references to other sections the
wiring diagrams. splices serves. Section 8W-70 only contains splice dia-
grams that are not shown in their entirety some-
LHD . . . . . . . . . . . . . . . . . Left Hand Drive Vehicles where else in the wiring diagrams.
RHD . . . . . . . . . . . . . . . Right Hand Drive Vehicles Section 8W-80 shows each connector and the cir-
ATX . . Automatic Transmissions-Front Wheel Drive cuits involved with that connector. The connectors
MTX . . . Manual Transmissions-Front Wheel Drive are identified using the name/number on the dia-
AT . . . . Automatic Transmissions-Rear Wheel Drive gram pages.
MT . . . . . Manual Transmissions-Rear Wheel Drive
SOHC . . . . . . . . . . . Single Over Head Cam Engine WIRING SECTION CHART
DOHC . . . . . . . . . . Double Over Head Cam Engine
Built-Up-Export . . . . . . . Vehicles Built For Sale In GROUP TOPIC
Markets Other Than North America 8W-01 thru General information and Diagram
Except Built-Up-Export . Vehicles Built For Sale In 8W-09 Overview
North America 8W-10 thru Main Sources of Power and
CIRCUIT INFORMATION 8W-19 Vehicle Grounding
Each wire shown in the diagrams contains a code 8W-20 thru Starting and Charging
which identifies gage of wire, and color. 8W-29
8W-30 thru Powertrain/Drivetrain Systems
WIRE COLOR CODE CHART 8W-39
8W-40 thru Body Electrical items and A/C
COLOR CODE COLOR 8W-49
BL BLUE 8W-50 thru Exterior Lighting, Wipers and
BK BLACK 8W-59 Trailer Tow
BR BROWN 8W-60 thru Power Accessories
DB DARK BLUE 8W-69
DG DARK GREEN 8W-70 Splice Information
GY GRAY 8W-80 Connector Pin Outs
LB LIGHT BLUE 8W-91 Connector, Ground and Splice
Locations
LG LIGHT GREEN
OR ORANGE CONNECTOR, GROUND, AND SPLICE
PK PINK INFORMATION
RD RED
CAUTION: Not all connectors are serviced. Some
TN TAN
connectors are serviced only with a harness. A typ-
VT VIOLET ical example might be the Supplemental Restraint
WT WHITE System connectors. Always check parts availability
YL YELLOW before attempting a repair.
* WITH TRACER
IDENTIFICATION
SECTION IDENTIFICATION AND INFORMATION In-line connectors are identified by a number, as
The wiring diagrams are grouped into individual follows:
sections. If a component is most likely found in a par- • In-line connectors located in the engine compart-
ticular group, it will be shown complete (all wires, ment are C100 series numbers
connectors, and pins) within that group. For exam- • In-line connectors located in the Instrument
ple, the Auto Shutdown Relay is most likely to be Panel area are C200 series numbers.
found in Group 30, so it is shown there complete. It • In-line connectors located in the body are C300
can, however, be shown partially in another group if series numbers.
it contains some associated wiring. • Jumper harness connectors are C400 series
numbers.
8W - 01 - 6 8W-01 WIRING DIAGRAM INFORMATION VA
WIRING DIAGRAM INFORMATION (Continued)
• Grounds and ground connectors are identified TOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATA-
with a “G” and follow the same series numbering as LYTIC CONVERTER AND MUFFLER.
the in-line connectors.
• Splices are identified with an “S” and follow the WARNING: DO NOT ALLOW FLAME OR SPARKS
same series numbering as the in-line connectors. NEAR THE BATTERY. GASES ARE ALWAYS
• Component connectors are identified by the com- PRESENT IN AND AROUND THE BATTERY.
ponent name instead of a number. Multiple connec-
tors on a component use a C1, C2, etc. identifier.
WARNING: ALWAYS REMOVE RINGS, WATCHES,
LOOSE HANGING JEWELRY AND AVOID LOOSE
LOCATIONS
CLOTHING.
Section 8W-91 contains connector/ground/splice
location illustrations. The illustrations contain the
connector name (or number)/ground number/splice
number and component identification. Connector/ DIAGNOSIS AND TESTING
ground/splice location charts in section 8W-91 refer-
ence the figure numbers of the illustrations. WIRING HARNESS
The abbreviation T/O is used in the component
location section to indicate a point in which the wir- TROUBLESHOOTING TOOLS
ing harness branches out to a component. The abbre- When diagnosing a problem in an electrical circuit
viation N/S means Not Shown in the illustrations there are several common tools necessary. These tools
are listed and explained below.
WARNINGS - GENERAL • Jumper Wire - This is a test wire used to con-
WARNINGS provide information to prevent per- nect two points of a circuit. It can be used to bypass
sonal injury and vehicle damage. Below is a list of an open in a circuit.
general warnings that should be followed any time a
vehicle is being serviced. WARNING: NEVER USE A JUMPER WIRE ACROSS
A LOAD, SUCH AS A MOTOR, CONNECTED
WARNING: ALWAYS WEAR SAFETY GLASSES FOR BETWEEN A BATTERY FEED AND GROUND.
EYE PROTECTION.
• Voltmeter - Used to check for voltage on a cir-
cuit. Always connect the black lead to a known good
WARNING: USE SAFETY STANDS ANYTIME A PRO- ground and the red lead to the positive side of the
CEDURE REQUIRES BEING UNDER A VEHICLE. circuit.

CAUTION: Most of the electrical components used


WARNING: BE SURE THAT THE IGNITION SWITCH
in today’s vehicles are Solid State. When checking
ALWAYS IS IN THE OFF POSITION, UNLESS THE
voltages in these circuits, use a meter with a 10 -
PROCEDURE REQUIRES IT TO BE ON.
megohm or greater impedance rating.

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.

WARNING: TO PREVENT SERIOUS BURNS, AVOID


CONTACT WITH HOT PARTS SUCH AS THE RADIA-
VA 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 7
WIRING DIAGRAM INFORMATION (Continued)
• Probing Tools - These tools are used for probing (3) Analyze the symptoms. Use the wiring dia-
terminals in connectors (Fig. 4). Select the proper grams to determine what the circuit is doing, where
size tool from Special Tool Package 6807, and insert the problem most likely is occurring and where the
it into the terminal being tested. Use the other end diagnosis will continue.
of the tool to insert the meter probe. (4) Isolate the problem area.
(5) Repair the problem area.
(6) Verify the proper operation. For this step,
check for proper operation of all items on the
repaired circuit. Refer to the wiring diagrams.

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

TROUBLESHOOTING WIRING PROBLEMS


When troubleshooting wiring problems there are
six steps which can aid in the procedure. The steps
are listed and explained below. Always check for non-
factory items added to the vehicle before doing any
diagnosis. If the vehicle is equipped with these items,
disconnect them to verify these add-on items are not
the cause of the problem.
(1) Verify the problem. Fig. 5 ELECTROSTATIC DISCHARGE SYMBOL
(2) Verify any related symptoms. Do this by per-
forming operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
8W - 01 - 8 8W-01 WIRING DIAGRAM INFORMATION VA
WIRING DIAGRAM INFORMATION (Continued)

TESTING FOR VOLTAGE POTENTIAL


(1) Connect the ground lead of a voltmeter to a
known good ground (Fig. 6).
(2) Connect the other lead of the voltmeter to the
selected test point. The vehicle ignition may need to
be turned ON to check voltage. Refer to the appropri-
ate test procedure.

Fig. 7 Testing for Continuity


1 - FUSE REMOVED FROM CIRCUIT

TESTING COMPONENTS FOR A SHORT TO


GROUND ON A FUSE POWERING SEVERAL
LOADS
(1) Refer to the wiring diagrams and disconnect or
Fig. 6 Testing for Voltage Potential isolate all items on the suspected fused circuit.
TESTING FOR CONTINUITY (2) Replace the blown fuse.
(3) Supply power to the fuse by turning ON the
(1) Remove the fuse for the circuit being checked
ignition switch or re-connecting the battery.
or, disconnect the battery.
(4) Start connecting the items in the fused circuit
(2) Connect one lead of the ohmmeter to one side
one at a time. When the fuse blows the component
of the circuit being tested (Fig. 7).
with the short to ground has been isolated.
(3) Connect the other lead to the other end of the
circuit being tested. Low or no resistance means good
continuity.

TESTING FOR A SHORT TO GROUND


(1) Remove the fuse and disconnect all items
involved with the fuse.
(2) Connect a test light or a voltmeter across the
terminals of the fuse.
(3) Starting at the fuse block, wiggle the wiring
harness about six to eight inches apart and watch
the voltmeter/test lamp.
(4) If the voltmeter registers voltage or the test
lamp glows, there is a short to ground in that gen-
eral area of the wiring harness.
VA 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 9
WIRING DIAGRAM INFORMATION (Continued)

TESTING FOR A VOLTAGE DROP


(1) Connect the positive lead of the voltmeter to
the side of the circuit closest to the battery (Fig. 8).
(2) Connect the other lead of the voltmeter to the
other side of the switch, component or circuit.
(3) Operate the item.
(4) The voltmeter will show the difference in volt-
age between the two points.

Fig. 9 REMOVAL OF DRESS COVER


1 - DRESS COVER
2 - CONNECTOR LOCK
3 - CONNECTOR

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

DIODE (3) Solder the connection together using rosin core


type solder only. Do not use acid core solder.
(4) Tape the diode to the harness using electrical
REMOVAL
tape. Make sure the diode is completely sealed from
(1) Disconnect the battery.
the elements.
(2) Locate the diode in the harness, and remove
(5) Re-connect the battery and test affected sys-
the protective covering.
tems.
(3) Remove the diode from the harness, pay atten-
tion to the current flow direction (Fig. 10).
TERMINAL
REMOVAL
(1) Follow steps for removing terminals described
in the connector removal section.
(2) Cut the wire 6 inches from the back of the con-
nector.

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).

Fig. 11 Diode Identification


1 - CURRENT FLOW
2 - BAND AROUND DIODE INDICATES CURRENT FLOW
3 - DIODE AS SHOWN IN THE DIAGRAMS
VA 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 11

WIRE (5) Solder the connection together using rosin core


type solder only (Fig. 14).

STANDARD PROCEDURE CAUTION: DO NOT USE ACID CORE SOLDER.

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

(6) Center the heat shrink tubing over the joint


and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing (Fig. 15).

Fig. 12 1 SPLICE BAND


1 - SPLICE BAND

(4) Using crimping tool, Mopar p/n 05019912AA,


crimp the splice clip and wires together (Fig. 13).

Fig. 15 4 HEAT SHRINK TUBE


1 - SEALANT
2 - HEAT SHRINK TUBE

Fig. 13 2 CRIMPING TOOL


1 - CRIMPING TOOL
VA 8W-02 COMPONENT INDEX 8W - 02 - 1

8W-02 COMPONENT INDEX


Component Page Component Page
A/C Auxiliary Fan . . . . . . . . . . . . . . . . . . . . . 8W-42 Door Lock Motor/Ajar Switch Assemblies . . . 8W-61
A/C Auxiliary Fan Relay . . . . . . . . . . . . . . . . 8W-42 Dosing Pump . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42
A/C Compressor Clutch . . . . . . . . . . . . . . . . . 8W-42 EGR Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
A/C Control Module-Roof . . . . . . . . . . . . . . . . 8W-42 Engine Control Module . . . . . . . . . . . . . . . . . 8W-30
A/C Switch-Roof . . . . . . . . . . . . . . . . . . . . . . 8W-42 Engine Control Relay . . . . . . . . . . . . . . . . . . 8W-31
A/C Temperature Setting Control-Roof . . . . . 8W-42 Engine Coolant Level Switch . . . . . . . . . . . . . 8W-30
Accelerator Pedal Position Sensor . . . . . . . . . 8W-30 Engine Coolant Temperature Sensor . . . . . . . 8W-30
Additional Heat Exchanger . . . . . . . . . . . . . . 8W-42 Engine Oil Sensor . . . . . . . . . . . . . . . . . . . . . 8W-30
Additional Heat Exchanger Relay . . . . . . . . . 8W-42 Evaporator Temperature Sensor . . . . . . . . . . 8W-42
Additional Heat Exchanger Switch . . . . . . . . 8W-42 Fan Stage 1 Relay . . . . . . . . . . . . . . . . . . . . . 8W-42
Air Outlet Temperature Sensor . . . . . . . . . . . 8W-42 Fog Lamp Relay . . . . . . . . . . . . . . . . . . . . . . 8W-50
Airbag Control Module . . . . . . . . . . . . . . . . . 8W-43 Fog Lamp Switch . . . . . . . . . . . . . . . . . . . . . 8W-50
Airbag Squibs . . . . . . . . . . . . . . . . . . . . . . . . 8W-43 Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
Ambient Temperature Sensor . . . . . . . . . . . . 8W-42 Fuel Level Sensor . . . . . . . . . . . . . . . . . . . . . 8W-30
Ash Receiver Lamp . . . . . . . . . . . . . . . . . . . . 8W-44 Fuel Pressure Sensor . . . . . . . . . . . . . . . . . . 8W-30
Automatic Temperature Control Module . . . . 8W-42 Fuel Pressure Solenoid . . . . . . . . . . . . . . . . . 8W-30
Auxiliary Heater Switch . . . . . . . . . . . . . . . . 8W-42 Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20 Fuel Pump Relay . . . . . . . . . . . . . . . . . . . . . . 8W-30
Battery Relay-Auxiliary . . . . . . . . . . . . . . . . 8W-20 Fuel Quantity Control Valve . . . . . . . . . . . . . 8W-30
Beam Select Switch . . . . . . . . . . . . . . . . . . . . 8W-50 Fuel Shutdown Solenoid . . . . . . . . . . . . . . . . 8W-30
Blower Motor Resistor Block . . . . . . . . . . . . . 8W-42 Fuel Temperature Sensor . . . . . . . . . . . . . . . 8W-30
Blower Motor-Front . . . . . . . . . . . . . . . . . . . . 8W-42 Fuse Blocks . . . . . . . . . . . . . . . . . . . . 8W-10, 11, 30
Body Plug Connector . . . . . . . . . . . . . . . . . . . 8W-11 Fuse/Relay Block . . . . . . . . . . . . . . . . . . . . . . 8W-11
Boost Pressure Sensor . . . . . . . . . . . . . . . . . . 8W-30 Fused Ignition Switch Run-Start Relay . . . . . 8W-11
Boost Pressure Servomotor . . . . . . . . . . . . . . 8W-30 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10, 11
Boost Pressure Solenoid . . . . . . . . . . . . . . . . 8W-30 Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20
Brake Fluid Level Switch . . . . . . . . . . . . . . . 8W-35 Glow Plug Control Module . . . . . . . . . . . . . . 8W-30
Brake Lamp Switch . . . . . . . . . . . . . . . . . . . . 8W-35 Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
Brake Wear Sensors . . . . . . . . . . . . . . . . . . . 8W-35 Grounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15
Cabin Heater Assembly . . . . . . . . . . . . . . . . . 8W-42 Hazard Warning Switch . . . . . . . . . . . . . . . . 8W-52
Camshaft Position Sensor . . . . . . . . . . . . . . . 8W-30 Headlamp Adjust Switch . . . . . . . . . . . . . . . . 8W-50
Center High Mounted Stop Lamp . . . . . . . . . 8W-51 Headlamp Assemblies . . . . . . . . . . . . . . . 8W-50, 52
Central Timer Module . . . . . . . . . . . . . . . . . . 8W-45 Headlamp Switch . . . . . . . . . . . . . . . . . . . . . 8W-50
Cigar Lighter . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41 Heated Seat Modules . . . . . . . . . . . . . . . . . . 8W-63
Cigar Lighter Lamp . . . . . . . . . . . . . . . . . . . 8W-44 Heated Seat Switches . . . . . . . . . . . . . . . . . . 8W-63
Circulation Pump . . . . . . . . . . . . . . . . . . . . . 8W-42 Heater Timer-Auxiliary . . . . . . . . . . . . . . . . . 8W-42
Circulation Pump Diode . . . . . . . . . . . . . . . . 8W-42 High Idle Switch . . . . . . . . . . . . . . . . . . . . . . 8W-30
Circulation Pump Relay . . . . . . . . . . . . . . . . 8W-42 Hood Ajar Switch . . . . . . . . . . . . . . . . . . . . . 8W-39
Clockspring . . . . . . . . . . . . . . . . . . . . . . . 8W-41, 43 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41
Controller Antilock Brake . . . . . . . . . . . . . . . 8W-35 Horn Relay . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41
Courtesy Lamps . . . . . . . . . . . . . . . . . . . . . . 8W-44 Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41
Crankcase Heater . . . . . . . . . . . . . . . . . . . . . 8W-30 Ignition Lock Switch . . . . . . . . . . . . . . . . . . . 8W-40
Crankshaft Position Sensor . . . . . . . . . . . . . . 8W-30 Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . 8W-10
CTEL Antenna Connector . . . . . . . . . . . . . . . 8W-55 Instrument Cluster . . . . . . . . . . . . . . . . . . . . 8W-40
CTEL Connector . . . . . . . . . . . . . . . . . . . . . . 8W-55 Instrument Panel Socket . . . . . . . . . . . . . . . . 8W-40
Cylinder Lock Switch-Driver . . . . . . . . . . . . . 8W-61 Intake Air Pressure Sensor . . . . . . . . . . . . . . 8W-30
D+ Relays . . . . . . . . . . . . . . . . . . . . . . . . 8W-10, 11 Intake Air Temperature Sensor . . . . . . . . . . . 8W-30
Data Link Connector . . . . . . . . . . . . . . . . . . . 8W-18 Interior Lamps . . . . . . . . . . . . . . . . . . . . . . . 8W-44
Daytime Running Lamp Relays . . . . . . . . . . . 8W-50 Interior Light Switches . . . . . . . . . . . . . . . . . 8W-44
Differential Lock Solenoid Valve . . . . . . . . . . 8W-31 Interior Lighting Connector . . . . . . . . . . . . . . 8W-44
Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44 Intrusion Sensors . . . . . . . . . . . . . . . . . . . . . 8W-39
Door Jamb Switches . . . . . . . . . . . . . . . . . . . 8W-44 Kickdown Switch . . . . . . . . . . . . . . . . . . . . . . 8W-30
8W - 02 - 2 8W-02 COMPONENT INDEX VA

Component Page Component Page


Lamp Relays . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50 Skreem Transponder . . . . . . . . . . . . . . . . . . . 8W-39
License Plate Lamps . . . . . . . . . . . . . . . . . . . 8W-51 Speakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47
Lockeres . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31 Speed Control Switch . . . . . . . . . . . . . . . . . . 8W-33
Low Fuel Pressure Sensor . . . . . . . . . . . . . . . 8W-30 Splices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70
Map/Reading Lamp Switch . . . . . . . . . . . . . . 8W-44 Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . 8W-21
Marker Lamp Connector . . . . . . . . . . . . . . . . 8W-51 Starter Motor Relay . . . . . . . . . . . . . . . . . . . 8W-21
Marker Lamps . . . . . . . . . . . . . . . . . . . . . 8W-50, 51 Tail Lamp Assemblies . . . . . . . . . . . . . . . . . . 8W-51
Mass Air Flow Sensor . . . . . . . . . . . . . . . . . . 8W-30 TCS Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35
Master Door Lock Switch . . . . . . . . . . . . . . . 8W-61 Time Delay Relay . . . . . . . . . . . . . . . . . . . . . 8W-44
Metering Pump . . . . . . . . . . . . . . . . . . . . . . . 8W-42 Towing/Intrusion Sensor On/Off Switch . . . . . 8W-39
Microphone Connector . . . . . . . . . . . . . . . . . . 8W-55 Trailer Tow Connector . . . . . . . . . . . . . . . . . . 8W-54
Multi-Function Switch . . . . . . . . . 8W-50, 52, 53, 54 Trailer Tow Control Module . . . . . . . . . . . . . . 8W-54
Optional Equipment Relay . . . . . . . . . . . . . . 8W-11 Transmission Control Module . . . . . . . . . . . . 8W-31
Oxygen Sensor . . . . . . . . . . . . . . . . . . . . . . . 8W-30 Transmission Relay . . . . . . . . . . . . . . . . . . . . 8W-31
Panic Alarm Switch . . . . . . . . . . . . . . . . . . . . 8W-39 Transmission Solenoid Assembly . . . . . . . . . . 8W-31
Parking Brake Switch . . . . . . . . . . . . . . . . . . 8W-35 Turn Signals . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52
Power Distribution Center . . . . . . . . . . . . . . 8W-10 Turn Signal Relay . . . . . . . . . . . . . . . . . . . . . 8W-52
Power Mirror Motors . . . . . . . . . . . . . . . . . . . 8W-62 Turn Signal Switch . . . . . . . . . . . . . . . . . . . . 8W-50
Power Mirror Switch . . . . . . . . . . . . . . . . . . . 8W-62 Turn Signal/Anti-Theft Alarm Relays . . . . . . 8W-39
Power Window Motors . . . . . . . . . . . . . . . . . . 8W-60 Warm Air Auxiliary Control Module . . . . . . . 8W-42
Power Window Switches . . . . . . . . . . . . . . . . 8W-60 Warm Air Auxiliary Heater Assembly . . . . . . 8W-42
Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47 Washer On/Off Switch . . . . . . . . . . . . . . . . . . 8W-53
Radio Antenna . . . . . . . . . . . . . . . . . . . . . . . . 8W-47 Washer Pump Motor-Front . . . . . . . . . . . . . . 8W-53
Radio/Cellular Antenna . . . . . . . . . . . . . . . . . 8W-55 Water Cycle Valve . . . . . . . . . . . . . . . . . . . . . 8W-42
Reading Lamp Connector . . . . . . . . . . . . . . . 8W-44 Water In Fuel Sensor . . . . . . . . . . . . . . . . . . 8W-30
Recirculated Air Solenoid Valve . . . . . . . . . . . 8W-42 Wheel Speed Sensors . . . . . . . . . . . . . . . . . . . 8W-35
Refrigerant Pressure Sensor . . . . . . . . . . . . . 8W-42 Window Defogger Module-Rear . . . . . . . . . . . 8W-48
Relay Block . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11 Window Defogger Relays . . . . . . . . . . . . . . . . 8W-48
Roof Fan Motor . . . . . . . . . . . . . . . . . . . . . . . 8W-42 Window Defogger Switch-Rear . . . . . . . . . . . 8W-48
Roof Fan Switch . . . . . . . . . . . . . . . . . . . . . . 8W-42 Window Defoggers . . . . . . . . . . . . . . . . . . . . . 8W-48
Seat Belt Switch . . . . . . . . . . . . . . . . . . . . . . 8W-43 Wiper Motor-Front . . . . . . . . . . . . . . . . . . . . 8W-53
Seat Belt Tensioners . . . . . . . . . . . . . . . . . . . 8W-43 Wiper On/Off Relay . . . . . . . . . . . . . . . . . . . . 8W-53
Security System Module . . . . . . . . . . . . . . . . 8W-39 Wiper Switch . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53
Sentry Key Remote Entry Module . . . . . . . . . 8W-39 Wiper/Turn Signal/Engine Start Control
Shifter Assembly . . . . . . . . . . . . . . . . . . . . . . 8W-31 Module . . . . . . . . . . . . . . . . . . . 8W-30, 31, 52, 53
Siren . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41
Skreem Antenna . . . . . . . . . . . . . . . . . . . . . . 8W-39
VA 8W-10 POWER DISTRIBUTION 8W - 10 - 1

8W-10 POWER DISTRIBUTION


Component Page Component Page
Airbag Control Module . . . . . . . . . . . . . . . . . 8W-10-19 Fuse Block No. 1 . 8W-10-3, 11, 12, 13, 14, 15, 18, 19, 20,
Automatic Temperature Control Module . . . . . 8W-10-30 21, 22, 23, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34
Auxiliary Heater Switch . . . . . . . . . . . . . . . . 8W-10-23 Fuse Block No. 2 . . . . . . . . . . . . . . 8W-10-10, 17, 25, 26
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-6, 11 Fused Ignition Switch Run-Start Relay . . . . . . 8W-10-19
Battery Relay-Auxiliary . . . . . . . . . . . . . . . . . . 8W-10-6 G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-31, 32
Beam Select Switch . . . . . . . . . . . . . . 8W-10-12, 18, 28 G202 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-10, 19
Bk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-13 Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-6
Bk/Rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-13 Glow Plug Control Module . . . . . . . . . . . . . . . 8W-10-11
Bk/Yl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-13 Gy/Dg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-13
Blower Motor Resistor Block . . . . . . . . . . . 8W-10-12, 30 Hazard Warning Switch . . . . . . 8W-10-13, 14, 21, 31, 32
Boost Pressure Servomotor . . . . . . . . . . . . . . . 8W-10-29 Headlamp Assembly-Left . . . . . . . . 8W-10-18, 26, 27, 28
Brake Lamp Switch . . . . . . . . . . . . . . . . . . . . 8W-10-20 Headlamp Assembly-Right . . . . . . . 8W-10-17, 18, 27, 28
Central Timer Module . . . . . . . . . . . . . . . . . . 8W-10-16 Headlamp Switch . . . . . . . . . . . 8W-10-12, 18, 25, 26, 27
Cigar Lighter . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-23 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-22
Circulation Pump Diode . . . . . . . . . . . . . . . . . 8W-10-30 Horn Relay . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-22
Circulation Pump Relay . . . . . . . . . . . . . . 8W-10-22, 30 Ignition Switch . . . . . . . . . . . . . . . . . . 8W-10-12, 13, 14
Courtesy Lamp-Driver Door . . . . . . . . . . . . . . 8W-10-24 Instrument Cluster . . . . . . . . . . . . . . . 8W-10-10, 18, 19
Courtesy Lamp-Left Sliding Door . . . . . . . . . . 8W-10-24 Interior Lamp-Left . . . . . . . . . . . . . . . . . . . . 8W-10-24
Courtesy Lamp-Passenger Door . . . . . . . . . . . 8W-10-24 Interior Lamp-Middle Front . . . . . . . . . . . . . . 8W-10-24
Courtesy Lamp-Right Sliding Door . . . . . . . . . 8W-10-24 Interior Lamp-Middle Rear . . . . . . . . . . . . . . 8W-10-24
Crankcase Heater . . . . . . . . . . . . . . . . . . . . . 8W-10-29 Interior Lamp-Rear No. 1 . . . . . . . . . . . . . . . . 8W-10-24
D+ Relay No. 1 . . . . . . . . . . . . . . . . . . . . . 8W-10-9, 10 Interior Lamp-Rear No. 2 . . . . . . . . . . . . . . . . 8W-10-24
Data Link Connector . . . . . . . . . . . . . . . . . . . 8W-10-20 Interior Lamp-Right . . . . . . . . . . . . . . . . . . . 8W-10-24
Daytime Running Lamp Relay-Left Side . . . 8W-10-10, 27 Lamp Relay-Left . . . . . . . . . . . . . . . . . . . . . . 8W-10-26
Daytime Running Lamp Relay-Right Side . . 8W-10-10, 27 Lamp Relay-Right . . . . . . . . . . . . . . . . . . . . . 8W-10-17
Daytime Running Lamps Relay . . . . . . . . . . . 8W-10-25 Mass Air Flow Sensor . . . . . . . . . . . . . . . . . . 8W-10-22
Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-24 Multi-Function Switch . . 8W-10-12, 13, 14, 18, 21, 25, 26,
27, 28, 31, 32, 33, 34
EGR Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-29
Optional Equipment Relay . . . . . . . . . . . 8W-10-6, 7, 22
Engine Control Module . . . . . . . 8W-10-12, 15, 19, 29, 34
Oxygen Sensor . . . . . . . . . . . . . . . . . . . . . . . 8W-10-29
Engine Control Relay . . . . . . . . . . . . . 8W-10-12, 29, 34
Power Distribution Center . . . . . . . . . . . 8W-10-2, 6, 11
Fog Lamp Relay . . . . . . . . . . . . . . . . . . . . . . 8W-10-28
Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-16, 23
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . 8W-10-12, 30
Radio/Cellular Antenna . . . . . . . . . . . . . . . . . 8W-10-16
Fuel Pump Relay . . . . . . . . . . . . . . . . . . . 8W-10-12, 30
Sentry Key Remote Entry Module . . . . . . . . . . 8W-10-22
Fuse 1 . . . . . . . . . . . . . . . . . . 8W-10-6, 8, 9, 17, 18, 25
Shifter Assembly . . . . . . . . . . . . . . . . . . . 8W-10-14, 19
Fuse 2 . . . . . . . . . . . . . . . . . . . . . . . 8W-10-6, 8, 11, 18
Starter Motor . . . . . . . . . . . . . . . . . . . . . 8W-10-11, 15
Fuse 3 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-6, 8, 9, 18
Starter Motor Relay . . . . . . . . . . . . . . . . . . . 8W-10-15
Fuse 4 . . . . . . . . . . . . 8W-10-8, 9, 11, 13, 14, 17, 19, 26
Tail Lamp Assembly-Left . . . . . . . . . . . . . . . . 8W-10-26
Fuse 5 . . . . . . . . . . . . . . . . . . . . 8W-10-8, 9, 11, 14, 20
Tail Lamp Assembly-Right . . . . . . . . . . . . . . . 8W-10-17
Fuse 6 . . . . . . . . . . . . . . . . . . 8W-10-7, 8, 11, 14, 21, 33
Trailer Tow Connector . . . . . . . . . . . . . . . . . . 8W-10-17
Fuse 7 . . . . . . . . . . . . . . . . . . . . . . . 8W-10-7, 8, 14, 22
Transmission Relay . . . . . . . . . . . . . . . . . . . . 8W-10-22
Fuse 8 . . . . . . . . . . . . . . . . . . . . . . . 8W-10-7, 9, 12, 23
Turn Signal Relay . . . . . . . . . . . . . . . . . . . . . 8W-10-31
Fuse 9 . . . . . . . . . . . . . . . . . . . . 8W-10-8, 9, 10, 12, 21
Turn Signal Switch . . . . . . . . . . . . . . . 8W-10-13, 26, 31
Fuse 10 . . . . . . . . . . . . . . . . . . . . . 8W-10-9, 10, 11, 25
Turn Signal/Anti-Theft Alarm Relay-Left . . . . . 8W-10-23
Fuse 11 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-9, 10, 26
Turn Signal/Anti-Theft Alarm Relay-Right . . . . 8W-10-23
Fuse 12 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-7, 27
Washer On/Off Switch . . . . . . . . . . . . . . . 8W-10-21, 34
Fuse 13 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-7, 27
Washer Pump Motor-Front . . . . . . . . . . . . . . . 8W-10-34
Fuse 14 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-7, 28
Window Defogger Switch-Rear . . . . . . . . . . . . 8W-10-22
Fuse 15 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-7, 13, 16
Wiper Motor-Front . . . . . . . . . . . . . . . . . . . . 8W-10-33
Fuse 16 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-12, 29
Wiper On/Off Relay . . . . . . . . . . . . . . . . . 8W-10-21, 33
Fuse 17 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-12, 29
Wiper Switch . . . . . . . . . . . . . . . . . . . 8W-10-21, 32, 33
Fuse 18 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-9, 14, 19
Wiper/Turn Signal/Engine Start Control
Fuse 19 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-12, 30 Module . . . . . . . . . . . . . 8W-10-14, 21, 31, 32, 33, 34
Fuse 20 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-7, 12, 30
Fuse 21 . . . . . . . . . . . . . . . . . . . . . . . 8W-10-12, 13, 30
VA 8W-11 FUSE BLOCK 8W - 11 - 1

8W-11 FUSE BLOCK


Component Page Component Page
A/C Auxiliary Fan Relay . . . . . . . . . . . . . . . . 8W-11-20 Heated Seat Switch-Passenger . . . . . . . . . . 8W-11-28, 33
A/C Control Module-Roof . . . . . . . . . . . . . . . . 8W-11-21 Heater Timer-Auxiliary . . . . . . . . . . . . . . . . . 8W-11-21
A/C Switch-Roof . . . . . . . . . . . . . . . . . . . . 8W-11-17, 28 High Idle Switch . . . . . . . . . . . . . . . . . . . 8W-11-28, 34
A/C Temperature Setting Control-Roof . . . . . . . 8W-11-28 Instrument Cluster . . . . . . . . . . . . . . . . . 8W-11-19, 26
Additional Heat Exchanger Relay . . . . . . . 8W-11-25, 35 Instrument Panel Socket . . . . . . . . . . . . . . . . 8W-11-26
Ash Receiver Lamp . . . . . . . . . . . . . . . . . . . . 8W-11-28 Interior Light Switch . . . . . . . . . . . . . . . . 8W-11-23, 28
Automatic Temperature Control Module . . . . . . 8W-11-28 Interior Light Switch-Driver . . . . . . . . . . . . . . 8W-11-23
Battery Relay-Auxiliary . . . . . . . . . . . . . . . . . 8W-11-17 Interior Light Switch-Passenger . . . . . . . . . . . 8W-11-23
Body Plug Connector . . . . . . . . . . . . . . 8W-11-29, 39, 40 Interior Light Switch-Rear . . . . . . . . . . . . . . . 8W-11-23
Cabin Heater Assembly . . . . . . . . . . . . . . 8W-11-22, 35 Interior Lighting Connector . . . . . . . . . . . . . . 8W-11-23
Central Timer Module . . . . . . . . . . . . . . . 8W-11-17, 19 Intrusion Sensor No. 1 . . . . . . . . . . . . . . . . . . 8W-11-38
Cigar Lighter Lamp . . . . . . . . . . . . . . . . . . . . 8W-11-28 Intrusion Sensor No. 2 . . . . . . . . . . . . . . . . . . 8W-11-38
Circulation Pump Diode . . . . . . . . . . . . . . . . . 8W-11-35 Intrusion Sensor No. 3 . . . . . . . . . . . . . . . . . . 8W-11-38
Controller Antilock Brake . . . . . . . . . . . . . 8W-11-22, 34 Lamp Relay-Left . . . . . . . . . . . . . . . . . . . 8W-11-17, 18
Ctel Connector . . . . . . . . . . . . . . . . . . . . . 8W-11-22, 31 Lamp Relay-Right . . . . . . . . . . . . . . . . . . 8W-11-17, 18
D+ Relay No. 1 . . . . . . . . . . . . . . . 8W-11-15, 16, 26, 39 License Plate Lamp No. 1 . . . . . . . . . . . . . . . 8W-11-26
D+ Relay No. 2 . . . . . . . . . . . . . . . . . . 8W-11-17, 29, 39 License Plate Lamp No. 2 . . . . . . . . . . . . . . . 8W-11-26
Data Link Connector . . . . . . . . . . . . . . . . . . . 8W-11-19 Locker Switch No. 1 . . . . . . . . . . . . . . . . . 8W-11-28, 34
Daytime Running Lamp Relay-Left Side . . . . . 8W-11-16 Locker Switch No. 2 . . . . . . . . . . . . . . . . . . . 8W-11-34
Daytime Running Lamp Relay-Right Side . . . . 8W-11-16 Map/Reading Lamp Switch . . . . . . . . . . . . 8W-11-23, 28
Daytime Running Lamps Relay . . . . . . 8W-11-17, 26, 27 Master Door Lock Switch . . . . . . . . . . . . . . . . 8W-11-28
Fan Stage 1 Relay . . . . . . . . . . . . . . . . . . . . . 8W-11-25 Multi-Function Switch . . . . . . . . . . . . . . . . . . 8W-11-27
Fog Lamp Switch . . . . . . . . . . . . . . . . . . . 8W-11-22, 28 Optional Equipment Relay . . 8W-11-30, 31, 32, 33, 34, 35
Fuse 1 . . . . . . . . . . . . . . . . 8W-11-14, 15, 20, 21, 26, 27 Panic Alarm Switch . . . . . . . . . . . . . . . . . . . . 8W-11-28
Fuse 2 . . . . . . . . 8W-11-14, 18, 30, 31, 32, 34, 35, 37, 38 Power Distribution Center . . 8W-11-14, 18, 19, 20, 21, 22,
Fuse 3 . . . . . . . . . . . . . 8W-11-14, 15, 18, 19, 20, 21, 22, 23, 24, 25, 26, 29, 30, 31, 32, 34, 35, 37
23, 24, 25, 26, 29 Power Mirror Motor-Driver . . . . . . . . . . . . . . 8W-11-36
Fuse 4 . . . . . . . . . . . . . . . . . . . . . 8W-11-14, 15, 18, 22 Power Mirror Motor-Passenger . . . . . . . . . . . . 8W-11-36
Fuse 5 . . . . . . . . . . . . . . . . . . . 8W-11-14, 15, 19, 22, 24 Power Mirror Switch . . . . . . . . . . . . . . . . . . . 8W-11-36
Fuse 6 . . . . . . . . . . . . . . . . 8W-11-14, 19, 25, 30, 34, 37 Power Window Switch-Driver . . . . . . . . . . . . . 8W-11-31
Fuse 7 . . . . . . . . . . . . . . . . 8W-11-14, 22, 30, 31, 34, 35 Power Window Switch-Master . . . . . . . . . . . . 8W-11-32
Fuse 8 . . . . . . . . . . . . . . . . 8W-11-15, 21, 25, 30, 35, 36 Power Window Switch-Passenger . . . . . . . . . . 8W-11-32
Fuse 9 . . . . . . . . . . . . . 8W-11-14, 15, 16, 17, 22, 26, 39 Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-28
Fuse 10 . . . . . . . . . . . . . . . . . . 8W-11-15, 16, 20, 27, 37 Relay Block . . 8W-11-3, 15, 16, 17, 18, 20, 24, 25, 26, 29,
Fuse 11 . . . . . . . . . . . . . . . . . . . . . . . 8W-11-15, 16, 21 30, 31, 32, 33, 34, 35
Fuse 12 . . . . . . . . . . . . . . . . . . . . . . . 8W-11-29, 30, 34 Roof Fan Switch . . . . . . . . . . . . . . . . . . . 8W-11-28, 32
Fuse 13 . . . . . . . . . . . . . . . . . . . . 8W-11-29, 30, 31, 40 Security System Module . . . . . . . . . . . 8W-11-31, 37, 38
Fuse 14 . . . . . . . . . . . . . . . . . . . . 8W-11-29, 30, 31, 39 Sentry Key Remote Entry Module . . . . . . . . . . 8W-11-24
Fuse 15 . . . . . . . . . . . . . . . . . . . . . . . 8W-11-30, 32, 33 Shifter Assembly . . . . . . . . . . . . . . . . . . . . . . 8W-11-28
Fuse 18 . . . . . . . . . . . . . . . . . . . . . . . 8W-11-15, 23, 40 Siren . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-38
Fuse 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-17 Tcs Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-28
Fuse 20 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-30, 32 Time Delay Relay . . . . . . . . . . . . . . . . . . . . . 8W-11-23
Fuse Block No. 1 . . . . . . . . . . . . . . . . 8W-11-27, 34, 40 Towing/Intrusion Sensor On/Off Switch . . . . . . 8W-11-28
Fuse Block No. 2 . 8W-11-4, 16, 18, 19, 26, 27, 29, 31, 32, Trailer Tow Connector . . . . . . . . . . . . . . . . . . 8W-11-25
35, 39, 40 Trailer Tow Control Module . . . . . . . . . . . . . . 8W-11-25
Fuse Block No. 3 . 8W-11-5, 17, 21, 22, 23, 25, 31, 32, 33, Transmission Relay . . . . . . . . . . . . . . . . . . . . 8W-11-18
34, 35, 37 Turn Signal/Anti-Theft Alarm Relay-Left . . . . . 8W-11-24
Fuse/Relay Block . . . . . . . . . 8W-11-2, 20, 21, 22, 24, 34 Turn Signal/Anti-Theft Alarm Relay-Right . . . . 8W-11-24
Fused Ignition Switch Run-Start Relay . . . . 8W-11-29, 40 Warm Air Auxiliary Heater Assembly . . . . . . . 8W-11-21
G202 . . . . . . . . . . . . . . . . . 8W-11-17, 26, 34, 35, 39, 40 Window Defogger Module-Rear . . . . . . . . . 8W-11-17, 20
Headlamp Adjust Switch . . . . . . . . . . . . . . . . 8W-11-28 Window Defogger Relay-Left Rear . . . . . . . . . . 8W-11-20
Headlamp Assembly-Left . . . . . . . . . . . . . 8W-11-16, 26 Window Defogger Relay-Right Rear . . . . . . . . . 8W-11-20
Headlamp Assembly-Right . . . . . . . . . . . . 8W-11-16, 26 Window Defogger Switch-Rear . . . . . . . . . . . . 8W-11-28
Headlamp Switch . . . . . . . . . . . . . . . . . . . . . 8W-11-27
Heated Seat Switch-Driver . . . . . . . . . . . . 8W-11-28, 33
VA 8W-15 GROUND DISTRIBUTION 8W - 15 - 1

8W-15 GROUND DISTRIBUTION


Component Page Component Page
A/C Auxiliary Fan . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-4 Interior Lamp No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6
A/C Auxiliary Fan Relay . . . . . . . . . . . . . . . . . . . . . . 8W-15-12 Interior Lamp No. 3 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6
A/C Control Module-Roof . . . . . . . . . . . . . . . . . . . . . 8W-15-28 Interior Lamp No. 4 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6
A/C Switch-Roof . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-24 Interior Lamp No. 5 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6
Additional Heat Exchanger . . . . . . . . . . . . . . . . . . . . 8W-15-12 Interior Lamp-Left . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6
Additional Heat Exchanger Relay . . . . . . . . . . . . . . . . . 8W-15-12 Interior Lamp-Middle Front . . . . . . . . . . . . . . . . . . . 8W-15-5, 6
Additional Heat Exchanger Switch . . . . . . . . . . . . . . . . 8W-15-24 Interior Lamp-Middle Rear . . . . . . . . . . . . . . . . . . . 8W-15-5, 6
Airbag Control Module . . . . . . . . . . . . . . . . . . . . . . . 8W-15-11 Interior Lamp-Rear No. 2 . . . . . . . . . . . . . . . . . . . . . . 8W-15-5
Ash Receiver Lamp . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-22 Interior Lamp-Right . . . . . . . . . . . . . . . . . . . . . . . 8W-15-5, 6
Automatic Temperature Control Module . . . . . . . . . . . . . 8W-15-24 Interior Light Switch . . . . . . . . . . . . . . . . . . . . . . . 8W-15-21
Auxiliary Heater Switch . . . . . . . . . . . . . . . . . . . . . . 8W-15-24 Interior Lighting Connector . . . . . . . . . . . . . . . . . . . . . 8W-15-6
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-8 Intrusion Sensor No. 1 . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6
Battery Relay-Auxiliary . . . . . . . . . . . . . . . . . . . . . . 8W-15-11 Intrusion Sensor No. 2 . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6
Battery-Auxiliary . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-11 Intrusion Sensor No. 3 . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6
Blower Motor-Front . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-9 Kickdown Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-8
Brake Fluid Level Switch . . . . . . . . . . . . . . . . . . . . . . 8W-15-8 Lamp Relay-Left . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-13
Brake Wear Sensor-Left Front . . . . . . . . . . . . . . . . . . . 8W-15-8 Lamp Relay-Right . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-13
Brake Wear Sensor-Left Rear . . . . . . . . . . . . . . . . . . . 8W-15-28 License Plate Lamp No. 1 . . . . . . . . . . . . . . . . . . . . . 8W-15-27
Brake Wear Sensor-Right Front . . . . . . . . . . . . . . . . . . 8W-15-8 License Plate Lamp No. 2 . . . . . . . . . . . . . . . . . . . . . 8W-15-27
Brake Wear Sensor-Right Rear . . . . . . . . . . . . . . . . . . 8W-15-28 Locker Switch No. 1 . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-20
Cabin Heater Assembly . . . . . . . . . . . . . . . . . . . . . . . 8W-15-3 Map/Reading Lamp Switch . . . . . . . . . . . . . . . . . . . . 8W-15-21
Center High Mounted Stop Lamp . . . . . . . . . . . . . . . . . 8W-15-6 Marker Lamp Connector . . . . . . . . . . . . . . . . . . . . . . 8W-15-17
Central Timer Module . . . . . . . . . . . . . . . . . . . . . . . 8W-15-15 Marker Lamp No. 1-Left Front . . . . . . . . . . . . . . . . . . 8W-15-16
Cigar Lighter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-22 Marker Lamp No. 1-Right Front . . . . . . . . . . . . . . . . . 8W-15-16
Cigar Lighter Lamp . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-22 Marker Lamp No. 2-Left Front . . . . . . . . . . . . . . . . . . 8W-15-16
Circulation Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-9 Marker Lamp No. 2-Right Front . . . . . . . . . . . . . . . . . 8W-15-16
Circulation Pump Relay . . . . . . . . . . . . . . . . . . . . . . 8W-15-12 Marker Lamp-Left Center . . . . . . . . . . . . . . . . . . . . . 8W-15-17
Clockspring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-10 Marker Lamp-Left Rear . . . . . . . . . . . . . . . . . . . . . . 8W-15-27
Controller Antilock Brake . . . . . . . . . . . . . . . . . . . . 8W-15-2, 28 Marker Lamp-Right Center . . . . . . . . . . . . . . . . . . . . 8W-15-17
Ctel Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-21 Marker Lamp-Right Rear . . . . . . . . . . . . . . . . . . . . . 8W-15-27
Cylinder Lock Switch-Driver . . . . . . . . . . . . . . . . . . 8W-15-7, 10 Master Door Lock Switch . . . . . . . . . . . . . . . . . . . . . 8W-15-25
D+ Relay No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-12 Metering Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-18
D+ Relay No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-14 Multi-Function Switch . . . . . . . . . . . . . . . . . . . . . . . 8W-15-7
Data Link Connector . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-10 Optional Equipment Relay . . . . . . . . . . . . . . . . . . . . 8W-15-19
Daytime Running Lamp Relay-Left Side . . . . . . . . . . . . . 8W-15-13 Panic Alarm Switch . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-20
Daytime Running Lamp Relay-Right Side . . . . . . . . . . . . 8W-15-13 Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . . . 8W-15-15
Daytime Running Lamps Relay . . . . . . . . . . . . . . . . . . 8W-15-13 Power Mirror Motor-Driver . . . . . . . . . . . . . . . . . . . . 8W-15-23
Differential Lock Solenoid Valve . . . . . . . . . . . . . . . . . . 8W-15-2 Power Mirror Motor-Passenger . . . . . . . . . . . . . . . . . . 8W-15-23
Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6 Power Mirror Switch . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-23
Dosing Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2 Power Window Switch-Driver . . . . . . . . . . . . . . . . . . . 8W-15-23
Engine Control Module . . . . . . . . . . . . . . . . . . . . . . . 8W-15-7 Power Window Switch-Master . . . . . . . . . . . . . . . . . . . 8W-15-23
Engine Coolant Level Switch . . . . . . . . . . . . . . . . . . . . 8W-15-2 Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-21
Fan Stage 1 Relay . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-11 Reading Lamp Connector . . . . . . . . . . . . . . . . . . . . . . 8W-15-6
Fog Lamp Relay . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-11 Recirculated Air Solenoid Valve . . . . . . . . . . . . . . . . . . . 8W-15-9
Fog Lamp Switch . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-22 Roof Fan Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-21
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-19 Seat Belt Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-15
Fuse Block No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-7 Security System Module . . . . . . . . . . . . . . . . . . . . . . 8W-15-15
Fused Ignition Switch Run-Start Relay . . . . . . . . . . . . . . 8W-15-14 Sentry Key Remote Entry Module . . . . . . . . . . . . . . . . . 8W-15-7
G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2, 3 Shifter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-20
G101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-4 Siren . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-9
G102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-4 Tail Lamp Assembly-Left . . . . . . . . . . . . . . . . . . . . . 8W-15-26
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6, 7, 8, 9, 10 Tail Lamp Assembly-Right . . . . . . . . . . . . . . . . . . . . . 8W-15-26
G201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-11 Tcs Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-25
G202 . . . . . . . . . . . . . . . . 8W-15-11, 12, 13, 14, 15, 16, 17, 18, 19 Time Delay Relay . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-17
G203 . . . . . . . . . . . . . . . . . . . . . . 8W-15-20, 21, 22, 23, 24, 25 Towing/Intrusion Sensor On/Off Switch . . . . . . . . . . . . . . 8W-15-22
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-26, 27, 28 Trailer Tow Connector . . . . . . . . . . . . . . . . . . . . . . . 8W-15-28
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-28 Trailer Tow Control Module . . . . . . . . . . . . . . . . . . . . 8W-15-19
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-28 Transmission Control Module . . . . . . . . . . . . . . . . . . . 8W-15-19
Glow Plug Control Module . . . . . . . . . . . . . . . . . . . . . 8W-15-2 Transmission Relay . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-19
Hazard Warning Switch . . . . . . . . . . . . . . . . . . . . . . . 8W-15-7 Turn Signal No. 1-Left Front . . . . . . . . . . . . . . . . . . . . 8W-15-3
Headlamp Adjust Switch . . . . . . . . . . . . . . . . . . . . . 8W-15-22 Turn Signal No. 1-Right Front . . . . . . . . . . . . . . . . . . . 8W-15-4
Headlamp Assembly-Left . . . . . . . . . . . . . . . . . . . . . . 8W-15-3 Turn Signal No. 2-Left Front . . . . . . . . . . . . . . . . . . . . 8W-15-3
Headlamp Assembly-Right . . . . . . . . . . . . . . . . . . . . . 8W-15-4 Turn Signal No. 2-Right Front . . . . . . . . . . . . . . . . . . . 8W-15-4
Heated Seat Module-Driver . . . . . . . . . . . . . . . . . . . . 8W-15-19 Warm Air Auxiliary Heater Assembly . . . . . . . . . . . . . . . 8W-15-18
Heated Seat Module-Passenger . . . . . . . . . . . . . . . . . . 8W-15-19 Washer Pump Motor-Front . . . . . . . . . . . . . . . . . . . . . 8W-15-4
Heated Seat Switch-Driver . . . . . . . . . . . . . . . . . . . . 8W-15-25 Water Cycle Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-9
Heated Seat Switch-Passenger . . . . . . . . . . . . . . . . . . 8W-15-25 Window Defogger Module-Rear . . . . . . . . . . . . . . . . . . 8W-15-15
Heater Timer-Auxiliary . . . . . . . . . . . . . . . . . . . . . . 8W-15-24 Window Defogger Relay-Left Rear . . . . . . . . . . . . . . . . 8W-15-14
High Idle Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-25 Window Defogger Relay-Right Rear . . . . . . . . . . . . . . . . 8W-15-14
Hood Ajar Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-4 Window Defogger Switch-Rear . . . . . . . . . . . . . . . . . . 8W-15-20
Horn Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-11 Window Defogger-Left Rear . . . . . . . . . . . . . . . . . . . . 8W-15-26
Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-10 Window Defogger-Right Rear . . . . . . . . . . . . . . . . . . . 8W-15-26
Ignition Lock Switch . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-10 Wiper Motor-Front . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-9
Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-10 Wiper/Turn Signal/Engine Start Control Module . . . . . . . . . 8W-15-7
Instrument Panel Socket . . . . . . . . . . . . . . . . . . . . . 8W-15-20
Interior Lamp No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6
VA 8W-18 BUS COMMUNICATIONS 8W - 18 - 1

8W-18 BUS COMMUNICATIONS


Component Page Component Page
Airbag Control Module . . . . . . . . . . . . . . . . 8W-18-5 Fuse Block No. 1 . . . . . . . . . . . . . . . . . . . . 8W-18-2
Automatic Temperature Control Module . 8W-18-4, 6 Fuse Block No. 2 . . . . . . . . . . . . . . . . . . . . 8W-18-3
Brake Lamp Switch . . . . . . . . . . . . . . . . . . 8W-18-2 G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-5
Cabin Heater Assembly . . . . . . . . . . . . . . . 8W-18-4 Instrument Cluster . . . . . . . . . . . . . . . . . 8W-18-4, 6
Central Timer Module . . . . . . . . . . . . . . . . 8W-18-4 Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-5
Controller Antilock Brake . . . . . . . . . . . . 8W-18-3, 6 Security System Module . . . . . . . . . . . . . . . 8W-18-4
Data Link Connector . . . . . . . . . . . 8W-18-2, 3, 4, 5 Sentry Key Remote Entry Module . . . . . 8W-18-5, 6
Engine Control Module . . . . . . . . . . . . . . 8W-18-5, 6 Shifter Assembly . . . . . . . . . . . . . . . . . . 8W-18-3, 6
Fuse 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-2 Transmission Control Module . . . . . . . . . 8W-18-5, 6
Fuse 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-3 Warm Air Auxiliary Heater Assembly . . . . . 8W-18-4
VA 8W-20 CHARGING SYSTEM 8W - 20 - 1

8W-20 CHARGING SYSTEM


Component Page Component Page
Battery . . . . . . . . . . . . . . . . . . . . 8W-20-2, 3, 4, 5, 6 Fuse Block No. 1 . . . . . . . . . . . . . . . . 8W-20-4, 5, 6
Battery Relay-Auxiliary . . . . . . . . . . . . . 8W-20-2, 3 Fuse Block No. 2 . . . . . . . . . . . . . . . . . . . . 8W-20-3
Battery-Auxiliary . . . . . . . . . . . . . . . . . . . . 8W-20-3 Fuse Block No. 3 . . . . . . . . . . . . . . . . . . . . 8W-20-3
D+ Relay No. 1 . . . . . . . . . . . . . . . . . . . . . . 8W-20-3 G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2
Engine Control Module . . . . . . . . . . . . . . . . 8W-20-6 G202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-3, 4
Fuel Pump Relay . . . . . . . . . . . . . . . . . . . . 8W-20-6 Generator . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2
Fuse 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2 Glow Plug Control Module . . . . . . . . . . . . . 8W-20-5
Fuse 2 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2, 4 Ignition Switch . . . . . . . . . . . . . . . . . . . . . . 8W-20-5
Fuse 3 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2, 5 Instrument Cluster . . . . . . . . . . . . . . . . . . . 8W-20-2
Fuse 4 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2, 5 Optional Equipment Relay . . . . . . . . . . . . . 8W-20-4
Fuse 5 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2, 5 Power Distribution Center . . . . . . . . . 8W-20-2, 4, 5
Fuse 6 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2, 5 Relay Block . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-4
Fuse 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-4 Starter Motor . . . . . . . . . . . . . . . . . . . . . 8W-20-2, 6
Fuse 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-3 Starter Motor Relay . . . . . . . . . . . . . . . . . . 8W-20-6
Fuse 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-3
VA 8W-21 STARTING SYSTEM 8W - 21 - 1

8W-21 STARTING SYSTEM


Component Page Component Page
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-2 Fuse Block No. 1 . . . . . . . . . . . . . . . . . . . . 8W-21-2
Engine Control Module . . . . . . . . . . . . . . . . 8W-21-2 Starter Motor . . . . . . . . . . . . . . . . . . . . . . . 8W-21-2
Fuel Pump Relay . . . . . . . . . . . . . . . . . . . . 8W-21-2 Starter Motor Relay . . . . . . . . . . . . . . . . . . 8W-21-2
VA 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 1

8W-30 FUEL/IGNITION SYSTEM


Component Page Component Page
Accelerator Pedal Position Sensor . . . . 8W-30-10, 21 Fuse 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-8
Airbag Control Module . . . . . . . . . . . . . . . . 8W-30-9 Fuse 17 . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-17, 24
Boost Pressure Sensor . . . . . . . . . . . . . 8W-30-9, 25 Fuse 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-9
Boost Pressure Servomotor . . . . . . . . . . . . 8W-30-24 Fuse 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-28
Boost Pressure Solenoid . . . . . . . . . . . . . . 8W-30-14 Fuse Block . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-28
Camshaft Position Sensor . . . . . . . . . . . . . . 8W-30-6 Fuse Block No. 1 . . . . . . . . . . 8W-30-8, 9, 17, 20, 24
Central Timer Module . . . . . . . . . . . . . . . . 8W-30-9 Fuse Block No. 3 . . . . . . . . . . . . . . . . . . . . 8W-30-2
Crankcase Heater . . . . . . . . . . . . . . . . 8W-30-17, 24 G100 . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-3, 13, 19
Crankshaft Position Sensor . . . . . . . . . . . . 8W-30-7 G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-8, 12
Data Link Connector . . . . . . . . . . . . . . . . . 8W-30-4 G202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-28
Daytime Running Lamps Relay . . . . . . . . . 8W-30-2 G203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-2
EGR Valve . . . . . . . . . . . . . . . . . . . . . 8W-30-17, 24 Glow Plug Control Module . . . . . . . . . 8W-30-13, 19
Engine Control Module . . . . . . . 8W-30-2, 4, 5, 6, 7, Glow Plug No. 1 . . . . . . . . . . . . . . . . . 8W-30-13, 19
8, 9, 10, 11, 12, 13, 14, 15, 16, Glow Plug No. 2 . . . . . . . . . . . . . . . . . 8W-30-13, 19
17, 19, 20, 21, 22, 23, 24, 25, 28 Glow Plug No. 3 . . . . . . . . . . . . . . . . . 8W-30-13, 19
Engine Control Relay . . . . . . . . . . . 8W-30-8, 17, 24 Glow Plug No. 4 . . . . . . . . . . . . . . . . . 8W-30-13, 19
Engine Coolant Level Switch . . . . . . . . . . . 8W-30-3 Glow Plug No. 5 . . . . . . . . . . . . . . . . . 8W-30-13, 19
Engine Coolant Temperature Sensor . . . . . 8W-30-6 High Idle Switch . . . . . . . . . . . . . . . . . . . . 8W-30-2
Engine Oil Sensor . . . . . . . . . . . . . . . . . . . 8W-30-17 Instrument Cluster . . . . . . . . . . . . . . . . . . . 8W-30-3
Fuel Injector No. 1 . . . . . . . . . . . . . . . 8W-30-15, 22 Intake Air Pressure Sensor . . . . . . . . . . . . 8W-30-20
Fuel Injector No. 2 . . . . . . . . . . . . . . . 8W-30-16, 23 Intake Air Temperature Sensor . . . . . . 8W-30-10, 21
Fuel Injector No. 3 . . . . . . . . . . . . . . . 8W-30-15, 22 Kickdown Switch . . . . . . . . . . . . . . . . . . . 8W-30-12
Fuel Injector No. 4 . . . . . . . . . . . . . . . 8W-30-15, 22 Low Fuel Pressure Sensor . . . . . . . . . . . . 8W-30-11
Fuel Injector No. 5 . . . . . . . . . . . . . . . 8W-30-16, 23 Mass Air Flow Sensor . . . . . . . . . . . . . 8W-30-14, 20
Fuel Level Sensor . . . . . . . . . . . . . . . . . . . . 8W-30-3 Optional Equipment Relay . . . . . . . . . . . . . 8W-30-2
Fuel Pressure Sensor . . . . . . . . . . . . . . . . . 8W-30-5 Oxygen Sensor . . . . . . . . . . . . . . . . . . . . . 8W-30-24
Fuel Pressure Solenoid . . . . . . . . . . . . . . . . 8W-30-7 Power Distribution Center . . . . . . . . . 8W-30-13, 19
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-28 Relay Block . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-2
Fuel Pump Relay . . . . . . . . . . . . . . . . . . . 8W-30-28 Speed Control Switch . . . . . . . . . . . . . . . . 8W-30-12
Fuel Quantity Control Valve . . . . . . . . . . . 8W-30-7 Starter Motor Relay . . . . . . . . . . . . . . 8W-30-11, 28
Fuel Shutdown Solenoid . . . . . . . . . . . . . . . 8W-30-7 Transmission Control Module . . . . . . . . . . . 8W-30-4
Fuel Temperature Sensor . . . . . . . . . . . . . . 8W-30-5 Water In Fuel Sensor . . . . . . . . . . . . . 8W-30-11, 25
Fuse 5 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-13, 19 Wiper/Turn Signal/Engine Start Control
Fuse 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-20 Module . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-8
Fuse 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-2
VA 8W-31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 1

8W-31 TRANSMISSION CONTROL SYSTEM


Component Page Component Page
Brake Lamp Switch . . . . . . . . . . . . . . . . . . 8W-31-9 Fuse Block No. 3 . . . . . . . . . . . . . . . . . . . . 8W-31-8
Controller Antilock Brake . . . . . . . . . . . . . . 8W-31-4 G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-8
Crankcase Heater . . . . . . . . . . . . . . . . . . . . 8W-31-3 G202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-2, 7
Data Link Connector . . . . . . . . . . . . . . . 8W-31-2, 9 G203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-8, 9
Daytime Running Lamps Relay . . . . . . . 8W-31-8, 9 Locker Switch No. 1 . . . . . . . . . . . . . . . . . . 8W-31-8
Differential Lock Solenoid Valve . . . . . . . . . 8W-31-8 Locker Switch No. 2 . . . . . . . . . . . . . . . . . . 8W-31-8
EGR Valve . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-3 Optional Equipment Relay . . . . . . . . . . . . . 8W-31-8
Engine Control Module . . . . . . . . . . . . . . 8W-31-3, 4 Shifter Assembly . . . . . . . . . . . . . . . 8W-31-2, 4, 7, 9
Engine Control Relay . . . . . . . . . . . . . . . . . 8W-31-3 Tail Lamp Assembly-Left . . . . . . . . . . . . . . 8W-31-9
Fuse 2 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-2, 7 Tail Lamp Assembly-Right . . . . . . . . . . . . . 8W-31-9
Fuse 4 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-7, 9 Trailer Tow Connector . . . . . . . . . . . . . . . . 8W-31-9
Fuse 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-7 Transmission Control Module . . . 8W-31-2, 4, 5, 6, 7
Fuse 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-8 Transmission Relay . . . . . . . . . . . . . . . . 8W-31-2, 7
Fuse 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-3 Transmission Solenoid Assembly . . . . . . 8W-31-5, 6
Fuse 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-3 Wiper/Turn Signal/Engine Start Control
Fuse Block No. 1 . . . . . . . . . . . . . . . . 8W-31-3, 7, 9 Module . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-3
Fuse Block No. 2 . . . . . . . . . . . . . . . . . . 8W-31-2, 7
VA 8W-33 VEHICLE SPEED CONTROL 8W - 33 - 1

8W-33 VEHICLE SPEED CONTROL


Component Page Component Page
Brake Lamp Switch . . . . . . . . . . . . . . . . . . 8W-33-2 Fuse Block No. 1 . . . . . . . . . . . . . . . . . . . . 8W-33-2
Controller Antilock Brake . . . . . . . . . . . . . . 8W-33-2 Shifter Assembly . . . . . . . . . . . . . . . . . . . . 8W-33-2
Engine Control Module . . . . . . . . . . . . . . . . 8W-33-3 Speed Control Switch . . . . . . . . . . . . . . . . . 8W-33-3
Fuse 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-2
VA 8W-35 ANTILOCK BRAKES 8W - 35 - 1

8W-35 ANTILOCK BRAKES


Component Page Component Page
Automatic Temperature Control Module . . 8W-35-2 G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-7, 8
Brake Fluid Level Switch . . . . . . . . . . . . . . 8W-35-7 G202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-7
Brake Lamp Switch . . . . . . . . . . . . . . . . 8W-35-3, 4 G203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-2
Brake Wear Sensor-Left Front . . . . . . . . . . 8W-35-8 G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-8
Brake Wear Sensor-Left Rear . . . . . . . . . . . 8W-35-8 G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-4
Brake Wear Sensor-Right Front . . . . . . . . . 8W-35-8 Instrument Cluster . . . . . . . . . . . . . . . 8W-35-4, 7, 8
Brake Wear Sensor-Right Rear . . . . . . . . . 8W-35-8 Optional Equipment Relay . . . . . . . . . . . . . 8W-35-5
Center High Mounted Stop Lamp . . . . . . . 8W-35-3 Parking Brake Switch . . . . . . . . . . . . . . . . 8W-35-7
Controller Antilock Brake . . . . . . 8W-35-2, 3, 4, 5, 6 Power Distribution Center . . . . . . . . . . . . . 8W-35-5
Data Link Connector . . . . . . . . . . . . . . . . . 8W-35-5 Relay Block . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-5
Daytime Running Lamps Relay . . . . . . . . . 8W-35-2 Shifter Assembly . . . . . . . . . . . . . . . . . . . . 8W-35-3
Fuse 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-5 Tail Lamp Assembly-Left . . . . . . . . . . . . . . 8W-35-3
Fuse 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-5 Tail Lamp Assembly-Right . . . . . . . . . . . . . 8W-35-3
Fuse 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-3 Tcs Switch . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-2
Fuse 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-5 Trailer Tow Control Module . . . . . . . . . . . . 8W-35-3
Fuse 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-5 Wheel Speed Sensor-Left Front . . . . . . . . . 8W-35-6
Fuse 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-5 Wheel Speed Sensor-Left Rear . . . . . . . . . . 8W-35-6
Fuse Block No. 1 . . . . . . . . . . . . . . . . . . . . 8W-35-3 Wheel Speed Sensor-Right Front . . . . . . . . 8W-35-6
Fuse/Relay Block . . . . . . . . . . . . . . . . . . . . 8W-35-5 Wheel Speed Sensor-Right Rear . . . . . . . . . 8W-35-6
G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-4
VA 8W-39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 1

8W-39 VEHICLE THEFT SECURITY SYSTEM


Component Page Component Page
Central Timer Module . . . . . . . . . . . . . 8W-39-6, 12 Intrusion Sensor No. 2 . . . . . . . . . . . . . . 8W-39-2, 3
Cylinder Lock Switch-Driver . . . . . . . . . . . 8W-39-6 Intrusion Sensor No. 3 . . . . . . . . . . . . . . 8W-39-2, 3
Data Link Connector . . . . . . . . . . . . . . 8W-39-7, 10 Optional Equipment Relay . . . . . . . . . . . . 8W-39-13
Door Jamb Switch-Left Sliding . . . . . . . . . 8W-39-14 Panic Alarm Switch . . . . . . . . . . . . . . . . . . 8W-39-7
Door Jamb Switch-Rear . . . . . . . . . . . . . . 8W-39-14 Relay Block . . . . . . . . . . . . . . . . . . . . . 8W-39-13, 14
Door Jamb Switch-Right Sliding . . . . . . . 8W-39-14 Security System
Fuse 2 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-3, 13 Module . . . . . . . . 8W-39-2, 3, 6, 7, 8, 9, 12, 13, 14
Fuse 5 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-4, 11 Sentry Key Remote Entry
Fuse 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-10 Module . . . . . . . . . . . . 8W-39-4, 5, 6, 8, 10, 11, 12
Fuse 8 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-4, 5 Siren . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-3
Fuse 10 . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-13, 14 Skreem Antenna . . . . . . . . . . . . . . . . . . . . 8W-39-12
Fuse 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-13 Skreem Transponder . . . . . . . . . . . . . . . . 8W-39-12
Fuse Block No. 1 . . . . . . . . . . . . . . . . 8W-39-4, 5, 10 Tail Lamp Assembly-Left . . . . . . . . . . . . . . 8W-39-8
Fuse Block No. 3 . . . . . . . . . . . . . . . . . . 8W-39-3, 13 Tail Lamp Assembly-Right . . . . . . . . . . . . . 8W-39-9
Fuse/Relay Block . . . . . . . . . . . . 8W-39-4, 11, 13, 14 Towing/Intrusion Sensor On/Off Switch . . . 8W-39-7
G101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-6 Trailer Tow Control Module . . . . . . . . . . 8W-39-8, 9
G200 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-3, 6, 10 Turn Signal No. 1-Left Front . . . . . . . . . . . 8W-39-8
G202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-13 Turn Signal No. 1-Right Front . . . . . . . . . . 8W-39-9
G203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-7 Turn Signal/Anti-Theft
Headlamp Assembly-Left . . . . . . . . . . . . . . 8W-39-8 Alarm Relay-Left . . . . . . . . . . . 8W-39-4, 5, 8, 11
Headlamp Assembly-Right . . . . . . . . . . . . . 8W-39-9 Turn Signal/Anti-Theft Alarm Relay-
Hood Ajar Switch . . . . . . . . . . . . . . . . . . . . 8W-39-6 Right . . . . . . . . . . . . . . . . . . . . . 8W-39-4, 5, 9, 11
Instrument Cluster . . . . . . . . . . . 8W-39-8, 9, 10, 14 Warm Air Auxiliary Heater Assembly . . . . 8W-39-14
Interior Lamp-Right . . . . . . . . . . . . . . . . . 8W-39-14 Window Defogger Relay-Left Rear . . . . . . 8W-39-14
Intrusion Sensor No. 1 . . . . . . . . . . . . . . 8W-39-2, 3 Window Defogger Relay-Right Rear . . . . . 8W-39-13
VA 8W-40 INSTRUMENT CLUSTER 8W - 40 - 1

8W-40 INSTRUMENT CLUSTER


Component Page Component Page
Airbag Control Module . . . . . . . . . . . . . . . . 8W-40-3 Fuse 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-2
Ambient Temperature Sensor . . . . . . . . . . . 8W-40-8 Fuse Block No. 1 . . . . . . . . . . . . . . . . . . . . 8W-40-2
Automatic Temperature Control Fuse Block No. 2 . . . . . . . . . . . . . . . . . . 8W-40-3, 6
Module . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-4, 8 G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-7
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-2 G200 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-2, 3, 5
Brake Fluid Level Switch . . . . . . . . . . . . . . 8W-40-3 G202 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-3, 7, 8
Brake Wear Sensor-Left Front . . . . . . . . . . 8W-40-5 G203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-6
Brake Wear Sensor-Left Rear . . . . . . . . . . . 8W-40-5 G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-5
Brake Wear Sensor-Right Front . . . . . . . . . 8W-40-5 Generator . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-2
Brake Wear Sensor-Right Rear . . . . . . . . . 8W-40-5 Headlamp Assembly-Left . . . . . . . . . . . . . . 8W-40-7
Courtesy Lamp-Driver Door . . . . . . . . . . . . 8W-40-6 Headlamp Assembly-Right . . . . . . . . . . . . . 8W-40-7
Courtesy Lamp-Passenger Door . . . . . . . . . 8W-40-6 Ignition Lock Switch . . . . . . . . . . . . . . . . . 8W-40-2
D+ Relay No. 1 . . . . . . . . . . . . . . . . . . . . . . 8W-40-8 Instrument Cluster . . . . . . . 8W-40-2, 3, 4, 5, 6, 7, 8
Data Link Connector . . . . . . . . . . . . . . . . . 8W-40-3 Instrument Panel Socket . . . . . . . . . . . . . . 8W-40-6
Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-6 Parking Brake Switch . . . . . . . . . . . . . . . . 8W-40-3
Door Jamb Switch-Driver . . . . . . . . . . . . . . 8W-40-6 Power Distribution Center . . . . . . . . . . . . . 8W-40-2
Door Jamb Switch-Passenger . . . . . . . . . . . 8W-40-6 Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-8
Engine Coolant Level Switch . . . . . . . . . . . 8W-40-7 Seat Belt Switch . . . . . . . . . . . . . . . . . . . . . 8W-40-7
Fuel Level Sensor . . . . . . . . . . . . . . . . . . . . 8W-40-3 Security System Module . . . . . . . . . . . . . . . 8W-40-6
Fuse 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-2 Sentry Key Remote Entry Module . . . . . . . 8W-40-4
Fuse 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-6 Turn Signal/Anti-Theft Alarm Relay-Left . . 8W-40-8
Fuse 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-3 Turn Signal/Anti-Theft Alarm Relay-Right . 8W-40-8
VA 8W-41 HORN/CIGAR LIGHTER 8W - 41 - 1

8W-41 HORN/CIGAR LIGHTER


Component Page Component Page
Cigar Lighter . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2 G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2, 3
Cigar Lighter Lamp . . . . . . . . . . . . . . . . . . 8W-41-2 G202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-3
Clockspring . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-3 G203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2
Fuse 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-3
Fuse 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-3 Horn Relay . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-3
Fuse 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2 Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-3
Fuse Block No. 1 . . . . . . . . . . . . . . . . . . 8W-41-2, 3 Security System Module . . . . . . . . . . . . . . . 8W-41-2
Fuse Block No. 3 . . . . . . . . . . . . . . . . . . . . 8W-41-2 Siren . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2
VA 8W-42 AIR CONDITIONING-HEATER 8W - 42 - 1

8W-42 AIR CONDITIONING-HEATER


Component Page Component Page
A/C Auxiliary Fan . . . . . . . . . . . . . . . . . . . 8W-42-2 Fuse 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-9
A/C Auxiliary Fan Relay . . . . . . . . . . . . . . . 8W-42-2 Fuse 8 . . . . . . . . . . . . . . . . . . . . . . . 8W-42-8, 12, 18
A/C Compressor Clutch . . . . . . . . . . . . . . . 8W-42-2 Fuse 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-3
A/C Control Module-Roof . . . . . . . . . . 8W-42-12, 13 Fuse 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-20
A/C Switch-Roof . . . . . . . . . . . . . . . . . 8W-42-10, 12 Fuse 20 . . . . . . . . . . . . . . . . . . . . . . . 8W-42-2, 9, 14
A/C Temperature Setting Fuse 21 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-6, 7
Control-Roof . . . . . . . . . . . . . . . . . . 8W-42-10, 13 Fuse Block No. 1 . . . . . . . . . . . . 8W-42-2, 6, 7, 9, 18
Additional Heat Exchanger . . . . . . 8W-42-15, 16, 17 Fuse Block No. 2 . . . . . . . . . . . . . . . . . . . . 8W-42-3
Additional Heat Exchanger Relay . . . . 8W-42-15, 16 Fuse Block No. 3 . . . . . . 8W-42-8, 11, 14, 15, 20, 22
Additional Heat Exchanger Switch . . . 8W-42-16, 17 Fuse/Relay Block . . . . . . . . . . . . . . . . . 8W-42-2, 12
Air Outlet Temperature Sensor . . . . . . . . . 8W-42-4 G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-11
Ambient Temperature Sensor . . . . . . . . . . . 8W-42-3 G102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-2
Automatic Temperature Control Module . . 8W-42-2, G200 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-3, 5, 9
3, 4, 5, 6, 7, 8, 9, 10, 11, 17, 19 G202 . . . . . . . . . . . . . . . . . 8W-42-2, 8, 9, 15, 16, 20
Auxiliary Heater Switch . . . . . . . . . . . 8W-42-10, 18 G203 . . . . . . . . . . . . . 8W-42-6, 7, 12, 14, 17, 18, 19
Blower Motor Resistor Block . . . . . . . 8W-42-5, 6, 7 G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-12
Blower Motor-Front . . . . . . . . . . . . . . . . 8W-42-5, 7 Heater Timer-Auxiliary . . . . . . . 8W-42-6, 7, 10, 17,
Cabin Heater 19, 21, 22
Assembly . . . . . . . . 8W-42-8, 9, 10, 11, 15, 18, 22 Instrument Cluster . . . . . . . . . . . . . . . . . . . 8W-42-3
Circulation Pump . . . . . . . . . . . . . . . . . . . . 8W-42-9 Metering Pump . . . . . . . . . . . . . . . . . . . . . 8W-42-20
Circulation Pump Diode . . . . . . . . . . . . 8W-42-9, 11 Optional Equipment Relay . . . . . . . . . . . . 8W-42-14
Circulation Pump Relay . . . . . . . . . . . . . . . 8W-42-9 Recirculated Air Solenoid Valve . . . . . . . . . 8W-42-5
Controller Antilock Brake . . . . . . . . . . . . . 8W-42-17 Refrigerant Pressure Sensor . . . . . . . . . . . . 8W-42-4
D+ Relay No. 1 . . . . . . . . . . . . . . . . . . . . . . 8W-42-3 Roof Fan Motor . . . . . . . . . . . . . . . . . . . . . 8W-42-14
Data Link Connector . . . . . . . . . . . 8W-42-5, 10, 20 Roof Fan Switch . . . . . . . . . . . . . . . . . 8W-42-10, 14
Daytime Running Lamps Security System Module . . . . . . . . . . . . . . 8W-42-20
Relay . . . . . . . . . . . . 8W-42-12, 13, 14, 17, 18, 19 Tcs Switch . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-17
Dosing Pump . . . . . . . . . . . . . . . . . . . . . . 8W-42-11 Warm Air Auxiliary Control Module . . 8W-42-20, 21
EVAPorator Temperature Sensor . . . . . . . . 8W-42-4 Warm Air Auxiliary
Fan Stage 1 Relay . . . . . . . . . . . . . . . . . . . 8W-42-8 Heater Assembly . . . . . . . . . . . . 8W-42-20, 21, 22
Fuse 1 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-2, 22 Water Cycle Valve . . . . . . . . . . . . . . . . . . . 8W-42-3
Fuse 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-15
Fuse 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-11
VA 8W-43 AIRBAG SYSTEM 8W - 43 - 1

8W-43 AIRBAG SYSTEM


Component Page Component Page
Airbag Control Module . . . . . . . . . . . . . . 8W-43-2, 3 Fuse Block No. 1 . . . . . . . . . . . . . . . . . . . . 8W-43-2
Airbag Squib-Driver . . . . . . . . . . . . . . . . . . 8W-43-3 G201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-2
Airbag Squib-Passenger . . . . . . . . . . . . . . . 8W-43-3 G202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-2
Central Timer Module . . . . . . . . . . . . . . . . 8W-43-2 Instrument Cluster . . . . . . . . . . . . . . . . . . . 8W-43-2
Clockspring . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-3 Seat Belt Switch . . . . . . . . . . . . . . . . . . . . . 8W-43-2
Data Link Connector . . . . . . . . . . . . . . . . . 8W-43-2 Seat Belt Tensioner-Driver . . . . . . . . . . . . . 8W-43-3
Engine Control Module . . . . . . . . . . . . . . . . 8W-43-2 Seat Belt Tensioner-Passenger . . . . . . . . . . 8W-43-3
Fuse 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-2
VA 8W-44 INTERIOR LIGHTING 8W - 44 - 1

8W-44 INTERIOR LIGHTING


Component Page Component Page
Ash Receiver Lamp . . . . . . . . . . . . . . . . . . 8W-44-11 Interior Lamp No. 1 . . . . . . . . . . . . . . . . . . 8W-44-6
Cigar Lighter . . . . . . . . . . . . . . . . . . . . . . 8W-44-11 Interior Lamp No. 2 . . . . . . . . . . . . . . . . . . 8W-44-6
Cigar Lighter Lamp . . . . . . . . . . . . . . . . . 8W-44-11 Interior Lamp No. 3 . . . . . . . . . . . . . . . . . . 8W-44-6
Courtesy Lamp-Driver Door . . . . . . . . . . . 8W-44-12 Interior Lamp No. 4 . . . . . . . . . . . . . . . . . . 8W-44-6
Courtesy Lamp-Left Sliding Door . . . . . . . 8W-44-12 Interior Lamp No. 5 . . . . . . . . . . . . . . . . . . 8W-44-6
Courtesy Lamp-Passenger Door . . . . . . . . 8W-44-12 Interior Lamp-Left . . . . . . . . . . . . . . . . . . . 8W-44-9
Courtesy Lamp-Right Sliding Door . . . . . . 8W-44-12 Interior Lamp-Middle Front . . . . . . . . . . . 8W-44-10
Daytime Running Lamps Relay . . . . . . 8W-44-2, 11 Interior Lamp-Middle Rear . . . . . . . . . . . 8W-44-10
Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-9 Interior Lamp-Rear No. 1 . . . . . . . . . . . . . . 8W-44-9
Door Jamb Switch-Driver . . . . . . . . . . . . . . 8W-44-9 Interior Lamp-Rear No. 2 . . . . . . . . . . . . . . 8W-44-8
Door Jamb Switch-Passenger . . . . . . . . . . . 8W-44-9 Interior Lamp-Right . . . . . . . . . . . . . . . . . . 8W-44-8
Door Jamb Switch-Rear . . . . . . . . . . . . . . . 8W-44-8 Interior Light Switch . . . . . . . . . . . . . 8W-44-2, 3, 5
Fuse 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-2 Interior Light Switch-Driver . . . . . . . . . . . 8W-44-4
Fuse 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-3 Interior Light Switch-Passenger . . . . . . . . . 8W-44-4
Fuse Block No. 1 . . . . . . . . . . . . . . . . . . . . 8W-44-2 Interior Light Switch-Rear . . . . . . . . . . . . . 8W-44-4
Fuse Block No. 3 . . . . . . . . . . . . . . . . . . . . 8W-44-3 Interior Lighting Connector . . . . . . . . 8W-44-4, 5, 7
G200 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-7, 8, 10 Map/Reading Lamp Switch . . . . . . . . . 8W-44-2, 3, 7
G202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-5 Reading Lamp Connector . . . . . . . . . . . . 8W-44-2, 7
G203 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-2, 11 Time Delay Relay . . . . . . . . . . . . . . . . 8W-44-2, 3, 5
VA 8W-45 CENTRAL TIMER MODULE 8W - 45 - 1

8W-45 CENTRAL TIMER MODULE


Component Page Component Page
Airbag Control Module . . . . . . . . . . . . . . . . 8W-45-3 Door Lock Motor/Ajar Switch Assembly-Right
Central Timer Module . . . . . . . 8W-45-2, 3, 4, 5, 6, 7 Sliding . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-5, 6
Data Link Connector . . . . . . . . . . . . . . . . . 8W-45-3 Fuse 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-3
Door Lock Motor/Ajar Switch Assembly- Fuse 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-3
Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-2 Fuse Block No. 1 . . . . . . . . . . . . . . . . . . . . 8W-45-3
Door Lock Motor/Ajar Switch Assembly-Left Fuse Block No. 2 . . . . . . . . . . . . . . . . . . . . 8W-45-3
Sliding . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-5, 6 G202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-3
Door Lock Motor/Ajar Switch Assembly- Master Door Lock Switch . . . . . . . . . . . . . . 8W-45-4
Passenger . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-7 Security System Module . . . . . . . . . . . . . . . 8W-45-2
Door Lock Motor/Ajar Switch Assembly- Sentry Key Remote Entry Module . . . . . . . 8W-45-2
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-4, 6 Window Defogger Module-Rear . . . . . . . . . 8W-45-3
VA 8W-47 AUDIO SYSTEM 8W - 47 - 1

8W-47 AUDIO SYSTEM


Component Page Component Page
Ctel Connector . . . . . . . . . . . . . . . . . . . . . . 8W-47-4 Radio . . . . . . . . . . . . . . . . . . . . . . . 8W-47-2, 3, 4, 5
Data Link Connector . . . . . . . . . . . . . . . . . 8W-47-3 Radio Antenna . . . . . . . . . . . . . . . . . . . . . . 8W-47-3
Daytime Running Lamps Relay . . . . . . . . . 8W-47-2 Radio/Cellular Antenna . . . . . . . . . . . . . . . 8W-47-3
Fuse 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-2 Speaker-Left Front Door Assembly . . . . . . . 8W-47-4
Fuse 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-2 Speaker-Left Rear . . . . . . . . . . . . . . . . . . . 8W-47-5
Fuse Block No. 1 . . . . . . . . . . . . . . . . . . . . 8W-47-2 Speaker-Right Front Door . . . . . . . . . . . . . 8W-47-5
G203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-3 Speaker-Right Rear . . . . . . . . . . . . . . . . . . 8W-47-5
Instrument Cluster . . . . . . . . . . . . . . . . . . . 8W-47-2
VA 8W-48 REAR WINDOW DEFOGGER 8W - 48 - 1

8W-48 REAR WINDOW DEFOGGER


Component Page Component Page
D+ Relay No. 1 . . . . . . . . . . . . . . . . . . . . 8W-48-4, 6 G203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-5
Daytime Running Lamps Relay . . . . . . . . . 8W-48-5 G300 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-3, 4, 6
Fuse 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-5 Security System Module . . . . . . . . . . . . . 8W-48-3, 4
Fuse 9 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-4, 6 Window Defogger Module-Rear . . 8W-48-2, 3, 4, 5, 6
Fuse 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-2 Window Defogger Relay-Left Rear . . . . . 8W-48-2, 3
Fuse Block No. 1 . . . . . . . . . . . . . . . . . . . . 8W-48-5 Window Defogger Relay-Right Rear . . . . 8W-48-2, 4
Fuse Block No. 2 . . . . . . . . . . . . . . . . . . 8W-48-4, 6 Window Defogger Switch-Rear . . . . . . . . . . 8W-48-5
Fuse/Relay Block . . . . . . . . . . . . . . . . . . . . 8W-48-2 Window Defogger-Left Rear . . . . . . . . . . 8W-48-3, 6
G202 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-3, 4, 6 Window Defogger-Right Rear . . . . . . . . . 8W-48-4, 6
VA 8W-50 FRONT LIGHTING 8W - 50 - 1

8W-50 FRONT LIGHTING


Component Page Component Page
Beam Select Switch . . . . . . . . . . . . . . . . 8W-50-4, 6 G203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-9
D+ Relay No. 1 . . . . . . . . . . . 8W-50-7, 8, 12, 14, 15 Hazard Warning Switch . . . . . . . . . . . . . . . 8W-50-2
Daytime Running Lamp Relay-Left Side . . 8W-50-7 Headlamp Adjust Switch . . . . . . . . . . 8W-50-7, 8, 9
Daytime Running Lamp Headlamp Assembly-Left . . . . . . . . . . 8W-50-3, 6, 7,
Relay-Right Side . . . . . . . . . . . . . . . . . 8W-50-6, 8 9, 10, 11, 13, 14
Daytime Running Lamps Relay . . . . . . 8W-50-3, 13 Headlamp Assembly-Right . . . . . . . . . 8W-50-3, 6, 8,
Fog Lamp Relay . . . . . . . . . . . . . . . . 8W-50-6, 9, 10 9, 10, 11, 13, 15
Fog Lamp Switch . . . . . . . . . . . . . . . . . . . . 8W-50-9 Headlamp Switch . . . . . . . . . . . . . . . . 8W-50-4, 5, 6
Fuse 1 . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-3, 4, 13 Lamp Relay-Left . . . . . . . . . . . . . . . . . . 8W-50-3, 14
Fuse 2 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-6, 8 Lamp Relay-Right . . . . . . . . . . . . . . . . . 8W-50-3, 15
Fuse 3 . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-6, 7, 12 Marker Lamp Connector . . . . . . . . . . . . . . 8W-50-11
Fuse 4 . . . . . . . . . . . . . . . . . . . . . . . 8W-50-3, 14, 15 Marker Lamp No. 1-Left Front . . . . . . . . . 8W-50-11
Fuse 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-9 Marker Lamp No. 1-Right Front . . . . . . . . 8W-50-11
Fuse 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-2 Marker Lamp No. 2-Left Front . . . . . . . . . 8W-50-11
Fuse 9 . . . . . . . . . . . . . . . . . . . 8W-50-12, 13, 14, 15 Marker Lamp No. 2-Right Front . . . . . . . . 8W-50-11
Fuse 10 . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-3, 4, 8 Marker Lamp-Left Center . . . . . . . . . . . . 8W-50-11
Fuse 11 . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-3, 4, 7 Marker Lamp-Left Rear . . . . . . . . . . . . . . 8W-50-11
Fuse 12 . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-4, 6, 8 Marker Lamp-Right Center . . . . . . . . . . . 8W-50-11
Fuse 13 . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-6, 7, 8 Marker Lamp-Right Rear . . . . . . . . . . . . . 8W-50-11
Fuse 14 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-6, 10 Multi-Function Switch . . . . . . . . . . 8W-50-2, 4, 5, 6
Fuse Block No. 1 . . . . . . . . . . . . . . . 8W-50-2, 4, 5, 6 Power Distribution Center . . . . . . . . . . . . 8W-50-12
Fuse Block No. 2 . . . . . 8W-50-3, 7, 8, 12, 13, 14, 15 Tail Lamp Assembly-Left . . . . . . . . . . . . . 8W-50-14
Fuse Block No. 3 . . . . . . . . . . . . . . . . . . . . 8W-50-9 Tail Lamp Assembly-Right . . . . . . . . . . . . 8W-50-15
G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-7, 10 Turn Signal Relay . . . . . . . . . . . . . . . . . . 8W-50-2, 5
G102 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-8, 10 Turn Signal Switch . . . . . . . . . . . . . . . . . 8W-50-4, 5
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-2 Wiper/Turn Signal/Engine Start Control
G202 . . . . . . . . . . . . . 8W-50-7, 8, 10, 11, 13, 14, 15 Module . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-2, 5
VA 8W-51 REAR LIGHTING 8W - 51 - 1

8W-51 REAR LIGHTING


Component Page Component Page
Brake Lamp Switch . . . . . . . . . . . . . . . . . . 8W-51-6 License Plate Lamp No. 1 . . . . . . . . . . . . . 8W-51-3
Center High Mounted Stop Lamp . . . . . . 8W-51-6, 8 License Plate Lamp No. 2 . . . . . . . . . . . . . 8W-51-3
Daytime Running Lamps Relay . . . . . . . . . 8W-51-2 Marker Lamp Connector . . . . . . . . . . . . . . 8W-51-2
Fuse 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-4 Marker Lamp-Left Rear . . . . . . . . . . . . . . . 8W-51-3
Fuse 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-5 Marker Lamp-Right Rear . . . . . . . . . . . . . . 8W-51-3
Fuse 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-4 Multi-Function Switch . . . . . . . . . . . . . . . . 8W-51-4
Fuse Block No. 1 . . . . . . . . . . . . . . . . . . 8W-51-4, 5 Tail Lamp Assembly-Left . . . . 8W-51-4, 5, 6, 7, 8, 9
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-6, 8 Tail Lamp Assembly-Right . . . 8W-51-4, 5, 6, 7, 8, 9
G202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-2 Turn Signal/Anti-Theft Alarm Relay-Left . . 8W-51-5
G300 . . . . . . . . . . . . . . . . . . . . . . 8W-51-3, 6, 7, 8, 9 Turn Signal/Anti-Theft Alarm Relay-Right . 8W-51-5
Headlamp Switch . . . . . . . . . . . . . . . . . . . . 8W-51-4
VA 8W-52 TURN SIGNALS 8W - 52 - 1

8W-52 TURN SIGNALS


Component Page Component Page
Fuse 5 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-3, 5 Sentry Key Remote Entry Module . . . . . 8W-52-3, 4
Fuse 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-2 Tail Lamp Assembly-Left . . . . . . . . . . . . . . 8W-52-4
Fuse 8 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-3, 5 Tail Lamp Assembly-Right . . . . . . . . . . . . . 8W-52-6
Fuse 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-2 Trailer Tow Control Module . . . . . . . . . . 8W-52-4, 6
Fuse Block No. 1 . . . . . . . . . . . . . 8W-52-2, 3, 4, 5, 6 Turn Signal No. 1-Left Front . . . . . . . . . . . 8W-52-4
Fuse/Relay Block . . . . . . . . . . . . . . . . . . 8W-52-3, 5 Turn Signal No. 1-Right Front . . . . . . . . . . 8W-52-6
G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-4 Turn Signal No. 2-Left Front . . . . . . . . . . . 8W-52-4
G102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-6 Turn Signal No. 2-Right Front . . . . . . . . . . 8W-52-6
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-2 Turn Signal Relay . . . . . . . . . . . . . . . . . . . 8W-52-2
Hazard Warning Switch . . . . . . . . . . . . . . . 8W-52-2 Turn Signal/Anti-Theft Alarm
Headlamp Assembly-Left . . . . . . . . . . . . 8W-52-2, 4 Relay-Left . . . . . . . . . . . . . . . . . . . . . . 8W-52-3, 4
Headlamp Assembly-Right . . . . . . . . . . . 8W-52-2, 6 Turn Signal/Anti-Theft Alarm Relay-
Instrument Cluster . . . . . . . . . . . . . . . . . 8W-52-4, 6 Right . . . . . . . . . . . . . . . . . . . . . . . 8W-52-3, 5, 6
Multi-Function Switch . . . . . . . . . . . . . . . . 8W-52-2 Wiper/Turn Signal/Engine Start Control
Security System Module . . . . . . . . . . . . . 8W-52-4, 6 Module . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-2
VA 8W-53 WIPERS 8W - 53 - 1

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-54 TRAILER TOW


Component Page Component Page
Controller Antilock Brake . . . . . . . . . . . . . . 8W-54-2 Lamp Relay-Right . . . . . . . . . . . . . . . . . . . 8W-54-3
Fuse 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-3 Multi-Function Switch . . . . . . . . . . . . . . . . 8W-54-2
Fuse 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-3 Shifter Assembly . . . . . . . . . . . . . . . . . . . . 8W-54-3
Fuse Block No. 1 . . . . . . . . . . . . . . . . . . . . 8W-54-2 Trailer Tow Connector . . . . . . . . . . . . . . . . 8W-54-3
Fuse Block No. 2 . . . . . . . . . . . . . . . . . . . . 8W-54-3 Trailer Tow Control Module . . . . . . . . . . 8W-54-2, 3
Fuse Block No. 3 . . . . . . . . . . . . . . . . . . . . 8W-54-3 Turn Signal Relay . . . . . . . . . . . . . . . . . . . 8W-54-2
G202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-2 Turn Signal Switch . . . . . . . . . . . . . . . . . . . 8W-54-2
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-3 Wiper/Turn Signal/Engine Start Control
Hazard Warning Switch . . . . . . . . . . . . . . . 8W-54-2 Module . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-2
VA 8W-55 NAVIGATION/TELECOMMUNICATIONS 8W - 55 - 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

8W-60 POWER WINDOWS


Component Page Component Page
Fuse 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-60-2 Power Window Motor-Driver . . . . . . . . . 8W-60-2, 4
Fuse 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-60-3 Power Window Motor-Passenger . . . . . . . . 8W-60-4
Fuse Block No. 2 . . . . . . . . . . . . . . . . . . 8W-60-2, 3 Power Window Switch-Driver . . . . . . . . . 8W-60-2, 4
G203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-60-2, 3 Power Window Switch-Master . . . . . . . . 8W-60-3, 4
Optional Equipment Relay . . . . . . . . . . . 8W-60-2, 3 Power Window Switch-Passenger . . . . . . . . 8W-60-4
VA 8W-61 POWER DOOR LOCKS 8W - 61 - 1

8W-61 POWER DOOR LOCKS


Component Page Component Page
Central Timer Module . . . . . . . 8W-61-2, 3, 4, 5, 6, 7 Door Lock Motor/Ajar Switch Assembly-
Cylinder Lock Switch-Driver . . . . . . . . . . . 8W-61-8 Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-3
Daytime Running Lamps Relay . . . . . . . . . 8W-61-2 Door Lock Motor/Ajar Switch Assembly-Right
Door Jamb Switch-Left Sliding . . . . . . . . . . 8W-61-8 Sliding . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-7
Door Jamb Switch-Rear . . . . . . . . . . . . . . . 8W-61-8 G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-8
Door Jamb Switch-Right Sliding . . . . . . . . 8W-61-8 G203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-2
Door Lock Motor/Ajar Switch Assembly- Interior Lamp-Right . . . . . . . . . . . . . . . . . . 8W-61-8
Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-4 Master Door Lock Switch . . . . . . . . . . . . . . 8W-61-2
Door Lock Motor/Ajar Switch Assembly-Left Security System Module . . . . . . . . . . . . . . . 8W-61-8
Sliding . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-6
Door Lock Motor/Ajar Switch Assembly-
Passenger . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-5
VA 8W-62 POWER MIRRORS 8W - 62 - 1

8W-62 POWER MIRRORS


Component Page Component Page
Fuse 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-62-2 Power Mirror Motor-Driver . . . . . . . . . 8W-62-2, 3, 4
Fuse Block No. 2 . . . . . . . . . . . . . . . . . . . . 8W-62-2 Power Mirror Motor-Passenger . . . . . . . . 8W-62-2, 4
G203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-62-2, 3 Power Mirror Switch . . . . . . . . . . . . . 8W-62-2, 3, 4
Optional Equipment Relay . . . . . . . . . . . . . 8W-62-2
VA 8W-63 POWER SEATS 8W - 63 - 1

8W-63 POWER SEATS


Component Page Component Page
Daytime Running Lamps Relay . . . . . . . . . 8W-63-2 Heated Seat Module-Driver . . . . . . . . . . . . 8W-63-4
Fuse 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-3 Heated Seat Module-Passenger . . . . . . . . . 8W-63-4
Fuse Block No. 3 . . . . . . . . . . . . . . . . . . . . 8W-63-3 Heated Seat Switch-Driver . . . . . . . . . 8W-63-2, 3, 4
G202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-4 Heated Seat Switch-Passenger . . . . . . 8W-63-2, 3, 4
G203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-2, 3 Optional Equipment Relay . . . . . . . . . . . . . 8W-63-3
VA 8W-70 SPLICE INFORMATION 8W - 70 - 1

8W-70 SPLICE INFORMATION


Component Page Component Page
S100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-8, 9 S260 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-6
S101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-11 S261 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-19
S102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-29 S262 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-29
S103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-11 S300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-33
S104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-28 S301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-33
S105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-9 S302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-33
S106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-24 S303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-23
S107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-2 S304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-23
S108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-28 S305 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-36
S175 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-29 S306 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-34
S176 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-16 S307 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-34
S177 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-15 S308 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-5
S178 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-17 S309 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6
S180 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-3 S310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-17
S200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-19 S311 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-30
S201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-17 S312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-6
S202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-36 S313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-6
S203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-25 S314 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-6
S204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-20 S315 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-6
S205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-27 S316 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-26
S206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-22 S317 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-11
S207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-5 S318 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-3
S208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-5 S319 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-3
S209 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-5 S320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-9
S210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-16 S321 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-32
S211 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-24 S322 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-5
S212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-38 S323 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-5
S213 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-2 S324 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-6
S214 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-38 S325 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-23
S215 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-6 S326 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-6
S216 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-18 S327 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-8
S217 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-29 S328 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-6
S218 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-4 S329 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-6
S219 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-15 S330 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-4, 6
S220 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-9 S331 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-3
S221 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-4 S332 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-28
S222 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-4 S333 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-17
S223 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-30 S350 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-10
S224 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-6 S351 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-4
S225 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-18 S352 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-6
S226 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-24 S353 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-24
S227 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-24 S354 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-2
S228 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-8 S355 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-20
S229 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-3 S356 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-26
S230 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-8 S357 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-4
S231 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-6 S358 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-25
S232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-6 S359 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-4
S250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-23 S360 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-23
S251 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-3 S361 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-23
S252 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-23 S362 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-35
S253 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-28 S363 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-4
S254 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-6 S364 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-31
S255 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-16 S365 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-32
S256 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-11-17 S366 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-4
S257 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-5 S375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-4
S258 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-7
S259 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-6
VA 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 1

8W-80 CONNECTOR PIN-OUTS


Component Page Component Page
A/C Control Module-Roof . . . . . . . . . . . . . . 8W-80-4 C203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-18
A/C Switch-Roof . . . . . . . . . . . . . . . . . . . . . 8W-80-4 C203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-18
A/C Temperature Setting Control-Roof . . . . 8W-80-4 C204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-18
Accelerator Pedal Position Sensor . . . . . . . 8W-80-4 C204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-18
Accelerator Pedal Position Sensor (OBD) . . 8W-80-5 C205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-19
Additional Heat Exchanger . . . . . . . . . . . . 8W-80-5 C205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-19
Additional Heat Exchanger Relay (In Relay C206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-19
Block) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-6 C206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-19
Additional Heat Exchanger Switch . . . . . . . 8W-80-7 C207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-20
Air Outlet Temperature Sensor . . . . . . . . . 8W-80-7 C207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-20
Airbag Control Module . . . . . . . . . . . . . . . . 8W-80-7 C208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-20
Airbag Squib-Driver . . . . . . . . . . . . . . . . . . 8W-80-8 C208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-20
Airbag Squib-Passenger . . . . . . . . . . . . . . . 8W-80-8 C209 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-20
Ambient Temperature Sensor . . . . . . . . . . . 8W-80-8 C209 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-21
Ash Receiver Lamp . . . . . . . . . . . . . . . . . . 8W-80-8 C210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-21
Automatic Temperature Control Module C210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-21
C1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-9 C211 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-21
Automatic Temperature Control Module C211 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-21
C2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-9 C214 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-22
Auxiliary Heater Switch . . . . . . . . . . . . . . . 8W-80-9 C214 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-22
Battery Relay-Auxiliary . . . . . . . . . . . . . . 8W-80-10 C215 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-22
Blower Motor Resistor Block . . . . . . . . . . 8W-80-10 C215 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-22
Blower Motor Resistor Block C1 . . . . . . . . 8W-80-10 C216 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-22
Blower Motor Resistor Block C2 . . . . . . . . 8W-80-10 C216 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-23
Blower Motor Resistor Block C3 . . . . . . . . 8W-80-10 C217 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-23
Blower Motor-Front . . . . . . . . . . . . . . . . . 8W-80-11 C217 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-23
Body Plug Connector . . . . . . . . . . . . . . . . 8W-80-11 C218 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-23
Boost Pressure Sensor (Except OBD) . . . . 8W-80-11 C218 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-23
Boost Pressure Sensor (OBD) . . . . . . . . . . 8W-80-11 C219 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-24
Boost Pressure ServoMotor (OBD) . . . . . . 8W-80-12 C219 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-24
Boost Pressure Solenoid . . . . . . . . . . . . . . 8W-80-12 C220 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-24
Brake Fluid Level Switch . . . . . . . . . . . . . 8W-80-12 C220 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-24
Brake Lamp Switch C1 . . . . . . . . . . . . . . 8W-80-12 C221 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-25
Brake Lamp Switch C2 . . . . . . . . . . . . . . 8W-80-12 C221 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-25
Brake Wear Sensor-Left Front . . . . . . . . . 8W-80-13 C224 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-25
Brake Wear Sensor-Left Rear . . . . . . . . . . 8W-80-13 C224 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-25
Brake Wear Sensor-Right Front . . . . . . . . 8W-80-13 C225 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-25
Brake Wear Sensor-Right Rear . . . . . . . . . 8W-80-13 C225 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-26
C100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-13 Cabin Heater Assembly C1 . . . . . . . . . . . . 8W-80-26
C100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-14 Cabin Heater Assembly C2 . . . . . . . . . . . . 8W-80-26
C101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-14 Camshaft Position Sensor . . . . . . . . . . . . . 8W-80-26
C101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-14 Center High Mounted Stop Lamp . . . . . . . 8W-80-27
C102 (Except OBD) . . . . . . . . . . . . . . . . . 8W-80-14 Central Timer Module C1 . . . . . . . . . . . . . 8W-80-27
C102 (Except OBD) . . . . . . . . . . . . . . . . . 8W-80-14 Central Timer Module C2 . . . . . . . . . . . . . 8W-80-27
C103 (OBD) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-15 Cigar Lighter . . . . . . . . . . . . . . . . . . . . . . 8W-80-28
C103 (OBD) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-15 Cigar Lighter Lamp . . . . . . . . . . . . . . . . . 8W-80-28
C200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-15 Circulation Pump (Cabin Heater
C200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-16 Module) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-28
C201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-16 Circulation Pump (Rest System) . . . . . . . . 8W-80-28
C201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-17 Circulation Pump Diode . . . . . . . . . . . . . . 8W-80-28
C202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-17 Clockspring C1 . . . . . . . . . . . . . . . . . . . . . 8W-80-29
C202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-17 Clockspring C2 . . . . . . . . . . . . . . . . . . . . . 8W-80-29
8W - 80 - 2 8W-80 CONNECTOR PIN-OUTS VA

Component Page Component Page


Controller Antilock Brake . . . . . . . . . . . . . 8W-80-29 Fuel Injector No. 4 . . . . . . . . . . . . . . . . . . 8W-80-41
Courtesy Lamp-Driver Door . . . . . . . . . . . 8W-80-30 Fuel Injector No. 5 . . . . . . . . . . . . . . . . . . 8W-80-41
Courtesy Lamp-Left Sliding Door . . . . . . . 8W-80-30 Fuel Level Sensor . . . . . . . . . . . . . . . . . . . 8W-80-41
Courtesy Lamp-Passenger Door . . . . . . . . 8W-80-30 Fuel Pressure Sensor . . . . . . . . . . . . . . . . 8W-80-41
Courtesy Lamp-Right Sliding Door . . . . . . 8W-80-30 Fuel Pressure Solenoid (Except OBD) . . . 8W-80-41
Crankcase Heater . . . . . . . . . . . . . . . . . . . 8W-80-30 Fuel Pump (OBD) . . . . . . . . . . . . . . . . . . . 8W-80-42
Crankshaft Position Sensor . . . . . . . . . . . 8W-80-31 Fuel Pump Relay (OBD) . . . . . . . . . . . . . . 8W-80-42
Ctel Antenna Connector . . . . . . . . . . . . . . 8W-80-31 Fuel Quantity Control Valve (OBD) . . . . . 8W-80-42
Ctel Connector . . . . . . . . . . . . . . . . . . . . . 8W-80-31 Fuel Shutdown Solenoid . . . . . . . . . . . . . . 8W-80-42
Cylinder Lock Switch-Driver . . . . . . . . . . 8W-80-31 Fuel Temperature Sensor . . . . . . . . . . . . . 8W-80-42
Data Link Connector . . . . . . . . . . . . . . . . 8W-80-32 Fuse Block No. 1 C1 . . . . . . . . . . . . . . . . . 8W-80-43
Differential Lock Solenoid Valve . . . . . . . . 8W-80-32 Fuse Block No. 1 C2 . . . . . . . . . . . . . . . . . 8W-80-43
Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . 8W-80-32 Fuse Block No. 1 C3 . . . . . . . . . . . . . . . . . 8W-80-43
Door Lock Motor/Ajar Switch Fuse Block No. 1 C4 . . . . . . . . . . . . . . . . . 8W-80-43
Assembly-Driver C1 . . . . . . . . . . . . . . . 8W-80-32 Fuse Block No. 1 C5 . . . . . . . . . . . . . . . . . 8W-80-44
Door Lock Motor/Ajar Switch Glow Plug Control Module C1 . . . . . . . . . 8W-80-44
Assembly-Driver C2 . . . . . . . . . . . . . . . 8W-80-33 Glow Plug Control Module C2 . . . . . . . . . 8W-80-44
Door Lock Motor/Ajar Switch Headlamp Adjust Switch . . . . . . . . . . . . . 8W-80-44
Assembly-Left Sliding C1 . . . . . . . . . . . 8W-80-33 Headlamp Assembly-Left . . . . . . . . . . . . . 8W-80-45
Door Lock Motor/Ajar Switch Headlamp Assembly-Right . . . . . . . . . . . . 8W-80-45
Assembly-Left Sliding C2 . . . . . . . . . . . 8W-80-33 Heated Seat Module-Driver . . . . . . . . . . . 8W-80-45
Door Lock Motor/Ajar Switch Heated Seat Module-Passenger . . . . . . . . 8W-80-46
Assembly-Passenger C1 . . . . . . . . . . . . 8W-80-33 Heated Seat Switch-Driver . . . . . . . . . . . . 8W-80-46
Door Lock Motor/Ajar Switch Heated Seat Switch-Passenger . . . . . . . . . 8W-80-46
Assembly-Passenger C2 . . . . . . . . . . . . 8W-80-34 Heater Timer-Auxiliary . . . . . . . . . . . . . . 8W-80-46
Door Lock Motor/Ajar Switch High Idle Switch . . . . . . . . . . . . . . . . . . . . 8W-80-47
Assembly-Rear C1 . . . . . . . . . . . . . . . . 8W-80-34 Hood Ajar Switch . . . . . . . . . . . . . . . . . . . 8W-80-47
Door Lock Motor/Ajar Switch Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-47
Assembly-Rear C2 . . . . . . . . . . . . . . . . 8W-80-34 Horn (VTSS) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-47
Door Lock Motor/Ajar Switch Ignition Lock Switch . . . . . . . . . . . . . . . . . 8W-80-48
Assembly-Right Sliding C1 . . . . . . . . . . 8W-80-34 Instrument Cluster C1 . . . . . . . . . . . . . . . 8W-80-48
Door Lock Motor/Ajar Switch Instrument Cluster C2 . . . . . . . . . . . . . . . 8W-80-48
Assembly-Right Sliding C2 . . . . . . . . . . 8W-80-34 Instrument Panel Socket . . . . . . . . . . . . . 8W-80-49
Dosing Pump . . . . . . . . . . . . . . . . . . . . . . 8W-80-35 Intake Air Pressure Sensor (OBD) . . . . . . 8W-80-49
EGR Valve . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-35 Intake Air Temperature Sensor . . . . . . . . 8W-80-49
Engine Control Module C1 Interior Lamp No. 1 . . . . . . . . . . . . . . . . . 8W-80-49
(Except OBD) . . . . . . . . . . . . . . . . . . . . 8W-80-35
Interior Lamp No. 2 . . . . . . . . . . . . . . . . . 8W-80-49
Engine Control Module C1 (OBD) . . . . . . 8W-80-36
Interior Lamp No. 3 . . . . . . . . . . . . . . . . . 8W-80-50
Engine Control Module C2 (OBD) . . . . . . 8W-80-37
Interior Lamp No. 4 . . . . . . . . . . . . . . . . . 8W-80-50
Engine Control Module C2
Interior Lamp No. 5 . . . . . . . . . . . . . . . . . 8W-80-50
(Except OBD) . . . . . . . . . . . . . . . . . . . . 8W-80-37
Interior Lamp-Left . . . . . . . . . . . . . . . . . . 8W-80-50
Engine Control Module C3
Interior Lamp-Middle Front . . . . . . . . . . . 8W-80-50
(Except OBD) . . . . . . . . . . . . . . . . . . . . 8W-80-38
Interior Lamp-Middle Rear . . . . . . . . . . . 8W-80-51
Engine Control Module C4
Interior Lamp-Rear No. 1 . . . . . . . . . . . . . 8W-80-51
(Except OBD) . . . . . . . . . . . . . . . . . . . . 8W-80-38
Interior Lamp-Rear No. 2 . . . . . . . . . . . . . 8W-80-51
Engine Control Module C5
Interior Lamp-Right . . . . . . . . . . . . . . . . . 8W-80-52
(Except OBD) . . . . . . . . . . . . . . . . . . . . 8W-80-39
Interior Light Switch . . . . . . . . . . . . . . . . 8W-80-52
Engine Coolant Level Switch . . . . . . . . . . 8W-80-39
Interior Light Switch-Driver . . . . . . . . . . . 8W-80-52
Engine Coolant Temperature Sensor . . . . 8W-80-39
Interior Light Switch-Passenger . . . . . . . . 8W-80-52
Engine Oil Sensor . . . . . . . . . . . . . . . . . . . 8W-80-39
Interior Light Switch-Rear . . . . . . . . . . . . 8W-80-53
Evaporator Temperature Sensor . . . . . . . . 8W-80-40
Interior Lighting Connector . . . . . . . . . . . 8W-80-53
Fog Lamp Switch . . . . . . . . . . . . . . . . . . . 8W-80-40
Intrusion Sensor No. 1 . . . . . . . . . . . . . . . 8W-80-53
Fuel Injector No. 1 . . . . . . . . . . . . . . . . . . 8W-80-40
Intrusion Sensor No. 2 . . . . . . . . . . . . . . . 8W-80-53
Fuel Injector No. 2 . . . . . . . . . . . . . . . . . . 8W-80-40
Intrusion Sensor No. 3 . . . . . . . . . . . . . . . 8W-80-53
Fuel Injector No. 3 . . . . . . . . . . . . . . . . . . 8W-80-40
VA 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 3

Component Page Component Page


Kick Down Switch . . . . . . . . . . . . . . . . . . 8W-80-54 Security System Module C2 . . . . . . . . . . . 8W-80-64
License Plate Lamp No. 1 . . . . . . . . . . . . . 8W-80-54 Sentry Key Remote Entry Module
License Plate Lamp No. 2 . . . . . . . . . . . . . 8W-80-54 (SKREEM) . . . . . . . . . . . . . . . . . . . . . . 8W-80-64
Locker Switch No. 1 . . . . . . . . . . . . . . . . . 8W-80-54 Shifter Assembly . . . . . . . . . . . . . . . . . . . 8W-80-64
Locker Switch No. 2 . . . . . . . . . . . . . . . . . 8W-80-54 Siren . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-65
Low Fuel Pressure Sensor . . . . . . . . . . . . 8W-80-55 Skreem Transponder . . . . . . . . . . . . . . . . 8W-80-65
Map/Reading Lamp Switch . . . . . . . . . . . . 8W-80-55 Speaker-Left Front Door Assembly C1 . . . 8W-80-65
Marker Lamp Connector . . . . . . . . . . . . . 8W-80-55 Speaker-Left Front Door Assembly C2 . . . 8W-80-65
Marker Lamp No. 1-Left Front . . . . . . . . . 8W-80-55 Speaker-Left Rear . . . . . . . . . . . . . . . . . . 8W-80-65
Marker Lamp No. 1-Right Front . . . . . . . 8W-80-55 Speaker-Right Front Door . . . . . . . . . . . . 8W-80-66
Marker Lamp No. 2-Left Front . . . . . . . . . 8W-80-56 Speaker-Right Rear . . . . . . . . . . . . . . . . . 8W-80-66
Marker Lamp No. 2-Right Front . . . . . . . 8W-80-56 Speed Control Switch . . . . . . . . . . . . . . . . 8W-80-66
Marker Lamp-Left Center . . . . . . . . . . . . 8W-80-56 Tail Lamp Assembly-Left . . . . . . . . . . . . . 8W-80-66
Marker Lamp-Left Rear . . . . . . . . . . . . . . 8W-80-56 Tail Lamp Assembly-Right . . . . . . . . . . . . 8W-80-66
Marker Lamp-Right Center . . . . . . . . . . . 8W-80-56 Tcs Switch (ASR) . . . . . . . . . . . . . . . . . . . 8W-80-67
Marker Lamp-Right Rear . . . . . . . . . . . . . 8W-80-57 Time Delay Relay . . . . . . . . . . . . . . . . . . . 8W-80-67
Mass Air Flow Sensor . . . . . . . . . . . . . . . . 8W-80-57 Towing/Intrusion Sensor On/Off Switch . . 8W-80-67
Master Door Lock Switch . . . . . . . . . . . . . 8W-80-57 Trailer Tow Connector . . . . . . . . . . . . . . . 8W-80-67
Metering Pump . . . . . . . . . . . . . . . . . . . . . 8W-80-57 Trailer Tow Control Module C1 . . . . . . . . 8W-80-68
Microphone Connector . . . . . . . . . . . . . . . 8W-80-58 Trailer Tow Control Module C2 . . . . . . . . 8W-80-68
Oxygen Sensor (OBD) . . . . . . . . . . . . . . . . 8W-80-58 Transmission Control Module C1 . . . . . . . 8W-80-68
Panic Alarm Switch . . . . . . . . . . . . . . . . . 8W-80-58 Transmission Control Module C2 . . . . . . . 8W-80-68
Parking Brake Switch . . . . . . . . . . . . . . . 8W-80-58 Transmission Solenoid Assembly . . . . . . . 8W-80-69
Power Mirror Motor-Driver . . . . . . . . . . . 8W-80-59 Turn Signal No. 1-Left Front . . . . . . . . . . 8W-80-69
Power Mirror Motor-Passenger . . . . . . . . . 8W-80-59 Turn Signal No. 1-Right Front . . . . . . . . . 8W-80-69
Power Mirror Switch . . . . . . . . . . . . . . . . 8W-80-59 Turn Signal No. 2-Left Front . . . . . . . . . . 8W-80-69
Power Window Motor-Driver . . . . . . . . . . 8W-80-59 Turn Signal No. 2-Right Front . . . . . . . . . 8W-80-70
Power Window Motor-Passenger . . . . . . . . 8W-80-60 Warm Air Auxiliary Heater Assembly C1 . 8W-80-70
Power Window Switch-Driver . . . . . . . . . . 8W-80-60 Warm Air Auxiliary Heater Assembly C2 . 8W-80-70
Power Window Switch-master . . . . . . . . . 8W-80-60 Washer Pump Motor-Front . . . . . . . . . . . . 8W-80-70
Power Window Switch-Passenger . . . . . . . 8W-80-60 Water Cycle Valve . . . . . . . . . . . . . . . . . . . 8W-80-70
Radio Antenna . . . . . . . . . . . . . . . . . . . . . 8W-80-60 Water In Fuel Sensor . . . . . . . . . . . . . . . . 8W-80-71
Radio C1 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-61 Wheel Speed Sensor-Left Front . . . . . . . . 8W-80-71
Radio C2 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-61 Wheel Speed Sensor-Left Rear . . . . . . . . . 8W-80-71
Radio/Cellular Antenna . . . . . . . . . . . . . . 8W-80-61 Wheel Speed Sensor-Right Front . . . . . . . 8W-80-71
Reading Lamp Connector . . . . . . . . . . . . . 8W-80-61 Wheel Speed Sensor-Right Rear . . . . . . . . 8W-80-71
Recirculated Air Solenoid Valve . . . . . . . . 8W-80-62 Window Defogger Module-Rear . . . . . . . . . 8W-80-72
Refrigerant Pressure Sensor . . . . . . . . . . . 8W-80-62 Window Defogger Switch-Rear . . . . . . . . . 8W-80-72
Remote Keyless Entry Antenna . . . . . . . . 8W-80-62 Window Defogger-Left Rear . . . . . . . . . . . 8W-80-72
Roof Fan Motor . . . . . . . . . . . . . . . . . . . . . 8W-80-62 Window Defogger-Right Rear . . . . . . . . . . 8W-80-72
Roof Fan Switch . . . . . . . . . . . . . . . . . . . . 8W-80-62 Wiper Motor-Front . . . . . . . . . . . . . . . . . . 8W-80-72
Seat Belt Switch . . . . . . . . . . . . . . . . . . . . 8W-80-63 Wiper/Turn Signal/engine Start Control Module
Seat Belt Tensioner-Driver . . . . . . . . . . . . 8W-80-63 (Fuse Block No. 1) . . . . . . . . . . . . . . . . 8W-80-73
Seat Belt Tensioner-Passenger . . . . . . . . . 8W-80-63
Security System Module C1 . . . . . . . . . . . 8W-80-63
8W - 80 - 4 8W-80 CONNECTOR PIN-OUTS VA

A/C CONTROL MODULE-ROOF - BLACK


CAV CIRCUIT FUNCTION
1 12BR GROUND
2 12RD FUSED B(+)
3 16YL A/C FAN MOTOR CONTROL-LOW SPEED
4 16VT A/C FAN MOTOR CONTROL-HIGH SPEED
5 16BK TEMPERATURE SENSOR SIGNAL
6 16BR TEMPERATURE SWITCH SENSE

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

A/C TEMPERATURE SETTING CONTROL-ROOF


CAV CIRCUIT FUNCTION
3 16BR TEMPERATURE SWITCH SENSE
5 16BK TEMPERATURE SENSOR SIGNAL
9 16GY/DG/RD LAMP DRIVER

ACCELERATOR PEDAL POSITION SENSOR (OBD)


CAV CIRCUIT FUNCTION
1 18BL/DG ACCEL PEDAL POSITION SENSOR SIGNAL NO. 1
2 18BR/GY ACCEL PEDAL POSITION SENSOR GROUND NO. 2
3 18GY/DG ACCEL PEDAL POSITION SENSOR SIGNAL NO. 2
4 18BL/RD ACCEL PEDAL POSITION SENSOR 5 VOLT SUPPLY
5 18BR/BL ACCEL PEDAL POSITION SENSOR GROUND NO. 1
VA 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 5

ACCELERATOR PEDAL POSITION SENSOR - BLACK


CAV CIRCUIT FUNCTION
1 18BL/RD ACCEL PEDAL POSITION SENSOR 5 VOLT SUPPLY
2 18BR/BL ACCEL PEDAL POSITION SENSOR GROUND NO. 1
3 18BL/DG ACCEL PEDAL POSITION SENSOR SIGNAL NO. 1
4 18BR/GY ACCEL PEDAL POSITION SENSOR GROUND NO. 2
5 18GY/DG ACCEL PEDAL POSITION SENSOR GROUND NO. 2

ADDITIONAL HEAT EXCHANGER


CAV CIRCUIT FUNCTION
A 12BR GROUND
B 12RD/BL AUXILIARY HEATER RELAY OUTPUT
C 16VT/BL ADDITIONAL HEAT EXCHANGER CAV C TO HEAT
EXCHANGER SWITCH CAV 7
D 16VT/YL ADDITIONAL HEAT EXCHANGER CAV D TO HEAT
EXCHANGER SWITCH CAV 4
8W - 80 - 6 8W-80 CONNECTOR PIN-OUTS VA

ADDITIONAL HEAT EXCHANGER RELAY (IN RELAY BLOCK)


CAV CIRCUIT FUNCTION
30 12RD/DG FUSED B(+)
85 18BK FUSED OPTIONAL EQUIPMENT RELAY OUTPUT
86 18BR GROUND
87 12RD/BL AUXILIARY HEATER RELAY OUTPUT
87A - -
VA 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 7

ADDITIONAL HEAT EXCHANGER SWITCH


CAV CIRCUIT FUNCTION
1 16GY/DG/RD LAMP DRIVER
3 16BK/BL/DG S201 COMMON CIRCUIT
4 16VT/YL ADDITIONAL HEAT EXCHANGER SWITCH CAV 4 TO
ADDITIONAL HEAT EXCHANGER CAV D
5 16BR GROUND
7 16VT/BL ADDITIONAL HEAT EXCHANGER SWITCH CAV 7 TO
ADDITIONAL HEAT EXCHANGER CAV C
8 16BK/BL/DG S201 COMMON CIRCUIT
10 16BR GROUND

AIR OUTLET TEMPERATURE SENSOR


CAV CIRCUIT FUNCTION
1 18BR/GY AIR OUTLET TEMPERATURE SENSOR SIGNAL
2 18BR/BL SENSOR GROUND

AIRBAG CONTROL MODULE - YELLOW


CAV CIRCUIT FUNCTION
1 20BL DRIVER SEAT BELT TENSIONER LINE 2
2 20BR/YL DRIVER SEAT BELT TENSIONER LINE 1
3 20BL PASSENGER SEAT BELT TENSIONER LINE 2
4 20BR PASSENGER SEAT BELT TENSIONER LINE 1
5 20BK FUSED IGNITION SWITCH OUTPUT (RUN-START)
6 20BR GROUND
7 20YL AIRBAG WARNING INDICATOR DRIVER
9 20BK/RD K-ACM
10 20DG DRIVER AIRBAG SQUIB 1 LINE 2
11 20VT DRIVER AIRBAG SQUIB 1 LINE 1
13 20BL/DG PASSENGER AIRBAG SQUIB 1 LINE 2
14 20BR/DG PASSENGER AIRBAG SQUIB 1 LINE 1
20 20DG ENHANCED ACCIDENT REPORT DRIVER
8W - 80 - 8 8W-80 CONNECTOR PIN-OUTS VA

AIRBAG SQUIB-DRIVER - YELLOW


CAV CIRCUIT FUNCTION
1 20DG DRIVER AIRBAG SQUIB 1 LINE 2
2 20VT DRIVER AIRBAG SQUIB 1 LINE 1

AIRBAG SQUIB-PASSENGER - YELLOW


CAV CIRCUIT FUNCTION
1 20BL/DG PASSENGER AIRBAG SQUIB 1 LINE 2
2 20BR/DG PASSENGER AIRBAG SQUIB 1 LINE 1

AMBIENT TEMPERATURE SENSOR


CAV CIRCUIT FUNCTION
1 20BL/DG AMBIENT TEMPERATURE SENSOR SIGNAL (+)
2 20BR/DG AMBIENT TEMPERATURE SENSOR SIGNAL RETURN

ASH RECEIVER LAMP


CAV CIRCUIT FUNCTION
1 18GY/DG/RD LAMP DRIVER
3 18BR GROUND
VA 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 9

AUTOMATIC TEMPERATURE CONTROL MODULE C1 - BROWN


CAV CIRCUIT FUNCTION
1 16RD/BL FUSED B(+)
2 18DG/RD (REST SYSTEM) CIRCULATION PUMP MOTOR (+)
3 18BK/RD A/C AUXILIARY FAN RELAY CONTROL
4 16BL/YL CIRCULATION PUMP MOTOR REQUEST
5 18BR/VT WATER CYCLE VALVE (DUTY CYCLE)
6 20RD/BL 5 VOLT SUPPLY
7 18BK/YL K-IC/ATC/HBM/CHM
8 20BL/VT IC 18 C2 TO ATCM 8-C1
8 16RD/YL/WT FUSED D(+) RELAY NO.1 OUTPUT
9 16GY/DG/RD LAMP DRIVER
10 16BL HEATER BOOSTER MODE CONTROL
11 16BK/BL/WT RECIRCULATED AIR SOLENOID VALVE (+)
12 16BL/DG A/C COMPRESSOR CLUTCH (+)
13 18BR/DG EVAPORATOR TEMPERATURE SENSOR SIGNAL
15 16BR GROUND
16 18BR/GY AIR OUTLET TEMPERATURE SENSOR SIGNAL
17 20DG/WT CAN C BUS (+)
18 18BR/BL SENSOR GROUND
19 20BR/RD REFRIGERANT PRESSURE SENSOR SIGNAL
20 20DG CAN C BUS (-)
21 16BK/BL/DG S201 COMMON CIRCUIT

AUTOMATIC TEMPERATURE CONTROL MODULE C2


CAV CIRCUIT FUNCTION
1 14BK/VT BLOWER MOTOR (+) SELECT 1
1 12YL BLOWER MOTOR (+) SELECT 1
2 12WT BLOWER MOTOR (+)
3 12WT/BK BLOWER MOTOR (+) SELECT 2
3 12BK/WT BLOWER MOTOR (+) SELECT 2
4 12YL/BK BLOWER MOTOR (+) SELECT 3
5 12RD/BL FUSED B(+)

AUXILIARY HEATER SWITCH


CAV CIRCUIT FUNCTION
1 16GY/DG/RD LAMP DRIVER
3 16RD/YL FUSED B(+)
7 16YL CABIN HEATER CONTROL
10 16BR GROUND
8W - 80 - 10 8W-80 CONNECTOR PIN-OUTS VA

BATTERY RELAY-AUXILIARY - BLACK


CAV CIRCUIT FUNCTION
30 6YL (EXCEPT HEAVY DUTY) AUXILIARY B(+)
30 4RD (HEAVY DUTY) AUXILIARY B(+)
85 16BR GROUND
86 16RD/DG/VT FUSED D+ RELAY NO. 1 OUTPUT
87 6RD (EXCEPT HEAVY DUTY) B(+)
87 4RD (HEAVY DUTY) B(+)
87A - -

BLOWER MOTOR RESISTOR BLOCK


CAV CIRCUIT FUNCTION
1 12YL/BK BLOWER MOTOR (+) SELECT 3
2 12YL BLOWER MOTOR (+) SELECT 1
3 12WT/BK BLOWER MOTOR (+) SELECT 2
4 12DG BLOWER MOTOR (+)

BLOWER MOTOR RESISTOR BLOCK C1


CAV CIRCUIT FUNCTION
1 12RD/BL FUSED B(+)
2 12WT BLOWER MOTOR (+)

BLOWER MOTOR RESISTOR BLOCK C2


CAV CIRCUIT FUNCTION
1 12YL/BK BLOWER MOTOR (+) SELECT 3
2 12YL BLOWER MOTOR (+) SELECT 1
3 12BK/WT BLOWER MOTOR (+) SELECT 2

BLOWER MOTOR RESISTOR BLOCK C3


CAV CIRCUIT FUNCTION
1 12RD FUSED B(+)
2 12RD/BL BLOWER MOTOR (+)
VA 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 11

BLOWER MOTOR-FRONT - BLACK


CAV CIRCUIT FUNCTION
1 12RD/BL BLOWER MOTOR (+)
2 12BK GROUND

BODY PLUG CONNECTOR


CAV CIRCUIT FUNCTION
1 14BL/YL D(+) RELAY NO. 2 OUTPUT
2 14RD FUSED B(+)
3 14BK/YL FUSED IGNITION SWITCH RUN-START RELAY OUT-
PUT

BOOST PRESSURE SENSOR (EXCEPT OBD) - BLACK


CAV CIRCUIT FUNCTION
1 18BR/WT BOOST PRESSURE SENSOR GROUND
2 18WT/DG BOOST PRESSURE SENSOR SIGNAL
3 18WT/RD BOOST PRESSURE SENSOR 5 VOLT SUPPLY

BOOST PRESSURE SENSOR (OBD)


CAV CIRCUIT FUNCTION
1 18BR/WT SENSOR GROUND
2 18WT/DG BOOST PRESSURE SENSOR SIGNAL
3 18WT/RD BOOST PRESSURE SENSOR 5 VOLT SUPPLY
8W - 80 - 12 8W-80 CONNECTOR PIN-OUTS VA

BOOST PRESSURE SERVOMOTOR (OBD)


CAV CIRCUIT FUNCTION
1 16YL/BK S175 COMMON CIRCUIT
2 16YL/WT GROUND
4 16YL/DG BOOST PRESSURE SERVOMOTOR CONTROL

BOOST PRESSURE SOLENOID - BLACK


CAV CIRCUIT FUNCTION
1 20WT BOOST PRESSURE SOLENOID CONTROL
2 20BR BOOST PRESSURE SOLENOID 12 VOLT SUPPLY

BRAKE FLUID LEVEL SWITCH


CAV CIRCUIT FUNCTION
1 20BR/YL BRAKE FLUID LEVEL INDICATOR SIGNAL
2 16BR GROUND

BRAKE LAMP SWITCH C1


CAV CIRCUIT FUNCTION
1 20WT BRAKE SWITCH OUTPUT
2 16RD/BK FUSED IGNITION SWITCH OUTPUT (RUN-START)
3 20BK/BL/RD BRAKE LAMP SWITCH

BRAKE LAMP SWITCH C2 - BLACK


CAV CIRCUIT FUNCTION
1 20BK/BL/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
2 16BK/RD BRAKE LAMP SWITCH OUTPUT
VA 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 13

BRAKE WEAR SENSOR-LEFT FRONT


CAV CIRCUIT FUNCTION
1 16BR GROUND
2 16BR/WT BRAKE WEAR SENSOR SIGNAL

BRAKE WEAR SENSOR-LEFT REAR


CAV CIRCUIT FUNCTION
1 16BR GROUND
2 16BR/WT BRAKE WEAR SENSOR SIGNAL

BRAKE WEAR SENSOR-RIGHT FRONT


CAV CIRCUIT FUNCTION
1 16BR GROUND
2 16BR/WT BRAKE WEAR SENSOR SIGNAL

BRAKE WEAR SENSOR-RIGHT REAR


CAV CIRCUIT FUNCTION
1 16BR GROUND
2 16BR/WT BRAKE WEAR SENSOR SIGNAL

C100 - (MAIN BODY SIDE)


CAV CIRCUIT
1 18BK/BL
2 18RD/DG
3 16WT/BL/RD
5 16RD
6 16BK
7 16BK/BL
8 14BK/VT
8W - 80 - 14 8W-80 CONNECTOR PIN-OUTS VA

C100 - BLACK (MAIN BODY)


CAV CIRCUIT
1 18BK/BL
2 18RD/DG
3 16WT/BL/RD
5 16RD
6 16BK
7 16BK/BL
8 14BK/VT

C101 - YELLOW (ENGINE SIDE)


CAV CIRCUIT
1 16WT/BL
2 14BK/YL
3 16BL/DG
4 16BK/RD

C101 - YELLOW (MAIN BODY SIDE)


CAV CIRCUIT
1 20BL
2 12BK/YL
3 16BL/DG
4 16BK/RD

C102 (EXCEPT OBD) - (ENGINE SIDE)


CAV CIRCUIT
A 18WT/BL

C102 (EXCEPT OBD) - (GENERATOR SIDE)


CAV CIRCUIT
A 18WT/BL
VA 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 15

C103 (OBD) - (GENERATOR SIDE)


CAV CIRCUIT
1 18WT/BL
2 14BK/YL
3 -
6 16YL/RD

C103 (OBD) - (MAIN BODY)


CAV CIRCUIT
1 20BL
2 12BK/YL
6 16YL/RD

C200 - BLACK (DASH SIDE)


CAV CIRCUIT
1 16GY
2 16GY/DG
3 16BK/YL
4 16DG/BL/WT
5 16YL/BL
6 16BL/RD
7 16BK/RD
8 16WT/BK
9 16WT/DG
10 16WT/YL
11 16WT/RD
12 16BK/RD
13 16VT/YL
14 16BR/WT
15 16YL
16 16BR/WT
17 16GY/RD
18 16BK/YL/DG
19 16BK/YL
8W - 80 - 16 8W-80 CONNECTOR PIN-OUTS VA

C200 - BLACK (MAIN BODY SIDE)


CAV CIRCUIT
1 16GY
2 16GY/DG
3 16BK/YL
4 16DG/BL/WT
5 16YL/BL
6 16BL/RD
7 16BK/RD
8 16WT/BK
9 16WT/DG
10 16WT/YL
11 16WT/RD
12 16BK/RD
13 18VT/YL
14 16BR/BK
15 16YL
16 16BR/WT
17 16GY/RD
18 16BK/YL/DG
19 16BK/YL

C201 - (DASH SIDE)


CAV CIRCUIT
2 16GY/DG/RD
3 16RD/BL
4 20BL/VT
4 16RD/YL/WT
5 16VT/WT
6 20BL/RD/WT
7 16BK/RD
8 16RD/YL
9 18BK/RD
10 18BK/BL
11 16YL
13 16RD
15 18RD/BK
VA 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 17

C201 - BLACK (MAIN BODY SIDE)


CAV CIRCUIT
2 16GY/DG/RD
3 16RD/BL
4 16RD/YL/WT
4 20BL/VT
5 16VT/WT
6 20BL/RD/WT
7 16BK/RD
8 16RD/YL
9 16BK/RD
10 18BK/BL
11 16YL
13 16RD
15 18RD/BK

C202 - (DASH SIDE)


CAV CIRCUIT
1 16WT/RD
2 16WT/BL/RD
3 20BK/BL/RD
4 20BL/DG
6 18BK/DG
7 20DG/WT
8 20DG
11 20YL

C202 - BLACK (MAIN BODY SIDE)


CAV CIRCUIT
1 16WT/RD
2 16WT/BL/RD
3 20BK/BL/RD
4 20BL/DG
6 18BK/DG
7 20DG/WT
8 20DG
11 20YL
8W - 80 - 18 8W-80 CONNECTOR PIN-OUTS VA

C203 - (DASH SIDE)


CAV CIRCUIT
1 18GY/YL
2 18GY/BR
3 18GY/WT
10 18VT/DG
11 16RD

C203 - BLACK (MAIN BODY SIDE)


CAV CIRCUIT
1 18GY/YL
2 18GY/BR
3 18GY/WT
10 18VT/DG
11 16RD

C204 - GRAY (DASH SIDE)


CAV CIRCUIT
1 18BK/RD
2 18BK/YL
3 20DG/WT
4 20DG
5 18DG/RD
6 18BR/VT
7 16BL
8 16BL/YL
9 16BL/DG
10 18BR/BL
11 20BR/RD
12 20RD/BL
13 16RD/BK
14 14BK/VT
15 16RD

C204 - GRAY (MAIN BODY SIDE)


CAV CIRCUIT
1 18BK/RD
2 18BK/YL
3 20DG/WT
4 20DG
5 18DG/RD
6 18BR/VT
7 16BL
8 16BL/YL
9 16BL/DG
10 18BR/BL
11 20BR/RD
12 20RD/BL
13 16RD/BK
14 4BK/VT
15 16RD
VA 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 19

C205 - YELLOW (DASH SIDE)


CAV CIRCUIT
1 20BL/DG
2 20BR/DG

C205 - YELLOW (MAIN BODY SIDE)


CAV CIRCUIT
1 20BL/DG
2 20BR/DG

C206 - (DASH SIDE)


CAV CIRCUIT
1 16RD
2 14BK/VT
3 16VT/DG
4 16VT/RD
5 16VT/YL
6 16VT/BK
7 16VT/BR
8 16VT
15 16BK/BL/WT
18 16VT/YL
19 16VT/BL
20 18RD/BK/WT
21 18BK/BL

C206 - (MAIN BODY SIDE)


CAV CIRCUIT
1 16BK/BL/WT
2 14BK/VT
3 16VT/DG
4 16VT/RD
5 16VT/YL
6 16VT/BK
7 16VT/BR
8 16VT
15 16BK/BL/WT
18 16VT/YL
19 16VT/BL
20 16RD/BK/WT
21 18BK/BL
8W - 80 - 20 8W-80 CONNECTOR PIN-OUTS VA

C207 - (DASH SIDE)


CAV CIRCUIT
11 16DG
12 16YL
17 16RD/YL

C207 - (MAIN BODY SIDE)


CAV CIRCUIT
11 16DG
12 16YL
17 16RD/YL

C208 - (CABIN SIDE)


CAV CIRCUIT
3 16WT
4 16BK

C208 - (DASH SIDE)


CAV CIRCUIT
3 16WT
4 16BK

C209 - (CABIN SIDE)


CAV CIRCUIT
1 16BR/BL
2 16WT/BL
3 16BR/DG
4 16WT/DG
VA 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 21

C209 - (DASH SIDE)


CAV CIRCUIT
1 16BR/BL
2 16WT/BL
3 16BR/GY
4 16WT/GY

C210 - (DRIVER DOOR SIDE)


CAV CIRCUIT
1 14BR
2 16B/YL
3 16BK/YL/DG
4 16BK/WT
5 16BL/WT

C210 - BLACK (MAIN BODY SIDE)


CAV CIRCUIT
1 14BR
2 16BK/YL
3 16BK/YL/DG
4 16BK/WT
5 16BL/WT

C211 - (POWER MIRROR SWITCH SIDE)


CAV CIRCUIT
1 18BR
2 18BK/RD
4 18BL/DG
5 18DG
6 18WT/GY

C211 - BLACK (POWER MIRROR SIDE)


CAV CIRCUIT
1 18BR
2 18BK/RD
4 18BL/DG
5 18DG
6 18WT/GY
8W - 80 - 22 8W-80 CONNECTOR PIN-OUTS VA

C214 - LT. BLUE (CABIN SIDE)


CAV CIRCUIT
1 16YL
2 16VT
3 16BK
4 16BR

C214 - LT. BLUE (DASH SIDE)


CAV CIRCUIT
1 16YL
2 16VT
3 16BK
4 16BR

C215 - BLACK (CABIN SIDE)


CAV CIRCUIT
1 16RD/YL
2 16BK/RD
5 16BR/WT
6 14BR

C215 - BLACK (MAIN BODY)


CAV CIRCUIT
1 16RD/YL
2 16BK/RD
5 20BR/WT
6 14BR

C216 - BLACK (CABIN SIDE)


CAV CIRCUIT
1 12RD
VA 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 23

C216 - BLACK (MAIN BODY SIDE)


CAV CIRCUIT
1 12RD

C217 - (CABIN SIDE)


CAV CIRCUIT
1 16RD/YL
2 16YL
3 16DG
4 16YL

C217 - (MAIN BODY SIDE)


CAV CIRCUIT
1 16RD/YL
2 16YL
3 16DG
4 16YL

C218 - (CABIN SIDE)


CAV CIRCUIT
1 16BR/WT
2 16BR/YL
3 16RD/DG
4 16DG/YL
5 20DG/BK
6 20GY/BK
7 20DG/WT/BL

C218 - (MAIN BODY SIDE)


CAV CIRCUIT
1 16BR/WT
2 16BR/YL
3 16RD/DG
4 16DG/YL
5 20DG/BK
6 20GY/BK
7 20DG/WT/BL
8W - 80 - 24 8W-80 CONNECTOR PIN-OUTS VA

C219 - (MAIN BODY SIDE)


CAV CIRCUIT
5 16BK/RD
6 16BL/RD
7 16YL/WT
8 16DG/BK
9 16BK/RD
10 16BL/RD
11 16YL/RD
12 16DG/YL

C219 - BLACK (CABIN SIDE)


CAV CIRCUIT
5 16BK/RD
6 16BL/RD
7 16YL/WT
8 16DG/BK
9 16BK/RD
10 16BL/RD
11 16YL/RD
12 16DG/YL

C220 - (CIGARETTE SIDE)


CAV CIRCUIT
1 16RD/YL
2 16BR
3 16GY/DG/RD

C220 - (DASH SIDE)


CAV CIRCUIT
1 16RD/YL
2 16BR
3 16GY/DG/RD
VA 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 25

C221 - (MAIN BODY SIDE)


CAV CIRCUIT
1 16BL/WT
2 16BK/YL/DG
3 16BK/WT

C221 - (PASSENGER DOOR SIDE)


CAV CIRCUIT
1 16BL/WT
2 16BK/YL/DG
3 16BK/WT

C224 - (BLOWER MOTOR/SOLENOID SIDE)


CAV CIRCUIT
1 12RD
2 12BK
2 16BK

C224 - (MAIN BODY SIDE)


CAV CIRCUIT
1 12RD
2 12BR

C225 - (BLOWER MOTOR/SOLENOID SIDE)


CAV CIRCUIT
1 12RD
2 12RD/BL
3 16RD
8W - 80 - 26 8W-80 CONNECTOR PIN-OUTS VA

C225 - (DASH SIDE)


CAV CIRCUIT
1 12RD/BL
2 12BL
3 16RD

CABIN HEATER ASSEMBLY C1


CAV CIRCUIT FUNCTION
B 16BL/YL (CABIN HEATER MODULE) CIRCULATION PUMP RELAY HIGH SIDE CONTROL
B 16BL/YL (REST SYSTEM) CIRCULATION PUMP MOTOR REQUEST

CABIN HEATER ASSEMBLY C2


CAV CIRCUIT FUNCTION
1 14RD FUSED B(+)
2 14BR GROUND
3 16BL/YL FAN STAGE 1 RELAY HIGH SIDE CONTROL
4 16DG DOSING PUMP CONTROL
5 16BL/RD K-IC/ATC/HBM/CHM
6 16BK/BL/DG (EXCEPT PROGRAM FUSED OPTIONAL EQUIPMENT RELAY OUTPUT
TIMER)
6 16BL (PROGRAM TIMER) HEATER BOOSTER MODE CONTROL
7 16BL (EXCEPT PROGRAM TIMER) AUXILIARY HEATER SWITCH (+)
7 16YL (PROGRAM TIMER) CABIN HEATER CONTROL

CAMSHAFT POSITION SENSOR - BLACK


CAV CIRCUIT FUNCTION
1 20BR/DG CAMSHAFT POSITION SENSOR GROUND
2 20YL/GY CAMSHAFT POSITION SENSOR SIGNAL
3 18RD/BL (EXCEPT OBD) CAMSHAFT POSITION SENSOR 12 VOLT SUPPLY
3 20RD/BL (OBD) CAMSHAFT POSITION SENSOR 5 VOLT SUPPLY
VA 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 27

CENTER HIGH MOUNTED STOP LAMP


CAV CIRCUIT FUNCTION
1 16BK/RD BRAKE LAMP SWITCH OUTPUT
2 16BR GROUND

CENTRAL TIMER MODULE C1 - PINK


CAV CIRCUIT FUNCTION
1 16DG/BK DRIVER DOOR UNLOCK SENSE
2 16BL/RD DRIVER DOOR LOCK DRIVER
3 16BK/RD DRIVER DOOR UNLOCK DRIVER
4 16YL/BK DRIVER DOOR LOCK SENSE
5 16DG/BL/WT PASSENGER FRONT DOOR UNLOCK SENSE
6 16YL/BL PASSENGER FRONT DOOR LOCK SENSE
7 16WT/YL MASTER DOOR LOCK SWITCH SENSE-ALL DOORS
8 16RD/BK FUSED D(+) RELAY NO. 1 OUTPUT
9 16WT/BL (EXCEPT VTSS) RKE INTERFACE
9 16WT/BL/RD (VTSS) RKE INTERFACE
10 16BK/RD FUSED IGNITION SWITCH OUTPUT (ACC-RUN-START)
11 16DG ENHANCED ACCIDENT REPORT DRIVER
12 20DG/WT/BL K-CTM/SSM
13 14RD/WT FUSED B(+)
14 14BR GROUND
15 16WT/BK DRIVER DOOR AJAR INDICATOR DRIVER

CENTRAL TIMER MODULE C2 - LT. GREEN


CAV CIRCUIT FUNCTION
3 16WT/DG PASSENGER DOOR AJAR INDICATOR DRIVER
6 16WT/RD MASTER DOOR LOCK SWITCH SENSE-PASSENGER
DOORS
7 16DG/BK LEFT SLIDING DOOR UNLOCK SENSE
10 16DG/RD REAR DOOR UNLOCK SENSE
11 16YL/WT LEFT SLIDING DOOR LOCK SENSE
12 16YL/BK REAR DOOR LOCK SENSE
13 16YL/RD RIGHT SLIDING DOOR LOCK SENSE
14 16DG/YL RIGHT SLIDING DOOR UNLOCK SENSE
17 16BK/RD PASSENGER DOORS UNLOCK DRIVER (+)
18 16BL/RD PASSENGER DOORS LOCK DRIVER (+)
8W - 80 - 28 8W-80 CONNECTOR PIN-OUTS VA

CIGAR LIGHTER
CAV CIRCUIT FUNCTION
1 16BR GROUND
2 16RD/YL FUSED B(+)

CIGAR LIGHTER LAMP


CAV CIRCUIT FUNCTION
1 16BR GROUND
2 16GY/DG/RD LAMP DRIVER

CIRCULATION PUMP (CABIN HEATER MODULE)


CAV CIRCUIT FUNCTION
1 18DG/RD CIRCULATION PUMP RELAY OUTPUT
2 18BR GROUND

CIRCULATION PUMP (REST SYSTEM)


CAV CIRCUIT FUNCTION
1 18DG/RD CIRCULATION PUMP MOTOR (+)
2 18BR GROUND

CIRCULATION PUMP DIODE


CAV CIRCUIT FUNCTION
3 18DG/RD CIRCULATION PUMP RELAY OUTPUT
4 18DG/BK (CABIN HEATER MODULE) CIRCULATION PUMP MOTOR (+)
4 18BK (EXCEPT PROGRAM TIMER) FUSED OPTIONAL EQUIPMENT RELAY OUTPUT
VA 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 29

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

CONTROLLER ANTILOCK BRAKE


CAV CIRCUIT FUNCTION
1 12BR GROUND
2 12RD FUSED B(+)
5 14BR GROUND
6 14RD FUSED B(+)
11 18BL/BK K-ABS/SHIFTER ASSEMBLY
12 18BK LEFT FRONT WHEEL SPEED SENSOR (+)
14 20WT LEFT REAR WHEEL SPEED SENSOR (+)
15 18BR RIGHT FRONT WHEEL SPEED SENSOR(-)
16 18BK RIGHT FRONT WHEEL SPEED SENSOR (+)
20 20WT BRAKE SWITCH OUTPUT
23 18BK/RD FUSED OPTIONAL EQUIPMENT RELAY OUTPUT
24 20DG/WT CAN C BUS (+)
27 18BK/BL TCS SWITCH (ASR) SENSE
28 18BR LEFT FRONT WHEEL SPEED SENSOR (-)
29 20BR LEFT REAR WHEEL SPEED SENSOR (-)
30 20BR RIGHT REAR WHEEL SPEED SENSOR (-)
31 20YL RIGHT REAR WHEEL SPEED SENSOR (+)
32 18BK/RD BRAKE LAMP SWITCH OUTPUT
40 20DG CAN C BUS (-)
8W - 80 - 30 8W-80 CONNECTOR PIN-OUTS VA

COURTESY LAMP-DRIVER DOOR


CAV CIRCUIT FUNCTION
1 16RD/YL FUSED B(+)
2 16BR/WT FRONT COURTESY LAMPS CONTROL

COURTESY LAMP-LEFT SLIDING DOOR


CAV CIRCUIT FUNCTION
1 16RD/YL FUSED B(+)
2 16BR/WT DOOR AJAR SWITCH SENSE

COURTESY LAMP-PASSENGER DOOR


CAV CIRCUIT FUNCTION
1 16RD/YL FUSED B(+)
2 16BR/WT FRONT COURTESY LAMPS CONTROL

COURTESY LAMP-RIGHT SLIDING DOOR


CAV CIRCUIT FUNCTION
1 16RD/YL FUSED B(+)
2 16BR/WT DOOR AJAR SWITCH SENSE

CRANKCASE HEATER - BLACK


CAV CIRCUIT FUNCTION
1 18BR (EXCEPT OBD) GROUND
1 18BK/RD (OBD) CRANKCASE HEATER SIGNAL
2 16BK/RD (EXCEPT OBD) FUSED ENGINE CONTROL RELAY OUTPUT
2 18BK/BR (OBD) CRANKCASE HEATER GROUND
VA 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 31

CRANKSHAFT POSITION SENSOR - BLACK


CAV CIRCUIT FUNCTION
1 20DG (EXCEPT OBD) CRANKSHAFT POSITION SENSOR SIGNAL NO. 2
1 20DG/WT (OBD) CRANKSHAFT POSITION SENSOR SIGNAL NO. 1
2 20DG/WT (EXCEPT OBD) CRANKSHAFT POSITION SENSOR SIGNAL NO. 1
2 20DG (OBD) CRANKSHAFT POSITION SENSOR SIGNAL NO. 2

CTEL ANTENNA CONNECTOR


CAV CIRCUIT FUNCTION
1 16BK CELLULAR ANTENNA W/SHIELD
2 - SHIELD

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

CYLINDER LOCK SWITCH-DRIVER


CAV CIRCUIT FUNCTION
1 16BK DRIVER CYLINDER UNLOCK SENSE
3 16BR GROUND
4 16RD DRIVER CYLINDER LOCK SENSE
8W - 80 - 32 8W-80 CONNECTOR PIN-OUTS VA

DATA LINK CONNECTOR - BLACK


CAV CIRCUIT FUNCTION
1 20WT/DG K-SKREEM
3 20DG/YL ENGINE RPM
4 20BR GROUND
5 20BR GROUND
7 20BL/YL K-ECM
8 20BK/BL/DG FUSED IGNITION SWITCH OUTPUT (RUN-START)
9 20BL/BK K-ABS/SHIFTER ASSEMBLY
11 20BL K-TCM/RADIO
12 20GY/DG/RD K-CTM/SSM
13 20BK/RD K-ACM
15 20WT/GY K-IC/ATC/HBM/CHM
16 20RD/YL FUSED B(+)

DIFFERENTIAL LOCK SOLENOID VALVE


CAV CIRCUIT FUNCTION
1 18VT/YL DIFFERENTIAL LOCK SOLENOID CONTROL
2 18BR GROUND

DOME LAMP
CAV CIRCUIT FUNCTION
1 16BR GROUND
2 16RD/YL FUSED B(+)
3 16BR/WT FRONT COURTESY LAMPS CONTROL

DOOR LOCK MOTOR/AJAR SWITCH ASSEMBLY-DRIVER C1


CAV CIRCUIT FUNCTION
1 16YL/BK DRIVER DOOR LOCK SENSE
2 16DG/BK DRIVER DOOR UNLOCK SENSE
VA 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 33

DOOR LOCK MOTOR/AJAR SWITCH ASSEMBLY-DRIVER C2


CAV CIRCUIT FUNCTION
1 16BK/RD DRIVER DOOR UNLOCK DRIVER
2 16BL/RD DRIVER DOOR LOCK DRIVER

DOOR LOCK MOTOR/AJAR SWITCH ASSEMBLY-LEFT SLIDING C1


CAV CIRCUIT FUNCTION
1 16BK/RD PASSENGER DOORS UNLOCK DRIVER (+)
2 16BL/RD PASSENGER DOORS LOCK DRIVER (+)

DOOR LOCK MOTOR/AJAR SWITCH ASSEMBLY-LEFT SLIDING C2


CAV CIRCUIT FUNCTION
3 16YL/WT LEFT SLIDING DOOR LOCK SENSE
4 16DG/BK LEFT SLIDING DOOR UNLOCK SENSE

DOOR LOCK MOTOR/AJAR SWITCH ASSEMBLY-PASSENGER C1


CAV CIRCUIT FUNCTION
1 16YL/BL PASSENGER FRONT DOOR LOCK SENSE
2 16DG/BL/WT PASSENGER FRONT DOOR UNLOCK SENSE
8W - 80 - 34 8W-80 CONNECTOR PIN-OUTS VA

DOOR LOCK MOTOR/AJAR SWITCH ASSEMBLY-PASSENGER C2


CAV CIRCUIT FUNCTION
1 16BK/RD PASSENGER DOORS UNLOCK DRIVER (+)
2 16BL/RD PASSENGER DOORS LOCK DRIVER (+)

DOOR LOCK MOTOR/AJAR SWITCH ASSEMBLY-REAR C1


CAV CIRCUIT FUNCTION
1 16BK/RD PASSENGER DOORS UNLOCK DRIVER (+)
2 16BL/RD PASSENGER DOORS LOCK DRIVER (+)

DOOR LOCK MOTOR/AJAR SWITCH ASSEMBLY-REAR C2


CAV CIRCUIT FUNCTION
3 16YL/BK (CARGO VAN) REAR DOOR LOCK SENSE
4 16DG/RD (CARGO VAN) REAR DOOR UNLOCK SENSE
4 16YL/BK (PASSENGER VAN) REAR DOOR LOCK SENSE
5 16DG/RD (PASSENGER VAN) REAR DOOR UNLOCK SENSE

DOOR LOCK MOTOR/AJAR SWITCH ASSEMBLY-RIGHT SLIDING C1


CAV CIRCUIT FUNCTION
1 16BK/RD PASSENGER DOORS UNLOCK DRIVER (+)
2 16BL/RD PASSENGER DOORS LOCK DRIVER (+)

DOOR LOCK MOTOR/AJAR SWITCH ASSEMBLY-RIGHT SLIDING C2


CAV CIRCUIT FUNCTION
3 16YL/RD RIGHT SLIDING DOOR LOCK SENSE
4 16DG/YL RIGHT SLIDING DOOR UNLOCK SENSE
VA 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 35

DOSING PUMP
CAV CIRCUIT FUNCTION
1 16DG DOSING PUMP CONTROL
2 16BR GROUND

EGR VALVE - BLACK


CAV CIRCUIT FUNCTION
1 20RD/YL (EXCEPT OBD) EGR VALVE CONTROL
1 20DG/WT (OBD) EGR VALVE CONTROL
2 16BK/GY (EXCEPT OBD) FUSED ENGINE CONTROL RELAY OUTPUT
2 16BK/DG (OBD) S175 COMMON CIRCUIT
3 18BR/BK (EXCEPT OBD) SENSOR GROUND
3 20BR/DG (OBD) SENSOR GROUND

ENGINE CONTROL MODULE C1 (EXCEPT OBD) - BLACK


CAV CIRCUIT FUNCTION
1 16BK/RD FUSED ENGINE CONTROL RELAY OUTPUT
4 14BR GROUND
5 14BR GROUND
6 14BR GROUND
7 14BK/BL FUSED ENGINE CONTROL RELAY OUTPUT
8 14BK/BL FUSED ENGINE CONTROL RELAY OUTPUT
8W - 80 - 36 8W-80 CONNECTOR PIN-OUTS VA

ENGINE CONTROL MODULE C1 (OBD)


CAV CIRCUIT FUNCTION
1 16BL FUEL INJECTOR NO. 1 HIGH-SIDE CONTROL
2 16BL/WT FUEL INJECTOR NO. 4 HIGH-SIDE CONTROL
3 16DG FUEL INJECTOR NO. 3 HIGH-SIDE CONTROL
4 20RD/WT FUEL QUANTITY CONTROL VALVE 12 VOLT SUPPLY
8 18BL/GY FUEL TEMPERATURE SENSOR SIGNAL
10 20RD/YL ENGINE OIL SENSOR 5 VOLT SUPPLY
11 20GY/BL ENGINE OIL SENSOR SIGNAL
12 20BR/RD INTAKE PRESSURE SENSOR GROUND
13 20VT/DG INTAKE PRESSURE SENSOR SIGNAL
14 20BR/DG CAMSHAFT POSITION SENSOR GROUND
15 20DG/BK ECM C1 CAV 15 TO 02 SENSOR CAV 1
20 18BK/YL WATER IN FUEL SENSOR SIGNAL
21 18BK/RD CRANKCASE HEATER SIGNAL
25 16BK FUEL INJECTOR NO. 2 HIGH-SIDE CONTROL
26 16BK/WT FUEL INJECTOR NO. 5 HIGH-SIDE CONTROL
28 18RD/BK FUEL SHUTDOWN SOLENOID 12 VOLT SUPPLY
31 20YL/BL MASS AIR FLOW SENSOR GROUND
32 18DG/BK FUEL TEMPERATURE SENSOR GROUND
35 20BR/BK SENSOR GROUND
36 20VT/RD INTAKE PRESSURE SENSOR 5 VOLT SUPPLY
37 20RD/BL CAMSHAFT POSITION SENSOR 5 VOLT SUPPLY
38 20YL/GY CAMSHAFT POSITION SENSOR SIGNAL
39 20GY ECM C1 CAV 39 TO 02 SENSOR CAV 6
40 20GY/WT ECM C1 CAV 40 TO 02 CAV 2
49 16BK/VT FUEL INJECTOR NO. 4 LOW-SIDE CONTROL
50 16BK/DG FUEL INJECTOR NO. 3 LOW-SIDE CONTROL
51 16BK/YL FUEL INJECTOR NO. 5 LOW-SIDE CONTROL
52 20BK/WT FUEL QUANTITY CONTROL VALVE CONTROL
55 18BR WATER IN FUEL SENSOR GROUND
56 20BR/WT ENGINE COOLANT TEMPERATURE SENSOR GROUND
57 20DG/RD ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
59 20DG/VT FUEL PRESSURE SENSOR SIGNAL
61 20BR/VT MASS AIR FLOW SENSOR 5 VOLT SUPPLY
62 20DG/YL ECM C1 CAV 62 TO 02 SENSOR CAV 5
72 20GY/BL ECM C1 CAV 72 TO 02 SENSOR CAV 3
73 16BK/RD FUEL INJECTOR NO. 1 LOW-SIDE CONTROL
74 16BK/BL FUEL INJECTOR NO. 2 LOW-SIDE CONTROL
76 18BR/YL FUEL SHUTDOWN SOLENOID CONTROL
79 18BR/RD WATER IN FUEL SENSOR 12 VOLT SUPPLY
84 20BR/GY FUEL PRESSURE SENSOR GROUND
85 20YL/DG MASS AIR FLOW SENSOR SIGNAL
86 20RD/DG FUEL PRESSURE SENSOR 5 VOLT SUPPLY
87 20DG/WT CRANKSHAFT POSITION SENSOR SIGNAL NO. 1
88 20DG CRANKSHAFT POSITION SENSOR SIGNAL NO. 2
90 20DG/WT EGR VALVE CONTROL
91 20BK/BR CRANKCASE HEATER GROUND
93 16YL/DG CHARGE PRESSURE POSITIONER CONTROL
VA 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 37

ENGINE CONTROL MODULE C2 (EXCEPT OBD) - BLACK


CAV CIRCUIT FUNCTION
3 18BR/WT HIGH IDLE ON SIGNAL
7 18BR/DG KICKDOWN SWITCH SIGNAL
9 18BR SENSOR GROUND
11 20DG/WT CAN C BUS (+)
12 20DG CAN C BUS (-)
13 18BK FUSED IGNITION SWITCH OUTPUT (RUN-START)
14 18DG ACCEL/SET SIGNAL
16 18YL DECEL/SET SIGNAL
17 20DG ENHANCED ACCIDENT REPORT DRIVER
19 18RD S/C SWITCH 12 VOLT SUPPLY
20 18BL RESUME SIGNAL
21 18BK VERIFICATION SIGNAL
22 18GY OFF SIGNAL

ENGINE CONTROL MODULE C2 (OBD)


CAV CIRCUIT FUNCTION
1 16BK/RD FUSED ENGINE CONTROL RELAY OUTPUT
2 14BR GROUND
3 14BK/BL FUSED ENGINE CONTROL RELAY OUTPUT
4 14BR GROUND
5 14BK/BL FUSED ENGINE CONTROL RELAY OUTPUT
6 14BR GROUND
7 18RD S/C SWITCH 12 VOLT SUPPLY
8 18BR/WT HIGH IDLE ON SIGNAL
10 18WT/RD BOOST PRESSURE SENSOR 5 VOLT SUPPLY
11 18WT/DG BOOST PRESSURE SENSOR SIGNAL
12 18BR/WT SENSOR GROUND
13 18GY/DG ACCEL PEDAL POSITION SENSOR SIGNAL NO. 2
14 18BR/GY ACCEL PEDAL POSITION SENSOR GROUND NO. 2
17 18BR/DG KICKDOWN SWITCH SIGNAL
18 20DG/YL ENGINE RPM
19 18BK FUSED IGNITION SWITCH OUTPUT (RUN-START)
24 18BL/RD ACCEL PEDAL POSITION SENSOR 5 VOLT SUPPLY
25 18BL/DG ACCEL PEDAL POSITION SENSOR SIGNAL NO. 1
26 18BR/BL ACCEL PEDAL POSITION SENSOR GROUND NO. 1
28 18BR/DG INTAKE AIR TEMPERATURE SENSOR GROUND
31 20BL/YL K-ECM
32 20DG ENHANCED ACCIDENT REPORT DRIVER
36 18VT IGNITION SWITCH OUTPUT (START)
37 18DG ACCEL/SET SIGNAL
38 18BK VERIFICATION SIGNAL
42 18DG/WT INTAKE AIR TEMPERATURE SENSOR SIGNAL
43 18BK/RD GLOW PLUG MODULE CONTROL
44 18YL/BL ENGINE CONTROL RELAY SIGNAL
50 18YL DECEL/SET SIGNAL
51 18GY OFF SIGNAL
52 18BL RESUME SIGNAL
53 20DG/WT CAN C BUS (+)
54 20DG CAN C BUS (-)
55 18BR/RD FUEL PUMP RELAY CONTROL
58 18VT/DG STARTER MOTOR RELAY CONTROL
8W - 80 - 38 8W-80 CONNECTOR PIN-OUTS VA

ENGINE CONTROL MODULE C3 (EXCEPT OBD) - BLACK


CAV CIRCUIT FUNCTION
1 18BR/DG INTAKE AIR TEMPERATURE SENSOR GROUND
5 18BL/RD ACCEL PEDAL POSITION SENSOR 5 VOLT SUPPLY
6 18WT/DG BOOST PRESSURE SENSOR SIGNAL
7 20BR/YL MASS AIR FLOW SENSOR GROUND
8 18BR/GY ACCEL PEDAL POSITION SENSOR GROUND NO. 2
9 18GY/DG ACCEL PEDAL POSITION SENSOR SIGNAL NO. 2
10 18BL/DG ACCEL PEDAL POSITION SENSOR SIGNAL NO. 1
12 18DG/WT INTAKE AIR TEMPERATURE SENSOR SIGNAL
17 18WT/RD BOOST PRESSURE SENSOR 5 VOLT SUPPLY
18 20YL/DG MASS AIR FLOW SENSOR SIGNAL
19 20BR/BK MASS AIR FLOW SENSOR 5 VOLT SUPPLY
20 18VT IGNITION SWITCH OUTPUT (START)
22 18BR/WT BOOST PRESSURE SENSOR GROUND
23 18BR/BL ACCEL PEDAL POSITION SENSOR GROUND NO. 1
25 18BK/RD GLOW PLUG MODULE CONTROL
28 20BL/YL K-ECM
30 18RD/BL STARTER MOTOR RELAY 12 VOLT SUPPLY
33 20YL/RD MASS AIR FLOW SENSOR 12 VOLT SUPPLY
35 20BR BOOST PRESSURE SOLENOID 12 VOLT SUPPLY
40 20DG/YL ENGINE RPM
43 18VT/DG STARTER MOTOR RELAY CONTROL
46 18YL/BL ENGINE CONTROL RELAY SIGNAL
48 20WT BOOST PRESSURE SOLENOID CONTROL

ENGINE CONTROL MODULE C4 (EXCEPT OBD) - BLACK


CAV CIRCUIT FUNCTION
2 20BR/DG CAMSHAFT POSITION SENSOR GROUND
3 20YL/GY CAMSHAFT POSITION SENSOR SIGNAL
4 20BR/GY FUEL PRESSURE SENSOR GROUND
7 18GY/YL LOW FUEL PRESSURE SENSOR GROUND
8 18GY/DG LOW FUEL PRESSURE SENSOR 5 VOLT SUPPLY
10 18BR/RD WATER IN FUEL SENSOR 12 VOLT SUPPLY
11 18BK/YL WATER IN FUEL SENSOR GROUND
12 18RD/BL CAMSHAFT POSITION SENSOR 12 VOLT SUPPLY
13 20RD/DG FUEL PRESSURE SENSOR 5 VOLT SUPPLY
14 20DG/VT FUEL PRESSURE SENSOR SIGNAL
15 20GY/BL ENGINE OIL SENSOR SIGNAL
17 20BR/BK SENSOR GROUND
18 20RD/YL ENGINE OIL SENSOR 5 VOLT SUPPLY
21 20BK/WT FUEL PRESSURE SOLENOID CONTROL
22 18RD/BK FUEL SHUTDOWN SOLENOID 12 VOLT SUPPLY
26 20DG CRANKSHAFT POSITION SENSOR SIGNAL NO. 2
27 20BR/BK ENGINE COOLANT TEMPERATURE SENSOR GROUND
30 18DG/BK FUEL TEMPERATURE SENSOR GROUND
31 20RD/WT FUEL PRESSURE SOLENOID 12 VOLT SUPPLY
32 20BR/YL FUEL SHUTDOWN SOLENOID CONTROL
34 18BR WATER IN FUEL SENSOR SIGNAL
36 20DG/RD ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
37 20DG/WT CRANKSHAFT POSITION SENSOR SIGNAL NO. 1
38 18GY/RD LOW FUEL PRESSURE SENSOR SIGNAL
39 18BL/GY FUEL TEMPERATURE SENSOR SIGNAL
40 20RD/YL EGR VALVE CONTROL
VA 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 39

ENGINE CONTROL MODULE C5 (EXCEPT OBD) - GRAY


CAV CIRCUIT FUNCTION
2 14BK COMMON INJECTOR DRIVER NO. 1
3 14BK/YL FUEL INJECTOR NO. 4 CONTROL
4 14BL COMMON INJECTOR DRIVER NO. 2
5 14BK/VT FUEL INJECTOR NO. 2 CONTROL
7 14BK/DG FUEL INJECTOR NO. 5 CONTROL
8 14BK/RD FUEL INJECTOR NO. 3 CONTROL
9 14BK/BL FUEL INJECTOR NO. 1 CONTROL

ENGINE COOLANT LEVEL SWITCH - BLACK


CAV CIRCUIT FUNCTION
1 20DG/WT/BL ENGINE COOLANT LEVEL SWITCH SIGNAL
2 16BR GROUND

ENGINE COOLANT TEMPERATURE SENSOR - BLACK


CAV CIRCUIT FUNCTION
1 20BR/WT ENGINE COOLANT TEMPERATURE SENSOR GROUND
2 20DG/RD ENGINE COOLANT TEMPERATURE SENSOR SIGNAL

ENGINE OIL SENSOR - BLACK


CAV CIRCUIT FUNCTION
1 20GY/BL ENGINE OIL SENSOR SIGNAL
2 20BR/BK SENSOR GROUND
3 20RD/YL ENGINE OIL SENSOR 5 VOLT SUPPLY
8W - 80 - 40 8W-80 CONNECTOR PIN-OUTS VA

EVAPORATOR TEMPERATURE SENSOR


CAV CIRCUIT FUNCTION
1 18BR/DG EVAPORATOR TEMPERATURE SENSOR SIGNAL
2 18BR/BL SENSOR GROUND

FOG LAMP SWITCH


CAV CIRCUIT FUNCTION
1 16GY/DG/RD LAMP DRIVER
3 16RD FUSED B(+)
7 18RD/BK FOG LAMP RELAY CONTROL
10 16BR GROUND

FUEL INJECTOR NO. 1 - BLACK


CAV CIRCUIT FUNCTION
1 14BK/BL (EXCEPT OBD) FUEL INJECTOR NO. 1 CONTROL
1 16BK/RD (OBD) FUEL INJECTOR NO. 1 LOW-SIDE CONTROL
2 14BK (EXCEPT OBD) COMMON INJECTOR DRIVER NO. 1
2 16BL (OBD) FUEL INJECTOR NO. 1 HIGH-SIDE CONTROL

FUEL INJECTOR NO. 2 - BLACK


CAV CIRCUIT FUNCTION
1 14BK/VT (EXCEPT OBD) FUEL INJECTOR NO. 2 CONTROL
1 16BK/BL (OBD) FUEL INJECTOR NO. 2 LOW-SIDE CONTROL
2 14BL (EXCEPT OBD) COMMON INJECTOR DRIVER NO. 2
2 16BK (OBD) FUEL INJECTOR NO. 2 HIGH-SIDE CONTROL

FUEL INJECTOR NO. 3 - BLACK


CAV CIRCUIT FUNCTION
1 14BK/RD (EXCEPT OBD) FUEL INJECTOR NO. 3 CONTROL
1 16BK/DG (OBD) FUEL INJECTOR NO. 3 LOW-SIDE CONTROL
2 14BK (EXCEPT OBD) COMMON INJECTOR DRIVER NO. 1
2 16DG (OBD) FUEL INJECTOR NO. 3 HIGH-SIDE CONTROL
VA 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 41

FUEL INJECTOR NO. 4 - BLACK


CAV CIRCUIT FUNCTION
1 14BK/YL (EXCEPT OBD) FUEL INJECTOR NO. 4 CONTROL
1 16BK/VT (OBD) FUEL INJECTOR NO. 4 LOW-SIDE CONTROL
2 14BK (EXCEPT OBD) COMMON INJECTOR DRIVER NO. 1
2 16BL/WT (OBD) FUEL INJECTOR NO. 4 HIGH-SIDE CONTROL

FUEL INJECTOR NO. 5 - BLACK


CAV CIRCUIT FUNCTION
1 14BK/DG (EXCEPT OBD) FUEL INJECTOR NO. 5 CONTROL
1 16BK/YL (OBD) FUEL INJECTOR NO. 5 LOW-SIDE CONTROL
2 14BL (EXCEPT OBD) COMMON INJECTOR DRIVER NO. 2
2 16BK/WT (OBD) FUEL INJECTOR NO. 5 HIGH-SIDE CONTROL

FUEL LEVEL SENSOR


CAV CIRCUIT FUNCTION
2 20BL/BK FUEL LEVEL SENSOR SIGNAL (+)
3 20BR FUEL LEVEL SENSOR SIGNAL RETURN

FUEL PRESSURE SENSOR - BLACK


CAV CIRCUIT FUNCTION
1 20BR/GY FUEL PRESSURE SENSOR GROUND
2 20DG/VT FUEL PRESSURE SENSOR SIGNAL
3 20RD/DG FUEL PRESSURE SENSOR 5 VOLT SUPPLY

FUEL PRESSURE SOLENOID (EXCEPT OBD)


CAV CIRCUIT FUNCTION
1 20BK/WT FUEL PRESSURE SOLENOID CONTROL
2 20RD/WT FUEL PRESSURE SOLENOID 12 VOLT SUPPLY
8W - 80 - 42 8W-80 CONNECTOR PIN-OUTS VA

FUEL PUMP (OBD)


CAV CIRCUIT FUNCTION
1 14BK FUEL PUMP RELAY OUTPUT
2 14BR GROUND

FUEL PUMP RELAY (OBD)


CAV CIRCUIT FUNCTION
30 14RD/BK FUSED B(+)
85 18BR/RD FUEL PUMP RELAY CONTROL
86 18BK/RD S108 COMMON CIRCUIT
87 14BK FUEL PUMP RELAY OUTPUT
87A - -

FUEL QUANTITY CONTROL VALVE (OBD)


CAV CIRCUIT FUNCTION
1 20BK/WT FUEL QUANTITY CONTROL VALVE CONTROL
2 18RD/BK FUEL QUANTITY CONTROL VALVE 12 VOLT SUPPLY

FUEL SHUTDOWN SOLENOID


CAV CIRCUIT FUNCTION
1 20BR/YL (EXCEPT OBD) FUEL SHUTDOWN SOLENOID CONTROL
1 18BR/YL (OBD) FUEL SHUTDOWN SOLENOID CONTROL
2 18RD/BK FUEL SHUTDOWN SOLENOID 12 VOLT SUPPLY

FUEL TEMPERATURE SENSOR


CAV CIRCUIT FUNCTION
1 18DG/BK FUEL TEMPERATURE SENSOR GROUND
2 18BL/GY FUEL TEMPERATURE SENSOR SIGNAL
VA 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 43

FUSE BLOCK NO. 1 C1


CAV CIRCUIT FUNCTION
1 INTERNAL FOG LAMP SWITCH OUTPUT
3 INTERNAL HIGH BEAM SWITCH OUTPUT
4 16RD/BL FUSED RIGHT LAMP RELAY OUTPUT
5 INTERNAL HIGH BEAM SELECT
6 INTERNAL FUSED LEFT RELAY OUTPUT
8 INTERNAL LAMP DRIVER
9 INTERNAL FUSED IGNITION SWITCH OUTPUT (RUN-START)
10 INTERNAL FUSED B(+)
11 INTERNAL TURN SIGNAL RELAY OUTPUT
14 INERNAL GROUND
15 INTERNAL WIPER SWITCH OUTPUT
16 INTERNAL WIPER SWITCH OUTPUT
18 INTERNAL FUSED IGNITION SWITCH OUTPUT (RUN-START)
19 INTERNAL 12 VOLT SUPPLY
21 INTERNAL WIPER ON/OFF SWITCH OUTPUT
22 INTERNAL FUSED B(+)

FUSE BLOCK NO. 1 C2


CAV CIRCUIT FUNCTION
1 14BK/RD FUSED IGNITION SWITCH OUTPUT (RUN)
2 14BK/YL FUSED IGNITION SWITCH OUTPUT (START)
3 16GY/DG FUSED IGNITION SWITCH OUTPUT (ACC OFF)
4 14BK FUSED IGNITION SWITCH OUTPUT (RUN-START)

FUSE BLOCK NO. 1 C3 - BLACK


CAV CIRCUIT FUNCTION
2 16BK/VT FUSED IGNITION SWITCH OUTPUT (RUN-START)
3 12VT IGNITION SWITCH OUTPUT (START)
5 12RD FUSED B(+)

FUSE BLOCK NO. 1 C4 - BLACK


CAV CIRCUIT FUNCTION
1 16RD/BL FUSED B(+)
2 14RD/BK (OBD) FUSED B(+)
4 16BK/RD ENGINE CONTROL RELAY OUTPUT
5 16WT FUSED HIGH BEAM SWITCH OUTPUT
7 16BK/YL FUSED IGNITION SWITCH OUTPUT (RUN-START)
8 16BK/YL/WT FOG LAMP RELAY SIGNAL
10 16WT FUSED HIGH BEAM SWITCH OUTPUT
11 16RD/YL FUSED IGNITION SWITCH OUTPUT (RUN-START)
12 16BR/BK WIPER MOTOR CONTROL
14 16WT/BL/RD FUSED IGNITION SWITCH OUTPUT (RUN-START)
8W - 80 - 44 8W-80 CONNECTOR PIN-OUTS VA

FUSE BLOCK NO. 1 C5 - BLACK


CAV CIRCUIT FUNCTION
1 16BK/BL/WT FUSED IGNITION SWITCH (RUN-START)
2 12BK/BL FUSED ENGINE CONTROL RELAY OUTPUT
3 18YL FUSED HEADLAMP SWITCH OUTPUT
4 16GY/BK LEFT LAMP RELAY OUTPUT
5 16BK/DG RIGHT TURN SIGNAL
6 16GY/RD RIGHT LAMP RELAY OUTPUT
7 16GY/DG LAMP DRIVER
8 16BK/WT LEFT TURN SIGNAL
13 16YL FUSED HEADLAMP SWITCH OUTPUT
14 16BK/VT/RD WASHER ON/OFF SWITCH OUTPUT
15 18YL/BL ENGINE CONTROL RELAY SIGNAL

GLOW PLUG CONTROL MODULE C1 - BLACK


CAV CIRCUIT FUNCTION
1 18BR GROUND
2 18BK/RD GLOW PLUG MODULE CONTROL

GLOW PLUG CONTROL MODULE C2 - BLACK


CAV CIRCUIT FUNCTION
1 14BK/DG GLOW PLUG NO. 5 SUPPLY VOLTAGE
2 14BK/YL GLOW PLUG NO. 4 SUPPLY VOLTAGE
3 14BK/RD GLOW PLUG NO. 3 SUPPLY VOLTAGE
4 14BK/VT GLOW PLUG NO. 2 SUPPLY VOLTAGE
5 14BK/BL GLOW PLUG NO. 1 SUPPLY VOLTAGE

HEADLAMP ADJUST SWITCH - BLACK


CAV CIRCUIT FUNCTION
3 16BR GROUND
5 16VT/WT HEADLAMP ADJUST SWITCH OUTPUT
9 16GY/DG/RD LAMP DRIVER
VA 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 45

HEADLAMP ASSEMBLY-LEFT - BLACK


CAV CIRCUIT FUNCTION
1 16GY/DG/RD LAMP DRIVER
2 16YL/WT FOG LAMP RELAY OUTPUT
3 16BR GROUND
4 16BR GROUND
5 16VT/WT HEADLAMP ADJUST SWITCH OUTPUT
6 16BK/WT LEFT TURN SIGNAL
7 18YL/DG (DRL) DAYTIME RUNNING LAMPS RELAY-LEFT SIDE OUT-
PUT
7 18YL (EXCEPT DRL) HEADLAMP SWITCH OUTPUT
8 16BR GROUND
9 16WT FUSED HIGH BEAM SWITCH OUTPUT
10 16GY/BK LEFT LAMP RELAY OUTPUT

HEADLAMP ASSEMBLY-RIGHT - BLACK


CAV CIRCUIT FUNCTION
1 16GY/DG/RD LAMP DRIVER
2 16YL/WT FOG LAMP RELAY OUTPUT
3 16BR GROUND
4 16BR GROUND
5 16VT/WT HEADLAMP ADJUST SWITCH OUTPUT
6 16BK/DG RIGHT TURN SIGNAL
7 18YL/DG (DRL) DAYTIME RUNNING LAMP RELAY-RIGHT SIDE OUT-
PUT
7 18YL (EXCEPT DRL) HEADLAMP SWITCH OUTPUT
8 16BR GROUND
9 16WT FUSED HIGH BEAM SWITCH OUTPUT
10 16GY/RD RIGHT LAMP RELAY OUTPUT

HEATED SEAT MODULE-DRIVER


CAV CIRCUIT FUNCTION
1 16VT/DG HEATED SEAT SWITCH-DRIVER LOW OUTPUT
2 16VT/RD S366 COMMON CIRCUIT
3 16VT/RD S366 COMMON CIRCUIT
4 16BR GROUND
8W - 80 - 46 8W-80 CONNECTOR PIN-OUTS VA

HEATED SEAT MODULE-PASSENGER


CAV CIRCUIT FUNCTION
1 16VT/BR HEATED SEAT SWITCH-PASSENGER LOW OUTPUT
2 16VT/BK S363 COMMON CIRCUIT
3 16VT/BK S363 COMMON CIRCUIT
4 16BR GROUND

HEATED SEAT SWITCH-DRIVER


CAV CIRCUIT FUNCTION
1 16GY/DG/RD LAMP DRIVER
3 16VT/YL FUSED OPTIONAL EQUIPMENT RELAY OUTPUT
4 16VT/RD S366 COMMON CIRCUIT
5 16BR GROUND
7 16VT/DG HEATED SEAT SWITCH-DRIVER LOW OUTPUT
8 16VT/YL FUSED OPTIONAL EQUIPMENT RELAY OUTPUT
10 16BR GROUND

HEATED SEAT SWITCH-PASSENGER


CAV CIRCUIT FUNCTION
1 16GY/DG/RD LAMP DRIVER
3 16VT FUSED OPTIONAL EQUIPMENT RELAY OUTPUT
4 16VT/BK S363 COMMON CIRCUIT
5 16BR GROUND
7 16VT/BR HEATED SEAT SWITCH-PASSENGER LOW OUTPUT
8 16VT FUSED OPTIONAL EQUIPMENT RELAY OUTPUT
10 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

HIGH IDLE SWITCH


CAV CIRCUIT FUNCTION
1 16GY/DG/RD LAMP DRIVER
3 18BR/WT HIGH IDLE ON SIGNAL
4 18BR/WT HIGH IDLE ON SIGNAL
7 18BR GROUND
9 16BK/RD FUSED OPTIONAL EQUIPMENT RELAY OUTPUT

HOOD AJAR SWITCH - BLACK


CAV CIRCUIT FUNCTION
1 16BK/BL HOOD AJAR SWITCH SENSE
3 16BR GROUND

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

IGNITION LOCK SWITCH - BLACK


CAV CIRCUIT FUNCTION
1 20BR GROUND
2 20BL/BK KEY-IN IGNITION SWITCH SIGNAL

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 (+)

INSTRUMENT CLUSTER C2 - WHITE


CAV CIRCUIT FUNCTION
3 20RD/YL FUSED B(+)
4 20BR/WT BRAKE WEAR SENSOR SIGNAL
6 18BR GROUND
7 20GY/DG/RD LAMP DRIVER
8 20BL/WT FUSED HIGH BEAM SWITCH OUTPUT
9 20BL/RD/WT VEHICLE SPEED SENSOR OUTPUT
10 20BK FUSED IGNITION SWITCH OUTPUT (RUN-START)
11 20BL/BK KEY-IN IGNITION SWITCH SIGNAL
13 20BK/WT LEFT TURN SIGNAL
14 20BR/YL BRAKE FLUID LEVEL INDICATOR SIGNAL
15 20BL GENERATOR FIELD DRIVER
16 20YL AIRBAG WARNING INDICATOR DRIVER
18 20BL/VT D(+) RELAY NO. 1 CONTROL
18 20BL/VT IC 18-C2 TO ATCM 8-C1
VA 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 49

INSTRUMENT PANEL SOCKET - BLACK


CAV CIRCUIT FUNCTION
1 16BR GROUND
2 16RD FUSED B(+)

INTAKE AIR PRESSURE SENSOR (OBD)


CAV CIRCUIT FUNCTION
1 20BR/RD INTAKE PRESSURE SENSOR GROUND
2 20VT/DG INTAKE PRESSURE SENSOR SIGNAL
3 20VT/RD INTAKE PRESSURE SENSOR 5 VOLT SUPPLY

INTAKE AIR TEMPERATURE SENSOR - BLACK


CAV CIRCUIT FUNCTION
1 18BR/DG INTAKE AIR TEMPERATURE SENSOR GROUND
2 18DG/WT INTAKE AIR TEMPERATURE SENSOR SIGNAL

INTERIOR LAMP NO. 1


CAV CIRCUIT FUNCTION
1 16DG INTERIOR LAMPS DRIVER
2 16BR GROUND

INTERIOR LAMP NO. 2


CAV CIRCUIT FUNCTION
1 16DG INTERIOR LAMPS DRIVER
2 16BR GROUND
8W - 80 - 50 8W-80 CONNECTOR PIN-OUTS VA

INTERIOR LAMP NO. 3


CAV CIRCUIT FUNCTION
1 16DG INTERIOR LAMPS DRIVER
2 16BR GROUND

INTERIOR LAMP NO. 4


CAV CIRCUIT FUNCTION
1 16DG INTERIOR LAMPS DRIVER
2 16BR GROUND

INTERIOR LAMP NO. 5


CAV CIRCUIT FUNCTION
1 16DG INTERIOR LAMPS DRIVER
2 16BR GROUND

INTERIOR LAMP-LEFT - BLACK


CAV CIRCUIT FUNCTION
1 16BR GROUND
2 16RD/YL FUSED B(+)
3 16BR/WT DOOR AJAR SWITCH SENSE

INTERIOR LAMP-MIDDLE FRONT


CAV CIRCUIT FUNCTION
1 16BR GROUND
2 16RD/YL FUSED B(+)
3 16BR/WT DOOR AJAR SWITCH SENSE
VA 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 51

INTERIOR LAMP-MIDDLE REAR


CAV CIRCUIT FUNCTION
1 16BR GROUND
2 16RD/YL FUSED B(+)
3 16BR/WT DOOR AJAR SWITCH SENSE

INTERIOR LAMP-REAR NO. 1 - BLACK


CAV CIRCUIT FUNCTION
1 16RD/YL FUSED B(+)
2 16BR/WT DOOR AJAR SWITCH SENSE

INTERIOR LAMP-REAR NO. 2 - BLACK


CAV CIRCUIT FUNCTION
1 16BR/WY GROUND
2 16RD/YL FUSED B(+)
3 16BR/WT DOOR AJAR SWITCH SENSE
8W - 80 - 52 8W-80 CONNECTOR PIN-OUTS VA

INTERIOR LAMP-RIGHT - BLACK


CAV CIRCUIT FUNCTION
1 16BR GROUND
2 16RD/YL FUSED B(+)
3 16BR/WT DOOR AJAR SWITCH SENSE

INTERIOR LIGHT SWITCH


CAV CIRCUIT FUNCTION
1 16GY/DG/RD LAMP DRIVER
3 16RD/YL FUSED B(+)
7 16YL INTERIOR LIGHT SWITCH OUTPUT
9 16DG INTERIOR LAMPS DRIVER
10 16BR GROUND

INTERIOR LIGHT SWITCH-DRIVER


CAV CIRCUIT FUNCTION
3 16RD/YL FUSED B(+)
7 16YL INTERIOR LIGHT SWITCH OUTPUT

INTERIOR LIGHT SWITCH-PASSENGER


CAV CIRCUIT FUNCTION
3 16RD/YL FUSED B(+)
7 16YL INTERIOR LIGHT SWITCH OUTPUT
VA 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 53

INTERIOR LIGHT SWITCH-REAR


CAV CIRCUIT FUNCTION
3 16RD/YL FUSED B(+)
7 16YL INTERIOR LIGHT SWITCH OUTPUT

INTERIOR LIGHTING CONNECTOR


CAV CIRCUIT FUNCTION
1 16RD/YL FUSED B(+)
2 16DG INTERIOR LAMPS DRIVER
3 16BR GROUND
4 16YL INTERIOR LIGHT SWITCH OUTPUT

INTRUSION SENSOR NO. 1 - BLACK


CAV CIRCUIT FUNCTION
1 20BR GROUND
2 20DG/BK INTRUSION SENSOR 1 SIGNAL
3 20DG/YL INTRUSION SENSOR INTERFACE
4 20RD/DG FUSED B(+)

INTRUSION SENSOR NO. 2 - BLACK


CAV CIRCUIT FUNCTION
1 20BR GROUND
2 20GY/BK INTRUSION SENSOR 2 SIGNAL
3 20DG/YL INTRUSION SENSOR INTERFACE
4 20RD/DG FUSED B(+)

INTRUSION SENSOR NO. 3 - BLACK


CAV CIRCUIT FUNCTION
1 20BR GROUND
2 20DG/WT/BL INTRUSION SENSOR 3 SIGNAL
3 20DG/YL INTRUSION SENSOR INTERFACE
4 20RD/DG FUSED B(+)
8W - 80 - 54 8W-80 CONNECTOR PIN-OUTS VA

KICK DOWN SWITCH - BLACK


CAV CIRCUIT FUNCTION
1 18BR/DG KICKDOWN SWITCH SIGNAL
2 18BR (EXCEPT OBD) SENSOR GROUND
2 18BR (OBD) GROUND

LICENSE PLATE LAMP NO. 1


CAV CIRCUIT FUNCTION
1 16GY/DG/RD LAMP DRIVER
2 16BR GROUND

LICENSE PLATE LAMP NO. 2


CAV CIRCUIT FUNCTION
1 16GY/DG/RD LAMP DRIVER
2 16BR GROUND

LOCKER SWITCH NO. 1


CAV CIRCUIT FUNCTION
1 16GY/DG/RD LAMP DRIVER
3 16BK/RD FUSED OPTIONAL EQUIPMENT RELAY OUTPUT
4 16BR/BK LOCKER SWITCH NO. 2 OUTPUT
7 16VT/YL DIFFERENTIAL LOCK SOLENOID CONTROL
10 20BR GROUND

LOCKER SWITCH NO. 2


CAV CIRCUIT FUNCTION
1 16BR/BK LOCKER SWITCH NO. 2 OUTPUT
2 16BK/RD FUSED OPTIONAL EQUIPMENT RELAY OUTPUT
VA 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 55

LOW FUEL PRESSURE SENSOR - BLACK


CAV CIRCUIT FUNCTION
1 18GY/DG LOW FUEL PRESSURE SENSOR 5 VOLT SUPPLY
2 18GY/YL LOW FUEL PRESSURE SENSOR GROUND
3 18GY/RD LOW FUEL PRESSURE SENSOR SIGNAL

MAP/READING LAMP SWITCH


CAV CIRCUIT FUNCTION
1 16GY/DG/RD LAMP DRIVER
3 16RD/YL FUSED B(+)
7 16RD/YL MAP/READING LAMP SWITCH OUTPUT
10 16BR GROUND

MARKER LAMP CONNECTOR


CAV CIRCUIT FUNCTION
1 16GY/RD LAMP DRIVER
2 16BR GROUND

MARKER LAMP NO. 1-LEFT FRONT


CAV CIRCUIT FUNCTION
1 16GY/BK LAMP DRIVER
2 16BR GROUND

MARKER LAMP NO. 1-RIGHT FRONT


CAV CIRCUIT FUNCTION
1 16GY/RD LAMP DRIVER
2 16BR GROUND
8W - 80 - 56 8W-80 CONNECTOR PIN-OUTS VA

MARKER LAMP NO. 2-LEFT FRONT


CAV CIRCUIT FUNCTION
1 16GY/BK LAMP DRIVER
2 16BR GROUND

MARKER LAMP NO. 2-RIGHT FRONT


CAV CIRCUIT FUNCTION
1 16GY/RD LAMP DRIVER
2 16BR GROUND

MARKER LAMP-LEFT CENTER


CAV CIRCUIT FUNCTION
1 16GY/BK LAMP DRIVER
2 16BR GROUND

MARKER LAMP-LEFT REAR


CAV CIRCUIT FUNCTION
1 16GY/BK LAMP DRIVER
2 16BR GROUND

MARKER LAMP-RIGHT CENTER


CAV CIRCUIT FUNCTION
1 16GY/RD LAMP DRIVER
2 16BR GROUND
VA 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 57

MARKER LAMP-RIGHT REAR


CAV CIRCUIT FUNCTION
1 16GY/RD/WT LAMP DRIVER
2 16BR GROUND

MASS AIR FLOW SENSOR - BLACK


CAV CIRCUIT FUNCTION
1 16YL/RD (OBD) FUSED IGNITION SWITCH OUTPUT (RUN-START)
2 20YL/RD (EXCEPT OBD) MASS AIR FLOW SENSOR 12 VOLT SUPPLY
2 20BR/VT (OBD) MASS AIR FLOW SENSOR 5 VOLT SUPPLY
3 20BR/YL (EXCEPT OBD) MASS AIR FLOW SENSOR GROUND
3 20YL/BL (OBD) MASS AIR FLOW SENSOR GROUND
4 20BR/BK (EXCEPT OBD) MASS AIR FLOW SENSOR 5 VOLT SUPPLY
4 20YL/DG (OBD) MASS AIR FLOW SENSOR SIGNAL
5 20YL/DG (EXCEPT OBD) MASS AIR FLOW SENSOR SIGNAL

MASTER DOOR LOCK SWITCH


CAV CIRCUIT FUNCTION
1 16GY/DG/RD LAMP DRIVER
2 16WT/DG PASSENGER DOOR AJAR INDICATOR DRIVER
3 16WT/YL MASTER DOOR LOCK SWITCH SENSE-ALL DOORS
8 16WT/RD MASTER DOOR LOCK SWITCH SENSE-PASSENGER
DOORS
9 16WT/BK DRIVER DOOR AJAR INDICATOR DRIVER
10 16BR GROUND

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

OXYGEN SENSOR (OBD)


CAV CIRCUIT FUNCTION
1 20DG/BK ENGINE CONTROL MODULE C1 CAV 15 TO OXYGEN
SENSOR CAV 1
2 20GY/WT ENGINE CONTROL MODULE C1 CAV 40 TO OXYGEN
SENSOR CAV 2
3 20GY/BL ENGINE CONTROL MODULE C1 CAV 72 TO OXYGEN
SENSOR CAV 3
4 20RD/DG S175 COMMON CIRCUIT
5 20DG/YL ENGINE CONTROL MODULE CAV 62 TO OXYGEN
SENSOR CAV 5
6 20GY ENGINE CONTROL MODULE CAV 39 TO OXYGEN
SENSOR CAV 6

PANIC ALARM SWITCH - BLACK


CAV CIRCUIT FUNCTION
1 18GY/DG/RD LAMP DRIVER
2 - -
3 18BR GROUND
4 - -
5 - -
6 - -
7 18GY/WT PANIC SWITCH SENSE
8 - -
9 - -
10 18BR GROUND

PARKING BRAKE SWITCH


CAV CIRCUIT FUNCTION
1 20BR/BK PARK BRAKE INDICATOR SIGNAL
2 16BR GROUND
VA 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 59

POWER MIRROR MOTOR-DRIVER


CAV CIRCUIT FUNCTION
1 18BK/RD FUSED OPTIONAL EQUIPMENT RELAY OUTPUT
2 18BR GROUND
3 18WT/DG DRIVER MIRROR HORIZONTAL MOTOR DRIVER
4 18DG/RD DRIVER MIRROR VERTICAL MOTOR DRIVER
5 18BL/BR DRIVER MIRROR COMMON DRIVER

POWER MIRROR MOTOR-PASSENGER - BLACK


CAV CIRCUIT FUNCTION
1 18BK/RD FUSED OPTIONAL EQUIPMENT RELAY OUTPUT
2 18BR GROUND
3 18WT/GY PASSENGER MIRROR HORIZONTAL MOTOR DRIVER
4 18DG PASSENGER MIRROR VERTICAL MOTOR DRIVER
5 18BL/DG PASSENGER MIRROR COMMON DRIVER

POWER MIRROR SWITCH


CAV CIRCUIT FUNCTION
1 18WT/GY PASSENGER MIRROR HORIZONTAL MOTOR DRIVER
2 18WT/DG DRIVER MIRROR HORIZONTAL MOTOR DRIVER
3 18BL/DG PASSENGER MIRROR COMMON DRIVER
6 18BR GROUND
7 18BK/RD FUSED OPTIONAL EQUIPMENT RELAY OUTPUT
8 18DG/RD DRIVER MIRROR VERTICAL MOTOR DRIVER
9 18DG PASSENGER MIRROR VERTICAL MOTOR DRIVER
10 18BL/BR DRIVER MIRROR COMMON DRIVER

POWER WINDOW MOTOR-DRIVER


CAV CIRCUIT FUNCTION
1 16BK DRIVER WINDOW DRIVER (UP)
2 16BL DRIVER WINDOW DRIVER (DOWN)
8W - 80 - 60 8W-80 CONNECTOR PIN-OUTS VA

POWER WINDOW MOTOR-PASSENGER


CAV CIRCUIT FUNCTION
1 16BL PASSENGER WINDOW DRIVER (DOWN)
2 16BK PASSENGER WINDOW DRIVER (UP)

POWER WINDOW SWITCH-DRIVER


CAV CIRCUIT FUNCTION
1 16BL DRIVER WINDOW DRIVER (DOWN)
2 16BK DRIVER WINDOW DRIVER (UP)
3 16BR GROUND
4 16BK/YL FUSED OPTIONAL EQUIPMENT RELAY OUTPUT
5 16BR GROUND

POWER WINDOW SWITCH-MASTER


CAV CIRCUIT FUNCTION
1 16BL/WT MASTER PASSENGER WINDOW DRIVER (DOWN)
2 16BK/WT MASTER PASSENGER WINDOW DRIVER (UP)
3 16BR GROUND
4 16BK/YL/DG FUSED OPTIONAL EQUIPMENT RELAY OUTPUT
5 16BR GROUND

POWER WINDOW SWITCH-PASSENGER


CAV CIRCUIT FUNCTION
1 16BL PASSENGER WINDOW DRIVER (DOWN)
2 16BK PASSENGER WINDOW DRIVER (UP)
3 16BL/WT MASTER PASSENGER WINDOW DRIVER (DOWN)
4 16BK/YL/DG FUSED OPTIONAL EQUIPMENT RELAY OUTPUT
5 16BK/WT MASTER PASSENGER WINDOW DRIVER (UP)

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

READING LAMP CONNECTOR


CAV CIRCUIT FUNCTION
1 16BR GROUND
2 16RD/YL MAP/READING LAMP SWITCH OUTPUT
8W - 80 - 62 8W-80 CONNECTOR PIN-OUTS VA

RECIRCULATED AIR SOLENOID VALVE


CAV CIRCUIT FUNCTION
1 16RD RECIRCULATED AIR SOLENOID VALVE (+)
2 16BK GROUND

REFRIGERANT PRESSURE SENSOR


CAV CIRCUIT FUNCTION
1 18BR/BL SENSOR GROUND
2 20BR/RD REFRIGERANT PRESSURE SENSOR SIGNAL
3 20RD/BL 5 VOLT SUPPLY

REMOTE KEYLESS ENTRY ANTENNA


CAV CIRCUIT FUNCTION
1 20BR RKE ANTENNA
3 - GROUND

ROOF FAN MOTOR


CAV CIRCUIT FUNCTION
1 16WT MOTOR (+/-)
2 16BK MOTOR (+/-)

ROOF FAN SWITCH


CAV CIRCUIT FUNCTION
1 16GY/DG/RD LAMP DRIVER
3 16BK/BL/WT FUSED OPTIONAL EQUIPMENT RELAY OUTPUT
4 16WT MOTOR (+/-)
5 16BR GROUND
6 16BR GROUND
7 16BK MOTOR (+/-)
8 16BK/BL/WT FUSED OPTIONAL EQUIPMENT RELAY OUTPUT
10 16BR GROUND
VA 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 63

SEAT BELT SWITCH


CAV CIRCUIT FUNCTION
1 16BR GROUND
2 20YL/RD SEAT BELT SWITCH SIGNAL

SEAT BELT TENSIONER-DRIVER - YELLOW


CAV CIRCUIT FUNCTION
1 20BL DRIVER SEAT BELT TENSIONER LINE 2
2 20BR/YL DRIVER SEAT BELT TENSIONER LINE 1

SEAT BELT TENSIONER-PASSENGER - YELLOW


CAV CIRCUIT FUNCTION
1 20BL PASSENGER SEAT BELT TENSIONER LINE 2
2 20BR PASSENGER SEAT BELT TENSIONER LINE 1

SECURITY SYSTEM MODULE C1 - BROWN


CAV CIRCUIT FUNCTION
1 16BK/WT LEFT TURN SIGNAL
4 16BK/DG RIGHT TURN SIGNAL
5 16BK/VT FAN STAGE 1 RELAY
6 16WT/RD WARM AIR AUXILIARY HEATER CONTROL
7 16RD/GY FUSED B(+)
8 16BK/GY FUSED OPTIONAL EQUIPMENT RELAY OUTPUT
9 18VT/DG TOWING/INTRUSION SENSOR INDICATOR DRIVER
11 16BR/YL FRONT COURTESY LAMPS CONTROL
12 16BR/WT DOOR AJAR SWITCH SENSE
13 16RD/DG FUSED B(+)
14 16BK/BL HOOD AJAR SWITCH SENSE
15 18GY/WT PANIC SWITCH SENSE
16 16BR GROUND
17 18GY/BR TOWING SENSOR SWITCH SENSE
18 18GY/YL INTRUSION SENSOR SWITCH SENSE
20 16BK DRIVER CYLINDER UNLOCK SENSE
21 16RD DRIVER CYLINDER LOCK SENSE
8W - 80 - 64 8W-80 CONNECTOR PIN-OUTS VA

SECURITY SYSTEM MODULE C2 - LT. GREEN


CAV CIRCUIT FUNCTION
1 16DG/YL INTRUSION SENSOR INTERFACE
2 16GY/BL WINDOW DEFOGGER RELAY-LEFT REAR OUTPUT
3 16GY WINDOW DEFOGGER RELAY-RIGHT REAR OUTPUT
4 20DG/BK INTRUSION SENSOR 1 SIGNAL
7 20GY/BK INTRUSION SENSOR 2 SIGNAL
8 16GY/DG K-CTM/SSM
9 18BK/BL SIREN SIGNAL CONTROL
10 20DG/WT/BL INTRUSION SENSOR 3 SIGNAL
11 16WT/BL RKE INTERFACE
12 16WT/BL/RD SECURITY SYSTEM INTERFACE

SENTRY KEY REMOTE ENTRY MODULE (SKREEM)


CAV CIRCUIT FUNCTION
1 18YL RKE ANTENNA
2 16BR GROUND
3 16RD/YL FUSED B(+)
4 16BK/WT LEFT TURN SIGNAL
5 20DG/WT CAN C BUS (+)
6 20DG CAN C BUS (-)
7 16BK/YL FUSED IGNITION SWITCH OUTPUT (RUN-START)
8 20WT/DG K-SKREEM
9 16WT/BL/RD (EXCEPT VTSS) RKE INTERFACE
9 16WT/BL/RD (VTSS) SECURITY SYSTEM INTERFACE
10 18DG/YL TURN SIGNAL/ANTI-THEFT ALARM RELAY-LEFT/
RIGHT CONTROL
11 20BR TRANSPONDER COIL (+)
12 - TRANSPONDER COIL (-)

SHIFTER ASSEMBLY - BLACK


CAV CIRCUIT FUNCTION
2 20GY/DG/RD LAMP DRIVER
3 20BL/DG K-ABS/SHIFTER ASSEMBLY
4 18BR GROUND
5 20BK/BL/RD BRAKE LAMP SWITCH
6 20DG/WT CAN C BUS (+)
7 20DG CAN C BUS (-)
8 18BK/DG TRANSMISSION RELAY OUTPUT
9 16WT/BL/RD FUSED IGNITION SWITCH OUTPUT (RUN-START)
10 16WT/RD BACK-UP LAMP
VA 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 65

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 FRONT DOOR ASSEMBLY C1


CAV CIRCUIT FUNCTION
1 18BL/YL SPEAKER-LEFT FRONT (+) CTEL
2 18BL/DG SPEAKER-LEFT FRONT (-) CTEL

SPEAKER-LEFT FRONT DOOR ASSEMBLY C2


CAV CIRCUIT FUNCTION
1 18BR/DG SPEAKER-LEFT FRONT (+)
2 18BR SPEAKER-LEFT FRONT (-)

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 FRONT DOOR


CAV CIRCUIT FUNCTION
1 18BR/RD SPEAKER-RIGHT FRONT (+)
2 18BK SPEAKER-RIGHT FRONT (-)

SPEAKER-RIGHT REAR
CAV CIRCUIT FUNCTION
1 16BR/GY SPEAKER-RIGHT REAR
2 16WT/GY SPEAKER-RIGHT REAR

SPEED CONTROL SWITCH


CAV CIRCUIT FUNCTION
1 18GY OFF SIGNAL
2 18BK VERIFICATION SIGNAL
3 18BL RESUME SIGNAL
4 18YL DECEL/SET SIGNAL
5 18DG ACCEL/SET SIGNAL
6 18RD S/C SWITCH 12 VOLT SUPPLY

TAIL LAMP ASSEMBLY-LEFT - BLACK


CAV CIRCUIT FUNCTION
2 16GY/BK LEFT LAMP RELAY OUTPUT
3 16BK/RD BRAKE LAMP SWITCH OUTPUT
4 16WT/RD BACK-UP LAMP
5 16BK/WT LEFT TURN SIGNAL
6 16BR GROUND

TAIL LAMP ASSEMBLY-RIGHT - BLACK


CAV CIRCUIT FUNCTION
2 16GY/RD RIGHT LAMP RELAY OUTPUT
3 16BK/RD BRAKE LAMP SWITCH OUTPUT
4 16WT/RD BACK-UP LAMP
5 16BK/DG RIGHT TURN SIGNAL
6 16BR GROUND
VA 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 67

TCS SWITCH (ASR) - BLACK


CAV CIRCUIT FUNCTION
1 16GY/DG/RD LAMP DRIVER
3 18BK/BL TCS SWITCH (ASR) SENSE
7 16BK/BL/DG S201 COMMON CIRCUIT
10 16BR GROUND

TIME DELAY RELAY


CAV CIRCUIT FUNCTION
1 16RD/YL FUSED B(+)
4 16RD/YL FUSED B(+)
7 16BR GROUND
13 16YL INTERIOR LIGHT SWITCH OUTPUT
15 16DG INTERIOR LAMPS DRIVER

TOWING/INTRUSION SENSOR ON/OFF SWITCH


CAV CIRCUIT FUNCTION
1 18GY/DG/RD LAMP DRIVER
3 18GY/YL INTRUSION SENSOR SWITCH SENSE
4 18BR GROUND
8 18GY/BR TOWING SENSOR SWITCH SENSE
9 18VT/DG TOWING/INTRUSION SENSOR INDICATOR DRIVER
10 18BR GROUND

TRAILER TOW CONNECTOR - BLACK


CAV CIRCUIT FUNCTION
2 16BK/DG/GY STOP/TURN SIGNAL-RIGHT
3 16BK/RD BACK-UP LAMP
4 14RD FUSED B(+)
5 16GY/RD RIGHT LAMP RELAY OUTPUT
7 14RD/BK ELECTRIC BRAKES
8 14BR GROUND
10 16BK/RD/WT STOP/TURN SIGNAL-LEFT
8W - 80 - 68 8W-80 CONNECTOR PIN-OUTS VA

TRAILER TOW CONTROL MODULE C1 - BLACK


CAV CIRCUIT FUNCTION
C 16BK/RD/WT STOP/TURN SIGNAL-LEFT
D 16BK/DG/GY STOP/TURN SIGNAL-RIGHT
F 14RD/BK ELECTRIC BRAKES

TRAILER TOW CONTROL MODULE C2 - BLACK


CAV CIRCUIT FUNCTION
A 16BK/RD BRAKE LAMP SWITCH OUTPUT
B 16BK/DG RIGHT TURN SIGNAL
C 16BR GROUND
D 14RD FUSED B(+)
E 16BK/WT LEFT TURN SIGNAL

TRANSMISSION CONTROL MODULE C1 - BLACK


CAV CIRCUIT FUNCTION
1 20BL K-TCM/RADIO
29 16BK/DG TRANSMISSION RELAY OUTPUT
30 18BR GROUND

TRANSMISSION CONTROL MODULE C2 - BLACK


CAV CIRCUIT FUNCTION
12 20BL/GY N2 INPUT SPEED SENSOR
13 20BK/BL SENSOR SUPPLY VOLTAGE
14 16WT 1-2/4-5 SOLENOID CONTROL
15 16YL 3-4 SOLENOID CONTROL
16 16WT/BL 2-3 SOLENOID CONTROL
17 16YL/BL TCC SOLENOID CONTROL
33 20PK SENSOR GROUND
34 20GY/BL TEMPERATURE SENSOR-P/N SWITCH
35 20BL/DG N3 INPUT SPEED SENSOR
36 16BR/GY MODULATION PRESSURE SOLENOID CONTROL
37 16BK/RD SHIFT PRESSURE SOLENOID CONTROL
38 16BK SOLENOID SUPPLY VOLTAGE
H 20DG/WT CAN C BUS (+)
L 20DG CAN C BUS (-)
VA 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 69

TRANSMISSION SOLENOID ASSEMBLY - BLACK


CAV CIRCUIT FUNCTION
1 20BL/DG N3 INPUT SPEED SENSOR
2 16BR/GY MODULATION PRESSURE SOLENOID CONTROL
3 20BL/GY N2 INPUT SPEED SENSOR
4 20GY/BL TEMPERATURE SENSOR-P/N SWITCH
6 16BK SOLENOID SUPPLY VOLTAGE
7 20BK/BL SENSOR SUPPLY VOLTAGE
8 16WT/BL 2-3 SOLENOID CONTROL
9 16YL 3-4 SOLENOID CONTROL
10 16BK/RD SHIFT PRESSURE SOLENOID CONTROL
11 16YL/BL TCC SOLENOID CONTROL
12 20PK SENSOR GROUND
13 16WT 1-2/4-5 SOLENOID CONTROL

TURN SIGNAL NO. 1-LEFT FRONT - BLACK


CAV CIRCUIT FUNCTION
1 16BK/WT LEFT TURN SIGNAL
2 16BR GROUND

TURN SIGNAL NO. 1-RIGHT FRONT - BLACK


CAV CIRCUIT FUNCTION
1 16BK/DG RIGHT TURN SIGNAL
2 16BR GROUND

TURN SIGNAL NO. 2-LEFT FRONT


CAV CIRCUIT FUNCTION
1 16BK/WT LEFT TURN SIGNAL
2 16BR GROUND
8W - 80 - 70 8W-80 CONNECTOR PIN-OUTS VA

TURN SIGNAL NO. 2-RIGHT FRONT


CAV CIRCUIT FUNCTION
1 16BK/DG RIGHT TURN SIGNAL
2 16BR GROUND

WARM AIR AUXILIARY HEATER ASSEMBLY C1


CAV CIRCUIT FUNCTION
1 16YL HEATER TIMER (CUT-IN SIGNAL)
2 14RD FUSED B(+)
3 20BK/YL K-CTM/SSM
4 14BR GROUND
5 16BR/WT HEATER TIMER
6 16GY/RD HEATER TIMER
7 16WT/RD WARM AIR AUXILIARY HEATER CONTROL

WARM AIR AUXILIARY HEATER ASSEMBLY C2


CAV CIRCUIT FUNCTION
1 16DG/RD METERING PUMP DRIVER
2 16BR GROUND

WASHER PUMP MOTOR-FRONT


CAV CIRCUIT FUNCTION
1 16BR GROUND
2 16BK/VT/RD WASHER ON/OFF SWITCH OUTPUT

WATER CYCLE VALVE


CAV CIRCUIT FUNCTION
1 18BR/VT WATER CYCLE VALVE CONTROL (DUTY CYCLE)
2 18BR GROUND
VA 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 71

WATER IN FUEL SENSOR - BLACK


CAV CIRCUIT FUNCTION
1 18BR WATER IN FUEL SENSOR SIGNAL
2 18BR/RD WATER IN FUEL SENSOR 12 VOLT SUPPLY
3 18BK/YL WATER IN FUEL SENSOR GROUND

WHEEL SPEED SENSOR-LEFT FRONT


CAV CIRCUIT FUNCTION
1 18BK LEFT FRONT WHEEL SPEED SENSOR (+)
2 18BR LEFT FRONT WHEEL SPEED SENSOR (-)

WHEEL SPEED SENSOR-LEFT REAR


CAV CIRCUIT FUNCTION
1 18WT LEFT REAR WHEEL SPEED SENSOR (+)
2 18BR LEFT REAR WHEEL SPEED SENSOR (-)

WHEEL SPEED SENSOR-RIGHT FRONT


CAV CIRCUIT FUNCTION
1 18BK RIGHT FRONT WHEEL SPEED SENSOR (+)
2 18BR RIGHT FRONT WHEEL SPEED SENSOR (-)

WHEEL SPEED SENSOR-RIGHT REAR


CAV CIRCUIT FUNCTION
1 18BK RIGHT REAR WHEEL SPEED SENSOR (+)
2 18BR RIGHT REAR WHEEL SPEED SENSOR (-)
8W - 80 - 72 8W-80 CONNECTOR PIN-OUTS VA

WINDOW DEFOGGER MODULE-REAR - BROWN


CAV CIRCUIT FUNCTION
1 14RD/DG FUSED B(+)
4 16RD/BK FUSED D(+) RELAY NO. 1 OUTPUT
6 14RD/DG FUSED B(+)
7 16BR GROUND
10 16GY/RD (DEFOGGER RELAYS) WINDOW DEFOGGER RELAY-RIGHT REAR CONTROL
10 16GY (EXCEPT DEFOGGER RELAYS) WINDOW DEFOGGER-RIGHT REAR SIGNAL
13 16GY WINDOW DEFOGGER SWITCH-REAR OUTPUT
15 16GYDG (DEFOGGER RELAYS) WINDOW DEFOGGER RELAY-LEFT REAR CONTROL
15 16GY/BL (EXCEPT DEFOGGER WINDOW DEFOGGER-LEFT REAR SIGNAL
RELAYS)
16 16GY/DG LAMP DRIVER

WINDOW DEFOGGER SWITCH-REAR - BLACK


CAV CIRCUIT FUNCTION
1 18GY/DG/RD LAMP DRIVER
3 16BK/YL FUSED IGNITION SWITCH OUTPUT (RUN-START)
7 16GY WINDOW DEFOGGER SWITCH-REAR OUTPUT
9 16GY/DG LAMP DRIVER
10 18BR GROUND

WINDOW DEFOGGER-LEFT REAR


CAV CIRCUIT FUNCTION
1 16GY (DEFOGGER RELAYS) WINDOW DEFOGGER RELAY-LEFT REAR OUTPUT
1 16GY (EXCEPT DEFOGGER RELAYS) WINDOW DEFOGGER-LEFT REAR SIGNAL
2 16BR GROUND

WINDOW DEFOGGER-RIGHT REAR


CAV CIRCUIT FUNCTION
1 16GY (DEFOGGER RELAYS) WINDOW DEFOGGER RELAY- RIGHT REAR OUTPUT
1 16GY (EXCEPT DEFOGGER RELAYS) WINDOW DEFOGGER-RIGHT REAR SIGNAL
2 16BR GROUND

WIPER MOTOR-FRONT - BLACK


CAV CIRCUIT FUNCTION
1 16BR GROUND
2 16BR/BK WIPER ON/OFF RELAY OUTPUT
3 16BK/VT FUSED IGNITION SWITCH OUTPUT (RUN-START)
5 16BK WIPER MOTOR CONTROL
6 16BK/GY/RD WIPER SWITCH OUTPUT
VA 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 73

WIPER/TURN SIGNAL/ENGINE START CONTROL MOD-


ULE (FUSE BLOCK NO. 1)
CAV CIRCUIT FUNCTION
2 INTERNAL WIPER ON/OFF RELAY
CONTROL
3 INTERNAL WIPER SWITCH OUTPUT
4 INTERNAL FUSED IGNITION SWITCH
OUTPUT (RUN-START)
6 INTERNAL WIPER ON/OFF RELAY
OUTPUT
7 INTERNAL TURN SIGNAL RELAY OUT-
PUT
8 INTERNAL TURN SIGNAL RELAY FEED
9 INTERNAL TURN SIGNAL RELAY
CONTROL
10 - -
11 INTERNAL TURN SIGNAL RELAY SIG-
NAL
12 INTERNAL ENGINE CONTROL RELAY
SIGNAL
13 INTERNAL ENGINE CONTROL RELAY
CONTROL
14 INTERNAL GROUND
15 INTERNAL WASHER ON/OFF SWITCH
OUTPUT
16 INTERNAL HAZARD WARNING
SWITCH SENSE
VA 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 1

8W-91 CONNECTOR/GROUND/SPLICE LOCATION

TABLE OF CONTENTS
page

CONNECTOR/GROUND/SPLICE LOCATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1

CONNECTOR/GROUND/SPLICE Connector, ground, and splice indexes are provided.


Use the wiring diagrams in each section for connec-
LOCATION tor, ground, and splice identification. Refer to the
appropriate index for the proper figure number. For
DESCRIPTION items that are not shown in this section N/S is placed
This section provides illustrations identifying con- in the Fig. column.
nector, ground, and splice locations in the vehicle.

CONNECTORS

CONNECTOR NAME/ COLOR LOCATION FIG.


NUMBER
A/C Auxiliary Fan Engine Compartment N/S
A/C Auxiliary Fan Relay (In Under Driver Seat N/S
Relay Block)
A/C Control Module-Roof BK Instrument Panel N/S
A/C Switch - Roof Instrument Panel N/S
Accelerator Pedal Position On Gas Pedal 18
Sensor (OBD)
Accelerator Pedal Position BK NS
Sensor
Additional Heat Exchanger NS
Air Outlet Temperature Engine Compartment (Right Rear) 7,19
Sensor
Airbag Control Module YL Under Driver Seat 12,20,22
Airbag Squib-Driver YL Steering Wheel 12
Airbag Squib-Passenger YL Instrument Panel (Passenger Side) N/S
Ambient Temperature Sensor Front Engine Compartment 2,19
Ash Receiver Lamp In Ash Tray N/S
Automatic Temperature BR Instrument Panel N/S
Control Module C1
Automatic Temperature Instrument Panel N/S
Control Module C2
Auxiliary Heater Relay (In Under Driver Seat N/S
Relay Block)
Auxiliary Heater Switch Instrument Panel N/S
Battery Relay-Auxiliary BK Engine Compartment N/S
Blower Motor Resistor Block Underhood Right (To The 6
Instrument Panel)
8W - 91 - 2 8W-91 CONNECTOR/GROUND/SPLICE LOCATION VA
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

CONNECTOR NAME/ COLOR LOCATION FIG.


NUMBER
Blower Motor Resistor Block Instrument Panel 19
C1
Blower Motor Resistor Block Instrument Panel 19
C2
Blower Motor Resistor Block Instrument Panel 19
C3
Blower Motor-Front BK Underhood Right (To The 6
Instrument Panel)
Body Plug Connector Under Driver Seat N/S
Boost Pressure Sensor Engine Compartment-Left 7
(Except OBD)
Boost Pressure Sensor NS
(OBD)
Boost Pressure Servomotor NS
(OBD)
Boost Pressure Solenoid BK NS
Brake Fluid Level Switch Engine Compartment 4
Brake Lamp Switch C1 Pedals Area (Brake) 18
Brake Lamp Switch C2 BK Pedals Area (Brake) 18
Brake Wear Sensor-Left On Left Front Wheel N/S
Front
Brake Wear Sensor-Left Rear On Left Rear Wheel N/S
Brake Wear Sensor-Right On Right Front Wheel N/S
Front
Brake Wear Sensor-Right On Right Rear Wheel N/S
Rear
C100 Under Driver Seat 22
C101 YL Under Instrument Panel-Left 18
C102 (Except OBD) NS
C103 (OBD) NS
C200 BK Under Instrument Panel-Left 14
C201 BK Under Instrument Panel-Left 14
C202 BK Under Instrument Panel-Left 14
C203 BK Instrument Panel N/S
C204 GY Upper Instrument Panel-Left 14
C205 YL Under Driver Seat N/S
C206 Instrument Panel N/S
C207 Near Interior Light Switch-Driver N/S
C208 Near A/C Fan Switch N/S
C209 Instrument Panel N/S
C210 BK Instrument Panel N/S
C211 BK Instrument Panel N/S
C214 BL Instrument Panel N/S
C215 BK Instrument Panel N/S
VA 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 3
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

CONNECTOR NAME/ COLOR LOCATION FIG.


NUMBER
C216 BK Instrument Panel N/S
C217 Instrument Panel N/S
C218 Under Driver Seat 22
C219 BK Under Driver Seat 23
C220 Instrument Panel N/S
C221 NS
C224 NS
C225 NS
Cabin Heater Assembly C1 Instrument Panel N/S
Cabin Heater Assembly C2 Instrument Panel N/S
Camshaft Position Sensor BK Engine Compartment 9
Center High Mounted Stop Rear Vehicle N/S
Lamp
Central Timer Module C1 PK Instrument Panel N/S
Central Timer Module C2 GR Instrument Panel N/S
Cigar Lighter Near Ash Tray N/S
Cigar Lighter Lamp Near Cigar Lighter N/S
Circulation Pump (Cabin Engine Compartment-Front 6
Heater Module)
Circulation Pump (Rest NS
System)
Circulation Pump Diode Engine Compartment N/S
Circulation Pump Relay Under Driver Seat N/S
(Relay Block)
Clockspring C1 Steering Wheel 12
Clockspring C2 YL Steering Wheel 12,18
Contact Plate-Left Rear Rear Of Vehicle On Left N/S
License Plate
Contact Switch Door-Right Right Rear Door 25
Rear
Controller Antilock Brake Engine Compartment-Left 2
Courtesy Lamp - Driver Door Driver Door 2324
Courtesy Lamp - Left Sliding Left B-Pillar 2324
Door
Courtesy Lamp - Passenger Passenger Door 24
Door
Courtesy Lamp - Right Right B-Pillar 2324
Sliding Door
Crankcase Heater BK Engine Compartment N/S
Crankshaft Position Sensor BK On Engine N/S
CTEL Antenna Connector NS
CTEL Connector Instrument Panel N/S
Cylinder Lock Switch-Driver Driver Door 25
8W - 91 - 4 8W-91 CONNECTOR/GROUND/SPLICE LOCATION VA
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

CONNECTOR NAME/ COLOR LOCATION FIG.


NUMBER
D(+) Relay No.1 (Relay Under Driver Seat N/S
Block)
D(+) Relay No.2 (Relay NS
Block)
Data Link Connector BK Under Dash N/S
Daytime Running Lamp Under Driver Seat N/S
Relay-Left Side (Relay Block)
Daytime Running Lamp Under Driver Seat N/S
Relay-Right Side (Relay
Block)
Daytime Running Lamps Under Driver Seat N/S
Relay (Relay Block)
Differential Lock Solenoid Underbody 29
Valve
Dome Lamp Dome Area 2324
Door Jamb Switch-Driver Driver Door 25
Door Jamb Switch-Left Left Sliding Door N/S
Sliding
Door Jamb Switch-Passenger Passenger Door 25
Door Jamb Switch-Right Right Sliding Door N/S
Sliding
Door Jamb Switch-Tailgate Tailgate N/S
Door Lock Motor/Ajar Switch Driver Door 25
Assembly - Driver C1
Door Lock Motor/Ajar Switch Driver Door 25
Assembly - Driver C2
Door Lock Motor/Ajar Switch Left Sliding Door 26
Assembly - Left Sliding C1
Door Lock Motor/Ajar Switch Left Sliding Door 26
Assembly - Left Sliding C2
Door Lock Motor/Ajar Switch Passenger Door 26
Assembly - Passenger C1
Door Lock Motor/Ajar Switch Passenger Door 26
Assembly - Passenger C2
Door Lock Motor/Ajar Switch Right Sliding Door N/S
Assembly - Rear C1
Door Lock Motor/Ajar Switch Right Sliding Door N/S
Assembly - Rear
Door Lock Motor/Ajar Switch Cargo Door 30
Assembly-Right Sliding C1
Door Lock Motor/Ajar Switch Cargo Door 30
Assembly-Right Sliding C2
Dosing Pump Engine Compartment N/S
EGR Valve Engine Compartment 10
Engine Control Module C1 BK Instrument Panel 15
(Except OBD)
VA 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 5
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

CONNECTOR NAME/ COLOR LOCATION FIG.


NUMBER
Engine Control Module C1 NS
(OBD)
Engine Control Module C2 BK Instrument Panel 15
(Except OBD)
Engine Control Module C2 NS
(OBD)
Engine Control Module C3 BK Instrument Panel 15
(Except OBD)
Engine Control Module C4 BK Instrument Panel 15
(Except OBD)
Engine Control Module C5 GY Instrument Panel 15
(Except OBD)
Engine Control Relay (Fuse NS
Block No.1
Engine Coolant Level Switch BK Engine Compartment 2, 4
Engine Coolant Temperature BK Engine Compartment 9
Sensor
Engine Oil Pressure Sensor BK Engine Compartment 10
Evaporator Temperature Instrument Panel-Right 19
Sensor
Fan Stage 1 Relay (Relay Under Driver Seat N/S
Block)
Fog Lamp Relay (Relay Under Driver Seat N/S
Block)
Fog Lamp Switch Instrument Panel N/S
Fuel Injector No. 1 BK Engine Compartment 9
Fuel Injector No. 2 BK Engine Compartment 8,9
Fuel Injector No. 3 BK Engine Compartment 8,9
Fuel Injector No. 4 BK Engine Compartment 8,9
Fuel Injector No. 5 BK Engine Compartment 9
Fuel Level Sensor Underbody-Middle 29
Fuel Pressure Sensor BK Engine Compartment 8
Fuel Pressure Solenoid Engine Compartment-Rear 77
(Except OBD)
Fuel Temperature Sensor Engine Compartment 9
Fuel Quanitity Control Valve 7
(OBD)
Fuse Block No.1 C1 Under Fuse Block No.1 N/S
Fuse Block No.1 C2 Under Fuse Block No.1 N/S
Fuse Block No.1 C3 BK Under Fuse Block No.1 N/S
Fuse Block No.1 C4 BK Under Fuse Block No.1 N/S
Fuse Block No.1 C5 BK Under Fuse Block No.1 N/S
Fuses (Fuse Block No. 1) Steering Column 17
Fuses (Fuse Block No. 2) Under Driver Seat 21
8W - 91 - 6 8W-91 CONNECTOR/GROUND/SPLICE LOCATION VA
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

CONNECTOR NAME/ COLOR LOCATION FIG.


NUMBER
Fuses (Fuse Block No. 3) Under Driver Seat N/S
Fuses (Fuse/Relay Block) Under Driver Seat 21,22
Fuses (PDC) Battery Area 4
Generator No.1 Engine Compartment N/S
Generator No.2 Engine Compartment-Right 2,10
Glow Plug Control Module C1 BK Engine Compartment-Left Front 1
Glow Plug Control Module C2 BK Engine Compartment-Left Front 1
Glow Plug No. 1 On Engine N/S
Glow Plug No. 2 On Engine N/S
Glow Plug No. 3 On Engine N/S
Glow Plug No. 4 On Engine N/S
Glow Plug No. 5 On Engine N/S
Headlamp Adjust Switch BK Instrument Panel N/S
Headlamp Assembly-Left BK On Front Of Vehicle (Left Side) N/S
Headlamp Assembly-Right BK On Front Of Vehicle (Right Side) N/S
Heat Exchanger Switch Engine Compartment N/S
Heated Seat Module-Driver Under Driver Seat N/S
Heated Seat Module- Under Passenger Seat N/S
Passenger
Heated Seat Switch-Driver On Driver Seat N/S
Heated Seat Switch- On Passenger Seat N/S
Passenger
Heater Timer-Auxiliary Under Driver Seat N/S
High Idle Switch NS
High Pressure Pump Shutoff Engine Compartment 8
Valve
Hood Ajar Switch Engine Compartment N/S
Horn Engine Compartment N/S
Horn (VTSS) Engine Compartment N/S
Horn Relay (Relay Block) Under Driver Seat N/S
Horn-Switch Steering Wheel 10
Ignition Lock Switch BK Steering Column N/S
Instrument Cluster C1 Instrument Panel 12
Instrument Cluster C2 WT Instrument Panel 12
Instrument Panel Socket BK Instrument Panel N/S
Intake Air Pressure Sensor Engine Compartment-Left 7
(OBD)
Intake Air Temperature BK NS
Sensor
Interior Lamp No. 1 Headliner-Front 2324
Interior Lamp No. 2 Headliner-Front 2324
Interior Lamp No. 3 Headliner-Front 24
Interior Lamp No. 4 Headliner-Front 24
VA 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 7
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

CONNECTOR NAME/ COLOR LOCATION FIG.


NUMBER
Interior Lamp No. 5 Headliner-Front 24
Interior Lamp-Left BK Left Upper Side 2324
Interior Lamp-Middle Front Headliner-Front 2324
Interior Lamp-Middle Rear Headliner Middle Rear 23
Interior Lamp-Rear No. 1 BK Headliner-Rear 24
Interior Lamp-Rear No. 2 BK Headliner-Rear 24
Interior Lamp-Right BK Right Upper Side 2324
Interior Lamp-Right Center Headliner-Rear 24
Interior Light Switch Instrument Panel N/S
Interior Light Switch-Driver Driver Side Of Vehicle N/S
Interior Light Switch- Passenger Side Of Vehicle N/S
Passenger
Interior Light Switch-Rear Rear Side Of Vehicle N/S
Interior Lighting Connector Instrument Panel N/S
Intrusion Sensor No. 1 BK Headliner-Front Body 28
Intrusion Sensor No. 2 BK Headliner-Front Body 28
Intrusion Sensor No. 3 BK Headliner-Rear Body 28
K138 Relay (Relay Block) Under Driver Seat N/S
Kick Down Switch BK Instrument Panel N/S
Lamp Relay-Left (Relay Under Driver Seat N/S
Block)
Lamp Relay-Right (Relay Under Driver Seat N/S
Block)
License Plate Lamp No. 1 On Rear Of Vehicle N/S
License Plate Lamp No. 2 On Rear Of Vehicle N/S
Locker Switch No. 1 Under Body-Front N/S
Locker Switch No. 2 Under Body-Rear 29
Low Fuel Pressure Sensor BK Engine Compartment 8,10
Map/Reading Lamp Switch Instrument Panel N/S
Marker Lamp Connector NS
Marker Lamp No.1-Left Front Front Of Vehicle-Left Side N/S
Marker Lamp No.1-Right Front Of Vehicle-Left Side N/S
Front
Marker Lamp No.2-Left Front NS
Marker Lamp No.2-Right NS
Front
Marker Lamp-Left Center Front Of Vehicle-Center Left Side N/S
Marker Lamp-Left Rear Rear Of Vehicle-Left Side N/S
Marker Lamp-Right Center Front Of Vehicle-Center Right Side N/S
Marker Lamp-Right Rear Rear Of Vehicle -Right Side N/S
Mass Air Flow Sensor BK Engine Compartment 7
Master Door Lock Switch Center Of Instrument Panel N/S
Metering Pump Instrument Panel N/S
8W - 91 - 8 8W-91 CONNECTOR/GROUND/SPLICE LOCATION VA
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

CONNECTOR NAME/ COLOR LOCATION FIG.


NUMBER
Microphone Connector Instrument Panel N/S
Multi-Function Switch Steering Wheel 14
Optional Equipment Relay Under Driver Seat N/S
(Relay Block)
Oxygen Sensor (OBD) NS
Panic Alarm Switch Instrument Panel N/S
Parking Brake Switch Under Instrument Panel 28
Power Mirror Motor-Driver In Driver Door N/S
Power Mirror Motor- BK In Passenger Door N/S
Passenger
Power Mirror Switch NS
Power Window Motor-Driver NS
Power Window Motor- NS
Passenger
Power Window Switch-Driver NS
Power Window Switch-Master NS
Power Window Switch- NS
Passenger
Radio Antenna Behind Radio N/S
Radio C1 BK Behind Radio N/S
Radio C2 Behind Radio N/S
Radio/Cellular Antenna Behind Radio N/S
Reading Lamp Connector Instrument Panel N/S
Recirculated Air Solenoid Underhood Right (To The 6
Valve Instrument Panel)
Refrigerant Pressure Sensor Engine Compartment-Left Front 4,6
Remote Keyless Entry NS
Antenna
Relay Block Under Driver Seat 22
Roof Fan Motor In Headliner N/S
Roff Fan Switch NS
Seat Belt Switch Driver Seat Belt Lock N/S
Seat Belt Tensioner-Driver YL Driver Seat-Back 20
Seat Belt Tensioner- YL Passenger Seat-Back 20
Passenger
Security System Module C1 BR Instrument Panel N/S
Security System Module C2 GR Instrument Panel N/S
Sentry Key Remote Entry Instrument Panel N/S
Module (SKREEM)
Shifter Assembly BK Center Console 15
Siren BK Engine Compartment-Left 1
SKREEM Transponder NS
VA 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 9
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

CONNECTOR NAME/ COLOR LOCATION FIG.


NUMBER
Speaker-Left Front Door Engine Compartment-Left N/S
Assembly C1
Speaker-Left Front Door In Left Front Door N/S
Assembly C2
Speaker-Left Rear Rear Of Vehicle On Left Side N/S
Speaker-Right Front Door In Right Front Door N/S
Speaker-Right Rear Rear Of Vehicle On Right Side N/S
Speed Control Switch NS
Speed Control Switch Steering Wheel Controls 12
Starter Motor Relay In Fuse/Relay Block N/S
(Fuse/Relay Block)
Tail Lamp Assembly-Left BK Rear Of Vehicle On Left Side N/S
Tail Lamp Assembly-Right BK Rear Of Vehicle On Right Side N/S
TCS Switch (ASR) BK Center Of Instrument Panel N/S
Temperature Switch Instrument Panel N/S
Time Delay Relay Under Driver Seat N/S
Towing/Intrusion Sensor Instrument Panel N/S
ON/OFF Switch
Trailer Tow Connector Under Rear Of Vehicle N/S
Trailer Tow Control Module BK Rear Of Vehicle N/S
C1
Trailer Tow Control Module BK Rear Of Vehicle N/S
C2
Transmission Control Module BK Engine Compartment N/S
C1
Transmission Control Module BK Engine Compartment N/S
C2
Transmission Relay (Relay In Fuse Block No.1 N/S
Block)
Transmission Solenoid BK Transmission 11
Assembly
Turn Signal Lamp No.1-Left BK Front Of Vehicle On Left Side N/S
Front
Turn Signal Lamp No.1-Right BK Front Of Vehicle On Right Side N/S
Front
Turn Signal Lamp No.2-Left Front Of Vehicle On The Left Side N/S
Front
Turn Signal Lamp No.2-Right Front Of Vehicle On The Right N/S
Front Side
Turn Signal Relay (Fuse In Fuse Block No.1 N/S
Block No.1)
Turn Signal/Anti-Theft Alarm Under Driver Seat N/S
Relay-Left (Relay Block)
Turn Signal/Anti-Theft Alarm Under Driver Seat N/S
Relay-Right (Relay Block)
8W - 91 - 10 8W-91 CONNECTOR/GROUND/SPLICE LOCATION VA
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

CONNECTOR NAME/ COLOR LOCATION FIG.


NUMBER
Warm Air Auxiliary Heater Instrument Panel 19
Assembly C1
Warm Air Auxiliary Heater Instrument Panel 19
Assembly C2
Washer Pump Motor-Front Engine Compartment N/S
Water Cycle Valve Underhood (To The Instrument 6
Panel)
Water In Fuel Sensor Engine Compartment 10
Wheel Speed Sensor-Left Left Front Wheel 2
Front
Wheel Speed Sensor-Left Left Rear Wheel 2
Rear
Wheel Speed Sensor-Right Right Front Wheel N/S
Front
Wheel Speed Sensor-Right Right Rear Wheel N/S
Rear
Window Defogger Module - BN Rear Of Vehicle N/S
Rear
Window Defogger Relay-Left Under Driver Seat N/S
Rear (Relay Block)
Window Defogger Relay- Under Driver Seat N/S
Right Rear (Relay Block)
Window Defogger Switch - BK Instrument Panel N/S
Rear
Window Defogger-Left Rear On Left Rear Window N/S
Window Defogger-Right Rear On Right Rear Window N/S
Wiper Motor-Front BK Underhood (To The Window) 4
Wiper On/Off Relay (Fuse In Fuse Block No.1 N/S
Block No. 1)
Wiper/Turn Signal/Engine In Fuse Block No.1 N/S
Start Control Module (In Fuse
Block 1)
VA 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 11
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

GROUNDS

GROUND NUMBER LOCATION FIG.


G100 Underhood-Left Front 30
G101 Underhood-Right Front 30
G102 Underhood-Right Front 30
G200 Engine Compartment-Left 4,6
G201 Under Driver Seat 30
G202 Under Driver Seat 22,23
G203 Dash 14
G300 Right Rear-Body 30
G301 Right Rear-Body Top 30
G302 Engine Compartment-Left Front 30

SPLICES

SPLICE LOCATION FIG.


NUMBER
S100 Under Drivers Seat 1423
S101 Under Drivers Seat 14
S102 Under Drivers Seat 14
S103 Engine Compartment-Left 14
S104 Near Headlamp Assembly-Left N/S
S105 Engine Compartment-Left 3
S175 Engine Compartment-Left 14
S176 Engine Compartment-Left 14
S177 Engine Compartment-Left 14
S178 Engine Compartment-Left 14
S200 Engine Compartment-Left 51
S201 Instrument Panel 15
S202 Instrument Panel 15
S203 Under Drivers Seat 14
S204 Near Brake Lamp Switch N/S
S205 Under Drivers Seat 14
S206 Near Optional Equipment Relay 14
S207 Near Time Delay Relay 14
S208 Near Time Delay Relay 14
S210 Near Radio 15
S211 Near Heater Timer-Auxiliary 15
S212 Near Security System Module 28
S213 Near Security System Module 2814
S214 Near Security System Module 14
S215 Instrument Panel 22
S216 Instrument Panel 14
8W - 91 - 12 8W-91 CONNECTOR/GROUND/SPLICE LOCATION VA
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

SPLICE LOCATION FIG.


NUMBER
S217 Near Engine Control Module 14
S218 Instrument Panel 15
S219 Under Drivers Seat 14
S220 Near Central Timer Module 14
S221 Near Data Link Connector 14
S222 Near Security System Module 14
S223 Instrument Panel 14
S224 Instrument Panel 22
S225 Instrument Panel 14
S226 Near Turn Signal/Anti-Theft Alarm Relay-Left 14
S227 Near Sentry Key Remote Entry Module 14
S228 Instrument Panel N/S
S229 Near C202 5
S250 Near Turn Signal/Anti-Theft Alarm Relay-Left 14
S251 Near Trailer Tow Control Module 5
S252 Near Trailer Tow Control Module 1514
S253 Instrument Panel 1515
S254 Near Interior Lamp No.5 5
S255 Near Control Timer Module N/S
S256 Near A/C Roof-Switch 1514
S257 Near Data Link Connector 14
S258 Near Transmission Control Module 14
S259 Under Drivers Seat 1423
S260 Under Drivers Seat 14
S261 Near Data Link Connector 14
S262 Under Drivers Seat 14
S299 Instrument Panel N/S
S300 Near Heated Seat Switch-Driver 15
S301 Near Heated Seat Switch-Passenger 15
S302 Under Drivers Seat 14
S303 Near Power Window Switch-Driver 15
S304 Near Power Window Motor-Driver 15
S305 Near Power Window Motor-Driver 15
S306 Near Locker Switch No.2 14
S307 Near Fuse/Relay Block 14
S308 Near Interior Lamp No.3 28
S309 Near Interior Lamp-Right 28
S310 Near Fuse Block No.2 1514
S311 Under Drivers Seat 1423
S312 Near Wheel Speed Sensor-Left Rear 27
S313 Near Wheel Speed Sensor-Left Rear 27
VA 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 13
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

SPLICE LOCATION FIG.


NUMBER
S314 Near Wheel Speed Sensor-Right Rear 27
S315 Near Wheel Speed Sensor-Right Rear 27
S316 Near Headlamp Assembly-Left 14
S317 Engine Compartment 14
S318 Near Marker Lamp-Left Rear 3
S319 Near Tail Lamp Assembly-Left 3
S320 Under Body-Rear Center 328
S321 Near Power Window Switch-Passenger N/S
S322 Instrument Panel 14
S323 Near Brake Wear Sensor-Left Rear 27
S324 Near Interior Lamp No.3 N/S
S325 Near Map/Reading Lamp Switch 15
S326 Top Body- Front Center 2324
S327 Near Security System Module 14
S328 Near Central Timer Module 14
S329 Near Central Timer Module 14
S330 Near Security System Module 14
S331 Near Security System Module 14
S332 Near Brake Wear Sensor-Left Rear 27
S333 14
S350 Near Trailer Tow Connector 14
S351 Near Trailer Tow Control Module 14
S352 Near Trailer Tow Control Module 14
S353 Near Dome Lamp 15
S354 Body-Upper Right Center 2824
S355 Near Window Defogger Module-Rear N/S
S356 Near Headlamp Assembly-Left N/S
S356 Near Central Timer Module 14
S357 Near Central Timer Module N/S
S358 Near Trailer Tow Control Module 14
S359 Near Interior Light Switch-Passenger 5
S360 Near Interior Light Switch-Rear 5
S361 Near Time Delay Relay 14
S362 Near Circulation Pump Diode 14
S363 Near Heated Seat Module-Passenger 27
S364 Near CTEL Connector 15
S365 Near A/C Fan Switch 15
S366 Near Heated Seat Module-Driver 14
8W - 91 - 14 8W-91 CONNECTOR/GROUND/SPLICE LOCATION VA
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

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

8W-97 POWER DISTRIBUTION

TABLE OF CONTENTS
page page

POWER DISTRIBUTION FUSE BLOCK #2


DESCRIPTION . . . . . . . . . .................1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . ...3
OPERATION . . . . . . . . . . . .................1 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . ...3
CIGAR LIGHTER OUTLET POWER DISTRIBUTION CENTER
DESCRIPTION . . . . . . . . . .............. ...1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . ...3
OPERATION . . . . . . . . . . . .............. ...2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . ...3
DIAGNOSIS AND TESTING - CIGAR LIGHTER POWER OUTLET
OUTLET ............ .............. ...2 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . ...3
REMOVAL ............ .............. ...2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . ...4
CIRCUIT BREAKER DIAGNOSIS AND TESTING - POWER OUTLET .4
DESCRIPTION . . . . . . . . . .................2 REMOVAL .......................... ...4
OPERATION . . . . . . . . . . . .................2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . ...4
DIAGNOSIS AND TESTING - CIRCUIT RELAY
BREAKER . . . . . . . . . . . .................2 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . .4
FUSE BLOCK #1 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . .2 DIAGNOSIS AND TESTING - RELAY ...... . . .5
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 REMOVAL .......................... . . .5
REMOVAL ............ . . . . . . . . . . . . . . . . .3 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . .5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . .3

POWER DISTRIBUTION OPERATION


The power distribution system for this vehicle is
DESCRIPTION designed to provide safe, reliable, and centralized dis-
This section describes the power distribution com- tribution points for the electrical current required to
ponents used on this model as well as the methods in operate all of the standard and optional factory-in-
which battery voltage and charging system voltage is stalled electrical and powertrain, chassis, safety,
distributed throughout the vehicle. The power distri- security and convenience systems. At the same time,
bution system for this vehicle consists of the follow- the power distribution system was designed to pro-
ing major components which are covered in further vide easy access to these electrical distribution points
detail later in this section: for the vehicle technician to use when conducting
• Fuseblock #1 diagnosis and repair of faulty circuits. The power dis-
• Fuseblock #2 tribution system can also prove useful for the addi-
• Power Distribution Center (PDC) tion of electrical circuits that may be required to
The power distribution system also incorporates operate accessories that the vehicle owner may
various types of circuit control and protection fea- choose to have installed in the aftermarket.
tures, including:
• Automatic resetting circuit breakers
• Blade-type fuses
CIGAR LIGHTER OUTLET
• Cartridge fuses
• Relays DESCRIPTION
Following are general descriptions and theory of The cigar lighter outlet is installed in the instru-
operation for the major components in the power dis- ment panel, near the center of the instrument panel.
tribution system. Refer to Wiring for the location of The cigar lighter outlet is secured by a snap fit
complete circuit diagrams for the various power dis- within the instrument panel.
tribution system components. The cigar lighter knob/heating element, and the
cigar lighter outlet are available for service. These
components cannot be repaired and, if faulty or dam-
aged, they must be replaced.
8W - 97 - 2 8W-97 POWER DISTRIBUTION VA
CIGAR LIGHTER OUTLET (Continued)

OPERATION The circuit breaker cannot be repaired and, if


The cigar lighter consists of two major components: faulty or damaged, it must be replaced.
a knob and heating element unit, and the cigar
lighter base or receptacle shell. The receptacle shell OPERATION
is connected to ground, and an insulated contact in The circuit breaker contains a bi-metal strip sand-
the bottom of the shell is connected to battery cur- wiched between two contacts forming the connection
rent. The cigar lighter receives battery voltage from a in the circuit. An overload condition causes the
fuse in the fuseblock only when the ignition switch is bi-metal strip to heat and bend to the open position,
in the Accessory or On positions. disconnecting current flow to the circuit. Then as the
The knob and heating element are encased within system overload or short circuit is removed, the
a spring-loaded housing, which also features a sliding bi-metal strip cools, re-establishing contact to allow
protective heat shield. When the heating element is current flow to the circuit.
inserted in the receptacle shell, the heating element
resistor coil is grounded through its housing to the DIAGNOSIS AND TESTING - CIRCUIT BREAKER
receptacle shell. If the cigar lighter knob is pushed For complete circuit descriptions and diagrams,
inward, the heat shield slides up toward the knob refer to Wiring.
exposing the heating element. (1) Locate the correct circuit breaker in the fuse-
Two small spring-clip retainers are located on block. Pull out the circuit breaker slightly, but be cer-
either side of the insulated contact inside the bottom tain that the circuit breaker terminals still contact
of the receptacle shell. These clips engage and hold the terminals in the fuseblock cavities.
the heating element against the insulated contact (2) Connect the negative lead of a 12-volt DC volt-
long enough for the resistor coil to heat up and glow. meter to a good ground.
When the resistor coil becomes sufficiently heated, (3) With the voltmeter positive lead, check both
excess heat radiates from the heating element caus- terminals of the circuit breaker for battery voltage.
ing the spring-clips to expand. Once the spring-clips If only one terminal has battery voltage, the circuit
expand far enough to release the heating element, breaker is faulty and must be replaced. If neither ter-
the spring-loaded housing forces the knob and heat- minal has battery voltage, repair the open circuit
ing element to pop back outward to their relaxed from the Power Distribution Center as required.
position. When the cigar lighter knob and element
are pulled out of the receptacle shell, the protective
heat shield slides downward on the housing so that FUSE BLOCK #1
the heating element is recessed and shielded around
its circumference for safety. DESCRIPTION
An electrical fuse block is concealed under the
DIAGNOSIS AND TESTING - CIGAR LIGHTER driver side steering column. The fuse block serves to
OUTLET distribute electrical current to many of the electrical
For cigar lighter outlet diagnosis and testing pro- systems in the vehicle. The fuse block contains blade-
cedures (Refer to 8 - ELECTRICAL/POWER DISTRI- type mini fuses, relays and micro processors that
BUTION/POWER OUTLET - DIAGNOSIS AND enable automatic control of some of the power distri-
TESTING) bution circuits throughout the vehicle.
The molded plastic fuse block housing has an inte-
gral mounting bracket that is secured with screws to
REMOVAL
the steering column. A finger recess is molded into
For cigar lighter outlet removal procedure (Refer to
the cover for easy removal. A fuse layout map is
8 - ELECTRICAL/POWER DISTRIBUTION/POWER
molded onto the back side of the cover to ensure
OUTLET - REMOVAL).
proper fuse identification.
The fuse block cannot be repaired, if the fuse block
CIRCUIT BREAKER is faulty or damaged or if any internal circuit is
faulty or damaged, the entire fuse block must be
replaced.
DESCRIPTION
Automatic resetting circuit breakers are used to
protect the power window voltage supply circuits.
OPERATION
All of the circuits entering and leaving the fuse
These circuit breakers can protect the systems from a
block do so through the instrument panel wire har-
short circuit, or from an overload condition caused by
ness. Internal connection of all of the fuse block cir-
an obstructed or stuck power window regulator or
cuits is accomplished by an intricate combination of
switch.
VA 8W-97 POWER DISTRIBUTION 8W - 97 - 3
FUSE BLOCK #1 (Continued)
hard wiring and bus bars. Internal relays and micro OPERATION
processors allow the vehicle electronics to control All of the circuits entering and leaving the fuse
some of the power distribution circuits throughout block do so through the body wire harness. Internal
the vehicle. Refer to the Wiring section for complete connection of all of the fuse block circuits is accom-
circuit diagrams. plished by an intricate combination of hard wiring
and bus bars.
REMOVAL
(1) Disconnect and isolate the negative battery
cable. POWER DISTRIBUTION
(2) Remove fuse block cover by rotating locking CENTER
screw 90°.
(3) Remove the steering column cover. Refer to the
Body section for the procedure.
DESCRIPTION
All of the electrical current distributed throughout
(4) Unscrew fuse block connections and disconnect
this vehicle is directed through the Power Distribu-
all electrical connectors from the fuse block.
tion Center (PDC). The molded plastic PDC housing
(5) Remove the fuse block from the steering col-
is located in the left front corner of the engine com-
umn.
partment, on the battery positive cable. The PDC
housing has a molded plastic cover that slides over
INSTALLATION
the PDC housing. The PDC cover is easily opened or
(1) Position the fuse block in the steering column.
removed for service access.
(2) Install fuse block connections and connect all
The PDC unit cannot be repaired and is only ser-
electrical connectors on the fuse block.
viced as a unit with the headlamp and dash wire
(3) Install the steering column cover. Refer to the
harness. If the internal circuits or the PDC housing
Body section for the procedure.
are faulty or damaged, the headlamp and dash wire
(4) Install fuse block cover by rotating locking
harness unit must be replaced.
screw 90°.
(5) Connect the negative battery cable.
(6) Set time and radio stations.
OPERATION
All of the current from the battery and the gener-
ator output enters the PDC through the positive bat-
FUSE BLOCK #2 tery cable. The PDC cover is removed to access the
battery and generator output connection B(+) termi-
DESCRIPTION nal studs. Internal connection of all of the PDC cir-
cuits is accomplished by an intricate combination of
An electrical fuse block is concealed under the
driver side front seat. The fuse block serves to dis- hard wiring and bus bars. Refer to Wiring Diagrams
for the location of complete PDC circuit diagrams.
tribute electrical current to many of the electrical
systems in the vehicle. The fuse block houses blade-
type mini fuses, blade-type automatic resetting cir- POWER OUTLET
cuit breakers and International Standards
Organization relays. Additional provisions are avail-
able in the fuse block for additional fuses and ISO
DESCRIPTION
The power outlet is installed in the instrument
relays.
panel accessory switch plate, which is located near
The molded plastic fuse block housing has an inte-
the center of the instrument panel. The power outlet
gral mounting bracket that is secured with screws to
base is secured by a snap fit within the instrument
the seat base. The driver side seat base also has a
panel. A plastic protective cap snaps over the power
snap-fit fuse access panel that can be removed for
outlet base when the power outlet is not being used.
service of the fuses and the relays. A finger recess is
While the power outlet is very similar to a cigar
molded into one end for easy removal. A fuse layout
lighter base unit, it does not include the two small
map is molded onto the back side of the panel to
spring-clip retainers inside the bottom of the recepta-
ensure proper fuse identification.
cle shell that are used to secure the cigar lighter
The fuse block is integral to the body wire harness.
heating element to the insulated contact.
If any internal circuit or the fuse block housing is
The power outlet receptacle unit are available for
faulty or damaged, the entire fuse block and body
service. The power outlet receptacle cannot be
wire harness unit must be replaced.
repaired and, if faulty or damaged, it must be
replaced.
8W - 97 - 4 8W-97 POWER DISTRIBUTION VA
POWER OUTLET (Continued)

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)

OPERATION (3) The relay normally open terminal (87) is con-


The ISO relay consists of an electromagnetic coil, a nected to the common feed terminal (30) in the ener-
resistor and three (two fixed and one movable) elec- gized position. This terminal supplies battery voltage
trical contacts. The movable (common feed) relay con- to the fused B(+) fuse in the fuse block that feeds the
tact is held against one of the fixed contacts accessory when the relay is energized by the ignition
(normally closed) by spring pressure. When the elec- switch. There should be continuity between the fuse
tromagnetic coil is energized, it draws the movable block cavity for relay terminal 87 and the fused B(+)
contact away from the normally closed fixed contact, fuse in the fuse block at all times. If OK, go to Step
and holds it against the other (normally open) fixed 4. If not OK, repair the open fused B(+) circuit to the
contact. fuse block fuse as required.
When the electromagnetic coil is de-energized, (4) The coil ground terminal (85) is connected to
spring pressure returns the movable contact to the the electromagnet in the relay. It receives battery
normally closed position. The resistor is connected in feed to energize the relay when the ignition switch is
parallel with the electromagnetic coil in the relay, in the Accessory or Run positions. Turn the ignition
and helps to dissipate voltage spikes that are pro- switch to the On position. Check for battery voltage
duced when the coil is de-energized. at the fused ignition switch output (acc/run) circuit
cavity for relay terminal 85 in the fuse block recep-
DIAGNOSIS AND TESTING - RELAY tacle for the relay. If OK, go to Step 5. If not OK,
(1) Remove the relay from its mounting location. repair the open fused ignition switch output (acc/run)
(2) A relay in the de-energized position should circuit to the ignition switch as required.
have continuity between terminals 87A and 30, and (5) The coil battery terminal (86) is connected to
no continuity between terminals 87 and 30. If OK, go the electromagnet in the relay. The fuse block cavity
to Step 3. If not OK, replace the faulty relay. for this terminal should have continuity to ground at
(3) Resistance between terminals 85 and 86 (elec- all times. If not OK, repair the open ground circuit to
tromagnet) should be 60.7 - 80.3 ohms. If OK, go to ground as required.
Step 4. If not OK, replace the faulty relay.
(4) Connect a battery to terminals 85 and 86. REMOVAL
There should now be continuity between terminals (1) Disconnect and isolate the negative battery
30 and 87, and no continuity between terminals 87A cable.
and 30. If OK, perform the Relay Circuit Test that (2) Remove the relay by grasping it firmly and
follows. If not OK, replace the faulty relay. pulling it straight out from its receptacle. A slight
back and fourth rocking motion may help the
DIAGNOSIS AND TESTING - RELAY CIRCUIT TEST removal process.
(1) The relay common feed terminal cavity (30) of
the fuse block is connected to battery voltage and INSTALLATION
should be hot at all times. Check for battery voltage (1) Position the relay to the proper receptacle.
at the fused B(+) circuit cavity in the fuse block (2) Align the relay terminals with the terminal
receptacle for the relay. If OK, go to Step 2. If not cavities in the receptacle.
OK, repair the fused B(+) circuit to the fuse block (3) Push firmly and evenly on the top of the relay
fuse as required. until the terminals are fully seated in the terminal
(2) The relay normally closed terminal (87A) is cavities in the receptacle.
connected to terminal 30 in the de-energized position, (4) Connect the negative battery cable.
but is not used for this application. Go to Step 3.
VA ENGINE 9-1

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

VACUUM PUMP INSTALLATION - OIL PUMP CHAIN . . . . . . . . 56


DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 48 OIL SENSOR
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 58
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 48 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
LEFT MOUNT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 58
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 INTAKE MANIFOLD
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 49 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
RIGHT MOUNT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 60
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 EXHAUST MANIFOLD
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 50 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
OIL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 61
REMOVAL - OIL SEPARATOR . . . . . . . . . . . . . . 50 TIMING CHAIN COVER
INSTALLATION - OIL SEPARATOR . . . . . . . . . . 50 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
OIL COOLER & LINES INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 63
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 TIMING CHAIN AND SPROCKETS
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 51 REMOVAL
OIL FILTER REMOVAL - TENSIONING AND SLIDE RAILS . 64
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 REMOVAL - INTERMEDIATE GEAR . . . . . . . . 64
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 51 REMOVAL - TIMING CHAIN TENSIONING
OIL JET RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 52 REMOVAL - TIMING CHAIN . . . . . . . . . . . . . . 66
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 INSTALLATION
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 52 INSTALLATION - TENSIONING AND SLIDE
OIL PAN RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 INSTALLATION - INTERMEDIATE GEAR . . . . 68
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 54 INSTALLATION - TIMING CHAIN
OIL PUMP TENSIONING RAIL . . . . . . . . . . . . . . . . . . . . 69
REMOVAL ADJUSTMENTS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 INSTALLATION - TIMING CHAIN . . . . . . . . . . 69
REMOVAL- OIL PUMP CHAIN . . . . . . . . . . . . 55 TIMING CHAIN TENSIONER
INSTALLATION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 55 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 73
VA ENGINE 9-3

ENGINE STANDARD PROCEDURE

DESCRIPTION STANDARD PROCEDURE - COMPRESSION


This 2.7 Liter five-cylinder Common Rail Diesel TESTING ENGINE
Injection (CDI) engine is an in-line overhead valve (1) Warm up engine to operating temperature
diesel engine. This engine utilizes a cast iron cylin- (approx. 80 °C, 176°F).
der block and an aluminum cylinder head. The (2) Shut off engine.
engine is turbocharged and intercooled. This engine (3) Remove engine cover (Refer to 9 - ENGINE -
also has for valve per cylinder and dual overhead REMOVAL).
camshafts (Fig. 1). (4) Remove glow plugs (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/GLOW PLUG - REMOVAL).
(5) Crank engine several times with the starter to
eliminate combustion residues in the cylinders.
(6) Insert compression tester adapter #8927 (Refer
to 9 - ENGINE - SPECIAL TOOLS) with check valve
installed into glow plug hole of cylinder to be tested.
(7) Connect compression tester hose adapter #9295
to compression gauge and test compression pressure
by cranking engine with starter for at least 8 revolu-
tions.
(8) Carry out test procedure at the remaining cyl-
inders in the same way.
(9) Compare pressure readings obtained with the
specified pressures. If the pressure reading is below
the minimum compression pressure or if the permis-
sible difference between the individual cylinders is
exceeded. Refer to cylinder leak down test.
(10) Remove compression tester and adapter from
cylinder head.
(11) Install glow plugs (Refer to 8 - ELECTRICAL/
IGNITION CONTROL/GLOW PLUG - INSTALLA-
TION).
Fig. 1 2.7L CDI ENGINE (12) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
DESCRIPTION SPECIFICATION
Engine 2.7L CDI COMPRESSION SPECIFICATIONS
Engine Description 5 Cylinder In-Line Engine
With 4-Valve Technology Maximum Compression 29-35 bar (420-507 psi)
Air Intake Turbo-Charged Engine Minimum Compression 18bar (261 psi)
with Charge Air Cooling Permissible Difference ± 3bar (± 44 psi)
Fuel Injection System 2 nd. Generation Between Cylinders
Common Rail Direct
Injection (CDI)
Fuel Diesel
Firing Order 1-2-4-5-3
Rated Output 154 HP at 3800 RPM
Torque 243 ft. lbs. at 1600-2400
RPM
Maximum Speed 4800 RPM
Compression Ratio 18:1
Bore/Stroke 3.46/3.48
Eff. Displacement 2688 cm3
9-4 ENGINE VA
ENGINE (Continued)

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.

(2) Carry out test of other cylinders in the firing


NOTE: Turn cap carefully as far as first detent, order of engine.
release pressure, then unscrew cap. CYLINDER LEAK DOWN VALUES
(2) Open cooling system cap at coolant recover
pressure container. CYLINDER LEAK DOWN
(3) Remove engine cover (Refer to 9 - ENGINE - PERMISSIBLE TOTAL ± 25%
REMOVAL). LOSS
(4) Unscrew oil filler cap. CYLINDER LEAK DOWN
(5) Remove glow plugs (Refer to 8 - ELECTRICAL/ PERMISSIBLE LOSS AT
IGNITION CONTROL/GLOW PLUG - REMOVAL). ± 10%
VALVES AND CYLINDER
HEAD
NOTE: Crank engine at crankshaft in direction of
CYLINDER LEAK DOWN
rotation of the engine (clockwise).
PERMISSIBLE LOSS AT ± 20%
(6) Position cylinder to be tested to ignition Top PISTON AND RINGS
Dead Center (DTC).

NOTE: Calibrate cylinder leak down tester and


remove check valve in screw-in fitting.
VA ENGINE 9-5
ENGINE (Continued)

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

AIR LOSS 1. Sealing 1. Remove


THROUGH AIR Surfaces Cylinder Head
INTAKE AREA for Further
Inspection
2. Intake Valves 2. Replace
and Seats Valves, Guides
or Seats

AIR LOSS Sealing Remove


THROUGH Surfaces Cylinder Head
EXHAUST for Further
Fig. 2 ENGINE COVER
Inspection
1 - ENGINE COVER
2. Exhaust 2. Replace 2 - FASTENERS
Valves and Valves, Guides
Seats or Seats REMOVAL
AIR LOSS 1. Sealing Remove Engine WARNING: NO SPARKS, OPEN FLAMES OR SMOK-
THROUGH OIL Surfaces for Further ING. RISK OF POISONING FROM INHALING AND
FILL OPENING Inspection SWALLOWING FUEL. RISK OF INJURY TO EYES
2. Pistons, 2. Replace AND SKIN FROM CONTACT WITH FUEL. POUR
Piston Rings Pistons or FUELS ONLY INTO SUITABLE AND APPROPRI-
Piston Rings ATELY MARKED CONTAINERS. WEAR PROTECTIVE
CLOTHING.
9-6 ENGINE VA
ENGINE (Continued)
WARNING: RISK OF INJURY TO SKIN AND EYES (3) Evacuate and recover air conditioning system
FROM SCALDING WITH HOT COOLANT. RISK OF (Refer to 24 - HEATING & AIR CONDITIONING/
POISONING FROM SWALLOWING COOLANT. DO PLUMBING - STANDARD PROCEDURE).
NOT OPEN COOLING SYSTEM UNLESS COOLANT (4) Remove the front grille and fascia assembly.
TEMPERATURE IS BELOW 90°C (194°F). OPEN CAP (5) Disconnect the engine wiring harness at the
SLOWLY TO RELEASE PRESSURE. STORE COOL- cabin side and carefully guide though the cowl into
ANT IN SUITABLE AND APPROPRIATELY MARKED the engine area.
CONTAINER. WEAR PROTECTIVE GLOVES, (6) Remove the turbocharger heat shield (Fig. 3).
CLOTHES, AND EYE WEAR. (7) Remove the engine cover (Fig. 3).
(8) Remove the air cleaner and hose at the turbo-
(1) Disconnect the negative battery cable. charger and air cleaner assembly.
(9) Disconnect the transmission lines at the radia-
NOTE: REPLACE THE AIR CONDITIONING DRIER tor.
WHEN EVER THE AIR CONDITIONING SYSTEM IS (10) Disconnect the upper and lower radiator
OPENED. hoses.
(11) Disconnect the A/C lines at the condenser.
(2) Drain cooling system (Refer to 7 - COOLING/
(12) Disconnect the condenser fan harness connec-
ENGINE/COOLANT - STANDARD PROCEDURE).
tor.

Fig. 3 ENGINE COVER


1 - ENGINE COVER 6 - HIGH PRESSURE FUEL PUMP
2 - FUEL RAIL 7 - VACUUM PUMP
3 - INTAKE MANIFOLD 8 - OIL LEVEL INDICATOR
4 - EGR VALVE 9 - HEAT SHIELD
5 - AIR INLET TUBE 10 - TRANSMISSION OIL LEVEL INDICATOR
VA ENGINE 9-7
ENGINE (Continued)
(13) Disconnect the power steering cooler lines at (24) Disconnect the coolant hose of heating return
the cooler. flow at the water pump.
(14) Disconnect the charge air cooler hose at the (25) Disconnect the coolant hose of the heater sup-
intake manifold (Fig. 3). ply at the coolant pipe at the side of the cylinder
(15) Remove charge air hose fasteners at the radi- head.
ator closure panel. (26) Disconnect the air inlet, CCV breather hoses
(16) Remove the fasteners retaining the radiator to and CCV heater at the turbocharger (Fig. 4).
the front crossmember. (27) Raise and support the vehicle.
(17) Remove the change air cooler, A/C conderser (28) Disconnect the front exhaust at the turbo-
and fan as an assembly. charger (Fig. 4).
(18) Disconnect the charge air hose at the intake (29) Disconnect the electrical connector at the
manifold (Fig. 3). transmission.
(19) Remove the radiator assembly. (30) Disconnect the engine valley drain hose fas-
(20) Disconnect the high pressure and return tener from the transmission (Fig. 5).
hoses at the power steering pump. (31) Remove the steering gear mounting bolts.
(21) Disconnect the fuel lines at the fuel filter. (32) Disconnect the transmission cooler lines at
(22) Disconnect the refrigerant line at the A/C transmission and oil pan.
compressor. (33) Remove the torque converter access plate.
(23) Disconnect the vacuum line for the brake (34) Remove the torque converter bolts.
booster at the vacuum pump (Fig. 3). (35) Remove the crank position sensor.

Fig. 4 TURBOCHARGER INLET


1 - CCV BREATHER 5 - MAF SENSOR
2 - OIL LEVEL INDICATOR 6 - AIR CLEANER COVER
3 - CCV HEATER 7 - TURBOCHARGER
4 - TURBOCHARGER INLET HOSE 8 - EXHAUST PIPE
9-8 ENGINE VA
ENGINE (Continued)

Fig. 5 2.7L CDI ENGINE


1 - INTAKE MANIFOLD 5 - FUEL FILTER
2 - ENGINE VALLEY DRAIN HOSE 6 - AIR CONDITIONING COMPRESSOR
3 - STARTER 7 - POWER STEERING PUMP
4 - ENGINE OIL LEVEL SENSOR 8 - EGR VALVE

(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.

(1) Align cover and install screws. tighten screws


to 11N·m (97 lbs. in.) (Fig. 2).

INSTALLATION
NOTE: Deburr and seal metal from cross plate
removal with anti corrosion material.

Fig. 6 FRONT CROSS PLATE


NOTE: Replace the air conditioning drier any time
1 - CUTTING POINT
2 - CORE SUPPORT the air conditioning system is opened to the atmo-
sphere.
NOTE: After removing the front cross plate, seal
metal with anti corrosion protection. (1) Install the engine lifting fixture, special tool #
9308 to the engine lifting eyelets.
(48) Using tin snips, remove the front cross plate (2) Attach the engine hoist.
at the cutting edges and deburr (Fig. 6). (3) Install the engine assembly into the vehicle
(49) Connect and engine hoist and carefully lift engine compartment, mating the transmission and
engine assembly from engine bay area (Fig. 7). the engine.
(4) Lower the engine assembly until the engine
brackets align with the mounts.
(5) Hand start the engine mount bolts and remove
the engine lifting devise.
(6) Tighten the engine mount bolts to 83 N·m (62
lbs.ft.).
(7) Raise and support the vehicle.
(8) Install the transmission housing to engine
bolts. Refer to (Refer to 21 - TRANSMISSION/
TRANSAXLE/AUTOMATIC - NAG1 - INSTALLA-
TION) for correct sequence and torque specification.
(9) Install the torque converter bolts. Refer to
(Refer to 21 - TRANSMISSION/TRANSAXLE/AUTO-
MATIC - NAG1 - INSTALLATION) for correct
sequence and torque specification.
(10) Install the crank sensor (Fig. 8).
(11) Install the torque converter access plate. Refer
to (Refer to 21 - TRANSMISSION/TRANSAXLE/AU-
TOMATIC - NAG1 - INSTALLATION) for correct
sequence and torque specification.
(12) Install the transmission cooler lines to trans-
mission. (Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC - NAG1 - INSTALLATION) for
Fig. 7 ENGINE HOIST CONNECTION
correct sequence and torque specification.
1 - ENGINE HOIST
2 - CENTER EYELET OF ENGINE LIFTING FIXTURE
(13) Connect the engine valley drain hose to the
3 - ENGINE LIFTING FIXTURE #9308 transmission (Fig. 5).
9 - 10 ENGINE VA
ENGINE (Continued)

Fig. 8 CRANKSHAFT POSITION SENSOR Fig. 9 FUEL FILTER


1 - ENGINE BLOCK 1 - FUEL SUPPLY FROM TANK
2 - WIRING HARNESS CONNECTOR 2 - FUEL SUPPLY TO HIGH PRESSURE PUMP
3 - CRANKSHAFT POSITION SENSOR 3 - POWER STEERING RESERVOIR
4 - STARTER SOLENOID 4 - FUEL FILTER
5 - OIL FILTER
6 - WATER IN FUEL SENSOR
(14) Install transmission electrical connector and
shifter hardware. Refer to (Refer to 21 - TRANSMIS-
(29) Install a air conditioning receiver/drier (Refer
SION/TRANSAXLE/AUTOMATIC - NAG1 - INSTAL-
to 24 - HEATING & AIR CONDITIONING/PLUMB-
LATION) for correct sequence and torque
ING/RECEIVER / DRIER - INSTALLATION) .
specification.
(30) Connect the upper and lower radiator hoses.
(15) Install the steering gear and tighten in two
(31) Connect the transmission lines at the radia-
stages. 25 N·m (18.5 lbs. ft.), then 45 N·m (33 lbs. ft.)
tor.
plus 90°.
(32) Install air cleaner housing and connect the air
(16) Install the starter.
inlet duct and air flow sensor.
(17) Connect the ground strap (left side).
(33) Connect the charge air cooler hose at intake
(18) Align and install the exhaust and bracket
manifold. (Refer to 9 - ENGINE/AIR INTAKE SYS-
(Refer to 11 - EXHAUST SYSTEM/EXHAUST PIPE -
TEM/AIR CLEANER HOUSING - INSTALLATION).
INSTALLATION).
(34) Route the engine wiring harness inside the
(19) Lower the vehicle.
vehicle and connect.
(20) Install the lower heater housing and filter.
(35) Install the turbocharger heat shield.
(21) Install the air inlet hose, CCV breather and
(36) Install the front grille and fascia assembly.
CCV heater at the turbocharger (Fig. 4).
(37) Connect the negative battery cable.
(22) Connect the coolant supply and return hoses.
(38) Check and fill engine oil (Refer to LUBRICA-
(23) Connect the brake booster vacuum hose at the
TION & MAINTENANCE/FLUID TYPES - SPECIFI-
vacuum pump.
CATIONS).
(24) Connect the fuel lines at the filter assembly
(39) Fill cooling system to proper level with the
(Fig. 9).
appropriate coolant.
(25) Connect the power steering hoses.
(40) Evacuate and recharge air conditioning.
(26) Install the radiator/charge air cooler and
(41) Check and refill all ancillary system fluid lev-
hose(s) assemblies (Refer to 7 - COOLING/ENGINE/
els.
RADIATOR - INSTALLATION).
(42) Start engine and inspect for leaks (Refer to 14
(27) Install A/C condenser and fan assemblies Con-
- FUEL SYSTEM - WARNING).
nect the fan harness connector.
(28) Connect the refrigerant lines.
VA ENGINE 9 - 11
ENGINE (Continued)

SPECIFICATIONS - TORQUE SPECIFICATIONS


2.7L DIESEL

DESCRIPTION N·m Ft. Lbs. In. Lbs.


Crankcase Ventilation
Screw-Air Charge Distribution Pipe to Air Charge Distribution 11 - 97
Panel
Cylinder Head
8m-Bolt- Cylinder Head to Timing Case Cover 20 15 -
Bolt-Front Cover to Cylinder Head 14 - 124
12m-Bolt-Cylinder Head to Crankcase (3 stages, torque, torque 60, 90°, 90° 44, 90°,90° -
angle, torque angle)
Crankcase, Timing Case Cover, End Cover
Bolt-Crankshaft Bearing Cap to Crankcase (2 stages, torque, 55, 90° 40, 90° -
torque angle)
Bolt-End Cover to Crankcase 9 - 80
Bolt-Timing Case Cover to Crankcase 20 15 -
Plug-Coolant Drain to Crankcase 30 22 -
Oil Pan
6m-Bolt-Oil Pan to Crankcase 9 - 80
8m-Bolt-Oil Pan to Crankcase 20 15 -
Bolt-Oil Pan to End Cover 9 - 80
Bolt-Oil Pan to Timing Case Cover 9 - 80
Bolt-Oil Pan to Transmission Bell Housing 40 30 -
Plug-Oil Pan to Oil Drain 47 35 -
Connecting Rod
Bolt-Connecting Rod Cap to Connecting Rod (3 stage, 1&2 5,25,90° - 44,221, 90°
torque, 1 torque angle)
Crankshaft
Bolt-Crankshaft Bearing Cap (2 stage, 1 torque, 1 torque angle 55,90° 40.5, 90° -
Flywheel, Driven Plate, Vibration Damper, Starter Ring Gear
8.8m-Bolt-Central Bolt of Vibration Damper (2 stage, 1 torque, 1 200,90° 147.5, 90° -
torque angle)
10.9m-Bolt-Central Bolt of Vibration Damper (2 stage, 1 torque, 325,90° 240, 90° -
1 torque angle)
Bolt-Stretch Shank for Flywheel or 2 Mass Flywheel to 45,90° 33, 90°
Crankshaft (2 stage, 1 torque, 1 torque angle)
Turbo Charger
Bolt-Oil Feed Line to Cylinder Head 9/22 - 80-194
Bolt-Oil Feed Line to Turbo Charger 30 22 -
Bolt-Turbo Charger Support 30 22 -
Bolt-Turbo Charger Support to Crankcase 20 - 177
Bolt-Oil Outlet Line to Turbo Charger 9 - 80
Connection-Flange of Exhaust Manifold to Turbo Charger 30 22 -
9 - 12 ENGINE VA
ENGINE (Continued)

DESCRIPTION N·m Ft. Lbs. In. Lbs.


Connection-Turbo Charger to Front Catalytic Converter 30 22 -
Charge Air Pipe/Charge Air Cooling
Bolt-Charge Air Distribution Pipe 16 - 141
Bolt-Inlet Port Shut Off Positioning Motor to Air Charge 9 - 80
Distribution Pipe
Bolt-Support to Charge Air Distribution Pipe 20 - 177
Bolt-Support to Engine Bracket 40 30 -
Clamp-Charge Air Pipes/Hoses 3 - 27
Belt Tensioning Device
Bolt-Guide Pulley to Coolant Pump 35 26 -
Bolt-Guide Pulley to Timing Case Cover 35 26 -
Bolt-V-Belt Tensioning Device to Tensioning Pulley 36 26.5 -
Bolt-V-Belt Tensioning Device to Timing Case Cover 30 22 -
Exhaust Manifold
Nut-Exhaust Manifold at Cylinder Head 30 22 -
Position Sensor
Nut/Bolt-Camshaft Position Sensor to Cylinder Head Cover 11 - 97
Nut/Bolt-Crankshaft Position Sensor to Engine Block 8 - 70
Pre-Glow System
Cylinder Head to Glow Plug 12 - 106
Starter
Bolt-Starter to Crankcase 42 31 -
Nut-Connection of Circuit 30 14 - 124
Nut-Connection of Circuit 50 6 - 53
Alternator
Bolt-Generator to Timing Case Cover 20 15 -
Bolt-Generator to Cooler Housing 6 - 53
Bolt-Cooler Housing of Generator to Crankcase 20 - 177
Nut-B+ Circuit to Generator 13-18 - 115-159
Nut-D+ Circuit to Generator 5 - 44
Nut-Collar to V-Belt Pulley 80 59 -
Oil Pump
Bolt-Oil Pump to Crankcase 18 - 133
Bolt-Oil Pipe to Crankshaft Bearing Cap 8 - 70
Oil Filter
Screw Cap to Oil Filter 25 18.5 -
Oil Cooling System
Bolt-Oil-Water Heat Exchanger to Timing Cover Case 15 - 133
Oil Level Pressure
Bolt-Dip Stick Guide Tube to Cylinder Head 14 - 123
Bolt-Oil Level Sensor to Oil Pan 14 - 123
VA ENGINE 9 - 13
ENGINE (Continued)

DESCRIPTION N·m Ft. Lbs. In. Lbs.


Coolant Pre-Heater
Coolant Pre-Heater in Engine Block 35 26 -
Engine Cooling General
Bolt-Belt Pulley to Coolant Pump 8-35 6 - 26 -
Bolt-Coolant Pump to Timing Case Cover 6m/8m 14/20 10 - 15 -
Bolt-Thremostat Housing to Cylinder Head 9 - 80
Coolant Drain Plug to Crankcase 30 22 -
Engine Suspension, Engine Mount, Engine Bracket
Bolt-Engine Bracket to Crankcase (2 stage, torque, torque
20/90° 15, 90° -
angle)
Bolt-Engine Mount to Engine Bracket 55 40.5 -
Bolt-Front Engine Mount to Front Axle Carrier 35 26 -
Bolt-Rear Engine Cross Member to Body 40 30 -
Bolt-Rear Engine Mount to Rear Engine Cross Member 35 26 -
Bolt/Nut- Rear Engine Mount to Transmission 40 26 -
Bolt-Shrowd to Engine Bracket 10 - 88.5
Nut-Front Engine Mount to Engine Bracket 65 48 -
Nut-Engine Mount to Vehicle Frame 35 26 -
Fuel Filter
Bolt-Clip to Fuel Filter 8 - 70
Bolt- Fuel Filter to Charge Air Distribution Pipe 14 - 124
Exhaust System
Bolt- Catalytic Converter Bracket to Crankcase 20 - 177
Bolt - Turbocharger Oil Supply Line at Turbocharger 25 18 -
Bolt - Turbocharger Oil Return Line at Turbocharger 10 - 89
Clamp-Connection Between Front Exhaust Pipe and Rear
55 41 -
Exhaust System
Clip-Front Catalytic Converter to Engine Mount 20 - 177
Exhaust Manifold to Cylinder Head 29 21 -
Nut-Bracket to Tail Pipe 55 40.5 -
Nut-Exhaust Bracket to Threaded Plate of Center Exhaust Pipe 20 - 177
Support-Exhaust Bracket on Transmission 20 - 177
Refrigerant Compressor
Bolt-Refrigerant Compressor to Timing Case Cover 20 - 177
Bolt-Refrigerant Compressor to Bracket 20 - 177
Bolt-Refrigerant Lines to Refrigerant Compressor 20 - 177
Timing Chain, Chain Tensioner
Bolt-Camshaft Sprocket to Exhaust Camshaft 18 - 159
Bolt-Intermediate Gear of High Pressure Pump to Cylinder Head 40 29.5 -
Timing Chain Tensioner to Timing Case Cover 80 59 -
Camshaft
Bolt-Camshaft Bearing Cap to Cylinder Head 9 - 80
Bolt-Driver to Inlet Camshaft 50 37 -
9 - 14 ENGINE VA
ENGINE (Continued)

DESCRIPTION N·m Ft. Lbs. In. Lbs.


Common Rail Diesel Injection
Bolt-Banjo Bolt of Leak Oil Line to Rail 20 - 177
Bolt-Bracket to High Pressure Pump 9 - 80
Bolt-High Pressure Pump to Cylinder Head 14 - 124
Bolt-Pre-delivery Pump to Top Cover of Cylinder Head 9 - 80
Bolt-Pressure Control Valve to Rail (2 stage, torque) 3/5 - 26/44
Bolt-Rail to Cylinder Head 14 - 124
Bolt-Shutoff Valve to Cylinder Head 8 - 70
Nut-Pressure Line to Rail/Injector (New,Reused) 22/25 16/18.5 -
Nut-Pressure Line to High Pressure Pump/Rail 22 16 -
Screw-Tensioning Claw to Injector (2 stage, 1 torque, 1 torque
7/90° - 62, 90°
angle)
Rail-Pressure Sensor to Rail 22 16 -
Pressure Pipe Connection to Injector 42 31 -
Threaded Rail to Rail 22 16 -
Fuel Cooling System
Bolt-Fuel Cooler to Charge Air Distribution Pipe 14 - 124
Heater Booster, Heater Unit
Bolt- Temperature Controlled Cut Out to Heater Booster Control
12 - 106
Module
Nut-Threaded Stud to Electronic Heater Booster 18 - 159
VA ENGINE 9 - 15
ENGINE (Continued)

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)

#8932 CRANKSHAFT LOCK #8938A EXTRACTION CLAW

#8936 FRONT CRANKSHAFT SEAL INSTALLER #8940 VIBRATION DAMPER REMOVER


VA ENGINE 9 - 17
ENGINE (Continued)

#8941 SLIDE HAMMER

#9307 VALVE SERVICE TOOLS

#8942 OIL JET INSTALLER

#8951 ASSEMBLY LINKS

#8944 REAR MAIN SEAL INSTALLER


9 - 18 ENGINE VA
ENGINE (Continued)

#9285 FUEL LINE WRENCH


# 9539 FUEL LINE PLIERS

# 9286 GLOW PLUG PLIERS

#9543 ADAPTOR

#9295 COMPRESSION HOSE ADAPTOR

#9544 VIBRATION DAMPER PULLER

#9525 TIMING CHAIN GUIDE


VA ENGINE 9 - 19

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).

Fig. 10 AIR CLEANER ELEMENT


1 - AIR CLEANER HOUSING COVER
2 - AIR FLOW SENSOR
3 - AIR CLEANER ELEMENT
4 - AIR CLEANER HOUSING
Fig. 11 AIR CLEANER HOUSING
INSTALLATION 1 - AIR FLOW SENSOR
(1) Position and seat the air cleaner element into 2 - GASKET
the lower housing (Fig. 10). 3 - AIR INTAKE HOSE
4 - AIR CLEANER HOUSING
(2) Install the housing cover and snap retainers 5 - AIR CLEANER ELEMENT
into place (Fig. 10). 6 - AIR INTAKE PRESSURE SENSOR
7 - AIR CLEANER HOUSING COVER
(3) Install air flow sensor into housing cover and
connect. (Fig. 10).
(4) Connect the air cleaner restriction sensor (Fig. INSTALLATION
10)..
NOTE: Ensure that the seal between the inner
(5) Install heat shield.
fender well and the air intake hose is correctly
installed.
AIR CLEANER HOUSING (1) Seat and retain bottom portion of the air
cleaner housing into the bushings on the inner
REMOVAL fender (Fig. 11).
(1) Disconnect the negative battery cable. (2) Install the air intake hose to the air cleaner
(2) Remove the heat shield. housing the align and install it in the inner fender
(3) Remove the air flow sensor (Refer to 14 - FUEL and wheel housing liner (Fig. 11).
SYSTEM/FUEL INJECTION/MANIFOLD AIR (3) Install air cleaner element (Fig. 11).
FLOW (MAF) SENSOR - REMOVAL).
9 - 20 ENGINE VA
AIR CLEANER HOUSING (Continued)
(4) Install and clip air cleaner top to air cleaner STANDARD PROCEDURE - MEASURE
body and connect the air intake pressure sensor (Fig.
CYLINDER HEAD SURFACE
11).
(5) Install air flow sensor (Fig. 11). NOTE: DO NOT machine the cylinder head surface.
(6) Install heat shield.
(7) Connect negative battery cable. (1) Disconnect negative battery cable.
(2) Remove cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
CYLINDER HEAD (3) Remove valves.
(4) Inspect cylinder head contact surface for flat-
DESCRIPTION ness, porous and damage.
The cylinder head is made of high temperature (5) Using a straight edge, measure cylinder head
resistant aluminum alloy and features optimized spi- and cylinder block flatness.
ral swirl intake ducts and a separate camshaft hous- (6) Measure cylinder head height at point (1) indi-
ing made of die cast aluminum. The combustion cated and retain reading (Fig. 13).
chamber features four valves per cylinder, central
injectors and glow plugs arranged slant wise. The NOTE: The camshaft housing Must Not be
intake and exhaust valves have solid valve stems and machined. Basic bore of the camshaft bearings will
conical valve springs. The cylinder head is not ser- be altered.
viceable and must be replaced should a repair
become necessary. (7) Measure cylinder head height (1) at point indi-
cated, record stock removal (Fig. 13) CYLINDER
HEAD SPECIFICATIONS.
STANDARD PROCEDURE (8) Measure valve setback at points (2) indicated
(Fig. 13) CYLINDER HEAD SPECIFICATIONS.
STANDARD PROCEDURE - CYLINDER HEAD
BOLT INSPECTION
(1) Measure cylinder head bolts between points
shown (Fig. 12).

Cylinder Head Thread 12 M


Bolts Diameter
Length When 102 mm
New
Maximum 104 mm
Length

Fig. 13 Cylinder Head Measurments


1 - CYLINDER HEAD HEIGHT
2 - VALVE SETBACK

Fig. 12 Measuring Cylinder Head Bolts


(2) If the cylinder head bolt length is greater than
the maximum allowable measurement, replace the
cylinder head bolts.
VA ENGINE 9 - 21
CYLINDER HEAD (Continued)
NOTE: If measurement is less than dimension “2” (4) Install retaining lock # 8932 for crankshaft/
no further correct valve clearance compensation is starter ring gear.
possible; replace the cylinder head.
WARNING: RISK OF INJURY TO SKIN AND EYES FROM
CYLINDER HEAD SPECIFICATIONS SCALDING COOLANT. DO NOT OPEN COOLING SYS-
TEM UNLESS TEMPERATURE IS BELOW 90°C (194°F).
Description Specification OPEN CAP SLOWLY TO RELEASE PRESSURE. STORE
COOLANT IN APPROVED CONTAINER ONLY. WEAR
Height of Cylinder Head 126.85mm to 127.15mm PROTECTIVE GLOVES, CLOTHING AND EYE WEAR.
(1), With Out Camshaft
Housing (5) Drain cooling system at radiator and crankcase
Valve Set Back (2) With Exhaust Valve: 1.0mm - (Refer to 7 - COOLING/ENGINE/COOLANT - STAN-
New Valves and New 1.4mm DARD PROCEDURE).
Valve Seat Rings (6) Loosen the lower turbo support bracket bolt.
(7) Remove the upper support bracket bolt.
Intake Valve: 1.1mm -
(8) Loosen the fasteners retaining the exhaust pipe
1.5mm
to the support bracket at the rear of the engine.
(9) Lower vehicle.
REMOVAL (10) Remove engine cover. (Refer to 9 - ENGINE
COVER- REMOVAL).
REMOVAL - CYLINDER HEAD (11) Remove camshafts (Refer to 9 - ENGINE/CYL-
(1) Disconnect negative battery cable. INDER HEAD/CAMSHAFT(S) - REMOVAL).
(2) Position piston of cylinder #1 to ignition TDC. (12) Remove the camshaft housing at the cylinder
(3) Raise and support vehicle. head (Fig. 14).

Fig. 14 CAMSHAFT HOUSING


1 - CAMSHAFT HOUSING 9 - HIGH PRESSURE PUMP INTERMEDIATE GEAR
2 - DOWEL 10 - EXHAUST MANIFOLD
3 - FUEL PIPE 11 - COOLANT PIPE
4 - O-RING 12 - TURBOCHARGER
5 - COOLANT HOSE 13 - O-RING
6 - COOLANT HOSE 14 - TURBOCHARGER OIL SUPPLY LINE
7 - BOLT 15 - BANJO BOLT
8 - BUSHING 16 - TAPPET
9 - 22 ENGINE VA
CYLINDER HEAD (Continued)
(13) Remove the high pressure pump. NOTE: Capture any fuel spillage when disconnect-
(14) Remove the front head cover plate. ing fuel lines.

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).

Fig. 15 CYLINDER HEAD


1 - CYLINDER HEAD BOLT 4 - GASKET
2 - CYLINDER HEAD 5 - BOLT TO TIMING COVER
3 - DOWEL
VA ENGINE 9 - 23
CYLINDER HEAD (Continued)

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).

WARNING: NO FIRE, OPEN FLAMES OR SMOKING.


REMOVAL - CYLINDER HEAD GUIDE RAIL
SERVICE VEHICLE IN WELL VENTILATED AREAS
(1) Disconnect negative battery cable.
AND AVOID IGNITION SOURCES. RISK OF POISON-
ING FROM INHALING AND SWALLOWING FUEL. CAUTION: Rotate engine at crankshaft only. DO
RISK OF INJURY FROM SKIN AND EYE CONTACT NOT rotate the engine with the bolt of the camshaft
WITH FUEL. POUR FUELS ONLY INTO SUITABLE sprocket. DO NOT rotate the engine back.
AND APPROPRIATELY MARKED CONTAINERS.
WEAR PROTECTIVE CLOTHING WHEN HANDLING
FUEL. NOTE: Markings on the camshaft and camshaft
bearing cap must be aligned.
(5) Remove vacuum pump (Refer to 9 - ENGINE/
ENGINE BLOCK/INTERNAL VACUUM PUMP - (2) Position piston of number 1 cylinder to ignition
REMOVAL). TDC.
(6) Remove bolts attaching front cover.

Fig. 16 CYLINDER HEAD FRONT COVER


1 - TOP GUIDE RAIL 5 - CYLINDER HEAD FRONT COVER
2 - CYLINDER HEAD COVER 6 - SEAL
3 - LOCKING PAWL 7 - TIMING CHAIN TENSIONER
4 - DOWEL PIN 8 - VACUUM PUMP
9 - 24 ENGINE VA
CYLINDER HEAD (Continued)
(3) Remove engine 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) Carefully raise locking pawl of top slide rail
and remove front cover at cylinder head (Fig. 16).
(6) Insert a locking pin through 1st camshaft bear-
ing cap into the hole in the inlet camshaft sprocket.
(7) Counter hold the camshaft with an open end
wrench to avoid damage and unbolt driver of inlet
camshaft sprocket.
(8) Remove top guide rail.

INSTALLATION Fig. 17 CYLINDER HEAD BOLT TORQUE


SEQUENCE
INSTALLATION - CYLINDER HEAD
(3) Install fuel return flow line between rail and
WARNING: (Refer to 14 - FUEL SYSTEM - WARN- high pressure pump (Fig. 14).
ING) (4) Connect the coolant hoses to the thermostat
housing (Fig. 14).
(5) Connect the coolant pipe at the cylinder head
NOTE: Thoroughly clean all mating surfaces with (Fig. 14).
appropriate solvents and blow out bolt holes, to (6) Reconnect transmission oil level indicator tube.
assure that no grease or oil is present during reas- Tighten to 14 N·m (124 lbs. in.) (Fig. 14).
sembly. If piston or connecting rods have been (7) Reconnect the turbocharger to the exhaust
replaced, measure piston protrusion. Inspect all cyl- manifold. Tighten to 30N·m (22 lbs.ft.) (Fig. 14).
inder head bolts for defects and stretching before (8) Install oil return flow line with new seals at
installation (Refer to 9 - ENGINE/CYLINDER HEAD - turbocharger. Tighten bolt of supply line to turbo-
STANDARD PROCEDURE). Inspect facing cylinder charger to 18N·m (160 lbs. in.) and bolt of supply line
head contact surface. to cylinder head to 9N·m (80 lbs. in.) (Fig. 14)
(9) Install charge air distribution pipe (Refer to 11
(1) Position the cylinder head and gasket properly - EXHAUST SYSTEM/TURBOCHARGER SYSTEM -
on engine using the dowel pins as a guide (Fig. 15). INSTALLATION).
(10) Install and properly route the engine wiring
CAUTION: The M12 cylinder head bolts must be harness, making appropriate connections.
torqued in 3 stages. (11) Install high pressure fuel pump intermediate
gear (Fig. 14).
NOTE: Add a small amount of clean engine oil to (12) Install high pressure pump (Refer to 14 -
the cylinder head bolt threads prior to installation. FUEL SYSTEM/FUEL DELIVERY/FUEL INJEC-
TION PUMP - INSTALLATION).
(2) Hand start clean head bolts and tighten per (13) Install the camshaft housing to cylinder head
the following procedure: (Fig. 14).
• Install M12 cylinder head bolts finger tight (Fig. (14) Install camshafts (Refer to 9 - ENGINE/CYL-
15). INDER HEAD/CAMSHAFT(S) - INSTALLATION).
• Torque bolts in numeric order starting with (15) Install top guide rail (Refer to 9 - ENGINE/
number 1 to 60 N·m (44 lbs.in.) (Fig. 17). VALVE TIMING/TIMING BELT/CHAIN AND
• Install M8 timing chain cover to cylinder head SPROCKETS - INSTALLATION).
bolts. Tighten to 20N·m (177 lbs.in.). (16) Install front cover at cylinder head (Refer to 9
• Tighten M12 cylinder head bolts in numeric - ENGINE/CYLINDER HEAD - INSTALLATION).
order starting with number 1 an additional 90° (Fig. (17) Install cylinder head cover (Refer to 9 -
17). ENGINE/CYLINDER HEAD/CYLINDER HEAD
• Tighten M12 cylinder head bolts in numeric COVER(S) - INSTALLATION).
order starting with number 1 an additional 90° again
(3 stages). (Fig. 17).
VA ENGINE 9 - 25
CYLINDER HEAD (Continued)
(18) Install fuel high pressure pipes and injectors
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
FUEL INJECTOR - INSTALLATION).
(19) Install timing chain tensioner with new gas-
ket. (Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT/CHAIN AND SPROCKETS - INSTALLATION)
Tighten to 80N·m (59 lbs.ft.).
(20) Remove retaining lock for crankshaft/starter
ring gear.
(21) Install air intake tube at turbocharger (Refer
to 11 - EXHAUST SYSTEM/TURBOCHARGER SYS-
TEM - INSTALLATION).
(22) Install the fasteners retaining the front
exhaust pipe to the support bracket at the read of
the engine.
(23) Install the upper support bracket fastener.
(24) Install the lower turbo support bracket bolt.
(25) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
Fig. 18 CYLINDER HEAD COVER SEALING
NOTE: DO NOT pressure test cooling system until SURFACE
engine has reached operating temperature. 1 - CYLINDER HEAD FRONT COVER
2 - SEALANT BEAD
(26) Refill cooling system with proper coolant mix-
ture to proper level (Refer to 7 - COOLING/ENGINE/ (2) Raise locking pawl of top guide rail and guide
COOLANT - STANDARD PROCEDURE). front cover onto guide pins.
(27) Connect negative battery cable. (3) Install bolts attaching front cover (Fig. 16)
Tighten bolts to 14N·m (124 lbs. in.).
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A WARNING: NO FIRE, OPEN FLAMES OR SMOKING.
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR REMOVE SOURCES OF IGNITION FROM THE AREA.
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO WEAR PROTECTIVE CLOTHING WHEN HANDLING
NOT WEAR LOOSE CLOTHES. FUEL. RISK OF POISONING FROM INHALING AND
SWALLOWING FUEL. RISK OF INJURY FROM SKIN
(28) Start engine and inspect for leaks. Care must AND EYE CONTACT WITH FUEL. POUR FUELS
be taken to observe the fuel system warning (Refer to ONLY INTO SUITABLE AND APPROPRIATELY
14 - FUEL SYSTEM - WARNING) MARKED CONTAINERS.

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.

(5) Install timing chain tensioner (Refer to 9 -


NOTE: Dowel pins are used as a guide during ENGINE/VALVE TIMING/TIMING BELT/CHAIN
assembly and must remain in the proper position to AND SPROCKETS - INSTALLATION).
assure a good sealing surface. (6) Connect negative battery cable.

(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).

INSTALLATION - CYLINDER HEAD GUIDE RAIL


(1) Carefully position the top guide rail onto the
guide pins.
(2) Counter hold the camshaft with an open end
wrench and install driver of inlet camshaft sprocket.
Tight bolt to 50N·m (37 lbs. ft.).
(3) Remove camshaft sprocket locking pin.
(4) Carefully raise locking pawl of top guide rail
and install front cover at cylinder head (Fig. 16).
(5) Install timing chain tensioner with new gasket
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT/CHAIN AND SPROCKETS - INSTALLA-
TION).
(6) Install engine cover (Refer to 9 - ENGINE/
CYLINDER HEAD/CYLINDER HEAD COVER(S) -
INSTALLATION).
(7) Reconnect negative battery cable.

WARNING: US 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.

(8) Start engine and inspect for leaks.

CAMSHAFT(S)
STANDARD PROCEDURE - CHECKING
CAMSHAFT POSITION
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE
COVER - REMOVAL).

WARNING: (Refer to 14 - FUEL SYSTEM - WARN-


ING)
Fig. 19 CHECKING CAMSHAFT POSITION
(3) Remove injectors (Refer to 14 - FUEL SYS- 1 - CAMSHAFT SPROCKET ALIGNMENT DOTS
2 - CAMSHAFT LOCK POSITION
TEM/FUEL INJECTION/FUEL INJECTOR - 3 - INTAKE CAMSHAFT SPROCKET
REMOVAL). 4 - CAMSHAFT AND BEARING CAP ALIGNMENT MARKS
(4) Clean injectors and recesses (Refer to 14 - 5 - CAMSHAFT LOCKING PIN (SPECIAL TOOL #8929)
6 - INTAKE CAMSHAFT SPROCKET
FUEL SYSTEM/FUEL INJECTION/FUEL INJEC-
TOR - STANDARD PROCEDURE).
NOTE: The two markings in the inlet camshaft
(5) Remove cylinder head cover (Refer to 9 -
sprockets must be positioned opposite and mark-
ENGINE/CYLINDER HEAD/CYLINDER HEAD
ings of camshaft and camshaft bearing cap must be
COVER(S) - REMOVAL).
aligned. If not, perform basic position of camshafts.
NOTE: Rotate engine at crankshaft only. DO NOT
(8) Remove locking pin from camshaft bearing cap
crank engine at the camshaft and DO NOT rotate
hole.
the engine backward.

(6) Position piston of cylinder #1 to ignition TDC.


VA ENGINE 9 - 27
CAMSHAFT(S) (Continued)
(9) Install cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
(10) Install injectors (Refer to 14 - FUEL SYS-
TEM/FUEL INJECTION/FUEL INJECTOR -
INSTALLATION).

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
NO WEAR LOOSE CLOTHING.

(11) Start the engine and inspect for leaks.

REMOVAL
(1) Disconnect negative battery cable.
(2) Remove engine cover. (Refer to 9 - ENGINE -
REMOVAL).

WARNING: (Refer to 14 - FUEL SYSTEM - WARN-


ING)

(3) Remove high pressure lines and injectors


(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
FUEL INJECTOR - REMOVAL).
(4) Remove cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).

NOTE: Rotate engine at the crankshaft only. DO


NOT rotate the engine at the camshaft. DO NOT
rotate the engine backward.

(5) Position piston of cylinder #1 to ignition TDC.


(6) Lock inlet camshaft (Fig. 20).
(7) Remove timing chain tensioner (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - REMOVAL). Fig. 20 CAMSHAFT ALIGNMENT
1 - EXHAUST CAMSHAFT SPROCKET AND CHAIN MARKING
NOTE: The lower portion of the cylinder head front 2 - EXHAUST CAMSHAFT SPROCKET BOLTS
cover is sealed with RTV sealant. Carefully tug front 3 - EXHAUST CAMSHAFT SPROCKET
4 - CAMSHAFT ALIGNMENT DOTS
cover after bolt removal to loosen from cylinder 5 - INTAKE CAMSHAFT LOCK POSITION
head. 6 - INTAKE CAMSHAFT SPROCKET
7 - INTAKE CAMSHAFT LOCK (SPECIAL TOOL #8929)
8 - INTAKE CAMSHAFT SPROCKET
(8) Remove cylinder head front cover (Refer to 9 -
ENGINE/CYLINDER HEAD - REMOVAL).
NOTE: Note the position of dowel pin for camshaft
(9) Remove top side rail (Refer to 9 - ENGINE/
sprocket alignment during reassembly.
CYLINDER HEAD - REMOVAL).
(12) Remove camshaft sprocket.
CAUTION: For all work in which the crankshaft
should not rotate, secure camshaft gear to timing CAUTION: Camshaft bearing caps must remain in
chain. proper order and position.
(10) Mark camshaft sprocket relative to timing
chain.
(11) Unbolt camshaft sprocket from exhaust cam-
shaft.
9 - 28 ENGINE VA
CAMSHAFT(S) (Continued)
NOTE: Slacken the bolts of the camshaft bearing
caps evenly in steps of one turn until the back
pressure is eliminated. Camshafts must not be
twisted when slackening the camshaft bearing
caps.

(13) Paint mark or scribe each camshaft bearing


cap, identifying which camshaft and which position.
(14) Remove the camshaft bearing caps at exhaust
camshaft bearing cap #1, #3,#4 and #6 in sequence.
(15) Remove the camshaft bearing caps at intake
camshaft bearing cap #1, #3,#4 and #6 in sequence.
(16) Slacken the exhaust camshaft bearing cap
bolts individually at the #2 cap then the #5 cap in
steps of one revolution until the back pressure is
removed.
(17) Slacken the intake camshaft bearing cap bolts
individually at the #2 cap then the #5 cap in steps of
one revolution until the back pressure is removed.
(18) Remove the inlet and exhaust camshafts (Fig.
21).

NOTE: Inspect camshaft for wear or damage. Also


inspect the camshaft end cover for wear or damage,
replace camshaft as necessary.

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.

CAUTION: Oil bucket tappets and camshaft bearing


points. Inspect ease of operation of bucket tappets. CAUTION: Do not rotate engine counter clockwise.

(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.

(2) Align inlet and exhaust camshafts at axial


bearing (Refer to 9 - ENGINE/CYLINDER HEAD/
CAMSHAFT(S) - STANDARD PROCEDURE).
VA ENGINE 9 - 29
CAMSHAFT(S) (Continued)
(4) Install the #2 and #5 Exhaust cam bearing
caps (Fig. 22).
(5) Install the #2 and #5 Intake cam bearing caps
(Fig. 22).

Fig. 23 CAMSHAFT BEARING TIGHTENING


SEQUENCE #2
(14) Install cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
Fig. 22 CAMSHAFT BEARING TIGHTENING COVER(S) - INSTALLATION).
SEQUENCE #1
NOTE: Refer to the appropriate injector servicing
(6) Tighten each of the #2 and #5 Intake and
procedures for cleaning of injectors and recesses.
Exhaust bearing cap bolts evenly to 9N·m (80 lbs.
in.) in steps each of 1 revolution (Fig. 22). (15) Clean and install injectors (Refer to 14 -
(7) Install the remaining Intake and Exhaust cam FUEL SYSTEM/FUEL INJECTION/FUEL INJEC-
bearing caps and tighten them evenly to 9N·m (80 TOR - STANDARD PROCEDURE), (Refer to 14 -
lbs. in.) in steps each of 1 revolution (Fig. 23). FUEL SYSTEM/FUEL INJECTION/FUEL INJEC-
TOR - INSTALLATION).
NOTE: The piston of cylinder #1 must be positioned
(16) Reconnect negative battery cable.
at ignition TDC when the inlet camshaft is locked.
WARNING: (Refer to 14 - FUEL SYSTEM - WARN-
(8) Insert locking pin through the first camshaft
ING).
bearing cap into the whole in the camshaft sprocket.

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).

Fig. 24 CYLINDER HEAD COVER


1 - ENGINE WIRING HARNESS 7 - GASKET
2 - GLOW PLUG CONNECTOR 8 - CYLINDER HEAD COVER
3 - CAMSHAFT POSITION SENSOR 9 - CRANKCASE VENT LINE
4 - OUTLET LINE 10 - GASKET
5 - INTAKE MANIFOLD 11 - FUEL INJECTOR
6 - GASKET 12 - GROUND
VA ENGINE 9 - 31
CYLINDER HEAD COVER(S) (Continued)
(9) Start engine and inspect for leaks. Care must WARNING: Valve springs and retainers must be
be take to observe the fuel system warning (Refer to kept in order of the cylinder they were removed.
14 - FUEL SYSTEM - WARNING).
NOTE: Using valve service tools #9307, screw
VALVE STEM SEALS retaining fork into threaded edge of cylinder head
and position thrust piece vertically at top of each
DESCRIPTION exhaust valve spring retainer. Use the cam bearing
The valve stem seals are made of Viton rubber. The cap threaded holes to position service tool for
seals are positioned over the valve stem and seated removal of intake valve spring retainers.
on the valve guide. For servicing of the valve seals
(12) Compress valve spring (Fig. 25).
(Refer to 9 - ENGINE/CYLINDER HEAD/VALVE
SPRINGS - REMOVAL).

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.

NOTE: Using tool, screw retaining fork into


threaded edge of cylinder head and position thrust
piece vertically at top of valve spring retainer.

(4) Using a suitable valve spring compressor, com-


press valve spring.
(5) Remove valve collets (Fig. 26).
(6) Remove top valve spring retainer and valve
spring (Fig. 26).
(7) Remove valve stem seals (Fig. 27).
(8) Repeat steps 5 through 9 for each valve as nec-
essary.
(9) Remove cylinder head from assembly board.

WARNING: Valves, springs and retainers must be


kept in order of the cylinder they were removed.
Fig. 26 VALVE ASSEMBLY (10) Remove valves.
1 - VALVE
2 - BOTTOM VALVE SPRING RETAINER
3
4
-
-
VALVE STEM SEAL
VALVE SPRING
INSTALLATION
5 - TOP VALVE SPRING RETAINER
6 - VALVE COLLATES INSTALLATION - VALVE SPRINGS
7 - CYLINDER HEAD
NOTE: Inspect all valve springs and retainers for
wear or damage. Replace as necessary. Do Not
reuse gaskets.

(1) Position piston of cylinder to be processed to


TDC by rotating the crankshaft clockwise. DO NOT
crank engine or rotate engine counter clock-
wise.
(2) Install crankshaft lock, special tool #8932.
(3) Seal injector hole with adaptor # 9534 and
retain with original tensioning claw.
(4) Connect regulated air supply to special tool #
9534 and pressurize the cylinder to 5 bar (73 psi.).
(5) Install lower valve spring retainer (Fig. 26).
(6) Install valve stem seal (Fig. 28).
(7) Install valve spring (Fig. 26).
(8) Install valve spring retainer (Fig. 26).

NOTE: Using valve service tools #9307, screw


retaining fork into threaded edge of cylinder head
and position thrust piece vertically at the top of
each exhaust valve spring retainer. Use the cam
bearing cap threaded holes to position service tool
Fig. 27 VALVE STEM SEAL for installation of intake valve spring retainers.
1 - PLIERS
2 - VALVE STEM SEAL
NOTE: Ensure that the valve keepers are seated
properly.
VA ENGINE 9 - 33
VALVE SPRINGS (Continued)
(19) Reconnect negative battery cable.
(20) Start the engine, allow to warm, turn engine
off and inspect for leaks. Care must be taken to
observe the fuel system warning (Refer to 14 - FUEL
SYSTEM - WARNING)
(21) Install engine cover (Refer to 9 - ENGINE
COVER - INSTALLATION).

INSTALLATION - VALVES
WARNING: Valves must be kept in their original
positions in cylinder head. Failure to do so will
result in engine damage.

NOTE: Inspect all valves, springs and retainers for


wear or damage. Replace as necessary.

(1) Install valves in their original position in the


cylinder head.
(2) Install lower valve spring retainer.
(3) Install valve stem seal.
Fig. 28 VALVE SEAL INSTALLATION
(4) Install valve spring.
1 - DRIFT (5) Install valve spring retainer.
2 - PROTECTIVE COVER
3 - VALVE
NOTE: Using tool, screw retaining fork into
(9) Compress valve and install valve collates (Fig. threaded edge of cylinder head and position thrust
25). piece vertically at the top of each valve spring
retainer.
CAUTION: Make sure the crankshaft lock is in posi-
tion and properly secured for each cylinder being
serviced. Failure to do so may result in damage to NOTE: Ensure that the valve keepers are seated
the vehicle or personal injury. properly.

(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

ENGINE BLOCK STANDARD PROCEDURE - MEASURING


CYLINDER BORES
STANDARD PROCEDURE NOTE: This must be done with engine completely
disassembled.
STANDARD PROCEDURE - REPLACING ENGINE
CORE AND OIL GALLERY PLUGS (1) Thoroughly clean all cylinder bores with appro-
Using a blunt tool such as a drift and a hammer, priate cleaning solvent.
strike the bottom edge of the cup plug. With the cup (2) Measure each cylinder at the three measuring
plug rotated, grasp firmly with pliers or other suit- points shown (Fig. 30).
able tool and remove plug (Fig. 29). (3) Using the three measurment point, measure
cylinder in the longitudinal and in the transverse
direction (Fig. 30).
(4) Use the measurment and table below to group
cylinder bores:

Standard size 88.0 mm


Group code letter A 88.000-88.006 mm
Group code letter X 88.006-88.012 mm
Group code letter B 88.012-88.018 mm
Wear limit in longitudinal 0.020 mm
in transverse direction
Permissible variation of 0.000-0.014 mm
cylinder shape (when
new)

Fig. 29 CORE HOLE PLUG REMOVAL CRANKSHAFT


1 - CYLINDER BLOCK
2 - REMOVE PLUG WITH PLIERS
3 - STRIKE HERE WITH HAMMER DESCRIPTION
4 - DRIFT PUNCH The engine features a forged crankshaft supported
5 - CUP PLUG
by six bearings. The bearing surfaces are induction
hardened. The connecting rods and main bearing
CAUTION: Do not drive cup plug into the casting as
journals are filleted. An optional vibration damper
restricted cooling can result and cause serious
with a second pulley is used to drive an additional
engine problems.
A/C compressor.
Thoroughly clean inside of cup plug hole in cylin-
der block or head. Be sure to remove old sealer. STANDARD PROCEDURE - MEASURE
Lightly coat inside of cup plug hole with Mopart CRANKSHAFT AND BLOCK JOURNALS
Stud and Bearing Mount. Make certain the new plug
is cleaned of all oil or grease. Using proper drive NOTE: After any bearing damage occurred, remove
plug, drive plug into hole so that the sharp edge of all debris which is present in the main oil gallery,
the plug is at least 0.5 mm (0.020 in.) inside the connecting rod bores, and in the crankshaft and oil
lead-in chamfer. galleries. Include removal of the inserting steel ball
It is not necessary to wait for curing of the sealant. of the main oil gallery before cleaning.
The cooling system can be refilled and the vehicle
placed in service immediately. (1) Remove crankshaft (Refer to 9 - ENGINE/EN-
GINE BLOCK/CRANKSHAFT - REMOVAL).
(2) Clean all engine parts thoroughly.
VA ENGINE 9 - 35
CRANKSHAFT (Continued)

Fig. 30 MEASURING CYLINDER BORES


1 - MEASURING POINT OF CYLINDER BORE 1b - BOTTOM DEAD CENTER OF PISTON
2 - MEASURING POINT OF CYLINDER BORE 1c - BOTTOM REVERSAL POINT OF OIL SCRAPER RING
3 - MEASURING POINT OF CYLINDER BORE 1A - LONGITUDINAL DIRECTION
1a - UPPER REVERSAL POINT OF #1 PISTON RING 1B - TRANSVERSE PDIRECTION

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).

CAUTION: The crankshaft bearing caps are num-


bered consecutively, beginning with the first crank-
shaft bearing cap at the front of the engine.
Attention must be paid to the way crankshaft bear-
ing caps fit.

(5) Unbolt crankshaft bearing caps (Fig. 31).


(6) Inspect crankshaft bearing caps and bolts for
wear and stretching.
(7) Remove crankshaft.

INSTALLATION
CAUTION: Oil the bearing shells before inserting
crankshaft.

CAUTION: Oil grooves in the thrust washers must


point toward the thrust collars of the crankshaft.
Fig. 31 CRANKSHAFT ASSEMBLY
1 - BEARING HALVES IN ENGINE BLOCK
CAUTION: Thrust washers in the bearing cap each 2 - THRUST WASHERS IN ENGINE BLOCK
3 - CRANKSHAFT
have two retaining lugs as a anti-twist lock. 4 - BEARING HALVES IN MAIN BEARING CAPS
5 - MAIN BEARING CAPS
6 - THRUST WASHERS IN MAIN BEARING CAPS
CAUTION: Oil thread and head contact surfaces of 7 - MAIN BEARING BOLTS
bolts that retain the crankshaft bearing caps;
tighten bolts from inside to outside, beginning at (4) Install the end cover (Refer to 9 - ENGINE/EN-
the fit bearing. Rotate crankshaft to check clear- GINE BLOCK/CRANKSHAFT OIL SEAL - REAR -
ance. INSTALLATION).
(5) Install the timing case cover (Refer to 9 -
(1) Install crankshaft. ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
CAUTION: The crankshaft bearing caps are num- (6) Install the engine (Refer to 9 - ENGINE -
bered consecutively, beginning with the first crank- INSTALLATION).
shaft bearing cap at the front of the engine. (7) Fill the crankcase with the correct engine oil,
Attention must be paid to the way the crankshaft to the proper level. Refer to the owners manual for
bearing caps fit. specifications.
(8) Fill the cooling system with the proper coolant,
(2) Install the crankshaft bearing caps. Tighten to the proper level (Refer to 7 - COOLING/ENGINE/
bolts in two stages. 55N·m (40.5 lbs. ft.), then 90°. COOLANT - STANDARD PROCEDURE).
(3) Install the pistons (Refer to 9 - ENGINE/EN- (9) Connect the negative battery cable.
GINE BLOCK/PISTON & CONNECTING ROD -
INSTALLATION).
VA ENGINE 9 - 37
CRANKSHAFT (Continued)
WARNING: USE EXTREME CAUTION WHEN THE NOTE: Inspect the oil pan gasket for damage. If the
ENGINE IS OPERATING. DO NOT STAND IN A oil pan gasket is damaged, remove the oil pan and
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR replace the oil pan gasket.
HANDS NEAR THE PULLEYS, BELTS, OR FAN. DO
NOT WEAR LOOSE CLOTHES. (4) Loosen the oil pan bolts.
(5) Remove the flywheel.
(10) Start engine and inspect for leaks. Care must
be taken to observe the fuel system warning (Refer to CAUTION: Care must be taken when removing the
14 - FUEL SYSTEM - WARNING). rear main seal and adaptor assembly. Failure to do
so will result in damage to the oil pan gasket.

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.

Fig. 32 REAR MAIN SEAL/ADAPTER


1 - FLYWHEEL 6 - CRANKSHAFT
2 - FLYWHEEL BOLTS 7 - ALIGNMENT DOWELS
3 - SPECIAL TOOL 8944 8 - REAR CRANKSHAFT SEAL ADAPTER RETAINING BOLT
4 - REAR CRANKSHAFT OIL SEAL 9 - OIL PAN TO REAR CRANKSHAFT SEAL ADAPTER
5 - REAR CRANKSHAFT SEAL ADAPTER RETAINING BOLT
9 - 38 ENGINE VA
CRANKSHAFT OIL SEAL - REAR (Continued)
(1) Position the rear main oil seal/adaptor with
assembly sleeve onto the crankshaft so that the
dowel sleeves fit into the guide holes (Fig. 32). Care
must be taken so that the oil pan gasket is not dam-
aged.
(2) Install the rear main seal/adaptor to crankcase
bolts and tighten to 9·Nm (80 lbs.in) (Fig. 32).
(3) Tighten the M6 oil pan bolts to 9N·m (80 lbs
in) and the M8 bolts to 20 N·m (15 lbs ft).
(4) Install the fly wheel and tighten bolts in two
stages (Fig. 32). 45N·m (33 lbs. ft.) then 90°.
(5) Install the oil pan drain plug and tighten to
25N·m (18 lbs ft).
(6) Lower the vehicle.
(7) Fill the crankcase with the correct engine oil,
to the proper level. Refer to owners manual for spec-
ifications.
(8) Connect the negative battery cable.

WARNING: USE EXTREME CAUTION WHEN THE


ENGINE IS OPERATING. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHES.

(9) Start the engine and inspect for leaks.


Fig. 33 FRONT SEAL REMOVAL/INSTALLATION
CRANKSHAFT OIL SEAL - 1 - FRONT CRANKSHAFT OIL SEAL
2 - SEAL INSTALLER SPECIAL TOOL #8936
FRONT 3 - WASHER
4 - RETAINING BOLT

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.

(7) Start the engine and inspect for leaks.

FLYWHEEL
REMOVAL
(1) Remove transmission (Refer to 21 - TRANS-
MISSION/TRANSAXLE/AUTOMATIC - W5J400 -
REMOVAL).

NOTE: M6x90 bolts must be used with retaining


lock to prevent damage to rear end cover.

(2) Install retaining lock for crankshaft/starter


ring gear.

NOTE: Flywheel does not need balancing or should


it be interchanged. Fig. 34 FLYWHEEL ASSEMBLY
1 - SPECIAL TOOL #8932 CRANKSHAFT LOCK
(3) Remove flywheel with inner washer (Fig. 34). 2 - RETAINING BOLTS
3 - ALIGNMENT PIN
4 - WASHER
5 - FLYWHEEL
INSTALLATION 6 - FLYWHEEL BOLT

INSTALLATION (4) Connect negative battery cable.

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).

Fig. 35 CRANKSHAFT LOCK #8932


1 - RETAINING BOLTS 3 - CRANKSHAFT LOCK #8932
2 - INSPECTION COVER 4 - RETAINING BOLTS
VA ENGINE 9 - 41

PISTON & CONNECTING ROD STANDARD PROCEDURE

DESCRIPTION STANDARD PROCEDURE - CHECKING AND


REPAIRING CONNECTING RODS
NOTE: No over sized pistons are available.
NOTE: Connecting rods with blue discoloration,
The pistons are of a free floating design and made cross scores or notches must be replaced. Com-
of optimized aluminum alloy with a graphite coated pensate for different weights by milling off the bal-
bearing surface. The crown of the piston has been ancing weight.
designed to accommodate higher injection pressures.
Oil jets in the engine block lubricate and cool the pis- (1) Inspect connecting rod for discoloring, cross
ton and pin assembly. The connecting rods have a scores and notches.
pressed in place wrist pin bushing featuring specially
adjusted lubrication grooves which are lubricated by NOTE: Connecting rod and bearing cap are marked
the oil jets (Fig. 36). The steel connecting rods fea- in sets and attached with two sleeves.
ture a small end of trapezoidal shape and a cracked
large end. (2) Bolt connecting rod bearing cap to connecting
rod. Tighten connecting rod bearing caps to initial
specification (Refer to 9 - ENGINE/ENGINE BLOCK/
PISTON & CONNECTING ROD - INSTALLATION).
(3) Using a dial indicator, measure connecting rod
bearing basic bore, repair as necessary (Fig. 37).

NOTE: If excessive wear is present, press in new


connecting rod bushings.

(4) Measure connecting rod bushing inner diame-


ter (Fig. 37).

Fig. 36 PISTON AND CONNECTING ROD ASSEMBLY


1 - PISTON PIN
2 - PISTON
3 - SNAP RING
4 - CONNECTING ROD ALIGNMENT NUMBERS
5 - CONNECTING ROD BOLT
6 - CONNECTING ROD BEARING
7 - CONNECTING ROD
8 - SNAP RING
Fig. 37 MEASURING CONNECTING RODS
9 - 42 ENGINE VA
PISTON & CONNECTING ROD (Continued)
(5) Inspect wristpin bushing. STANDARD PROCEDURE - MEASURING
(6) Measure piston pin end play in connecting rod
PISTON PROTRUSION
bushing.
After replacing the pistons/connecting rods or
(7) Measure peak to valley height of connecting
machining the engine block contact surface, it is then
rod bushing on inside.
necessary to measure the piston protrusion.
Measure protrusion between piston crown and cyl-
CONNECTING ROD SPECIFICATIONS
inder head contact surface without the head gasket
installed. The measurment must be carried out in
Distance between middle the direction of the piston pin in order to eliminate
connecting rod bore to 148.970 mm to 149.030 piston rock.
connecting rod bushing mm (1) Measure piston protrusion at the two measur-
bore ing points (arrows) (Fig. 38).
Width of connecting rod Piston protrusion with new crankcase should be
bearing bore at 0.38 - 0.62 mm.
21.940 mm to 22 mm
connecting rod bushing
bore
Connecting rod bearing 51.600 mm to 51.614
shell basic bore mm
Allowable out-of-
roundness and taper of .020 mm
basic bore
Allowable twist of
connecting rod bearing
bore to connecting rod .100 mm
bushing bore over a
length of 100 mm
Allowable variation of
axial parallelism of
connecting rod bearing
.045 mm
bore to connecting rod
bushing bore over a
length of 100 mm
Allowable difference in
weight of complete
2g
connecting rod of an
engine
Connecting rod inner
30.018 to 30.024 mm
bushing
Connecting rod outer 32.575 mm to 32.600
bushing mm
Connecting rod basic 32.500 mm to 32.525
bore mm
Piston pin play in
.018 mm to .024 mm Fig. 38 MEASURING PISTON PROTRUSION
connecting rod
1 - PISTON PROTRUSION MEASUREMENT
Peak-to-Valley height
(Rz) of connecting rod 5
bushing on inside
REMOVAL
(1) Disconnect the negative battery cable.
Connecting rod bolt (2) Remove the engine (Refer to 9 - ENGINE -
M8 x 1
thread REMOVAL).
(3) Remove the cylinder head (Refer to 9 -
ENGINE/CYLINDER HEAD - REMOVAL).
VA ENGINE 9 - 43
PISTON & CONNECTING ROD (Continued)
(4) Remove the oil pan (Refer to 9 - ENGINE/LU- The carbon deposits on the pistons must be
BRICATION/OIL PAN - REMOVAL). removed.
(5) Push back on the chain tensioner and remove
the oil pump chain from the oil pump. NOTE: If the arrows indicating the driving direction
(6) Remove the oil pump. on the piston are no longer visible, they must be
marked again.
NOTE: Mark the connecting rod and connecting rod
bearing cap to each other at the inlet side. (9) Remove the connecting rod together with the
piston through the top of the engine.
(7) Remove the connecting rod bearing cap.
NOTE: DO NOT mix up the top and bottom connect-
NOTE: Do Not mix up the top and bottom connect- ing rod bearing shells.
ing rod bearing shells.
(10) Mark the connecting rod bearing shell and
(8) Mark the connecting rod bearing shell and the connecting rod to each other.
connecting rod bearing cap to each other.
CAUTION: Care must be taken not to damage the
NOTE: If the pistons are used, the direction of piston.
travel arrows and the marking of the pistons may
no longer be visible because of carbon deposits. (11) Remove the piston pin circle clip. (Fig. 39).

Fig. 39 PISTON AND CONNECTING ROD ASSEMBLY


1 - PISTON PIN CIRCLIP 5 - CONNECTING ROD CAP
2 - PISTON PIN 6 - CONNECTING ROD BOLTS
3 - PISTON ASSEMBLY 7 - ENGINE BLOCK
4 - CONNECTING ROD AND CAP ALIGNMENT MARKS
9 - 44 ENGINE VA
PISTON & CONNECTING ROD (Continued)
(12) Press the piston pin out of the piston and con- CAUTION: Offset the piston ring gaps by 120°.
necting rod bushing. (Fig. 39).
(13) Inspect the connecting rod for wear and dam- (7) Position a ring compressor over piston and
age. rings. Tighten ring compressor (Fig. 41).Ensure that
ring position does not change during this oper-
INSTALLATION ation.
(1) Assign piston to the cylinder bore.
(2) Using the appropriate clean engine oil, oil pis- CAUTION: Rotate the crankshaft sufficiently so that
ton pin and connecting rod bushing. the connecting rod does not touch the connecting
rod journal when the piston is pushed onto the cyl-
CAUTION: Assemble the piston and connecting rod inder bore.
so that the arrow is pointing in the direction of
travel (in the opposite direction of power flow). The (8) Install piston with arrow pointing in the direc-
marking on the connecting rod is pointing toward tion of travel (in the opposite direction to power flow)
the inlet side. (the marking on the connecting rod should be point-
ing toward the inlet side). (Fig. 41).
(3) Assemble piston and connecting rod (Fig. 40). (9) Clean and inspect the connecting rod bolts.
(4) Insert piston pin by hand (Fig. 40).
CAUTION: Assure that the correct top and bottom
CAUTION: Care must be taken not to damage the connecting rod bearings shells are used in accor-
piston. dance with the markings.

(5) Insert circle clip of piston pin into groove on


piston (Fig. 40). CAUTION: The anti-twist locks of the connecting
rod bearing shells must be located in the slots of
the connecting rod bearing caps.

(10) Insert connecting rod bearing shell into con-


necting rod bearing cap.

CAUTION: The markings on the connecting rod and


connecting rod cap must be lined up.

(11) Install connecting rod bearing cap. Tighten


bolts in 3 stages, 5N·m (44 lbs in), 25N·m (221 lbs
in), 90°.
(12) Rotate crankshaft fully and check the clear-
ance.
(13) Install oil pump (Refer to 9 - ENGINE/LU-
BRICATION/OIL PUMP - INSTALLATION).
(14) Install engine oil pan and oil pan drain plug
(Refer to 9 - ENGINE/LUBRICATION/OIL PAN -
INSTALLATION).

CAUTION: Install a cylinder head gasket of standard


thickness or a cylinder head gasket of repair thick-
ness depending on piston protrusion.
Fig. 40 PISTON AND CONNECTING ROD ASSEMBLY (15) Measure piston protrusion (Refer to 9 -
1 - CIRCLE CLIP ENGINE/ENGINE BLOCK - STANDARD PROCE-
2 - PISTON PIN
3 - PISTON ASSEMBLY DURE).
4 - CONNECTING ROD ALIGNMENT MARKINGS (16) Install cylinder head (Refer to 9 - ENGINE/
5 - CONNECTING ROD BOLTS CYLINDER HEAD - INSTALLATION).
6 - CONNECTING ROD CAP
7 - CONNECTING ROD (17) Install engine (Refer to 9 - ENGINE -
INSTALLATION).
(6) Using the appropriate clean engine oil, clean (18) Fill the crankcase with correct engine oil, to
the cylinder bores, connecting rod bearing journals, proper level. Refer to owners manual for specifica-
connecting rod bearing shells and pistons. tions.
VA ENGINE 9 - 45
PISTON & CONNECTING ROD (Continued)

Fig. 41 PISTON AND CONNECTING ROD INSTALLATION


1 - PISTON RING COMPRESSOR 6 - CONNECTING ROD
2 - WOOD HAMMER HANDLE 7 - CIRCLE CLIP
3 - CONNECTING ROD ALIGNMENT MARKINGS 8 - PISTON PIN
4 - CONNECTING ROD BOLTS 9 - PISTON ASSEMBLY
5 - CONNECTING ROD CAP

(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

RING GAP MEASUREMENT CHART

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.)

Fig. 42 Measuring Piston Ring Side Clearance


1 - FEELER GAUGE

RING SIDE CLEARANCE CHART

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)

(5) The oil control rings are symmetrical, and can


be installed with either side up. It is not necessary to
use a tool to install the upper and lower rails. Insert
oil rail spacer first, then side rails.
(6) Using a ring expander, install compression
rings with manufactures designation pointing toward
piston crown (Fig. 44).

Fig. 44 Compression Ring Installation


1 - COMPRESSION RING
2 - RING EXPANDER RECOMMENDED

Ring Gap Orientation Fig. 45 Ring Gap Orientation


• Position the gaps on the piston as shown (Fig. 1 - TOP COMPRESSION RING
2 - BOTTOM COMPRESSION RING
45). 3 - TOP OIL CONTROL RAIL
• Oil spacer - Gap on center line of piston skirt. 4 - OIL RAIL SPACER
• Oil rails - gap 180° apart on centerline of piston 5 - BOTTOM OIL CONTROL RAIL
6 - IMAGINARY LINE PARALLEL TO PISTON PIN
pin bore. 7 - IMAGINARY LINE THROUGH CENTER OF PISTON SKIRT
• No. 2 Compression ring - Gap 120° from top oil
rail gap. NOTE: If hub of belt pulley/vibration damper is
• No. 1 Compression ring - Gap 120° from No. 2 tight, use puller # 8940 to remove. DO NOT tilt
compression ring gap. puller when in use. Grooves of the puller must
mesh fully into the slots of the belt pulley.

VIBRATION DAMPER (5) Remove the belt pulley/vibration damper (Fig.


46).
REMOVAL
NOTE: If grooves can be felt in the belt pulley/vibra-
NOTE: If vehicle is equipped with the additional air tion damper during inspection, the pulley/damper
conditioner compressor, you must first remove the must be replaced.
coolant module and additional A/C belt then use
damper puller # 9544. (6) Inspect hub at belt pulley/vibration damper for
wear grooves.
(1) Disconnect negative battery cable. (7) Replace front crankshaft seal.
(2) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION
REMOVAL).
(3) Install retaining lock for crankshaft/ring gear NOTE: Align parallel key, fix in place with grease.
(Fig. 46). Turn to ensure the slot is aligned with parallel key
(4) Remove crankshaft center bolt and washer in crankshaft.
(Fig. 46).
9 - 48 ENGINE VA
VIBRATION DAMPER (Continued)
(6) Install the coolant module (if equipped with the
additional A/C compressor).
(7) Reconnect negative battery cable.

WARNING: USE EXTREME CAUTION WHEN THE


ENGINE IS IN OPERATION. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHING.

(8) Start vehicle and inspect for leaks.

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.

Fig. 46 VIBRATION DAMPER/CRANKSHAFT PULLEY


OPERATION
Vacuum pump output is transmitted to the Heater,
1 - SPECIAL TOOL #8932
2 - RETAINING BOLTS Electronic, Vacuum, Air Conditioner (HEVAC) and
3 - VIBRATION DAMPER/CRANKSHAFT PULLEY speed control, systems through a supply hose. The
4 - WASHER hose is connected to an outlet port on the pump hous-
5 - CRANKSHAFT BOLT
ing and uses an in-line check valve to retain system
NOTE: Front crankshaft seal must be replaced vacuum when vehicle is not running.
before installing the belt pulley/vibration damper. Pump output ranges from a minimum of 8.5 to 25
inches vacuum.
(1) Position the belt pulley/vibration damper. The pump rotor and vanes are rotated by the pump
(2) Install crankshaft center bolt and washer. drive gear. The drive gear is operated by the exhaust
Tighten bolt in two stages. M8.8 bolt to 200N·m (148 camshaft gear.
lbs. ft.) then 90°, M10.9 bolt to 325N·m (240 lbs. ft.)
then 90°. REMOVAL
(3) Remove the retaining lock for the crankshaft/ (1) Disconnect negative battery cable.
ring gear (Fig. 46). (2) Remove vacuum line at vacuum pump (Fig.
47).
NOTE: Inspect accessory drive belt for wear.
Replace as necessary. NOTE: Observe position of driver on rear of 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)

Fig. 47 VACUUM PUMP


1 - VACUUM PUMP
2 - VACUUM LINE
3 - O-RING Fig. 48 LEFT ENGINE MOUNT
4 - O-RING 1 - NUT
5 - EXHAUST CAMSHAFT 2 - WASHER
6 - BOLTS 3 - STOP PLATE
4 - ENGINE MOUNT
(2) Position driver on rear of pump and install vac- 5 - ENGINE SUPPORT
6 - BRACKET
uum pump with new seals. Tighten bolts to 14N·m 7 - GROUND CABLE
(124 lbs. in.). (Fig. 47) 8 - WASHER
(3) Install vacuum line to vacuum pump (Fig. 47). 9 - BOLT
(4) Connect negative battery cable.
INSTALLATION
WARNING: USE EXTREME CAUTION WHEN THE (1) Position the engine mount into the stop plate
ENGINE IS OPERATING. DO NOT STAND IN A (Fig. 48)
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR (2) Position the engine mount into position and
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO tighten the retaining nuts to 45 N·m (33 lbs. ft.) (Fig.
NOT WEAR LOOSE CLOTHES. 48)
(3) Lower the vehicle.
(5) Start the engine and inspect for leaks. (4) Lower the engine on to the engine mounts until
they contact (Fig. 48)
(5) Hand tighten the engine support to engine
LEFT MOUNT mount bolt (Fig. 48).
(6) Lower the engine on to the engine mount and
REMOVAL tighten bolt to 83 N·m (61 lbs.ft.) (Fig. 48)
(1) Install engine support fixture #8534 with adap- (7) Remove the engine support fixture and adap-
tors #8534–16 and raise the engine slightly. tors.
(2) Raise and support the vehicle.
(3) Remove the engine mount bolts (Fig. 48)
(4) Lower the vehicle.
(5) Using the engine support fixture # 8934, raise
the engine until the weight is no longer on the
mounts.
(6) Raise and support the vehicle.
9 - 50 ENGINE VA

RIGHT MOUNT (3) Lower the vehicle.


(4) Lower the engine on to the engine mounts until
they contact (Fig. 49)
REMOVAL
(5) Hand tighten the engine support to engine
(1) Install engine support fixture #8534 with adap-
mount bolt (Fig. 49).
tors #8534-16 and raise the engine slightly.
(6) Lower the engine on to the engine mount and
(2) Raise and support the vehicle.
tighten bolt to 83 N·m (61 lbs.ft.) (Fig. 49)
(3) Remove the engine mount bolts (Fig. 49)
(7) Remove the engine support fixture and adap-
(4) Lower the vehicle.
tors.
(5) Using the engine support fixture, raise the
engine until the weight is no longer on the mounts.
(6) Raise and support the vehicle. OIL
(7) Remove the engine mount nuts and remove the
mount (Fig. 49)
REMOVAL - OIL SEPARATOR
(1) Disconnect breather hose.
(2) Remove the separator retaining bolts
(3) Twist to remove oil separator from cover.

INSTALLATION - OIL SEPARATOR


(1) Lubricate the oil separator o - ring with clean
engine oil.
(2) Position separator above cover and apply down-
ward pressure to seat.
(3) Install retaining bolts and tighten to 8N·m (70
lbs. in.).
(4) Connect breather hose.

OIL COOLER & LINES


REMOVAL
WARNING: RISK OF INJURY TO SKIN AND EYES
DUE TO SCALDING FROM HOT COOLANT. DO NOT
OPEN THE COOLING SYSTEM UNLESS THE TEM-
PERATURE IS BELOW 194°F (90°C). WEAR PRO-
Fig. 49 RIGHT ENGINE MOUNT TECTIVE CLOTHING AND EYE WEAR. RISK OF
1 - NUT POISONING IF COOLANT IS SWALLOWED. STORE
2 - WASHER COOLANT IN PROPER AND APPROPRIATELY
3 - STOP PLATE
4 - ENGINE MOUNT
MARKED CONTAINERS.
5 - ENGINE SUPPORT
6 - WASHER (1) Partailly drain cooling system.
7 - BOLT (2) Remove the oil filter.
(3) Remove the coolant hoses from the oil cooler
INSTALLATION (Fig. 50).
(1) Position the engine mount into the stop plate (4) Remove the oil cooler from the timing case
(Fig. 49) cover (Fig. 50).
(2) Position the engine mount into position and
tighten the retaining nuts to 45 N·m (33 lbs. ft.) (Fig.
49)
VA ENGINE 9 - 51
OIL COOLER & LINES (Continued)

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).

Fig. 50 ENGINE OIL COOLER


1 - OIL FILTER
2 - OIL FILTER COVER
3 - GASKET
4 - BOLT
5 - COOLANT HOSE
6 - ENGINE OIL COOLER

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 JET INSTALLATION


(1) Install oil jet into special tool #8924.
DESCRIPTION (2) Align oil jet in location in engine block.
There are five oil jets installed in the engine block
NOTE: Align oil jet with the groove in special tool
(Fig. 52). These oil jets are used to cool and lubricate
#8924.
the piston assemblies.
(3) Drive oil jets into block using special tool #8924
until oil jet is fully seated into engine block (Fig. 53).

Fig. 52 OIL JET LOCATION


1 - ENGINE BLOCK
2 - OIL JET
Fig. 53 OIL JET INSTALLATION
1 - OIL JET INSTALLER #8942
REMOVAL 2 - ENGINE BLOCK
The engine must be removed from the vehicle and 3 - OIL JET
completely dissassembled to replace the oil jets.
(1) Remove engine from vehicle. (4) Reassemble engine.
(2) Completely dissassemble engine. (5) Install engine into vehicle.
(3) Using an extraction claw and a slide hammer,
remove the oil jets from engine block.
VA ENGINE 9 - 53

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

Fig. 55 OIL PAN


1 - O-RING 6 - CONNECTOR FOR OIL LEVEL SENSOR
2 - OIL PUMP 7 - OIL PAN
3 - GASKET 8 - TRANSMISSION LINE
4 - WIRING HARNESS DUCT 9 - OIL PUMP CHAIN
5 - TRANSMISSION LINE 10 - OIL PUMP CHAIN TENSIONER
9 - 54 ENGINE VA
OIL PAN (Continued)

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).

NOTE: Clean the strainer of the oil pump. If the oil


pump is dry, coat the inside with clean engine oil.

NOTE: Thoroughly clean all mating surfaces with


the appropriate solvents to assure that no grease or
oil is present during reassembly.

(1) Slide the oil pan into position.

Fig. 57 OIL PAN BOLTS


1 - M8X40
2 - M8X50
3 - M6X85
4 - M6X20
5 - M6X35
6 - M10X55

(9) Lower the engine until the engine mount and


engine supports make contact.
(10) Start and hand tighten the engine mount
bolts.
(11) Lower the engine the rest of the way and
remove the engine support fixture.
(12) Tighten the engine mount bolts to 83 N·m (61
lbs. ft.).
(13) Install the sway bar and tighten bolts to 30
Fig. 56 OIL PAN GASKET N·m (22 lbs. ft.).
(2) Slide the gasket into position. (14) Refill crankcase with the proper engine oil to
(3) Add sealant to the joints on the engine block the proper level (Refer to LUBRICATION & MAIN-
where indicated (Fig. 56). TENANCE/FLUID TYPES - SPECIFICATIONS).
(4) Install the oil pan. Tighten M6 bolts to 9N·m (15) Reconnect negative battery cable.
(80 lbs. in.) and M8 bolts to 20N·m (15 lbs. ft.) (Fig.
WARNING: USE EXTREME CAUTION WHEN THE
57).
ENGINE IS OPERATING. DO NOT PUT YOUR
(5) Tighten the bolt of the transmission bell hous-
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
ing to oil pan to 40N·m (30 lbs. ft.).
NOT WEAR LOOSE CLOTHES.
(6) Install the wiring harness duct (Fig. 55).
(7) Connect the oil level sensor (Fig. 55). (16) Start the engine and inspect for leaks.
(8) Lower the vehicle.
VA ENGINE 9 - 55

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).

REMOVAL- OIL PUMP CHAIN


(1) Disconnect negative battery cable.
(2) Remove oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - REMOVAL).
(3) Remove oil pump (Refer to 9 - ENGINE/LU-
BRICATION/OIL PUMP - REMOVAL).

NOTE: Make sure the pin of the thrust spindle is


backed out into the thrust spindle before seating Fig. 58 OIL PUMP CHAIN LINK REMOVAL
the thrust spindle to the oil pump chain. 1 - VIBRATION DAMPER/PULLEY
2 - OIL PUMP CHAIN
(4) Using special tool #9312–1 riveting tool, thrust 3 - SPECIAL TOOL #9312-1
spindle #9312–4 and thrust pin pin #9312–3, position
(1) Clean all sealing surfaces.
and fit chain seperating tool and thrust spindle onto
(2) Position the oil pump onto the drive chain and
a link of the oil pump chain (Fig. 58).
reset tensioner.
(5) Screw the thrust pin in and seperate the oil
(3) Install oil pump retaining bolts and tighten to
pump chain link.
18 N·m (160 lbs. in.).
(6) Remove pressed - out oil pump chain pin from
(4) Install the oil pan (Refer to 9 - ENGINE/LU-
chain seperation tool.
BRICATION/OIL PUMP - INSTALLATION).
CAUTION: IT IS ESSENTIAL that the installation pro- (5) Refill the crankcase to the appropriate level
cedure for the oil pump chain is followed exactly. with the proper engine oil (Refer to LUBRICATION
Failure to do so will result in severe engine dam- & MAINTENANCE/FLUID TYPES - SPECIFICA-
age. TIONS) .

WARNING: USE EXTREME CAUTION WHEN THE


ENGINE IS OPERATING. DO NOT PUT YOUR
INSTALLATION HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHES.
INSTALLATION
(6) Start the vehicle and inspect for leaks.
NOTE: If the oil pump is dry, fill it with clean engine
oil before installation. Clean the oil pick–up tube
and strainer.
9 - 56 ENGINE VA
OIL PUMP (Continued)

INSTALLATION - OIL PUMP CHAIN


CAUTION: IT IS ESSENTIAL that the installation pro-
cedure is followed exactly. Failure to do so will
result in severe engine damage.

(1) Connect old oil pump chain and new chain with
temporary link, outer plate and locking element (Fig.
59).

Fig. 60 REMOVING OIL PUMP CHAIN TEMPORARY


LINK
1 - NEW OIL PUMP CHAIN
2 - OLD OIL PUMP CHAIN
3 - TEMPORARY LINK

Fig. 59 INSTALLING OIL PUMP CHAIN TEMPORARY


LINK
1 - VIBRATION DAMPER/CRANKSHAFT PULLEY
2 - OLD OIL PUMP CHAIN
3 - NEW OIL PUMP CHAIN
4 - TEMPORARY LINK

(2) Slowly rotate crankshaft in a clockwise direc-


tion until it is possible to connect the ends of the new
and old oil pump chains.
(3) Remove assembly locking element, outer plate
and assembly link (Fig. 60).

CAUTION: Insert new riveted link from the rear.

(4) Connect ends of new oil pump chain with new


riveted link (Fig. 61).

NOTE: When assembling riveting tool, one piece is


secured by a screw and the other can move loosely
Fig. 61 INSTALLING NEW RIVETED LINK
on the thrust spindle.
1 - NEW RIVETED LINK
2 - OIL PUMP CHAIN
NOTE: The outer plate will be held in place by a
magnet. NOTE: Ensure that the riveted link and riveting tool
are aligned.
(5) Place new outer plate into tool insert.
VA ENGINE 9 - 57
OIL PUMP (Continued)
(6) Position riveting tool over new link and press
in new rivet as far as the tool stop.
(7) Remove riveting tool to change inserts.
(8) Install insert on riveting tool and secure with
screw.
(9) Install insert on riveting tool (Fig. 62).

Fig. 63 NEW LINK RIVETING


1 - SPECIAL TOOL #9312-5 INSERT
2 - SPECIAL TOOL #9312-1 RIVETING TOOL
3 - SPECIAL TOOL #9312-4 THRUST SPINDLE
Fig. 62 INSTALLING RIVETING INSERTS INTO 4 - SPECIAL TOOL #9312-3 THRUST PIN
RIVETING TOOL 5 - SPECIAL TOOL #9312-12 INSERT
6 - OIL PUMP CHAIN
1 - SPECIAL TOOL #9312-1
2 - SPECIAL TOOL #9312-5 and #9312-9
(19) Repeat procedure for both rivets.
NOTE: The outer plate is held in place magnetically
by riveting tool.

(10) Insert new outer plate into the moving assem-


bly insert.
(11) Position riveting tool so that spacer webs of
the guide are side by side.
(12) Ensure that riveted link and outer plate are
aligned.

NOTE: When turning spindle of riveting tool, be


sure that pins of riveted link are inserted into holes
of outer plate.

(13) Screw in spindle of riveting tool until firm


resistance is felt.
(14) Remove riveting tool.
(15) Turn over tool moving assembly insert to the
riveting profile.

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.

(1) Disconnect the negative battery cable.


(2) Partially drain coolant from the radiator.
(3) Remove the engine cover (Refer to 9 - ENGINE
- REMOVAL).
(4) Remove the high pressure fuel lines (Fig. 66).
(5) Remove the fuel rail (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/FUEL RAIL - REMOVAL).
(6) Remove the fuel rail support block between cyl-
inders #1 and #2 (Fig. 66).
(7) Disconnect the charge air hose at the intake
manifold (Fig. 67).
(8) Disconnect the EGR wiring harness connector
(Fig. 67).
(9) Remove the bolt retaining the engine wiring
harness to the intake manifold. Fig. 66 FUEL INJECTORS AND HIGH PRESSURE
(10) Disconnect the coolant hose at the EGR valve. FUEL LINES
1 - FUEL RAIL
NOTE: Collect and store any fluid spillage when 2 - HIGH PRESSURE FUEL INJECTOR LINES
disconnecting components. 3 - INTAKE MANIFOLD
4 - FUEL INJECTOR
5 - CRANKCASE VENTILATION BREATHER
(11) Disconnect both fuel lines at the fuel filter 6 - CAMSHAFT POSITION SENSOR
(Fig. 67).
(12) Remove the lower intake manifold support engine wiring harness and fuel lines through the
bracket (Fig. 68). openings in the intake manifold, then remove the
(13) Raise and support the vehicle. gasket (Fig. 68).
(14) Remove the rear intake manifold mounting
bolts while accessible from below. NOTE: Install the EGR valve with new gasket onto
(15) Lower the vehicle. the new intake manifold if the intake manifold is
being replaced.
NOTE: Access to one of the intake manifold bolts is
through a supplied hole in the manifold.

(16) Remove the remaining intake manifold bolts,


lift the intake manifold up and out while guiding the
9 - 60 ENGINE VA
INTAKE MANIFOLD (Continued)

Fig. 67 INTAKE MANIFOLD


1 - CLIP 6 - ENGINE OIL COOLER
2 - INTAKE MANIFOLD 7 - HIGH PRESSURE FUEL RAIL
3 - EGR VALVE 8 - COOLANT TEMPERATURE SENSOR
4 - EGR VALVE COOLANT HOSE 9 - FUEL RAIL PRESSURE SENSOR
5 - FUEL FILTER 10 - CHARGE AIR HOSE

INSTALLATION (5) Lower the vehicle.


(6) Connect both fuel lines to fuel filter assembly
NOTE: If the intake manifold is being replaced, (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/
install the EGR valve with new gasket. FUEL FILTER - INSTALLATION).
(7) Connect the coolant hose at the EGR valve
(1) Clean both mating surfaces and install a new (Fig. 67).
intake manifold gasket with the intake manifold. (8) Secure the engine wiring harness and cable
Guide the engine wiring harness and fuel lines duct to the intake manifold. tighten fastener to 9N·m
through the intake manifold openings. Tighten man- (80 in. lbs.).
ifold bolts to 16 N·m (142 lbs. in.) in a cross direc- (9) Connect the EGR wiring harness connector
tional pattern beginning with the middle bolts and (Fig. 67).
tightening outward to the ends. (10) Connect the fuel pressure sensor electrical
(2) Raise and support the vehicle. connector
(3) Install the rear intake manifold bolts and (11) Install the fuel rail (Refer to 14 - FUEL SYS-
tighten to 16 N·m (142 lbs. in.) (Fig. 68). TEM/FUEL DELIVERY/FUEL RAIL - INSTALLA-
(4) Install the lower intake manifold support TION).
bracket. Tighten bolts to 20 N·m (177 lbs. in.) (Fig.
68). NOTE: The high pressure fuel lines must be counter
held when tightening to prevent damage.
VA ENGINE 9 - 61
INTAKE MANIFOLD (Continued)

Fig. 68 INTAKE MANIFOLD Fig. 69 TURBOCHARGER


1 - INTAKE BOLT ACCESS HOLE 1 - EXHAUST MANIFOLD
2 - INTAKE MANIFOLD 2 - HEATER PIPE
3 - SUPPORT BRACKET 3 - AIR INLET TUBE
4 - TURBOCHARGER
(12) Install the high pressure fuel lines (Refer to 5 - AIR CLEANER HOUSING
6 - EXHAUST CLAMP
14 - FUEL SYSTEM/FUEL DELIVERY/FUEL LINES 7 - FRONT EXHAUST PIPE
- INSTALLATION).
(13) Connect the charge air hose to the intake (10) Remove the air cleaner housing hose from the
manifold (Fig. 67). turbocharger and position aside (Fig. 69).
(14) Install the engine cover (Refer to 9 - ENGINE (11) Remove the turbocharger oil cooler lines (Fig.
- INSTALLATION). 70).
(15) Fill the cooling system. (12) Remove the turbocharger to exhaust manifold
(16) Connect the negative battery cable. fasteners and remove turbocharger (Fig. 70).
(17) Start the engine, run until warm, turn engine (13) Remove the self locking exhaust manifold fas-
off and inspect for leaks. Care must be taken to teners (Fig. 70).
observe the fuel system warning. (Refer to 14 - FUEL (14) Remove exhaust manifold and clean mating
SYSTEM - WARNING). surface.

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.

NOTE: Rotate engine on crankshaft. DO NOT crank


the engine at the bolt of the camshaft sprocket.

NOTE: DO NOT crank engine back.

(2) Position piston of cylinder 1 to ignition TDC.


Markings on the camshaft bearing cap must be
aligned.
(3) Drain coolant (Refer to 7 - COOLING/ENGINE/
COOLANT - STANDARD PROCEDURE).
(4) Install retaining lock for crankshaft/starter
ring gear (Refer to 9 - ENGINE/ENGINE BLOCK/
FLEX PLATE - INSTALLATION).
(5) Drain engine oil.
(6) Remove the oil filter to allow the oil to flow off
into the oil pan.
(7) Remove the radiator assembly (Refer to 7 -
Fig. 70 EXHAUST MANIFOLD COOLING/ENGINE/RADIATOR - REMOVAL).
1 - CYLINDER HEAD (8) Remove engine cover (Refer to 9 - ENGINE -
2 - TURBOCHARGER OIL COOLER LINE
3 - TIMING CHAIN TENSIONER REMOVAL).
4 - BANJO BOLT (9) Remove front cover at cylinder head (Refer to 9
5 - EXHAUST MANIFOLD - ENGINE/CYLINDER HEAD - REMOVAL).
(10) Remove accessory drive belt.
NOTE: Replace the turbocharger oil cooler line (11) Remove the high pressure fuel pump (Refer to
banjo bolt seals before installing the oil cooler line. 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL PUMP
- REMOVAL).
(5) Install turbocharger (Refer to 11 - EXHAUST
(12) Remove water pump (Refer to 7 - COOLING/
SYSTEM/TURBOCHARGER SYSTEM/TURBO-
ENGINE/WATER PUMP - REMOVAL).
CHARGER - INSTALLATION).
(13) Remove accessory drive belt pulley and vibra-
(6) Raise and support the vehicle.
tion damper (Refer to 9 - ENGINE/ENGINE BLOCK/
(7) Install the front exhaust pipe to turbocharger
VIBRATION DAMPER - REMOVAL).
(Fig. 69).
(14) Remove the power steering pump.
(8) Install the exhaust hanger fasteners at the
muffler. NOTE: NO NOT open the air conditioning system.
(9) Tighten the exhaust hanger bracket to engine
block. (15) Unplug AC compressor electrical connector
(10) Install the turbocharger support bracket. and unbolt AC compressor. Relocate in lower engine
(11) Lower the vehicle. compartment with out opening the system.
(12) Install the air cleaner duct to the turbo- (16) Remove the generator with wiring attached
charger (Fig. 69). and relocate somewhere in the engine compartment.
(13) Install the exhaust heat shield. (17) Install engine support fixture.
(14) Connect the negative battery cable. (18) Remove the oil pan.
(19) Detach the coolant hose to oil-water heat
exchanger at crankcase (Fig. 71).
TIMING CHAIN COVER (20) Remove the cylinder head to timing cover
bolts (Fig. 71).
REMOVAL (21) Remove the timing cover bolts and cover (Fig.
71).
WARNING: DO NOT OPEN COOLING SYSTEM (22) Remove remaining ancillary components
UNLESS TEMPERATURE IS BELOW 90°C (194°F). attached to the timing case cover (Fig. 71).
OPEN CAP SLOWLY TO RELEASE PRESSURE.
STORE COOLANT IN APPROVED CONTAINER
VA ENGINE 9 - 63
TIMING CHAIN COVER (Continued)
NOTE: Inspect condition of hoses and clamps, (4) Apply sealant to the marked surfaces with a
replace as necessary. bead thickness of 1.5 ± 0.5 mm (Fig. 72).

(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.

Fig. 71 TIMING CHAIN COVER


1 - CYLINDER HEAD TO TIMING COVER BOLT
2 - OIL-WATER HEAT EXCHANGER
3 - GASKET
4 - DRIVE BELT TENSIONER Fig. 72 TIMING CHAIN COVER SEALING SURFACE
5 - FRONT CRANKSHAFT SEAL
6 - TIMING CHAIN COVER 1 - TIMING CHAIN COVER
2 - SEALANT BEAD
INSTALLATION (5) Position and install timing case cover. Tighten
CAUTION: Care must be taken to closley inspect bolts to 20 N·m (177 lbs in) (Fig. 71).
the gasket area around the time case cover to cyl- (6) Install the M8 bolts of cylinder head on timing
inder head gasket coolant port. If damage is found, case cover. Tighten bolts to 20 N·m (177 lbs in) (Fig.
replace the cylinder head gasket. Failure to do so 71).
may result in engine damage. (7) Install timing chain tensioner with new seal
(Refer to 9 - ENGINE/VALVE TIMING/TMNG BELT/
CHAIN TENSIONER&PULLEY - INSTALLATION).
NOTE: Thoroughly clean all mating surfaces with (8) Position and install the oil pan. Tighten M6
the appropriate solvents to assure that no grease or bolts to 9 N·m (80 lbs in) and M8 bolts to 20 N·m
oil is present during assembly. (177 lbs in).
(9) Install belt /pulley vibration damper. Tighten
(1) Inspect cylinder head gasket and oil pan gas- M8.8 bolt in two stages, 200N·m (147 lbs ft.) then
ket. If damaged, replace. 90°, M10.9 bolt 325N·m (240 lbs ft) then 90°.
(2) Replace the front crankshaft seal (Refer to 9 - (10) Remove the engine support fixture.
ENGINE/ENGINE BLOCK/CRANKSHAFT OIL (11) Install generator (Refer to 8 - ELECTRICAL/
SEAL - FRONT - INSTALLATION). CHARGING/GENERATOR - INSTALLATION).
(3) Install ancillary components to timing case (12) Install the air conditioning compressor.
cover. (13) Install the power steering pump.
9 - 64 ENGINE VA
TIMING CHAIN COVER (Continued)
(14) Install water pump (Refer to 7 - COOLING/ TIMING CHAIN AND
ENGINE/WATER PUMP - INSTALLATION).
(15) Connect coolant hose to oil-water heat SPROCKETS
exchanger.
(16) Install high pressure fuel pump (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL PUMP -
REMOVAL
INSTALLATION).
(17) Apply sealant to lower portion of, and install, REMOVAL - TENSIONING AND SLIDE RAILS
front cover to cylinder block. Tighten bolts to 20N·m
NOTE: If it necessary to replace the tensioning rail,
(177 lbs in) (Refer to 9 - ENGINE/CYLINDER HEAD
slide rail or tensioning arm, they are always
- INSTALLATION).
replaced together.
(18) Remove retaining lock for crankshaft/starter
ring gear. (1) Disconnect negative battery cable.
(19) Tighten the oil drain plug to 30N·m (265 lbs (2) Remove cylinder head (Refer to 9 - ENGINE/
in). CYLINDER HEAD - REMOVAL).
(20) Install a new oil filter. tighten screw cap for
filter to 25N·m (221 lbs. in.). NOTE: Remove timing case cover carefully. Care
(21) Install the accessory drive belt. must be taken not to damage oil pan gasket.
(22) Install the radiator assembly (Refer to 7 -
COOLING/ENGINE/RADIATOR - INSTALLATION). (3) Remove timing case cover (Refer to 9 -
(23) Install air intake hose. ENGINE/VALVE TIMING/TIMING BELT / CHAIN
(24) Fill coolant to the proper level, with the COVER(S) - REMOVAL).
proper coolant (Refer to 7 - COOLING/ENGINE/ (4) Pull the tensioning rail off of the bearing pins
COOLANT - STANDARD PROCEDURE). (Fig. 73).
(25) Fill the crankcase with the correct oil, to the (5) Release the spring at the slide rail and take it
proper level. Refer to owners manual for specifica- off of the tensioning arm (Fig. 73).
tions.
(26) Connect the negative battery cable. REMOVAL - INTERMEDIATE GEAR
(1) Disconnect negative battery cable.
WARNING: USE EXTREME CAUTION WHEN THE (2) Remove engine cover (Refer to 9 - ENGINE -
ENGINE IS OPERATING. DO NOT STAND IN A REMOVAL).
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO WARNING: NO FIRE, FLAMES OR SMOKING. RISK
NOT WEAR LOOSE CLOTHES. OF POISONING FROM INHALING OR SWALLOWING
FUEL. RISK OF INJURY TO EYES AND SKIN FROM
CONTACT WITH FUEL. POUR FUELS ONLY INTO
CAUTION: DO NOT pressure test cooling system SUITABLE AND APPROPRIATELY MARKED CON-
until the engine reaches operating temperature. TAINERS. WEAR PROTECTIVE CLOTHING.
(27) Start engine and inspect for leaks. care must
be taken to observe the fuel system warning (Refer to
14 - FUEL SYSTEM - WARNING).
VA ENGINE 9 - 65
TIMING CHAIN AND SPROCKETS (Continued)

Fig. 73 TENSIONING AND SLIDE RAILS


1 - TENSIONING RAIL 5 - TENSIONING CLAMP
2 - BEARING PIN 6 - BEARING PIN
3 - SLIDE RAIL 7 - SPRING
4 - BEARING PIN 8 - OIL PUMP

(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. 75 TIMING CHAIN TENSIONING RAIL


1 - TIMING CHAIN COVER
2 - TENSIONING RAIL
3 - BEARING PIN
4 - OIL PAN

Fig. 74 HIGH RESSURE PUMP INTERMEDIATE


REMOVAL - TIMING CHAIN
GEAR
(1) Remove cylinder head cover (Refer to 9 -
1 - CAMSHAFT SPROCKET BOLTS
2 - INTAKE CAMSHAFT
ENGINE/CYLINDER HEAD/CYLINDER HEAD
3 - DOWEL PIN COVER(S) - REMOVAL).
4 - INTERMEDIATE GEAR BUSHING
5 - INTERMEDIATE GEAR NOTE: Cover the timing chain area. Care must be
6 - CAMSHAFT LOCKING PIN #8929
7 - INTAKE CAMSHAFT SPROCKET taken not to drop any repair debris or pieces into
the engine when separating the timing chain links.
REMOVAL - TIMING CHAIN TENSIONING RAIL (2) Install special tool # 9525 using two of the cyl-
(1) Disconnect negative battery cable.
inder head cover bolts (Fig. 76).
(2) Remove cylinder head (Refer to 9 - ENGINE/
(3) Assemble special tool #9312–1 using 9312– 3
CYLINDER HEAD - REMOVAL).
and 9312–4. Install insert #9312–13 and retain with
screw provided. (Fig. 77).
VA ENGINE 9 - 67
TIMING CHAIN AND SPROCKETS (Continued)

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.

NOTE: When installing special tool #9312–1 onto


timing chain link, be sure to back off the smaller
nut of the thrust pin #9312–3 until the pin is
recessed inside of the spindle, #9312–4. Screw the
thrust spindle #9312–4 in until it is seated and
aligned properly over the rivet of the timing chain.

NOTE: When fitting the thrust spindle, ensure that


the thrust pin is positioned at the left timing chain
pin of a chain link.

(4) Install special tool #9312 onto timing chain


link (Fig. 77).

NOTE: Cover the timing chain area. Care must be


taken not to drop any repair debris or pieces into
the engine when separating the timing chain links.

(5) Carefully turn the thrust pin #9312–3 of spe-


cial tool #9312–1 clockwise while holding the handle
until the rivet is pressed out and the chain is sepa- Fig. 78 TIMING CHAIN SEPARATION
rated (Fig. 78). Discard the loose link and plates.
1 - LEFT TIMING CHAIN PORTION
2 - EXHAUST CAMSHAFT GEAR
NOTE: One whole timing chain link must be 3 - RIGHT TIMING CHAIN PORTION
removed. 4 - SPECIAL TOOL #9525
9 - 68 ENGINE VA
TIMING CHAIN AND SPROCKETS (Continued)
NOTE: Care must be taken not to drop any repair (2) Install timing cover (Refer to 9 - ENGINE/
debris or pieces into the engine when separating VALVE TIMING/TIMING BELT / CHAIN COVER(S)
the timing chain links. - INSTALLATION).
(3) Install oil pan bolts. Tighten M6 bolts to 9N·m
(6) Connect new timing chain with the oil holes (80 lbs.in.) and M8 bolts to 20N·m (15 lbs. ft.).
facing up, and old timing chain with the assembly (4) Install cylinder head (Refer to 9 - ENGINE/
link, assembly plate and locking element, and secure CYLINDER HEAD - INSTALLATION).
(Fig. 79). (5) Reconnect negative battery cable.

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.

(6) Start the engine, allow to warm, turn engine


off and inspect for leaks. Care must be take to
observe the fuel system warning (Refer to 14 - FUEL
SYSTEM - WARNING).

INSTALLATION - INTERMEDIATE GEAR


NOTE: Refer to appropriate injector servicing proce-
dures for cleaning of injectors and recesses.

(1) Install intermediate gear and bushing. Tighten


bolt to 40N·m (30 lbs.ft.)
(2) Install the intake camshaft (Refer to 9 -
ENGINE/CYLINDER HEAD/CAMSHAFT(S) -
INSTALLATION).
(3) Install exhaust camshaft sprocket, noting
Fig. 79 TEMPORARY TIMING CHAIN LINK dowel pin alignment. Tighten bolt to 18 N·m (159 lbs.
1 - TEMPORARY TIMING CHAIN LINK in.).
2 - LEFT TIMING CHAIN PORTION
3 - NEW TIMING CHAIN
4 - SPECIAL TOOL 9525
WARNING: NO FIRE, FLAMES OR SMOKING. SER-
VICE VEHICLE IN WELL VENTILATED AREA. RISK
CAUTION: IT IS ESSENTIAL that the installation pro- OF INJURY FROM INHALING OR SWALLOWING
cedure for the timing chain is followed exactly. Fail- FUEL. RISK OF INJURY TO EYES AND SKIN FROM
ure to do so will result in severe engine damage. CONTACT WITH FUEL. WEAR PROTECTIVE CLOTH-
ING.

(4) Install high pressure pump (Refer to 14 -


INSTALLATION FUEL SYSTEM/FUEL DELIVERY/FUEL INJEC-
TION PUMP - INSTALLATION).
INSTALLATION - TENSIONING AND SLIDE RAIL (5) Install top slide rail (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
NOTE: Carefully clean all mating surfaces with SPROCKETS - INSTALLATION).
appropriate solvents to assure that no grease or oil (6) Install cylinder head front cover (Refer to 9 -
is present during reassembly. ENGINE/CYLINDER HEAD - INSTALLATION).
(7) Install timing chain tensioner with new gasket
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
CAUTION: ENSURE THAT THE SPRING IS COR-
BELT/CHAIN AND SPROCKETS - INSTALLA-
RECTLY INSTALLED ON THE TENSIONING CLAMP
TION).
AND SLIDE RAIL.
NOTE: Inspect basic position of camshaft and reset
(1) Install rail on bearing pin (Fig. 73).
if necessary (Refer to 9 - ENGINE/CYLINDER HEAD/
CAMSHAFT(S) - STANDARD PROCEDURE).
VA ENGINE 9 - 69
TIMING CHAIN AND SPROCKETS (Continued)
(8) Remove camshaft locking pin. ADJUSTMENTS
(9) Install cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD INSTALLATION - TIMING CHAIN
COVER(S) - INSTALLATION).
CAUTION: IT IS ESSENTIAL that the installation pro-
WARNING: NO FIRE, FLAMES OR SMOKING. SER- cedure is followed exactly. Failure to do so will
VICE VEHICLE IN WELL VENTILATED AREA. RISK result in severe engine damage.
OF INJURY FROM INHALING OR SWALLOWING
FUEL. RISK OF INJURY TO EYES AND SKIN FROM
CONTACT WITH FUEL. WEAR PROTECTIVE CLOTH- CAUTION: Cover timing case recesses to prevent
ING. foreign material from entering engine.

(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.

WARNING: USE EXTREME CAUTION WHEN THE


ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHING.

(13) Start engine and inspect for leaks. Care must


be taken to observe the fuel system warning (Refer to
14 - FUEL SYSTEM - WARNING).

INSTALLATION - TIMING CHAIN TENSIONING


RAIL
NOTE: Carefully clean all mating surfaces with
appropriate solvents to assure that no grease or oil
is present during reassembly.

(1) Install tensioning rail on bearing pin


(2) Install timing cover (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT / CHAIN COVER(S)
- INSTALLATION). Fig. 80 OLD AND NEW TIMING CHAIN UNION
(3) Install oil pan and bolts. Tighten M6 bolts to 1 - TEMPORARY TIMING CHAIN LINK
2 - SPECIAL TOOL 9525
9N·m (80 lbs.in.) and M8 bolts to 20N·m (15 lbs. ft.). 3 - OLD TIMING CHAIN
(4) Install cylinder head (Refer to 9 - ENGINE/ 4 - NEW TIMING CHAIN
CYLINDER HEAD - INSTALLATION).
(5) Reconnect negative battery cable. CAUTION: Always install the new timing chain with
the oil holes pointing up. Failure to do so will result
WARNING: USE EXTREME CAUTION WHEN THE in severe engine damage.
ENGINE IS OPERATING. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHES. NOTE: Always keep new timing chain meshed with
camshaft sprocket.
(6) Start the engine and inspect for leaks. Care
must be taken to observe the fuel system warning
CAUTION: DO NOT CRANK ENGINE and DO NOT
(Refer to 14 - FUEL SYSTEM - WARNING).
ROTATE ENGINE BACKWARD. Engine rotation is
clockwise, as you are looking at the engine. Rotate
engine at crankshaft only.
9 - 70 ENGINE VA
TIMING CHAIN AND SPROCKETS (Continued)
NOTE: Draw out the end of old timing chain evenly
as it becomes free, to the same extent that new tim-
ing chain is drawn in.

(2) Draw in new timing chain with the oil holes


facing up, by rotating the crankshaft slowly in direc-
tion of rotation of engine. (Fig. 81).

Fig. 82 TIMING CHAIN ROTATION COMPLETE


1 - NEW TIMING CHAIN
2 - SPECIAL TOOL #9525
3 - TEMPORARY LINK
4 - OLD TIMING CHAIN

Fig. 81 TIMING CHAIN INSTALLATION


1 - NEW TIMING CHAIN
2 - OLD TIMING CHAIN

(3) Rotate the engine until the ends of the new


timing chain meet and can be connected (Fig. 82).

NOTE: Assembly link is only an assembly aid and


NOT designed for engine running.

(4) Remove assembly locking element, assembly


outer plate and assembly link.

CAUTION: Cover timing case recesses to prevent


foreign material from entering engine.

(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.

NOTE: The outer plate is held magnetically by rivet-


ing tool.

(11) Insert new outer plate into the moving assem-


bly insert.
(12) Position riveting tool so that spacer webs of
the guide are side by side (Fig. 86).
(13) Ensure that riveted link and outer plate are
aligned.

NOTE: When turning spindle of riveting tool, be


sure that pins of riveted link are inserted into holes
of outer plate
Fig. 84 INSTALLING ASSEMBLY INSERTS INTO (14) Screw in spindle of riveting tool until firm
RIVETING TOOL resistance is felt (Fig. 86).
1 - SPECIAL TOOL #9312-1
2 - SPECIAL TOOL #9312-7 and 9312-10

NOTE: Ensure that the riveted link and riveting tool


are aligned.

(7) Press in new riveted link as far as the stop


(Fig. 85).

Fig. 86 OUTER PLATE INSTALLATION


1 - SPECIAL TOOL #9312-1
2 - THRUST SPINDLE #9312-4
3 - TOOL INSERT #9312-8
4 - TOOL INSERT #9312-6

Fig. 85 PRESSING THE NEW LINK


1 - SPECIAL TOOL #9312-1
2 - GUIDE LINK
3 - SPECIAL TOOL INSERT 9#312-7
4 - SPECIAL TOOL INSERT #9312-10
5 - THRUST SPINDLE #9312-4
9 - 72 ENGINE VA
TIMING CHAIN AND SPROCKETS (Continued)
(15) Remove riveting tool. (20) Inspect riveting, re-rivet if required (Fig. 88).
(16) Install moving assembly insert #9312–11 to
#9312–1.
(17) Position riveting tool exactly over middle of
pin.
(18) Tighten riveting tool spindle to end of travel
(Fig. 87).
(19) Repeat procedure for both riveting pins (Fig.
87).

Fig. 88 RIVET INSPECTION


(21) Install cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
(22) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
(23) Connect negative battery cable.
(24) Start engine and inspect for leaks. Care must
be taken to observe the fuel system warning (Refer to
14 - FUEL SYSTEM - WARNING).
Fig. 87 RIVETING THE LINK PINS
1 - SPECIAL TOOL #9312-1
2 - THRUST SPINDLE
3 - RIVETING PROFILE
4 - INSERT 9312-6
VA ENGINE 9 - 73

TIMING CHAIN TENSIONER


REMOVAL
(1) Disconnect negative battery cable.

CAUTION: Rotate engine at crankshaft only. DO


NOT rotate the engine with the bolt of the camshaft
sprocket. DO NOT rotate the engine counter clock-
wise.

NOTE: Markings on the camshaft and camshaft


bearing cap must be aligned.

(2) Position piston of number 1 cylinder to ignition


TDC.
(3) Remove intake air duct.
(4) Remove accessory drive belt and idler pulley
above generator (Refer to 7 - COOLING/ACCES-
SORY DRIVE/DRIVE BELTS - REMOVAL).
(5) Remove timing chain tensioner (Fig. 89).

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.

WARNING: USE EXTREME CAUTION WHEN THE


ENGINE IS OPERATING. DO NOT PUT YOUR
VA EXHAUST SYSTEM 11 - 1

EXHAUST SYSTEM
TABLE OF CONTENTS

page page

EXHAUST SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . .....4


DESCRIPTION - 2.7L DIESEL . . . . . . . . . . . . ...1 DIAGNOSIS AND TESTING - CHARGE AIR
DIAGNOSIS AND TESTING - DIESEL ENGINE ..2 COOLER SYSTEM - LEAKS . . . . . . . . . . . . . . .4
CATALYTIC CONVERTER REMOVAL ........................ . . . . .5
REMOVAL .......................... ...3 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . ...3 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . .5
EXHAUST PIPE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . .5
REMOVAL .......................... ...3 TURBOCHARGER
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . ...3 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . .....6
TAILPIPE OPERATION . . . . . . . . . . . . . . . . . . . . . . . .....6
REMOVAL .......................... ...3 REMOVAL
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . ...3 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . .....7
TURBOCHARGER SYSTEM REMOVAL - VACUUM TRANSDUCER . . .....7
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . ...3 INSTALLATION
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . ...4 INSTALLATION . . . . . . . . . . . . . . . . . . . .....8
CHARGE AIR COOLER AND PLUMBING INSTALLATION - VACUUM TRANSDUCER ...8
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . ...4

EXHAUST SYSTEM The exhaust system must be properly aligned and


secured to prevent stress, leakage and body contact.
The exhaust components should be kept a minimum
DESCRIPTION - 2.7L DIESEL
of 25.4 mm (1.0 in.) away from the body and frame.
CAUTION: Avoid application of rust prevention com- If the system contacts any body panel, it may amplify
pounds or undercoating materials to exhaust sys- objectionable noises from the engine or body.
tem floor pan exhaust heat shields. Light overspray
near the edges is permitted. Application of coating
will result in excessive floor pan temperatures and
objectionable fumes.

The diesel engine exhaust system consists of an


engine exhaust manifold, turbocharger, exhaust pipe,
resonator, extension pipe (if needed), muffler and
exhaust tailpipe (Fig. 1).
11 - 2 EXHAUST SYSTEM VA
EXHAUST SYSTEM (Continued)

Fig. 1 Exhaust System


1 - TURBOCHARGER 7 - WASHER
2 - HEAT SHIELD 8 - INSULATOR
3 - CLAMP 9 - BOLT
4 - EXHAUST PIPE 10 - MUFFLER/CATALYTIC CONVERTER ASSEMBLY
5 - FRONT INSULATOR 11 - TAILPIPE
6 - NUT

DIAGNOSIS AND TESTING - DIESEL ENGINE


EXHAUST SYSTEM DIAGNOSIS CHART

CONDITION POSSIBLE CAUSE CORRECTION

EXCESSIVE EXHAUST NOISE OR 1. Leaks at pipe joints. 1. Tighten/replace clamps/bolts at


LEAKING EXHAUST GASES leaking joints.
2. Rusted or expanded muffler. 2. Replace muffler. Inspect exhaust
system.
3. Broken or rusted exhaust pipe. 3. Replace exhaust pipe.
4. Exhaust pipe leaking at manifold 4. Tighten/replace flange attaching
flange. nuts/bolts.
5. Exhaust manifold cracked or 5. Replace exhaust manifold.
broken.
6. Leak between exhaust manifold 6. Tighten/replace exhaust manifold
and cylinder head. to cylinder head bolts.
7. Turbocharger mounting flange 7. Remove turbocharger and
cracked. inspect.
8. Restriction in exhaust system. 8. Remove restriction, if possible.
Replace restricted part if necessary.
VA EXHAUST SYSTEM 11 - 3

CATALYTIC CONVERTER (3) Install clamp.


(4) Lower the vehicle.
(5) Start the vehicle and inspect for exhaust leaks.
REMOVAL
Repair exhaust leaks as necessary.
(1) Raise and support the vehicle.
(6) Check the exhaust system for contact with the
(2) Saturate the clamp nuts with heat valve lubri-
body panels. Make necessary adjustments, if neces-
cant. Allow 5 minutes for penetration. Remove the
sary.
rear clamp. (Fig. 1)
(3) Saturate the clamp nuts with heat valve lubri-
cant. Allow 5 minutes for penetration. Remove the TAILPIPE
front clamp.
(4) Remove the cataylic converter and muffler
REMOVAL
assembly from the isolators.
(1) Raise and support the vehicle.
(5) Seperat the cataylic converter and muffler
(2) Saturate the clamp nuts with heat valve lubri-
assembly from the tailpipe and the exhaust pipe.
cant. Allow 5 minutes for penetration (Fig. 1).
(6) Remove the cataylic converter and muffler
(3) Remove the clamp.
assembly and isolators from the vehicle.
(4) Remove the tailpipe and insulator form the
(7) Remove the bolt, nut and front isolator from
vehicle
the cataylic converter and muffler assembly.
(5) Remove the insulator from the tailpipe.
(8) Remove the rear isolator from the cataylic con-
verter and muffler assembly.
(9)
INSTALLATION
(1) Position the tail pipe into the cataylic converter
and muffler assembly until alignment tab is inserted
INSTALLATION
into the alignment slot.
(1) Install bolt, front isolator and nut (Fig. 1).
(2) Install the insulator.
(2) Install rear insulator onto the cataylic con-
(3) Install the clamp.
verter and muffler assembly
(4) Lower the vehicle.
(3) Position the cataylic conveter and muffler
(5) Start the vehicle and inspect for exhaust leaks.
assembly into the exhaust pipe and tailpipe until
Repair exhaust leaks as necessary.
alignment tab is inserted into the alignment slot.
(6) Check the exhaust system for contact with the
(4) Install the front and rear insulators.
body panels. Make necessary adjustments, if neces-
(5) Install the real clamp.
sary.
(6) Install the front clamp.
(7) Lower vehicle.
(8) Start the vehicle and inspect for exhaust leaks. TURBOCHARGER SYSTEM
Repair exhaust leaks as necessary.
(9) Check the exhaust system for contact with the
DESCRIPTION
body panels. Make necessary adjustments, if neces-
sary. CAUTION: The turbocharger is a performance part
and must not be tampered with. The boost pressure
bracket is an integral part of the turbocharger. Tam-
EXHAUST PIPE pering with the boost pressure components can
reduce durability by increasing cylinder pressure
REMOVAL and thermal loading due to incorrect inlet and
(1) Raise and support the vehicle. exhaust manifold pressure. Poor fuel economy and
(2) Saturate the clamp nuts with heat valve lubri- failure to meet regulatory emissions laws may
cant. Allow 5 minutes for penetration. Remove the result. Increasing the turbocharger boost WILL NOT
front and rear clamp (Fig. 1). increase engine power.
(3) Remove the mounting bracket nuts.
(4) Remove the exhaust pipe. The turbocharger used on this vehicle is of the
variable turbine type. These turbochargers use the
INSTALLATION entire exhaust energy to boost efficiency of the turbo-
(1) Position the exhaust pipe into the exhaust pipe charger and the engine.
into the cataylic converter and muffler assembly The advantages of a turbocharger with variable
until alignment tab is inserted into the alignment turbine geometry are:
slot. • Higher charge pressure already in the lower and
(2) Install mounting bracket and nuts (Fig. 1). in upper engine speed ranges.
11 - 4 EXHAUST SYSTEM VA
TURBOCHARGER SYSTEM (Continued)
• Higher torque as a result of improved cylinder
charge.
• Reduction in exhaust emissions as a result of an
improvement in the air supply of the engine.
• Increased power output as a result of the higher
charge pressure combined with a reduced exhaust
backpressure and thus improved charge cycle.

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.).

CAUTION: Do not apply more than 138 kpa (20 psi)


air pressure to the charge air cooler system, sever
damage to the charge air cooler system may occur.

(3) Connect regulated air supply to air fitting on


Special Tool 8442 Adapter. Set air pressure to a Max-
imum of 138 kpa (20 psi).
(4) Using soapy water check the air inlet ducts,
rubber sleeves, charge air cooler and intake manifold
for leaks.

REMOVAL Fig. 3 CHARGE AIR COOLER


(1) Remove front bumper.
1 - POWER STEERING COOLER LOOP
(2) Remove headlamp assemblies. 2 - CHARGE AIR HOSE
(3) Remove front cross member together with front 3 - CHARGE AIR COOLER HOSE
grille. 4 - CHARGE AIR COOLER
5 - LEFT RADIATOR TRIM PANEL
(4) Remove left and right radiator trim (Fig. 3). 6 - RIGHT RADIATOR TRIM PANEL
(5) Disconnect charge air hoses at charge air cooler
(Fig. 3). (5) Continue flushing until all debris or oil are
(6) Disconnect power steering cooler loop from removed.
charge air cooler (Fig. 3). (6) Rinse the cooler with hot soapy water to
(7) Remove charge air cooler from radiator assem- remove any remaining solvent.
bly (Fig. 3). (7) Rinse thoroughly with clean water and blow
dry with compressed air.
CLEANING
INSPECTION
CAUTION: Do not use caustic cleaners to clean the Visually inspect the charge air cooler for cracks,
charge air cooler. Damage to the charge air cooler holes, or damage. Inspect the tubes, fins, and welds
will result. for tears, breaks, or other damage. Replace the
charge air cooler if damage is found.
Pressure test the charge air cooler, using Charge
NOTE: If internal debris cannot be removed from
Air Cooler Tester Kit.
the cooler, the charge air cooler MUST be replaced.

(1) If the engine experiences a turbocharger failure INSTALLATION


or any other situation where oil or debris get into the (1) Install charge air cooler to radiator (Fig. 3).
charge air cooler, the charge air cooler must be (2) Connect power steering cooler loop to charge
cleaned internally. air cooler (Fig. 3).
(2) Position the charge air cooler so the inlet and (3) Connect charge air hoses (Fig. 3).
outlet tubes are vertical. (4) Install both radiator trim pieces (Fig. 3).
(3) Flush the cooler internally with solvent in the (5) Install front grille with front cross member.
direction opposite of normal air flow. (6) Install headlamp assemblies.
(4) Shake the cooler and lightly tap on the end (7) Install front bumper.
tanks with a rubber mallet to dislodge trapped
debris.
11 - 6 EXHAUST SYSTEM VA

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. 5 TURBOCHARGER VACUUM ROUTING


1 - ENGINE 5 - VACUUM SOLENOID
2 - BRAKE BOOSTER CHECK VALVE 6 - VACUUM RESERVOIR
3 - VACUUM PUMP 7 - ACCESSORY VACUUM JUNCTION
4 - TURBOCHARGER 8 - FILTER
VA EXHAUST SYSTEM 11 - 7
TURBOCHARGER (Continued)

REMOVAL (8) Remove the turbocharger support bracket (Fig.


6).
REMOVAL (9) Remove turbocharger from exhaust manifold
(Fig. 6).
NOTE: Capture any fluid spillage and store in an
appropriately marked and suitable containers. REMOVAL - VACUUM TRANSDUCER
(1) Disconnect the negative battery cable.
(1) Disconnect the negative battery cable. (2) Remove the air cleaner housing (Refer to 9 -
(2) Remove the heat shield (Fig. 6). ENGINE/AIR INTAKE SYSTEM/AIR CLEANER
(3) Separate the front exhaust pipe from the tur- HOUSING - REMOVAL).
bocharger (Fig. 6) (3) Disconnect the electrical connector.
(4) Separate the charge air and intake air hoses at (4) Disconnect the vacuum hoses.
the turbocharger (Fig. 6). (5) Remove the vacuum transducer retaining bolts
(5) Remove the vacuum line from the turbocharger and remove vacuum transducer.
vacuum unit (Fig. 6).
(6) Separate the oil supply at the cylinder head
and turbocharger (Fig. 6).
(7) Separate the oil return flow line at the turbo-
charger (Fig. 6).

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)

INSTALLATION (6) Attach turbocharger vacuum line to vacuum


unit (Fig. 6).
INSTALLATION (7) Attach air intake and charge air hoses (Fig. 6).
(1) Clean all mating surfaces (8) Connect front exhaust pipe to turbocharger.
(2) Install turbocharger to exhaust manifold. Tighten flange clamp to 22 lbs.ft. (30 N·m) (Fig. 6).
Tighten bolts to 22 lbs. ft. (20 N·m) (Fig. 6). (9) Install heat shield (Fig. 6).
(10) Connect negative battery cable.
NOTE: Slacken the bottom bolt of the turbocharger
support bracket to install bracket stress free. INSTALLATION - VACUUM TRANSDUCER
(1) Position vacuum transducer and install the
(3) Install turbocharger support bracket. Tighten retaining bolts. Tighten bolts to 70 lbs.in (8 N·m).
bolts to 177 lbs. in. (20 N·m) at engine and 22 lbs. ft. (2) Connect vacuum hoses.
(30 N·m) at turbocharger (Fig. 6). (3) Connect electrical connector
(4) Replace gaskets and install oil return line at (4) Install air cleaner housing (Refer to 9 -
turbocharger. Tighten bolt to 80 lbs. in. (9 N·m) (Fig. ENGINE/AIR INTAKE SYSTEM/AIR CLEANER
6). HOUSING - INSTALLATION)
(5) Connect negative battery cable.
NOTE: Counterhold the connection at the turbo-
charger when tightening the oil supply line bolt.

(5) Replace gaskets and install oil supply line at


turbocharger. Tighten bolt to 160 lbs. in. (18 N·m)
(Fig. 6).
VA FRAME & BUMPERS 13 - 1

FRAME & BUMPERS


TABLE OF CONTENTS

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

DESCRIPTION N·m Ft. Lbs. In. Lbs.


FRONT BUMPER - STEPS BOLTS 20 15 —
FRONT FASCIA SCREWS 23 17 —
REAR BUMPER STEP FRAME BOLTS/ 38 17 —
NUTS
REAR BUMPER STEP SUPPORT BOLTS 90 66 —
REAR FASCIA BOLTS 23 17 —
13 - 2 FRAME & BUMPERS VA

FRONT BUMPER - STEPS FRONT FASCIA


REMOVAL REMOVAL
(1) Remove fascia. (Refer to 13 - FRAME & (1) Remove the screws and cover. (Fig. 2)
BUMPERS/BUMPERS/FRONT FASCIA - (2) Remove push pin fasteners.
REMOVAL) (3) Remove fascia screws.
(2) Remove the bolts and remove the steps. (Fig. 1) (4) Pull bumper forward off support brackets.
(5) Disconnect electrical connector.

Fig. 2 FRONT FASCIA


1 - ELECTRICAL CONNECTOR
Fig. 1 BUMPER STEPS 2 - OUTSIDE TEMPERATURE SENSOR
3 - FASCIA SUPPORT BRACKET
1 - BOLTS (2 PER STEP) 4 - FASCIA
2 - STEPS 5 - SCREWS (2)
6 - COVER
INSTALLATION 7 - PUSH PIN FASTENERS

(1) Install step and bolts.


(2) Tighten bolts to 20 N·m (15 ft. lbs.). INSTALLATION
(3) Install fascia. (Refer to 13 - FRAME & (1) Connect outside temperature sensor electrical
BUMPERS/BUMPERS/FRONT FASCIA - INSTAL- connector.
LATION) (2) Slide fascia onto the support brackets.
(3) Install fascia screws and tighten to 23 N·m (17
ft. lbs.).
(4) Install push pin fasteners.
(5) Install cover and screws.
VA FRAME & BUMPERS 13 - 3

REAR BUMPER - STEP REAR FASCIA


REMOVAL REMOVAL
(1) Remove rear fascia. (Refer to 13 - FRAME & (1) Remove screws and remove reflectors. (Fig. 4)
BUMPERS/BUMPERS/REAR FASCIA - REMOVAL) (2) Remove fascia bolts.
(2) Remove frame bolts/nuts. (Fig. 3) (3) Release bumper support brackets clips below
(3) Remove the remaining support bolts. end panel.
(4) Press dowel pins out of and remove four plastic
rivets connecting fascia to rear step, if equipped.
(5) Separate the corners of the fascia from the sup-
port brackets and remove fascia.

Fig. 4 REAR FASCIA


1 - FASCIA
2 - BOLTS
3 - TAB
4 - REFLECTOR
5 - SUPPORT BRACKET

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)

Fig. 5 FRAME DIMENSIONS


13 - 6 FRAME & BUMPERS VA
FRAME (Continued)

SPECIFICATIONS - TORQUE ENGINE CRADLE


TORQUE SPECIFICATIONS
CROSSMEMBER
DESCRIPTION N·m Ft. Lbs. In. Lbs. REMOVAL
Brake line nuts 14 10 — (1) Install engine support tool 8534 or equivalent.
Brake pads wear 10 7 89 (2) Raise and support the vehicle. (Refer to
indicator caliper bolt LUBRICATION & MAINTENANCE/HOISTING -
STANDARD PROCEDURE)
Engine cradle bolts 125 92 —
(3) Remove engine mount nuts. (Fig. 6)
Engine mount bolt 83 61 —
to engine bracket
Engine mount nuts 45 33 —
to engine cradle
Power steering line 37 27 —
nuts
Steering gear 25 18 —
mounting bolts - 1st
stage
Steering Gear 45 33 —
mounting bolts -
2nd stage
Steering Gear 90° — —
mounting bolts - 3rd
stage
Steering gear 24 18 —
u-joint bolt
Sway bar bushing 30 22 —
bolts
Trailer hitch angle 50* 37* —
bracket bolts/nuts See See Fig. 6 ENGINE MOUNT
Warning Warning 1 - ENGINE MOUNT
Trailer hitch frame 110 81 — 2 - SHIELD
3 - NUTS (2 PER MOUNT)
bolts
Transmission 45 33 — (4) Remove front spring. (Refer to 2 - SUSPEN-
crossmember nuts SION/FRONT/SPRING - REMOVAL)
Transmission mount 45 33 —
bolts/nuts

WARNING: Microencapsulated bolts and self-lock-


ing nuts may only be used once. If you use
microencapsulated bolt or self-locking nuts more
than once, the self-locking function is rendered
useless. The trailer hitch may become detached
from the vehicle, possibly resulting in a serious risk
of injury and/or damage to property, including dam-
age to the vehicle.
VA FRAME & BUMPERS 13 - 7
ENGINE CRADLE CROSSMEMBER (Continued)
(5) Remove calipers. (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/DISC BRAKE CALIPERS
- REMOVAL) (Fig. 7)

Fig. 8 STEERING GEAR


1 - U-JOINT
2 - HIGH PRESSURE POWER STEERING HOSE
3 - RETURN HOSE
Fig. 7 FRONT DISC BRAKE CALIPER 4 - OUTER TIE ROD END RETAINING NUT
5 - STEERING GEAR
1 - WEAR INDICATOR CABLE
6 - STEERING GEAR RETAINING BOLT
2 - WEAR INDICATOR
7 - STEERING GEAR NUT
3 - BOLT
8 - WASHER
4 - BRAKE HOSE
9 - ENGINE MOUNT BOLT
5 - DISC BRAKE CALIPER/ADAPTER
10 - U-JOINT CLAMPING BOLT
6 - ADAPTER BOLTS

(6) Cut tie straps holding wheel speed sensor and


brake pad wear sensor wire harness to the cradle.
(7) Cut tie straps holding transmission harness to
the cradle.
(8) Remove lower pinch bolt from steering shaft
and disconnect shaft. (Fig. 8)
(9) Siphon the power steering fluid out of the res-
ervoir.
(10) Remove both the high pressure and return
hoses from the steering gear (Refer to 19 - STEER-
ING/PUMP/HOSES - REMOVAL) (Fig. 8).
(11) Remove bolt and remove power steering hose
support bracket from the cradle. (Fig. 9)

Fig. 9 POWER STEERING HOSE BRACKET


1 - POWER STEERING LINE
2 - SUPPORT BRACKET BOLT
13 - 8 FRAME & BUMPERS VA
ENGINE CRADLE CROSSMEMBER (Continued)
(12) Disconnect brake lines from body side, at the
couplings. (Fig. 10)

Fig. 10 BRAKE LINES


1 - BRAKE LINES
2 - LINE COUPLINGS

(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)

Fig. 11 ENGINE CRADLE BOLTS


1 - ENGINE CRADLE Fig. 13 IDENTIFICATION PLATE
2 - CRADLE BOLTS (4 PER SIDE)
1 - IDENTIFICATION PLATE
2 - ENGINE CRADLE
(15) Lower engine cradle.
(16) Release support clips and remove brake lines.
(17) Remove nuts and remove jounce bumpers.
INSTALLATION
(18) Remove nuts and remove mount heat shield. (1) Using a suitable RTV sealant, attach identifica-
(Fig. 12) tion plate to engine cradle.
(19) Remove stabilizer bar as necessary. (Refer to 2 (2) Install steering gear onto engine cradle. (Refer
- SUSPENSION/FRONT/STABILIZER BAR - to 19 - STEERING/GEAR - INSTALLATION)
REMOVAL)
NOTE: Steering gear must be torqued in a three
(20) Remove steering gear. (Refer to 19 - STEER-
step procedure below.
ING/GEAR - REMOVAL)
VA FRAME & BUMPERS 13 - 9
ENGINE CRADLE CROSSMEMBER (Continued)
(3) Tighten steering gear bolts in three stages as
follows.
1. Tighten to 25 N·m (18 ft. lbs.)
2. Then tighten to 45 N·m (33 ft. lbs.)
3. Then tighten bolts an additional 90°.
(4) Install stabilizer bar. (Refer to 2 - SUSPEN-
SION/FRONT/STABILIZER BAR - INSTALLATION)
(5) Install heat shield and nuts.
(6) Install jounce bumpers and install nuts.
(7) Install support clips and brake lines.
(8) Raise engine cradle into place and install bolts.
(9) Tighten bolts to 125 N·m (92 ft. lbs.).
(10) Connect brake lines at couplings and tighten
to 14 N·m (10 ft. lbs.).
(11) Position power steering hose and install sup-
port bracket bolt.
(12) Install both power steering hoses at steering
gear. (Refer to 19 - STEERING/PUMP/HOSES -
INSTALLATION)
(13) Connect steering shaft to gear and install the
lower pinch bolt.
(14) Tighten lower pinch bolt to 24 N·m (18 ft.
lbs.).
(15) Install new tie straps holding transmission
harness to cradle.
(16) Install front spring. (Refer to 2 - SUSPEN-
SION/FRONT/SPRING - INSTALLATION)
(17) Install engine mount nuts and tighten to 45
N·m (33 ft. lbs.). Fig. 14 TRANSMISSION CROSSMEMBER
(18) Install calipers. (Refer to 5 - BRAKES/HY- 1 - TRANSMISSION MOUNT BOLTS (2)
DRAULIC/MECHANICAL/DISC BRAKE CALIPERS 2 - TRANSMISSION MOUNT COVER
- INSTALLATION) 3 - TRANSMISSION CROSSMEMBER NUTS (4)
4 - TRANSMISSION MOUNT NUTS (2)
(19) Install new tie straps holding wheel speed 5 - TRANSMISSION SUPPORT
sensors and brake pad wear sensors wire harness to 6 - CROSSMEMBER
cradle. 7 - TRANSMISSION MOUNT
(20) Check and align vehicle to specifications.
(Refer to 2 - SUSPENSION/WHEEL ALIGNMENT - INSTALLATION
STANDARD PROCEDURE) (1) Install crossmember and install nuts.
(2) Tighten crossmember nut to 45 N·m (33 ft.
lbs.).
REAR CROSSMEMBER - (3) Remove transmission support.
TRANSMISSION (4) Install transmission mount bracket.
(5) Install transmission mount bolts/nuts and
REMOVAL tighten to 45 N·m (33 ft. lbs.).
(1) Raise and support the vehicle. (Refer to
LUBRICATION & MAINTENANCE/HOISTING - TRAILER HITCH
STANDARD PROCEDURE)
(2) Support transmission with a suitable lifting
device.
REMOVAL
(1) Disconnect and isolate battery negative cable.
(3) Remove the bolts/nuts and remove transmis-
(2) Raise and support the vehicle. (Refer to
sion mount cover. (Fig. 14)
LUBRICATION & MAINTENANCE/HOISTING -
(4) Remove crossmember nuts and crossmember.
STANDARD PROCEDURE)
(3) Disconnect electrical connector. (Fig. 15)
13 - 10 FRAME & BUMPERS VA
TRAILER HITCH (Continued)
WARNING: Microencapsulated bolts and self-lock-
ing nuts may only be used once. If you use
microencapsulated bolt or self-locking nuts more
than once, the self-locking function is rendered
useless. The trailer hitch may become detached
from the vehicle, possibly resulting in a serious risk
of injury and/or damage to property, including dam-
age to the vehicle.

(4) Remove and discard microencapsulated angle


bracket bolts/nuts. (Fig. 16)
(5) Support hitch and remove frame bolts. (Fig. 17)
(6) Lower hitch.

Fig. 16 TRAILER HITCH MOUNTING


1 - LOCK NUTS (8)
2 - MOUNTING PLATE
3 - BOLTS (8)
4 - ANGLE BRACKETS (2)
5 - BOLTS (4)
6 - HITCH
7 - BRACKET BOLTS/NUTS

Fig. 15 TRAILER HITCH ELECTRICAL CONNECTION


1 - TRAILER CONNECTION SOCKET
2 - ELECTRICAL CONNECTOR TAB
3 - SUPPORT BRACKET
4 - ELECTRICAL CONNECTOR
5 - SCREWS (4)

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

FUEL SYSTEM STANDARD PROCEDURE


WARNING STANDARD PROCEDURES - CLEANING
WARNING - HIGH FUEL SYSTEM FUEL SYSTEM COMPONENTS . . . . . . . . . . . . 3
PRESSURE . . . . . . . . . . . . . . . . . . . . . . .....1 STANDARD PROCEDURES - DRAINING
WARNING . . . . . . . . . . . . . . . . . . . . . . . .....1 WATER FROM FUEL FILTER . . . . . . . . . . . . . . 3
DIAGNOSIS AND TESTING STANDARD PROCEDURE - LOW
DIAGNOSIS AND TESTING - HIGH PRESSURE FUEL PUMP TEST . . . . . . . . . . . . 3
PRESSURE FUEL LINES . . . . . . . . . . . . .....1 FUEL DELIVERY . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DIAGNOSIS AND TESTING - AIR IN FUEL FUEL INJECTION . . . . . . . . . . . . . . . . . . . . . . . . 26
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . .....2
DIAGNOSIS AND TESTING - INJECTOR
LEAK QUANTITY . . . . . . . . . . . . . . . . . . .....2

FUEL SYSTEM CLES TO SPREAD THROUGH OUT THE FUEL


CIRCUIT. ALL CDI FUEL SYSTEM COMPONENTS
CONNECTED TO THE FUEL CIRCUIT WILL HAVE TO
WARNING BE EXCHANGED AND THE LINES FLUSHED.

WARNING - HIGH FUEL SYSTEM PRESSURE DIAGNOSIS AND TESTING


WARNING: HIGH-PRESSURE FUEL LINES DELIVER
FUEL UNDER EXTREME PRESSURE FROM THE DIAGNOSIS AND TESTING - HIGH PRESSURE
INJECTION PUMP TO THE INJECTORS. THIS FUEL LINES
MAYBE AS HIGH AS 1600BAR (23,200PSI). USE
EXTREME CAUTION WHEN INSPECTING FOR HIGH- WARNING: HIGH-PRESSURE FUEL LINES DELIVER
PRESSURE FUEL LEAKS. FUEL UNDER THIS FUEL UNDER EXTREME PRESSURE FROM THE
AMOUNT OF PRESSURE CAN PENETRATE SKIN INJECTION PUMP TO THE INJECTORS. THIS
CAUSING PERSONAL INJURY OR DEATH. INSPECT MAYBE AS HIGH AS 1600BAR (23,200PSI). USE
FOR HIGH-PRESSURE FUEL LEAKS WITH A SHEET EXTREME CAUTION WHEN INSPECTING FOR HIGH-
OF CARDBOARD PLACED IN THE SUSPECTED PRESSURE FUEL LEAKS. FUEL UNDER THIS
AREA WHILE THE ENGINE IS NOT RUNNING. AMOUNT OF PRESSURE CAN PENETRATE SKIN
START THE VEHICLE AND ALLOW THE ENGINE TO CAUSING PERSONAL INJURY OR DEATH. INSPECT
RUN FOR A SHORT PERIOD. TURN THE ENGINE FOR HIGH-PRESSURE FUEL LEAKS WITH A SHEET
OFF AND INSPECT THE PIECE OF CARDBOARD. OF CARDBOARD PLACED IN THE SUSPECTED
WEAR SAFETY GOGGLES AND ADEQUATE PRO- AREA WHILE THE ENGINE IS NOT RUNNING.
TECTIVE CLOTHING WHEN SERVICING FUEL SYS- START THE VEHICLE AND ALLOW THE ENGINE TO
TEM. RUN FOR A SHORT PERIOD. TURN THE ENGINE
OFF AND INSPECT THE PIECE OF CARDBOARD.
WEAR SAFETY GOGGLES AND ADEQUATE PRO-
WARNING TECTIVE CLOTHING WHEN SERVICING FUEL SYS-
TEM.
WARNING: UNDER NO CIRCUMSTANCES SHOULD
GASOLINE BE MIXED WITH DIESEL FUEL (NOT High-pressure fuel line leaks can cause starting
EVEN DURING WINTER). THE HIGH PRESSURE problems and poor engine performance.
PUMP IS LUBRICATED BY DIESEL FUEL. IMMEDI- • Turn the engine off.
ATE FUEL SYSTEM DAMAGE MAY OCCUR CAUS- • Place a piece for cardboard in the suspected area
ING REPLACEMENT AND FLUSHING OF THE (Fig. 1).
COMPLETE DIESEL FUEL SYSTEM. HIGH PRES- • Start the engine and allow to run for a short
SURE PUMP SEIZURE WILL CAUSE METAL PARTI- period.
14 - 2 FUEL SYSTEM VA
FUEL SYSTEM (Continued)
• Turn the engine off. lines for damage that might allow air into the sys-
• Inspect the cardboard. tem.
If a high-pressure line connection is leaking, coun- With the DRBIIIt connected to the vehicle, select
terhold and tighten the connection to specification Engine and the select Sensor Display. Page down to
then perform this procedure again (Refer to 14 - view Fuel Pressure Set Point and Actual Fuel Pres-
FUEL SYSTEM - STANDARD PROCEDURE). sure. Start the engine and observe the Fuel Pressure
Replace any damaged, restricted or leaking high- Set Point and the Actual Fuel Pressure. If the Actual
pressure fuel lines with the correct replacement line. Fuel Pressure Oscillates above and below the Fuel
Pressure Set Point in a regular cycle, inspect the fuel
system for air intrusion.
If the Actual Fuel Pressure gradually drops below
the Fuel Pressure Set Point then spikes well above
the Fuel Pressure Set Point, replace the fuel pres-
sure control valve (Refer to 14 - FUEL SYSTEM/
FUEL INJECTION/FUEL PRESSURE SOLENOID -
REMOVAL), and recheck.

DIAGNOSIS AND TESTING - INJECTOR LEAK


QUANTITY
WARNING: REVIEW THE HIGH PRESSURE FUEL
SYSTEM WARNING BEFORE BEGINNING SERVICE
(Refer to 14 - FUEL SYSTEM - WARNING).

NOTE: If an injector is found to be out of specifica-


tion, repeat this test procedure after the injector
replacement. Hydraulic flow will take the path of
least resistance and multiple failures may be identi-
fied.
Fig. 1 Typical Test for Leaks with Cardboard
1 - HIGH-PRESSURE LINE Perform this test with the engine at operating tem-
2 - CARDBOARD perature. This test will assist in determining a defec-
3 - FITTING tive or internally leaking injector(s) is present by
measuring the amount of fuel return.
CAUTION: The high-pressure fuel lines cannot con- (1) Turn the ignition off.
tact each other or other components. Do not (2) Remove the engine cover (Refer to 9 - ENGINE
attempt to weld high-pressure fuel lines or to repair - REMOVAL).
lines that are damaged. Only use the recommended (3) Disconnect the fuel return hoses at the top of
lines when replacement of high-pressure fuel line is the injectors.
necessary. (4) Disconnect and block off the oil return line at
the banjo bolt fitting of the fuel rail.
(5) Disconnect the fuel rail solenoid.
DIAGNOSIS AND TESTING - AIR IN FUEL (6) Install the test vials onto the injectors and
SYSTEM secure with the return hose clips (Fig. 2).
Air will enter the fuel system whenever fuel supply (7) Crank the engine for ten seconds while moni-
lines, separator filters, injection pump, high-pressure toring each inner test vial.
lines or injectors are removed or disconnected. Air After ten seconds, a maximum of two graduation
trapped in the fuel system can result in hard start- lines may be reached. If the level has exceeded the
ing, a rough running engine, engine misfire, low two graduation line, replace that effected cylinder’s
power, excessive smoke and fuel knock. injector, clear the memory using the scan tool, empty
Inspect the fuel system from the fuel tank to the the test vials, and retest. If the level did not pass the
injectors for loose connections (Refer to 14 - FUEL two graduation line limit, continue to the next step.
SYSTEM - WARNING). Leaking fuel is an indicator (8) Turn the ignition off. Leave the emptied test
of loose connections or defective seals. Air can also vials in place. Reconnect the fuel pressure solenoid.
enter the fuel system between the fuel tank and the Disconnect the cam position sensor, crank the engine
fuel pump. Inspect the fuel tank module and fuel for ten seconds.
VA FUEL SYSTEM 14 - 3
FUEL SYSTEM (Continued)

STANDARD PROCEDURES - DRAINING WATER


FROM FUEL FILTER
Connect a hose to the Water in Fuel (WIF) drain
and place it in a clearly marked and suitable con-
tainer. Open the WIF drain by turning counterclock-
wise (Fig. 3). Turn the ignition key on for 20 seconds
(Refer to low pressure fuel pump operation). Repeat
the procedure until all water is removed, close the
drain and remove the hose.

Fig. 2 Special Tool # 9545


1 - SPECIAL TOOL #9545

After ten seconds, a maximum of four graduation


lines of the inner test vial may be reached. If the
level has exceeded the four graduation line, replace
that effected cylinder’s injector, clear the memory
using the scan tool, empty the test vials, and retest.
If the level did not pass the four graduation line
limit, continue with the diagnostic manual.

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).

Fig. 5 FUEL PRESSURE TEST AT HIGH PRESSURE


PUMP

Fig. 4 FUEL GAUGE CONNECT AT HIGH PRESSURE


PUMP
1 - FUEL SUPPLY FITTING
2 - ADAPTOR
3 - FUEL GAUGE HOSE
4 - HIGH PRESSURE PUMP
5 - FUEL RETURN FITTING

(3) Connect negative battery cable.


(4) Turn the ignition to the On position and
observe the fuel gauge reading (Fig. 5).
If the fuel pressure is within specification, recon-
nect the fuel line to the high pressure pump and con-
tinue with the diagnostics. If the fuel pressure is
below specification, disconnect the low pressure fuel
pump input line to the fuel filter and re-test follow-
ing the steps above (Fig. 6).
If the fuel pressure is below specification, replace
the fuel pump. If the fuel pressure is equal to the
specification, replace the fuel filter.
FUEL PRESSURE SPECIFICATIONS Fig. 6 FUEL PRESSURE TEST AT FILTER
1 - FUEL SUPPLY FROM FUEL TANK
2 - FUEL FILTER ASSEMBLY
SUCTION PRESSURE 7.25 PSI (0.5 bar)
DELIVERY PRESSURE 65 PSI (4.5 bar)
MAXIMUM FUEL 53 gallons/hour(200
DELIVERY liters/hour)
VA FUEL DELIVERY 14 - 5

FUEL DELIVERY

TABLE OF CONTENTS
page page

FUEL DELIVERY OPERATION - LOW PRESSURE PUMP . . . . . 13


DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 5 REMOVAL - HIGH PRESSURE PUMP . . . . . . . . 14
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 INSTALLATION - HIGH PRESSURE PUMP . . . . 14
SPECIFICATIONS FUEL PUMP MODULE
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 15
SPECIAL TOOLS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 8 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16
FUEL DRAIN TUBES FUEL QUANTITY CONTROL VALVE
DIAGNOSIS AND TESTING - FUEL SUPPLY DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 17
RESTRICTIONS . . . . . . . . . . . . . . . . . . . . . . . . 8 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
FUEL FILTER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18
REMOVAL .............................8 FUEL RAIL
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 18
FUEL LINES OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
REMOVAL - HIGH PRESSURE LINES . . . . . . . . . 9 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
INSTALLATION - HIGH PRESSURE LINES . . . . . 9 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19
FUEL RAIL PRESSURE SENSOR FUEL TANK
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 20
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11 FUEL LEVEL SENDING UNIT / SENSOR
FUEL PUMP DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 24
DESCRIPTION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
DESCRIPTION - HIGH PRESSURE PUMP . . . 11 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24
DESCRIPTION - LOW PRESSURE PUMP . . . 11 WATER IN FUEL SENSOR
OPERATION DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 25
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 11 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

FUEL DELIVERY temperature, charge air temperature and atmo-


spheric pressure are use to correct the quantity of
pilot injection. The quantity of pilot injection now
DESCRIPTION
determined is deducted from the quantity of main
Fuel is collected in the fuel tank. The fuel is drawn
injection in order to establish whether sufficient
in by the fuel pump module in the tank and distrib-
quantity is available for the following main injection.
uted to the fuel filter and onto the high pressure fuel
The rail pressure is chosen sufficiently high so that
pump. From there the fuel is distributed onto the
a minimum quantity is injected. If the quantity of
fuel rail and then to the various injectors. Any fuel
main injection is too small the pilot injection is
not needed flows back to the fuel tank through the
switched off by the ECM.
cooler lines and mixes with the cool fuel in the fuel
The start of actuation of pilot injection is calcu-
pump module bowl to be used again (Fig. 1).
lated dependent on operating point, the following
data being taken into account:
OPERATION Shutting Off Pre-injection The pre-injection is shut
There are several modes of operation for the Com- off when:
mon Rail Diesel Injection System.
• The moment of pre-injection is exceeded
Pre-injection The purpose of the pre-injection func-
• Engine speed too high
tion is to reduce noise and pollutants. The coolant • Pre-injected quantity too low
14 - 6 FUEL DELIVERY VA
FUEL DELIVERY (Continued)

Fig. 1 FUEL SUPPLY


1 - HIGH PRESSURE FUEL PUMP 8 - FUEL INJECTOR
2 - FUEL FROM LOW PRESSURE PUMP 9 - HIGH PRESSURE FUEL FROM HIGH PRESSURE PUMP
3 - FUEL FILTER 10 - FUEL PRESSURE SOLENOID
4 - LOW PRESSURE FUEL PUMP 11- FUEL RAIL
5 - FUEL TANK 12 - FUEL RAIL PRESSURE SENSOR
6 - RETURN FUEL 13 - FUEL QUANTITY CONTROL VALVE
7 - HIGH PRESSURE FUEL FROM HIGH PRESSURE PUMP 14 - FUEL TEMPERATURE VALVE

• Main injected quantity too low • Boost air temperature


• Insufficient fuel rail pressure • Atmospheric pressure
• Engine is switched off • Pre-injection corrected YES/NO
Calculating Pre-injection Quantity The pre-injec-
tion quantity is calculated on the basis of: Switching Off Main Injection
• Engine speed Main injection is switched off when:
• Atmospheric pressure • Engine speed is too high >4700 - 4800 rpm
• Coolant temperature • Main injection quantity too low
• Boost air temperature • Low fuel pressure in fuel rail
• Fuel rail pressure • Engine off
Main Injection The purpose of main injection func- • External quantity control
tion is to enable the injection time and injection • Deceleration mode
period calculated by the ECM. The injection quantity
required by the engine is divided into the per-injec- Calculating Main Injection
tion and main injection quantity. If the main injec- The quantity of main injection is calculated by:
tion quantity computed by the ECM is too small, no • Engine speed
pre-injection takes place. • Atmospheric pressure
• Coolant temperature
Start of Actuation • Boost air temperature
The start of actuation of main injection is depen- • Fuel rail pressure
dent on engine speed and quantity. In addition, it is • Boost pressure
corrected depending on the following values:
• Coolant temperature
VA FUEL DELIVERY 14 - 7
FUEL DELIVERY (Continued)
Period of Actuation Limiting Maximum Engine Speed
For calculating the period of actuation of the main The ECM determines the engine speed based on
injection it is necessary to know whether a pre-injec- the signal supplied by the crankshaft sensor and lim-
tion has occurred or not. its this by interrupting the operation of the fuel
The coolant temperature, charge air temperature injectors.
and the atmospheric pressure are used for correcting
the main injection quantity. If main injection quan- Fuel Quantity Control
tity is less than a minimum quantity which is depen- The fuel quantity is controlled separately for each
dent on fuel rail pressure, no preinjection takes cylinder by the ECM inline with the firing order.The
place. In this case, only main injection is performed. ECM detects the operating state which exists at the
If the quantity is then still below the minimum engine by means of the sensors. In order adapt the
quantity, neither main injection or pre-injection takes quantity injected, either the fuel rail pressure can be
place (deceleration mode). adjusted by the fuel solenoid and quantity control
valve or the actuation time of the solenoid valves in
Deceleration Mode the injectors
The purpose of the deceleration mode is to inter-
rupt the operation of the injectors. The ECM deter- Boiling Protection
mines the accelerator pedal position from a supplied In order to protect against thermal overload and
signal and it determines the engine speed by the along with criteria programmed in the ECM, the
crank sensor. In the overrun and with the engine injection quantity is reduced as a function of the cool-
speed above 1600, with the accelerator pedal no ant temperature and vehicle speed. If the coolant
pressed, the injectors are no longer actuated and the temperature sensor fails the oil temperature signal
fuel rail pressure is lowered by the pressure regula- from the oil sensor is used as a suitable value.
tor valve.
Fuel Tank Protection
Full Load Injected Quantity The fuel rail pressure is lowered in order to protect
The purpose of the full load injected quantity is to the fuel tank from overheating. The fuel temperature
minimize the formation of smoke. The ECM limits sensor measures the temperature of the fuel being
the fuel rail pressure when the engine is operating at supplied from the tank, in the high pressure flange.
full load by way of the quantity control valve, and If the fuel is too warm the fuel rail pressure is fur-
quantity of fuel injected by the injectors. this mini- ther reduced by the quantity control valve.
mizes the formation of smoke when accelerating and
driving at constant speeds. If a fault occurs at the
boost pressure control, full load injected quantity is
reduced.

SPECIFICATIONS

TORQUE

DESCRIPTION N·m Ft. Lbs. In. Lbs.


FUEL TANK MOUNTING NUTS 15 - 17 11 - 13 -
FUEL TANK MODULE LOCKRING 60 44 -
(LOCKNUT)
PRESSURE CONTROL VALVE NUT TO 60, loosen 90°, 44, loosen 90°,
-
FUEL RAIL (2 STAGES) retighten to 80 retighten to 59
14 - 8 FUEL DELIVERY VA
FUEL DELIVERY (Continued)

SPECIAL TOOLS FUEL DRAIN TUBES


FUEL SYSTEM DIAGNOSIS AND TESTING - FUEL SUPPLY
SPECIAL TOOL CROSS REFERENCE CHART RESTRICTIONS
MB MILLER DESCRIPTION LOW-PRESSURE LINES
TOOL # TOOL # Fuel supply line restrictions can cause starting
N/A 5069-2 FUEL GAUGE problems and prevent engine from accelerating. The
starting problems include; low power and/or white
N/A 6856 SPANNER WRENCH
fog like exhaust.
N/A 9068 FUEL GAUGE ADAPTER Test all fuel supply lines for restrictions or block-
N/A 9285 FUEL LINE WRENCH age. Flush or replace as necessary.

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.

(1) Disconnect negative battery cable.

CAUTION: Counterhold with wrench at threaded


connections of injectors. DO NOT EXCEED the
tightening torque in order to avoid also slackings
the threaded connection.
Fig. 2 FUEL FILTER
1 - FUEL SUPPLY LINE TO HIGH PRESSURE PUMP
2 - FUEL FILTER CAUTION: DO NOT crimp or bend lines.
3 - WIF SENSOR
4 - FUEL FILTER DRAIN
NOTE: After removing injection lines, seal connec-
INSTALLATION tions and ensure cleanliness.

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)

FUEL RAIL PRESSURE


SENSOR
DESCRIPTION
The fuel rail pressure sensor is attached to the
front of the fuel rail. The sensor supplies the current
fuel rail pressure to the ECM.

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).

NOTE: Place a shop towel underneath the sensor to


Fig. 3 FUEL RAIL capture any fuel spillage.
1 - CAMSHAFT POSITION SENSOR
2 - FUEL INJECTOR (3) Unscrew the sensor and discard the seal.
3 - FUEL INJECTOR VALLEY DRAIN
4 - FUEL RAIL PRESSURE CONTROL VALVE
5 - BANJO BOLT
6 - FUEL RAIL
7 - HIGH PRESSURE FUEL LINE

(1) Loosen the fuel rail mounting bolts to install


lines free of stress.

CAUTION: Inspect sealing cone at lines. Replace if


compression points exist. Ensure lines are exactly
located.

(2) Position and install fuel lines (Fig. 3). Tighten


to 22N·m (195 lbs. in.) using a wrench to counterhold
at threaded connection.
(3) Tighten fuel rail to 14N·m (124 lbs. in.).
(4) Connect negative battery cable.

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. Fig. 4 FUEL RAIL PRESSURE SENSOR
1 - FUEL RAIL PRESSURE SENSOR
(5) Start engine, run for a few minutes, turn 2 - FUEL RAIL
engine off and inspect for leaks (Refer to 14 - FUEL 3 - COOLANT TEMPERATURE SENSOR
SYSTEM - WARNING), (Refer to 14 - FUEL SYS-
TEM - DIAGNOSIS AND TESTING).
VA FUEL DELIVERY 14 - 11
FUEL RAIL PRESSURE SENSOR (Continued)

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.

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.

(4) (Refer to 14 - FUEL SYSTEM - WARNING).


Start engine, allow to run for a few minutes, turn the
engine off and inspect for leaks.

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).

Fig. 6 LOW PRESSURE SIDE


1 - HIGH PRESSURE PUMP 7 - FUEL BLEED PORT
2 - FUEL TEMPERATURE SENSOR 8 - SHAFT LUBRACATION PORT
3 - FUEL SUPPLY TO PUMP ELEMENTS 9 - FUEL PRESSURE RELIEF VALVE
4 - FUEL ANNULAR PORT 10 - ZERO DELIVERY RESTRICTOR
5 - FUEL SUPPLY 11- FUEL QUANTITY VALVE
6 - FUEL RETURN
VA FUEL DELIVERY 14 - 13
FUEL PUMP (Continued)
HIGH PRESSURE SIDE OPERATION - LOW PRESSURE PUMP
A. Filling the piston: The piston (6) is moved When the ignition switch is on, fused battery posi-
down as a result of the piston spring (7). The fuel tive voltage is supplied to the electric lift pump,
supplied by the fuel delivery pump flows along the which will run for 20–30 seconds and then stop. If
ring passage (10), the valve disk and the valve spring the engine is cranked, the pump will begin running
(3) into the cylinder. The check ball (4) prevents the immediately supplying fuel through fuel filter and
fuel from being able to flow back from the high pres- onto the high pressure pump. The lift pump and low
sure passage (5) (Fig. 7). pressure fuel circuit operate at a pressure between
B. Producing high pressure: The piston (6) is 5-7 bar (72.5- 101 psi.).
moved up by the rising eccentric shaft (9) and the
fuel is compressed. The valve (2) disk shuts off the
delivery volume to the fuel supply. Once the fuel
pressure in the cylinder rises beyond the pressure
which exists in the high pressure circuit (5), the
check ball (4) opens and the fuel is pumped into the
high pressure circuit (5) (Fig. 7).

Fig. 7 PRODUCING HIGH PRESSURE


1 - FUEL SUPPLY TO PUMP 6 - PISTON
2 - VALVE 7 - PISTON SPRING
3 - VALVE SPRING 8 - CAM
4 - CHECK BALL 9 - ECCENTRIC SHAFT
5 - HIGH PRESSURE PASSAGE 10 - CIRCULAR PASSAGE
14 - 14 FUEL DELIVERY VA
FUEL PUMP (Continued)

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).

INSTALLATION - HIGH PRESSURE PUMP

Fig. 8 HIGH PRESSURE FUEL PUMP


1 - INTERMEDIATE GEAR
2 - HIGH PRESSURE PUMP
3 - SEALING RING
4 - DRIVER
5 - HIGH PRESSURE LINE
6 - FUEL SUPPLY LINE Fig. 9 HIGH PRESSURE FUEL PUMP
7 - FUEL RETURN LINE
1 - INTERMEDIATE GEAR
8 - BOLTS
2 - HIGH PRESSURE PUMP
9 - FUEL QUANTITY CONTROL VALVE
3 - SEALING RING
10 - FUEL TEMPERATURE SENSOR
4 - DRIVER
5 - HIGH PRESSURE LINE
(Refer to 14 - FUEL SYSTEM - WARNING) 6 - FUEL SUPPLY LINE
(1) Disconnect negative battery cable. 7 - FUEL RETURN LINE
8 - BOLTS
(2) Remove viscous fan clutch (Refer to 7 - COOL- 9 - FUEL QUANTITY CONTROL VALVE
ING/ENGINE/FAN DRIVE VISCOUS CLUTCH - 10 - FUEL TEMPERATURE SENSOR
REMOVAL).
(3) Unplug electrical connectors at high pressure (Refer to 14 - FUEL SYSTEM - WARNING)
pump.
CAUTION: Clean sealing surfaces with appropriate
CAUTION: DO NOT slacken the threaded connec- solvents and replace all seals.
tion. Use a wrench to counterhold at the threaded
connection when loosening and tightening the
NOTE: Inspect then attach high pressure pump
union nut. DO NOT EXCEED tightening torque.
drive if pump is being replaced. If wear is present at
drive, replace drive and gear.
CAUTION: DO NOT crimp or bend fuel line. Capture
all fluids that flow out of connections. (1) Position and secure the high pressure pump to
cylinder head (Fig. 9). Tighten bolts to 14 N·m (124
(4) Disconnect the high pressure line at high pres- lbs. in.).
sure pump (Fig. 8).
(5) Detach fuel supply and return flow line at high CAUTION: NEVER slacken the thread connection.
pressure pump using special tool #9539 (Fig. 8). Use a wrench to counterhold at threaded connec-
tion when slackening and tightening torque in order
NOTE: Care must be taken not to drop the high to avoid also slackening the threaded connection
pressure pump drive when removing pump. Inspect the next time.
VA FUEL DELIVERY 14 - 15
FUEL PUMP (Continued)
CAUTION: DO NOT crimp or bend fuel line. Inspect
sealing cone at line; replace line if compression exists.

NOTE: Care must be taken not to cross the fuel


return and supply lines during installation.

(2) Attach fuel flow supply and return lines,


recrimping clamps using special tool #9539 (Fig. 9).

CAUTION: NEVER slacken the thread connection. Use


a wrench to counterhold at threaded connection when
slackening and tightening torque in order to avoid
also slackening the threaded connection the next time.

CAUTION: DO NOT crimp or bend fuel line. Inspect


sealing cone at line; replace line if compression exists.

(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.

(1) Drain and remove fuel tank. Refer to Fuel


Tank Removal/Installation.
(2) Thoroughly clean area around pump module at Fig. 11 FUEL PUMP MODULE R/I
top of tank. 1 - LOCKNUT (LOCKRING)
(3) Disconnect both fuel lines from pump module 2 - SPECIAL TOOL #6856
fittings. 3 - TOP OF PUMP MODULE
14 - 16 FUEL DELIVERY VA
FUEL PUMP MODULE (Continued)
(5) Pull module assembly up just a few inches to (7) Twist rod (3) slightly (Fig. 14) to remove from
gain access to float support arm/rod (3) (Fig. 12). Be fuel level sensor. Do not allow float assembly to fall
careful not to bend float support rod while removing into fuel tank.
pump module.

Fig. 14 FLOAT ROD CLIP REMOVED


Fig. 12 FLOAT ROD CLIP 1 - FUEL LEVEL SENSOR
1 - FUEL LEVEL SENSOR 2 - CLIP
2 - CLIP 3 - FLOAT ROD
3 - FLOAT ROD
(8) While holding float rod, remove fuel pump
(6) Rotate clip (2) (Fig. 13) to release float rod (3) module from fuel tank.
from fuel level sensor (1). (9) Remove float assembly from fuel tank.
(10) Remove and discard rubber gasket (seal) from
pump module.

INSTALLATION
CAUTION: Whenever the fuel pump module is ser-
viced, the rubber gasket must be replaced.

(1) Thoroughly clean locknut (lockring) and lock-


nut threads at top of tank.
(2) Position new gasket (seal) to fuel tank opening.
(3) Position float rod assembly partially into fuel
tank.
(4) Position fuel pump module partially into fuel
tank.

Fig. 13 FLOAT ROD CLIP REMOVAL


1 - FUEL LEVEL SENSOR
2 - CLIP
3 - FLOAT ROD
VA FUEL DELIVERY 14 - 17
FUEL PUMP MODULE (Continued)
(5) Twist rod (3) (Fig. 15) into clip (2) on fuel level (9) Both fuel line fittings should be pointed to the
sensor (1). right side of the vehicle. Rotate and position align-
ment arrow (Fig. 17) towards right side of vehicle (if
necessary) before tightening locknut. This step
must be performed to prevent the module’s
float from contacting the side of fuel tank.
(10) Tighten locknut using Special Tool #6856.
Refer to Torque Specifications.
(11) Install fuel tank. Refer to Fuel Tank Removal/
Installation.

Fig. 15 FLOAT ROD CLIP INSTALLATION


1 - FUEL LEVEL SENSOR
2 - CLIP
3 - FLOAT ROD

(6) Rotate clip (2) (Fig. 16) to attach rod (3) to clip.

Fig. 17 ALIGN PUMP MODULE


1 - LOCKNUT
2 - ALIGNMENT ARROW (POSITION TOWARDS RIGHT SIDE OF
VEHICLE)

FUEL QUANTITY CONTROL


VALVE
DESCRIPTION
The fuel quantity control valve mounts to front of
the high pressure pump and is controlled by the
ECM. The quantity control valve assists in maintain-
ing proper fuel quantity injected under all operating
conditions. Fuel tank heat protection is also provided
Fig. 16 FLOAT ROD CLIP INSTALLATION by the quantity control valve. The valve meters the
1 - FUEL LEVEL SENSOR exact amount of fuel to prevent excess heated fuel
2 - CLIP
3 - FLOAT ROD from returning to the tank.

(7) After attaching float assembly to fuel level sen- OPERATION


sor, carefully position fuel pump module into opening The ECM monitors the fuel system and measures
in fuel tank. for pressure vibrations. The ECM will then react by
(8) Position locknut over top of fuel pump module. signaling the quantity control valve to regulate the
Install locknut finger tight. amount of fuel to the high pressure pump plunger
and barrel assemblies. The valve then adjusts the
14 - 18 FUEL DELIVERY VA
FUEL QUANTITY CONTROL VALVE (Continued)
injection correction quantity for each individual cyl-
inder in line with the firing order, there by eliminat-
ing the pressure resonance in the fuel rail and
improving each independent injectors operation. The
fuel quantity valve also interrupts the fuel supply to
the high pressure pump plunger and barrel assem-
blies when the engine is switched off.
The ECM detects the operating state which exists
at the engine by means of the sensors. In order to
adapt the quantity injected, either the rail pressure
can be adjusted by way of the pressure regulator
valve and the quantity control valve, or the actuation
time of the solenoid valves in the fuel injectors can
be extended or shortened.
Fuel quantity control is performed under the fol-
lowing operating conditions:
• Approximately 30 seconds after the engine has
started
• Fuel temperature > 20°C (68°F)
• Engine not in deceleration mode

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).

CAUTION: Inspect sealing cones at the lines.


Replace as necessary. Ensure that all fuel pressure
lines are exactly located in original position.

(4) Install the high pressure fuel lines and hand


tighten.

CAUTION: When tightening fuel injection line union


nuts, counter hold with a wrench at the thread con-
nection. ON NO ACCOUNT exceed the tightening
torque at any time.

(5) Tighten fuel rail bolts to 14 N·m (124 lbs.in.)


(Fig. 19)
(6) Reconnect engine harness electrical connectors.
(7) Connect the intake manifold air inlet duct.
(8) Connect negative battery cable.

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
Fig. 19 FUEL RAIL the left rear corner of the cover. Failure to do so
1 - CAMSHAFT POSITION SENSOR may pinch or damage the hose causing fuel leakage
2 - FUEL INJECTOR or a driveability concern.
3 - FUEL INJECTOR VALLEY DRAIN
4 - FUEL RAIL PRESSURE CONTROL VALVE
5 - BANJO BOLT
6 - FUEL RAIL WARNING: USE EXTREME CAUTION WHEN THE
7 - HIGH PRESSURE FUEL LINE ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH FAN. DO NOT PUT YOUR
(8) Detach fuel return flow line to high pressure HANDS NEAR PULLEYS, BELTS OR FAN. DO NOT
pump at rail WEAR LOOSE CLOTHING.
(9) Detach fuel return flow line at banjo bolt (Fig.
19) (9) Start engine, run for a few minutes, turn the
(10) Remove fuel rail. engine off and inspect for leaks (Refer to 14 - FUEL
SYSTEM - WARNING).
INSTALLATION
(Refer to 14 - FUEL SYSTEM - WARNING)

WARNING: NO FIRE, FLAMES OR SMOKING. RISK


OF POISONING FROM INHALING OR SWALLOWING
14 - 20 FUEL DELIVERY VA

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

Fig. 20 FUEL TANK ASSEMBLY


1 - Strap Bolts (2) 8 - Nuts (2)
2 - Hose (not with all engines) 9 - Filler Tube
3 - Fuel Outlet Line 10 - Vent Hose
4 - Fuel Return Line 11 - Hose
5 - Plug 12 - Clamps
6 - Fuel Tank 13 - Cushioning Material
7 - Tank Straps (2) 14 - Two-Way Valve
VA FUEL DELIVERY 14 - 21
FUEL TANK (Continued)

Fig. 21 FUEL COOLER LINES Fig. 22 TOP OF FUEL TANK


1 - Expansion Tank 1 - Cooler Lines
2 - Top of Tank 2 - Top of Tank
3 - Thermostat (Preheating Valve) 3 - Expansion Tank
4 - Cooler Lines 4 - Check Valves
5 - Connecting Hoses/Clamps 5 - Check Valve
6 - Module Lock Ring
7 - Fuel Pump Module

Fig. 23 FUEL TANK ASSEMBLY


1 - Strap Bolts (2) 8 - Nuts (2)
2 - Hose (not with all engines) 9 - Filler Tube
3 - Fuel Outlet Line 10 - Vent Hose
4 - Fuel Return Line 11 - Hose
5 - Plug 12 - Clamps
6 - Fuel Tank 13 - Cushioning Material
7 - Tank Straps (2) 14 - Two-Way Valve
14 - 22 FUEL DELIVERY VA
FUEL TANK (Continued)
(11) If fuel tank is to be replaced, remove fuel INSTALLATION
pump module from tank. Refer to Fuel Pump Module (1) If fuel cooler lines (Fig. 27) are to be installed,
Removal/Installation procedures. use special pliers #9539 (Fig. 28).
(12) If fuel cooler lines (Fig. 24) are to be removed, (2) If fuel tank is to be replaced, install fuel pump
use special pliers #9539 (Fig. 25). module into tank. Refer to Fuel Pump Module
Removal/Installation procedures.
(3) Position fuel tank to hydraulic jack.
(4) Raise tank until positioned near body.
(5) Connect fuel pump module electrical connector
at top of tank.
(6) Connect fuel supply and return lines.
(7) Continue raising tank while guiding fill hose
into body. Raise tank until positioned snug to body.
(8) Install and position both fuel tank support
straps (7) (Fig. 26) to mounting bolts (1).
(9) Install 2 fuel tank strap nuts (8). Refer to
Torque Specifications.
(10) Remove hydraulic jack.
(11) Connect fill and vent hoses to body. Install
ground wire to fill hose.
(12) Lower vehicle.
(13) Fill fuel tank with fuel.
(14) Start engine and check for fuel leaks near top
of module.
Fig. 24 FUEL COOLER LINES
1 - Expansion Tank
2 - Top of Tank
3 - Thermostat (Preheating Valve)
4 - Cooler Lines
5 - Connecting Hoses/Clamps

Fig. 25 FUEL LINE PLIERS-9539


VA FUEL DELIVERY 14 - 23
FUEL TANK (Continued)

Fig. 26 FUEL TANK ASSEMBLY


1 - Strap Bolts (2) 8 - Nuts (2)
2 - Hose (not with all engines) 9 - Filler Tube
3 - Fuel Outlet Line 10 - Vent Hose
4 - Fuel Return Line 11 - Hose
5 - Plug 12 - Clamps
6 - Fuel Tank 13 - Cushioning Material
7 - Tank Straps (2) 14 - Two-Way Valve

Fig. 28 FUEL LINE PLIERS-9539

Fig. 27 FUEL COOLER LINES


1 - Expansion Tank
2 - Top of Tank
3 - Thermostat (Preheating Valve)
4 - Cooler Lines
5 - Connecting Hoses/Clamps
14 - 24 FUEL DELIVERY VA

FUEL LEVEL SENDING UNIT /


SENSOR
DESCRIPTION
The fuel gauge sending unit (fuel level sensor) is
attached to the side of the fuel pump module (Fig.
29). The sending unit consists of a float, an arm, and
a variable resistor track (card).

Fig. 30 FUEL LEVEL SENSOR


1 - RELEASE TABS
2 - ELECTRIC FUEL PUMP
3 - BOTTOM OF FUEL PUMP MODULE
4 - SENDING UNIT

(2) Plug 2–wire harness connector into pump mod-


ule electrical connector.
(3) Position sending unit (4) (Fig. 31) to tracks on
fuel pump module. Slide and snap into place.
Fig. 29 FUEL LEVEL SENSOR (4) Install fuel pump module. Refer to Fuel Pump
1 - RELEASE TABS Module Removal/Installation.
2 - ELECTRIC FUEL PUMP
3 - BOTTOM OF FUEL PUMP MODULE
4 - SENDING UNIT

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

WATER IN FUEL SENSOR OPERATION


The non-dielectric properties of the water allow the
DESCRIPTION sensors probes to close the electronic circuit when
The water in fuel sensor (WIF) is located in the water is present in the system. When diesel fuel is
fuel filter housing (Fig. 32). The sensor detects the present in the system, it’s dielectric (does not conduct
presence of water in the fuel. If water is present in electricity well) properties do not allow any electrical
the fuel a signal is sent to the ECM and the ECM contact between the probes. A 12V power signal is
signals the instrument cluster, over the CAN bus, to always present in order to illuminate the indicator on
illuminate the water in fuel warning. the instrument cluster. For removal and installation
procedure refer to (Refer to 14 - FUEL SYSTEM/
FUEL DELIVERY/FUEL FILTER - REMOVAL).

Fig. 32 WATER IN FUEL SENSOR


1 - WIF SENSOR
2 - WIF DRAIN
3 - FUEL FILTER
4 - FUEL SUPPLY FROM TANK
5 - FUEL SUPPLY TO HIGH PRESSURE PUMP
14 - 26 FUEL INJECTION VA

FUEL INJECTION

TABLE OF CONTENTS
page page

ACCELERATOR PEDAL POSITION SENSOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34


DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 27 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 34
BOOST PRESSURE SENSOR FUEL PRESSURE SOLENOID
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 27 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 34
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
DIAGNOSIS AND TESTING - BOOST REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
PRESSURE SENSOR . . . . . . . . . . . . . . . . . . 28 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 35
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 FUEL TEMPERATURE SENSOR
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 28 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 36
CAMSHAFT POSITION SENSOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 28 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 36
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 INTAKE AIR TEMPERATURE SENSOR
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 29 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 36
CRANKSHAFT POSITION SENSOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 29 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 INTAKE AIR PRESSURE SENSOR
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 30 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 37
FUEL INJECTOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
DESCRIPTION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
FUEL INJECTOR . . . . . . . . . . . . . . . . . . . . . . 30 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 MANIFOLD AIR FLOW (MAF) SENSOR
STANDARD PROCEDURE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 37
STANDARD PROCEDURE - INJECTOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
CLASSIFICATION . . . . . . . . . . . . . . . . . . . . . 31 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
STANDARD PROCEDURE - CLEANING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 38
FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . 32 O2 SENSOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 39
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 33 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
FUEL PRESSURE SENSOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 33 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 41
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
VA FUEL INJECTION 14 - 27

ACCELERATOR PEDAL BOOST PRESSURE SENSOR


POSITION SENSOR
DESCRIPTION
DESCRIPTION The boost pressure sensor is mounted to the charge
The accelerator pedal position sensor is located on air pipe (Fig. 2). The sensor allows the ECM to mon-
the accelerator pedal assembly. The driver supplies itor intake air down stream of the turbocharger.
the torque requirements for the engine by operating
the accelerator pedal in accordance with the desired
speed or acceleration. The pedal sensor converts the
mechanical operation of the pedal into an electrical
signal and sends the information to the ECM. The
ECM adjusts the quantity of the fuel that is injected
into the engine (Fig. 1).
The accelerator pedal position sensor is serviced as
an assembly with the accelerator assembly.

Fig. 2 BOOST PRESSURE SENSOR


OPERATION
When the intake manifold pressure is low (high
vacuum) sensor voltage output is 0.25-1.8 volts at the
ECM. When the intake manifold pressure is high due
to turbo boost, sensor voltage output is 2.0-4.7 volts.
The sensor receives a 5-volts reference from the
ECM. Sensor ground is also provides by the ECM.
The ECM uses boost pressure combined with intake
Fig. 1 ACCELERATOR PEDAL POSITION SENSOR air temerature to determine the volume of air enter-
ing the engine (Fig. 2).
14 - 28 FUEL INJECTION VA
BOOST PRESSURE SENSOR (Continued)

DIAGNOSIS AND TESTING - BOOST PRESSURE CAMSHAFT POSITION


SENSOR SENSOR
If the boost pressure sensor fails, the ECM records a
DTC into memory and continues to operate the engine DESCRIPTION
in one of the three limp-in modes. When the ECM is The camshaft position sensor is mounted on the
operating in this mode, a loss of power will be present, cylinder head cover toward the rear of the engine.
as if the turbocharger was not operating. The best The camshaft sensor utilizes a non contact method
method for diagnosing faults with the boost pressure on one segment of the camshaft to record the cam-
sensor is with the DRB IIIt scan tool. Refer to the Die- shaft position. When the ECM receives the signal
sel Powertrain Diagnostic Manual for more information. from this sensor, it can then detect TDC of cylinder
Refer to On-Board Diagnostics in Emissions Con- number one. The signal from the camshaft sensor is
trol System for a list of Diagnostic Trouble Codes only required during engine starting. Injection timing
(DTC’s) for certain fuel system components. is synchronized by means of the camshaft signal and
the crankshaft signal.
REMOVAL
(1) Disconnect the negative battery cable.
(2) Unplug the electrical connector.
(3) Remove the sensor retaining bolts, remove the
sensor (Fig. 3) and O-ring.

Fig. 4 CAMSHAFT POSITION SENSOR


1 - WIRING HARNESS CONNECTOR
2 - CAM POSITION SENSOR
3 - O-RING
Fig. 3 BOOST PRESSURE AND INLET AIR 4 - CYLINDER HEAD COVER
TEMPERATURE SENSORS
1 - CHARGE AIR DUCT OPERATION
2 - INTAKE AIR TEMPERATURE SENSOR On the camshaft sensor’s signal line, a high signal
3 - BOOST PRESSURE SENSOR
correspons to a voltage of 0-5V. If the segment
machined into the exhaust camshaft sprocket is posi-
INSTALLATION tioned opposite the camshaft sensor, the camshaft
(1) Inspect boost pressure sensor O-ring for cuts or signal is low, approximately 0V. This signal is used
abrasions, replace as necessary. by the engine control module (ECM) for detecting
(2) Position the boost pressure sensor above access ignition TDC of cylinder 1 as the engine rotates. If no
hole in the charge air pipe and push down to fit flush signal is supplied by the camshaft position sensor,
(Fig. 17). the vehicle will not start because cylinder order can
(3) Install the bolts and tighten to 44 lbs. in. (5 not be detected (Fig. 4).
N·m) (Fig. 17).
(4) Reconnect the sensor electrical connector (Fig. 17).
(5) Connect negative battery cable
VA FUEL INJECTION 14 - 29
CAMSHAFT POSITION SENSOR (Continued)

REMOVAL CRANKSHAFT POSITION


(1) Disconnect negative battery cable.
(2) Remove engine cover
SENSOR
(3) Disconnect camshaft position sensor electrical
connector (Fig. 5). DESCRIPTION
(4) Remove retaining bolt and remove sensor (Fig. The crankshaft position sensor is located opposite
5). the teeth on the flywheel and uses a non contact
method to record the position of the crankshaft. The
leading edges of each tooth on the flywheel generate
a positive signal in the position sensor, while the
trailing edges generate a negative signal. When the
crankshaft is rotating, an alternating voltage is pro-
duced as a result.
The period of the signal is the time required by the
crankshaft to turn through the gap between two fly-
wheel teeth. The clearance between the crankshaft
position sensor and the teeth of the flywheel is fixed
by the installation.
Two teeth on the flywheel are missing. The result-
ing signal gap is used by the ECM to detect the TDC
position of cylinder number one.

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 parts inside the injector are graphite coated to assist


(1) Disconnect the negative battery cable. with the lubrication process.
(2) Unplug the crankshaft wiring harness connec-
tor.
(3) Remove the crankshaft sensor retaining bolt
and remove sensor (Fig. 6).

Fig. 7 FUEL INJECTOR


1 - FUEL INJECTOR
2 - NOZZLE
3 - FUEL INLET FITTING
4 - ELECTRICAL CONNECTION
Fig. 6 CRANKSHAFT POSITION SENSOR
1 - ENGINE BLOCK OPERATION
2 - WIRING HARNESS CONNECTOR The injector operation can be subdivided into four
3 - CRANKSHAFT POSITION SENSOR
4 - STARTER SOLENOID operating states with the engine running and the
high-pressure pump generating pressure:
INSTALLATION • Injector closed (with high pressure applied)
(1) Position the crankshaft position sensor into the • Injector opens (start of injection)
access hole and install retaining bolt. • Injector opened fully
(2) Tighten the retaining bolt to 80 lbs. in. (9 N·m) • Injector closes (end of injection)
(Fig. 6).
(3) Connect crankshaft position sensor wiring har- Injector closed (with high pressure applied)
ness connector (Fig. 6). With the injector closed (at-rest state), the solenoid
(4) Connect negative battery cable. valve is not energized and is therefore closed. With
the bleed orifice closed, the valve spring forces the
armature’s ball onto the bleed-orifice seat. The rail’s
FUEL INJECTOR high pressure build up in the valve control chamber,
and the same pressure is also present in the nozzle’s
chamber volume. The rail pressure applied at the
DESCRIPTION control plunger’s end face, together with the force of
the nozzle spring, maintain the nozzle in the closed
FUEL INJECTOR position against the opening forces applied to its
There are individual fuel injectors for all five cyl- pressure stage (Fig. 8).
inders. Each injector nozzle has seven holes. The fuel
injectors are used to spray fuel into the combustion Injector opens (start of injection)
chamber. Each injector has a six digit alphanumeric The solenoid valve is energized with the pickup
code on the injector top which must be entered into current which serves to ensure that it open quickly.
to ECM using the DRBIIIt (Fig. 7). Specific moving The force exerted by the triggered solenoid now
VA FUEL INJECTION 14 - 31
FUEL INJECTOR (Continued)
sure balance, and the pressure in the valve control
chamber sinks as a result. This leads to the pressure
in the valve-control chamber being lower than that in
the nozzle’s chamber volume which is still at the
same pressure level as the rail. The reduced pressure
in the valve-control chamber causes a reduction in
the force exerted on the control plunger, the nozzle
needle open as a result, and injection starts (Fig. 8).

Injector opens fully


The control plunger reaches its upper stop where it
remains supported by a cushion of fuel which is gen-
erated by the flow of fuel between the bleed and feed
orifices. The injector nozzle has now opened fully,
and the fuel is injected into the combustion chamber
at a pressure almost equal to that in the fuel rail
(Fig. 8).

Injector closes (end of injection)


As soon as the solenoid valve is no longer trig-
gered, the valve spring forces the armature down-
wards and the ball closes the bleed orifice. The
armature is a 2–piece design. Here, although the
armature plate is guided by a driver shoulder in its
downward movement, it can “overspring” with the
return spring so that it exerts no downwards-acting
forces on the armature and the ball. The closing of
the bleed orifice lead to pressure build up in the con-
trol chamber via the input from the feed orifice. This
pressure is the same as that in the rail and exerts an
increased force on the control plunger through its
end face. This force, together with that of the spring,
now exceeds the force exerted by the chamber volume
and the nozzle needle closes. Injection ceases as soon
as the nozzle needle comes up against its bottom stop
again (Fig. 8).

Fig. 8 INJECTOR COMPONENTS


STANDARD PROCEDURE
1 - INJECTOR CLOSED (AT-REST STATUS)
2 - ELECTRICAL CONNECTION
3 - TRIGGERING ELEMENT (SOLENOID VALVE) STANDARD PROCEDURE - INJECTOR
4 - FUEL INLET (HIGH PRESSURE) FROM THE RAIL
5 - VALVE BALL CLASSIFICATION
6 - BLEED ORIFICE
7 - FEED ORIFICE NOTE: Fuel Injectors have different flow rates.
8 - VALVE CONTROL CHAMBER
9 - VALVE CONTROL PLUNGER When ALL injectors are removed, re-enter all injec-
10 - FEED PASSAGE TO THE NOZZLE tor six digit codes.
11 - NOZZLE NEEDLE
The classification of injectors into 3 classes
exceeds that of the valve spring and the armature describes the quantity characteristic of the injector.
opens the bleed orifice. Almost immediately, the high- This will make it possible in the future to match the
level pick-up current is reduced to the lower holding engine software to the tolerances of the injector
current required for the electromagnet. This is possi- within a more narrowly graduated range. Classifica-
ble due to the magnetic circuit’s air gap now being tion can be clearly recognized, and assigned only by
smaller. When the bleed orifice opens, fuel can flow means of a DRBIIIt.
from the valve control chamber into the cavity situ- Classified injectors can be recognized by the part
ated above it, and from there via the fuel return to number and identification on the magnetic head (cir-
the tank. The bleed orifice prevents complete pres-
14 - 32 FUEL INJECTION VA
FUEL INJECTOR (Continued)
cle with a number between 1 and 3 inside) (Fig. 9). appropriate pin to prevent debris from falling into
The number corresponds to the classification stage. the recesses and entering the motor.
These general conditions equally apply if, as a (1) Seal the injector holes inside the cylinder head
result of replacing an engine, carrying out repairs to recesses.
the cylinder head etc., the cylinder selective assign- (2) Wipe out injector recesses with a non-woven
ment of the injectors or the engine control module cloth, then clean with a cylinder brush.
assignment may have changed. If proper attention is (3) Clean the bottom of the cylinder recess with a
not paid to the classification on these vehicles drive- round brush.
ability and smoking concerns could result. (4) Blow out the recess and clean again with a
If an injector is replaced, it is then necessary to non-woven cloth and cover over.
assign the classification number to the corresponding (5) Perform these steps for each injector recess.
cylinder with the DRBIIIt in the control module.
NOTE: DO NOT clean the tip of the injector with a
wire brush. Use a non - woven cloth.

(6) Clean injector body with a wire brush.


(7) Clean injector tips with a non-woven cloth.

NOTE: Do Not apply antiseize lubricant to the injec-


tor nozzle area.

(8) Grease injector body with anti seize lubricant.

NOTE: Always replace the seals that seal off the


injectors at the cylinder head to the combustion
chamber and replace the retaining screws.

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).

NOTE: If locking clamp has been pulled off at injec-


tor, the locking clamp must be replaced.

(4) Position fuel return line at injectors and secure


locking clamps (Fig. 10).

NOTE: Counterhold injection lines with wrench


socket at threaded connections of injectors. DO
NOT over tighten.

(5) Install high pressure injection lines (Refer to


14 - FUEL SYSTEM/FUEL DELIVERY/FUEL LINES
- INSTALLATION).
(6) Reconnect injector electrical connectors (Fig.
10).
(7) Connect negative battery cable.

NOTE: Fuel Injectors have different flow rates.


When injectors are removed, re-enter all injector six
digit codes.

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.

REMOVAL FUEL PRESSURE SOLENOID


(1) (Refer to 14 - FUEL SYSTEM/FUEL INJEC-
TION - WARNING) Disconnect the negative battery DESCRIPTION
cable. The fuel pressure solenoid is attached to the rear
(2) Remove the mixing housing. of the fuel rail. A sealing metal disc seals the valve to
(3) Unplug the sensor (Fig. 11). the rail. The seal is not serviceable and looses it’s
(4) Counter-hold the threaded connection at the sealing properties upon removal of the solenoid.
fuel rail and unscrew the sensor (Fig. 11). Therefore, the solenoid must be replaced when ever
it is removed from the rail. The solenoid controls and
maintains the rail pressure constant along with a
control current transmitted by the engine control
module (ECM) (Fig. 12).

Fig. 11 FUEL RAIL PRESSURE SENSOR


1 - WIRING CONNECTOR
2 - FUEL RAIL PRESSURE SENSOR
3 - SEALING RING
4 - FUEL RAIL Fig. 12 FUEL PRESSURE SOLENOID
1 - FUEL PRESSURE SENSOR
INSTALLATION 2 - FUEL RAIL
(1) (Refer to 14 - FUEL SYSTEM/FUEL INJEC- 3 - FUEL PRESSURE SOLENOID
TION - WARNING) Install the sealing ring on to the
sensor (Fig. 11). OPERATION
(2) Screw the sensor in to the fuel rail. Counter- High pressure which is present in the fuel rail
hold the threaded connection and tighten the sensor flows to the ball seat of the pressure solenoid (Fig.
to 18 lbs. ft. (25 N·m.) (Fig. 11). 13). The specified pressure required by the system is
(3) Connect the wiring harness to the sensor. built up in the rail by the fuel pressure solenoid
(4) Install the mixing housing. building up a magnetic force which corresponds to
this specific pressure by means of a control current
VA FUEL INJECTION 14 - 35
FUEL PRESSURE SOLENOID (Continued)
from the electronic control module (ECM) (Fig. 13). (2) Remove fuel rail (Refer to 14 - FUEL SYSTEM/
This magnetic force equals a certain outlet cross sec- FUEL INJECTION/FUEL INJECTOR - REMOVAL).
tion at the ball seat of the valve. The rail pressure is (3) Clamp fuel rail securely in vise with protective
altered as a result of the quantity of fuel which flows jaws.
off (Fig. 13). The current fuel pressure is signaled by
the fuel rail pressure sensor to the engine control NOTE: Once removed, the solenoid must always be
module (ECM). The controlled fuel flows back along replaced.
the return fuel line, into the tank.
In a de-energized state, the fuel pressure solenoid (4) Counterhold and unscrew the fuel pressure
is closed as the spring force presses the ball into the solenoid and discard the sealing ring (Fig. 14).
ball seat (Fig. 13). When driving, the fuel pressure
solenoid is constantly open (Fig. 13). When engine is
started, the fuel pressure solenoid is held closed by
magnetic force (Fig. 13). When driving, the pressure
of the fluid counteracts the magnetic force of the coil
and the slight spring force (Fig. 13).

Fig. 14 FUEL PRESSURE SOLENOID


1 - FUEL PRESSURE SOLENOID
2 - METAL SEALING DISC
3 - FUEL RAIL
Fig. 13 FUEL PRESSURE SOLENOID OPERATION 4 - VISE
1 - BALL SEAT
2 - SPRING FORCE INSTALLATION
3 - MAGNETIC FORCE
4 - COIL
5 - FUEL PRESSURE SOLENOID Review the high pressure fuel system warning before
6 - HIGH PRESSURE SUPPLY beginning repair (Refer to 14 - FUEL SYSTEM - WARNING)

REMOVAL WARNING: NO SPARKS, OPEN FLAMES OR SMOK-


ING. RISK OF POISONING FROM INHALING AND
Review the high pressure fuel system warning before SWALLOWING FUEL. RISK OF INJURY TO EYES
beginning repair (Refer to 14 - FUEL SYSTEM - WARNING) AND SKIN FROM CONTACT WITH FUEL. POUR
FUELS ONLY INTO SUITABLE AND APPROPRI-
WARNING: NO SPARKS, OPEN FLAMES OR SMOK- ATELY MARKED CONTAINERS. WEAR PROTECTIVE
ING. RISK OF POISONING FROM INHALING AND CLOTHING.
SWALLOWING FUEL. RISK OF INJURY TO EYES
AND SKIN FROM CONTACT WITH FUEL. POUR
FUELS ONLY INTO SUITABLE AND APPROPRI- CAUTION: There is a special tightening procedure
ATELY MARKED CONTAINERS. WEAR PROTECTIVE for the fuel rail solenoid that must be followed
CLOTHING. along with the proper use of a torque wrench.
Therefore the fuel rail must be removed before
(1) Disconnect negative battery cable. installing the fuel pressure solenoid.
14 - 36 FUEL INJECTION VA
FUEL PRESSURE SOLENOID (Continued)
(1) Screw the fuel pressure solenoid with new seal-
ing disc to the fuel rail until hand tight (Fig. 14).
(2) Tighten the fuel rail solenoid as follows :
• Tighten the nut to 60 N·m (44 ft. lbs.)
• Loosen the nut 90 degrees.
• Retighten the nut to 80 N·m (59 ft. lbs.).
(3) Install fuel rail (Refer to 14 - FUEL SYSTEM/
FUEL INJECTION/FUEL INJECTOR - INSTALLA-
TION).
(4) Connect negative battery cable.
(5) Start engine, allow to warm, turn engine off
and inspect for leaks (Refer to 14 - FUEL SYSTEM -
DIAGNOSIS AND TESTING).

FUEL TEMPERATURE SENSOR


DESCRIPTION
The fuel temperature sensor is integrated in the
high pressure fuel pump next to the fuel quantity
valve. The sensor detects the temperature of the fuel
and supplies that information to the ECM. The sen-
sor ranges from - 40°F (- 40C) to 284°F (140°C). If Fig. 15 HIGH PRESSURE FUEL PUMP
the engine is cold, the actual value sent will read 1 - HIGH PRESSURE PUMP
ambient temperature. The value rises after the 2 - FUEL SUPPY TO FUEL RAIL
3 - FUEL SUPPLY LINE
engine has been started. 4 - FUEL RETURN LINE
5 - FUEL TEMPERATURE SENSOR
OPERATION 6 - FUEL QUANTITY CONTROL VALVE
7 - OIL LEVEL INDICATOR
An negative temperature coefficient (NTC) resistor 8 - VACUUM PUMP
integrated in the fuel temperature sensor alters it’s
electrical resistance in line with the fuel temperature (5) Start engine, allow to warm, shut engine off
(the resistance drops as the temperature rises). The and inspect for leaks (Refer to 14 - FUEL SYSTEM/
ECM uses this reading to calculate optimum engine FUEL INJECTION - WARNING).
performance under all driving conditions. If the fuel
is to warm, the rail pressure in the system is low-
ered. The controller quantity of the pressure regulat- INTAKE AIR TEMPERATURE
ing valve is reduced and the fuel temperature is SENSOR
lowered.
DESCRIPTION
REMOVAL The intake air temperature sensor is located
NOTE: Capture and properly store all fluid seepage between the charge air pipe and the charge air dis-
in appropriately marked containers. tribution of the cylinders. The intake air temperature
sensor measures the temperature of the air as it is
(1) Disconnect the negative battery cable. supplied to the cylinders and transmits the value to
(2) Remove the fuel temperature sensor from the the ECM. This is required in order to determine the
high pressure pump (Fig. 15). density of the air being supplied for the combustion
process. The value range is from minus 40°F up to
INSTALLATION 302°F (minus 40°C to 150°C).
(1) Clean sealing surfaces.
(2) Install new seal on sensor. OPERATION
(3) Screw the sensor into the high pressure pump The Negative Temperature Coefficient (NTC)
and tighten to 18 lbs.ft. (25 N·m) (Fig. 15) resister located within the intake air temperature
(4) Connect negative battery cable. sensor alters it’s resistance in line with the charge
air temperature. If the engine is cold, the value
equals ambient temperature. For a temperature of
68°F (20°C) the resistance is approximately 6000
VA FUEL INJECTION 14 - 37
INTAKE AIR TEMPERATURE SENSOR (Continued)

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.

INTAKE AIR PRESSURE MANIFOLD AIR FLOW (MAF)


SENSOR SENSOR

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.

Fig. 18 AIR CLEANER HOUSING


1 - AIR FLOW SENSOR
2 - GASKET
3 - AIR INTAKE HOSE
4 - AIR CLEANER HOUSING
5 - AIR CLEANER ELEMENT
6 - AIR INTAKE PRESSURE SENSOR
7 - AIR CLEANER HOUSING COVER

signal to the ECM, which evaluates the signal to


adjust the exhaust gas recirculation valve.

Fig. 20 MANIFOLD AIR FLOW SENSOR


1 - WIRING HARNESS
2 - AIR INTAKE HOSE
3 - CLAMP
4 - MAF SENSOR
Fig. 19 MASS AIR FLOW (MAF) SENSOR 5 - AIR CLEANER HOUSING

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

Fig. 22 WIDE BAND OPERATION


1 - OXYGEN PUMP CELL CIRCUIT 2 - SENSOR CELL CIRCUIT
VA FUEL INJECTION 14 - 41
O2 SENSOR (Continued)
The ECM uses this voltage signal to determine
how and when to run the oxygen pump cell. The goal
of the ECM is to modulate the pumping current
through the pump cell to always maintain stoichio-
metric air-fuel ratio (14.7 to 1) in the gas sample
chamber. When stoichiometry is reached, there is no
current flowing to the oxygen pump.
High Excess Air Mode When the exhaust gas is too
lean, the oxygen concentration in the gas sample
chamber is high. The sensor cell measures the differ-
ence between the oxygen concentrations in the sam-
pler chamber and the reference air channel. A voltage
lower than 450mV is generated across the sensor
cell, which is proportional to the air-fuel ratio in the
sample chamber. The ECM compares the sensor cell
voltage with the reference voltage (V Ref), which cor-
responds to the stoichiometric point voltage. Since
sensor cell voltage is lower than V Ref, the ECM
determines a lean condition exists. Am amplifier
applies an appropriate voltage to the pump cell to
transfer oxygen from the gas sample chamber
Low Excess Air Mode With low excess air mode,
the oxygen concentration in the gas sample chamber Fig. 23 HEAT SHIELD
is low. The sensor cell measures the difference 1 - FASTENERS
between oxygen concentrations in the gas sample 2 - SHIELD
chamber and the reference air channel. A voltage 3 - O2 SENSOR HARNESS CONNECTOR
higher than 450 mV is generated across the sensor
cell, which is proportional to the air-fuel ratio in the
sample chamber. The ECM determines a low excess
air condition exists. The polarity of the pump cell is
reversed and so is the direction of the current flow.

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.

Fig. 24 OXYGEN SENSOR


1 - OXYGEN SENSOR
VA STEERING 19 - 1

STEERING
TABLE OF CONTENTS

page page

STEERING COLUMN ...............................5


DESCRIPTION . . . . . . . . . .................1 GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OPERATION . . . . . . . . . . . .................1 LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
DIAGNOSIS AND TESTING - POWER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
STEERING SYSTEM . . . .................2

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.

Power steering systems consist of:


• Steering column
• Rack and pinion steering gear
• Belt driven hydraulic steering pump
• Pump pressure and return hoses Fig. 1 STEERING COMPONENTS
• Oil Cooler 1 - POWER STEERING PUMP ASSEMBLY
2 - RESERVOIR
3 - HOSES
OPERATION 4 - TIE ROD ENDS
The steering column shaft is attached to the gear 5 - MOUNTING BOLTS
pinion. The rotation of the pinion moves the gear 6 - RACK & PINION
rack from side-to-side. This lateral action of the rack
pushes and pulls the tie rods to change the direction
of the front wheels (Fig. 1).
Power assist is provided by an engine mounted
hydraulic pump which supplies hydraulic fluid pres-
sure to the steering gear.
19 - 2 STEERING VA
STEERING (Continued)

DIAGNOSIS AND TESTING - POWER STEERING SYSTEM


There is some noise in all power steering systems. One of the most common is a hissing sound evident at a
standstill parking. Or when the steering wheel is at the end of it’s travel. Hiss is a high frequency noise similar
to that of a water tap being closed slowly. The noise is present in all valves that have a high velocity fluid passing
through an orifice. There is no relationship between this noise and steering performance.

STEERING NOISE

CONDITION POSSIBLE CAUSES CORRECTION

OBJECTIONAL HISS OR 1. Steering intermediate shaft to dash panel 1. Check and repair seal at dash
WHISTLE seal. panel.

2. Noisy valve in power steering gear. 2. Replace steering gear.

RATTLE OR CLUNK 1. Gear mounting bolts loose. 1. Tighten bolts to specification.

2. Loose or damaged suspension 2. Inspect and repair suspension.


components.
3. Internal gear noise. 3. Replace steering gear.
4. Pressure hose in contact with other 4. Reposition hose.
components.
5. Loose or damaged intermediate shaft or 5. Inspect and repair or replace.
column.

CHIRP OR SQUEAL 1. Loose belt. 1. Adjust or replace.

WHINE OR GROWL 1. Low fluid level. 1. Fill to proper level.

2. Pressure hose in contact with other 2. Reposition hose.


components.
3. Internal pump noise. 3. Replace pump.
4. Air in fluid 4. Check for lekas, Evacuate air
from P/S system.

SUCKING AIR SOUND 1. Loose return line clamp. 1. Replace clamp.

2. O-ring missing or damaged on hose 2. Replace o-ring.


fitting.
3. Low fluid level. 3. Fill to proper level.
4. Air leak between pump and reservoir. 4. Repair as necessary.
5. Reservoir cap not installed correctly. 5. Install reservoir cap correctly.

SCRUBBING OR 1. Wrong tire size. 1. Verify tire size.


KNOCKING
VA STEERING 19 - 3
STEERING (Continued)
BINDING AND STICKING

CONDITION POSSIBLE CAUSE CORRECTION

DIFFICULT TO TURN WHEEL 1. Low fluid level. 1. Fill to proper level.


STICKS OR BINDS 2. Tire pressure. 2. Adjust tire pressure.
3. Steering components (ball 3 Inspect and repair as necessary.
joints/tie rod ends).
4. Loose belt. 4. Adjust or replace.
5. Low pump pressure. 5. Pressure test and replace if
necessary.
6. Column shaft coupler binding. 6. Replace coupler.
7. Steering gear worn. 7. Replace gear.
8. Pump seized / Stuck valve 8. Replace pump.

INSUFFICIENT ASST. OR POOR RETURN TO CENTER

CONDITION POSSIBLE CAUSE CORRECTION

HARD TURNING OR MOMENTARY 1. Tire pressure. 1. Adjust tire pressure.


INCREASE IN TURNING EFFORT
2. Low fluid level. 2. Fill to proper level.
3. Loose belt. 3. Adjust or replace.
4. Low pump pressure. 4. Pressure test and repair as
necessary.
5. Internal gear leak. 5. Replace gear.

STEERING WHEEL DOES NOT 1. Tire pressure. 1. Adjust tire pressure.


WANT TO RETURN TO CENTER 2. Wheel alignment. 2. Align front end.
POSITION
3. Lack of lubrication. 3. Inspect and lubricate suspension
compnents.
4. High friction in steering gear. 4. Replace gear.
19 - 4 STEERING VA
STEERING (Continued)
LOOSE STEERING AND VEHICLE LEAD

CONDITION POSSIBLE CAUSE CORRECTION

EXCESSIVE PLAY IN STEERING 1. Worn or loose suspension or 1. Inspect and repair as necessary.
WHEEL steering components.

2. Worn or loose wheel bearings. 2. Inspect and repair or adjust


bearings.
3. Steering gear mounting. 3. Tighten gear mounting bolts to
specification.
4. Gear out of adjustment. 4. Replace gear.
5. Worn or loose steering coupler. 5. Inspect and replace as
necessary.

VEHICLE PULLS OR LEADS TO 1. Tire Pressure. 1. Adjust tire pressure.


ONE SIDE. 2. Radial tire lead. 2. Rotate tires.
3. Brakes dragging. 3. Repair as necessary.
4. Wheel alignment. 4. Align front end.
VA COLUMN 19 - 5

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

DESCRIPTION N·m Ft. Lbs. In. Lbs.


Steering Wheel With 80 59 —
Airbag To Steering Shaft
Jacket Tube For Steering 25 18 221
Shaft To Waist Rail
U-Joint To Steering Gear 24 18 212
Shaft

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. 1 U-JOINT REMOVE / INSTALL


1 - FITTED BOLT
2 - U-JOINT

Fig. 3 TRANSPONDER
1 - TRANSPONDER
2 - STEERING COLUMN

(4) Insert the key into the ignition lock.


(5) Turn the ignition key to the first detent (Fig.
4).

Fig. 2 STEERING COLUMN BOLTS


1 - BOLT
2 - COLUMN BOLT

(5) Install the spring for the brake pedal to the


steering column.
(6) Reconnect the electrical connector to the igni-
tion lock.
(7) Install the combination switch.
(8) Install the clockspring.
(9) Install the steering wheel.
(10) Install the electrical center.
(11) Reconnect the ground cable to the battery.
Fig. 4 IGNITION LOCK FIRST DETENT
1 - LOCK HOUSING
2 - FIRST DETENT WITH KEY INSTALLED
VA COLUMN 19 - 7
KEY/LOCK CYLINDER (Continued)
(6) Turn the cap a 1/4 turn to the left (Fig. 5). (5) Install the transponder coil onto the ignition
lock (Fig. 3).
(6) Install the steering column shroud. Pay atten-
tion to the cables routed under the steering col-
umn cover. Do not trap the cables.
(7) Install the cover for the central electronics.

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

(7) Remove cap together with the lock cylinder off


the ignition lock (Fig. 6).

Fig. 7 STEERING WHEEL


1 - STEERING WHEEL
2 - STEERING WHEEL BOLT

Fig. 6 LOCK CYLINDER OFF THE IGNITION LOCK INSTALLATION


(1) Install the steering wheel onto the column (Fig.
1 - LOCK HOUSING
2 - LOCK CYLINDER 7).
(2) Install the steering wheel bolt (Fig. 7). Tighten
INSTALLATION to 80 N·m (59 ft. lbs.).
(1) Install the cap together with the lock cylinder (3) Install the air bag module.
onto the ignition lock (Fig. 6). (4) Reconnect the battery ground cable.
(2) Turn the cap a 1/4 turn to the right. (5) Reset all the times and encode the radio.
(3) Turn the ignition key to the first detent (Fig. (6) Perform a road test to check the position of the
4). steering wheel.
(4) Remove the ignition key from the ignition lock.
19 - 8 GEAR VA

GEAR

TABLE OF CONTENTS
page page

GEAR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8 SPECIFICATIONS - TORQUE CHART . . . . . . . . . 9
REMOVAL .............................8

GEAR (7) Remove both spring clamp plates (Refer to 2 -


SUSPENSION/FRONT/SPRING CLAMP PLATES -
REMOVAL).
DESCRIPTION
(8) Remove both the high pressure and return
A rack and pinion steering gears (Fig. 1) is made
hoses from the steering gear (Refer to 19 - STEER-
up of two main components, the pinon shaft and the
ING/PUMP/HOSES - REMOVAL) (Fig. 2).
rack. The gear cannot be adjusted or internally ser-
(9) Remove the steering shaft clamping bolt from
viced. If a malfunction or a fluid leak occurs, the gear
the steering gear (Fig. 2).
must be replaced as an assembly.
(10) Separate the universal joint from the steering
gear (Fig. 2).
(11) Remove the steering gear bolts from the front
axle.
(12) Remove the steering gear by sliding it toward
the passengers side of the vehicle and then tilt down-
ward on the drivers side and remove from vehicle.

Fig. 1 STEERING GEAR


1 - OUTER TIE ROD ENDS
2 - MOUNTING BUSHINGS
3 - BELLOWS

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).

SPECIFICATIONS - TORQUE CHART


TORQUE SPECIFICATIONS

DESCRIPTION N·m Ft. Lbs. In. Lbs.


U-Joint To Steering Gear 24 18 212
High Pressure Hose To 37 27 328
Steering Gear
Return Line To Steering 37 27 328
Gear
Steering Gear To Frame 25 18 221
Initial Torque
Steering Gear To Frame 45 33 398
Second Torque
Then additional 90° turn
19 - 10 LINKAGE VA

LINKAGE

TABLE OF CONTENTS
page page

LINKAGE TIE ROD END


DIAGNOSIS AND TESTING - OUTER TIE ROD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11
SPECIFICATIONS - TORQUE CHART . . . . . . . . 10
SPECIAL TOOLS
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . 11

LINKAGE (4) Position indicator plunger on the topside of the


outer tie rod end.
DIAGNOSIS AND TESTING - OUTER TIE ROD NOTE: The dial indicator plunger must be perpen-
END dicular to the machined surface of the outer tie rod
end.
NOTE: If the outer tie rod end is equipped with a
lubrication fitting, grease the joint then road test (5) Position a pry bar in order to pry downwards
the vehicle before performing test. on the outer tie rod end.
(6) If the travel exceeds 0.5 mm (0.020 in.), replace
(1) Raise the front of the vehicle. Place safety floor the outer tie rod end (Refer to 19 - STEERING/
stands under both lower control arms as far outboard LINKAGE/TIE ROD END - REMOVAL).
as possible. Lower the vehicle to allow the stands to (7) If the outer tie rod end is within specs reinstall
support some or all of the vehicle weight. the front tires (Refer to 22 - TIRES/WHEELS/
(2) Remove the front tires. WHEELS - STANDARD PROCEDURE).
(3) Mount a dial indicator solidly to the vehicle
steering knuckle and then zero the dial indicator.

SPECIFICATIONS - TORQUE CHART


TORQUE SPECIFICATIONS

DESCRIPTION N·m Ft. Lbs. In. Lbs.


Outer Tie Rod End Nut 130 96 —
Outer Tie Rod End 50 37 —
Locking Nut
Steering Gear Boot Clamp 7 — 62
VA LINKAGE 19 - 11
LINKAGE (Continued)

SPECIAL TOOLS
FRONT SUSPENSION

Puller Tie Rod C-3894-A


TIE ROD END
REMOVAL Fig. 1 OUTER TIE ROD END
(1) Raise and support the vehicle. 1 - OUTER TIE ROD END RETAINING NUT
(2) Remove the front wheels. 2 - TIE ROD SEPERATOR TOOL
(3) Loosen the lock nut (Fig. 1). 3 - OUTER TIE ROD END
4 - LOCKING NUT
(4) Remove the tie rod end retaining nut (Fig. 1). 5 - INNER TIE ROD END
(5) Separate the tie rod end from the steering
knuckle (Fig. 1) using special tool C-3894–A. (3) Tighten the outer tie rod end nut (Fig. 1).
(6) Remove the outer tie rod end from the inner tie Tighten to 130 N·m (96 ft. lbs.).
rod end by unscrewing (Fig. 1). (4) Install the front wheels.
(5) Lower the vehicle.
INSTALLATION (6) Perform toe adjustment.
(1) Install the outer tie rod end by screwing it onto (7) Tighten the lock nut after toe adjustment (Fig.
thew inner tie rod end (Fig. 1). 1). Tighten to 50 N·m (37 ft. lbs.).
(2) Install the outer tie rod end into the steering
knuckle (Fig. 1).
19 - 12 PUMP VA

PUMP

TABLE OF CONTENTS
page page

PUMP FLUID COOLER TUBE


DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 12 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
DIAGNOSIS AND TESTING - PUMP LEAKAGE . 12 HOSES
STANDARD PROCEDURE REMOVAL
STANDARD PROCEDURE - POWER REMOVAL - PRESSURE HOSE . . . . . . . . . . . 15
STEERING PUMP - INITIAL OPERATION . . . . 12 REMOVAL - RETURN LINE FROM PUMP TO
STANDARD PROCEDURE - FLUSHING COOLER TUBE . . . . . . . . . . . . . . . . . . . . . . . 15
POWER STEERING SYSTEM . . . . . . . . . . . . 13 REMOVAL - RETURN HOSE FROM GEAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 TO COOLER TUBE . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13 INSTALLATION
SPECIFICATIONS - TORQUE CHART . . . . . . . . 14 INSTALLATION - PRESSURE HOSE . . . . . . . 15
FLUID INSTALLATION - RETURN LINE FROM
STANDARD PROCEDURE PUMP TO COOLER TUBE . . . . . . . . . . . . . . . 15
POWER STEERING PUMP FILL AND BLEED INSTALLATION - RETURN HOSE FROM
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 14 GEAR TO COOLER TUBE . . . . . . . . . . . . . . . 15

PUMP DIAGNOSIS AND TESTING - PUMP LEAKAGE


The pump is serviced as an assembly and should
DESCRIPTION not be disassembled. The plastic pump reservoir and
the reservoir o-rings can be replaced.
CAUTION: Mopar ATF+4 Automatic Transmission Check for leaks in the following areas:
fluid or equivalent is to be used in the power steer- • Pump shaft seal behind the pulley
ing system. No other power steering or automatic • Pump to reservoir O-ring
transmission fluid is to be used in the system. • Reservoir cap
Damage may result to the power steering pump and • Pressure and return lines
system if any other fluid is used, and do not over- • Flow control valve fitting
fill.

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.

CAUTION: Mopar ATF+4 Automatic Transmission


OPERATION fluid or equivalent is to be used in the power steer-
Hydraulic pressure is provided for the power steer- ing system. No other power steering or automatic
ing gear by the belt driven power steering pump. The transmission fluid is to be used in the system.
power steering pumps are constant flow rate and dis- Damage may result to the power steering pump and
placement, vane-type pumps. system if any other fluid is used, and do not over-
fill.
VA PUMP 19 - 13
PUMP (Continued)
Wipe filler cap clean, then check the fluid level. (9) Start the engine and run it for fifteen minutes
The dipstick should indicate COLD when the fluid is then stop the engine.
at normal temperature. (10) Remove the return line/lines from the pump
(1) Turn steering wheel all the way to the left and plug the pump port/ports.
(2) Fill the pump fluid reservoir to the proper level (11) Pour fresh fluid into the reservoir and check
and let the fluid settle for at least two (2) minutes. the draining fluid for contamination. If the fluid is
(3) Raise the front wheels off the ground. still contaminated, then flush the system again.
(4) Slowly turn the steering wheel lock-to-lock 20 (12) Install the return line/lines and perform
times with the engine off while checking the fluid level. Steering Pump Initial Operation, (Refer to 19 -
STEERING/PUMP - STANDARD PROCEDURE).
NOTE: For vehicles with long return lines or oil
coolers turn wheel 40 times. REMOVAL
(1) Remove the belt from the power steering pump.
(5) Start the engine. With the engine idling main-
(2) Siphon as much power steering fluid as possi-
tain the fluid level.
ble out of the reservoir.
(6) Lower the front wheels and let the engine idle
(3) Remove the high pressure power steering hose
for two minutes.
at the pump (Fig. 1).
(7) Turn the steering wheel in both direction and
(4) Remove the return hose from the pump (Fig. 1).
verify power assist and quiet operation of the pump. (5) Remove the bolts securing the power steering
If the fluid is extremely foamy or milky looking, pump to the engine (Fig. 1).
allow the vehicle to stand a few minutes and repeat
the procedure.

CAUTION: Do not run a vehicle with foamy fluid for


an extended period. This may cause pump damage.

STANDARD PROCEDURE - FLUSHING POWER


STEERING SYSTEM
Flushing is required when the power steering/hy-
draulic booster system fluid has become contami-
nated. Contaminated fluid in the steering/booster
system can cause seal deterioration and affect steer-
ing gear/booster spool valve operation.
(1) Raise the front end of the vehicle off the
ground until the wheels are free to turn.
(2) Remove the return line from the pump.
Fig. 1 POWER STEERING PUMP
NOTE: If vehicle is equipped with a hydraulic 1 - PUMP MOUNTING BOLT
booster remove both return lines from the pump. 2 - CLAMP
3 - RETURN HOSE
(3) Plug the return line port/ports at the pump. 4 - HIGH PRESSURE HOSE
5 - O-RING
(4) Position the return line/lines into a large con- 6 - PUMP RESERVOIR
tainer to catch the fluid. 7 - PUMP
(5) While an assistant is filling the pump reservoir 8 - PULLEY
9 - PULLEY BOLT
start the engine.
(6) With the engine running at idle turn the wheel
back and forth.
INSTALLATION
(1) Install the power steering pump to the engine
NOTE: Do not contact or hold the wheel against the and tighten the bolts (Fig. 1). Tighten to 21 N·m (15
steering stops. ft. lbs.).
(2) Replace all o-rings and hose clamps (Fig. 1).
(7) Run a quart of fluid through the system then (3) Install the return hose to the pump and tighten
stop the engine and install the return line/lines. the clamp (Fig. 1).
(8) Fill the system with fluid and perform Steering (4) Install the high pressure hose to the pump
Pump Initial Operation, (Refer to 19 - STEERING/ (Fig. 1). Tighten to 38 N·m (28 ft. lbs.).
PUMP - STANDARD PROCEDURE). (5) Fill the power steering fluid (Refer to 19 - STEER-
ING/PUMP/FLUID - STANDARD PROCEDURE).
19 - 14 PUMP VA
PUMP (Continued)

SPECIFICATIONS - TORQUE CHART


TORQUE SPECIFICATIONS

DESCRIPTION N·m Ft. Lbs. In. Lbs.


Power Steering Pump To 21 15 185
Timing Case Cover/
Support
High Pressure Flexible 38 28 336
Hose To Power Steering
Pump
Power Steering Pulley To 30 22 265
Pump

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.

FLUID COOLER TUBE Fig. 2 FLUID COOLER TUBE


1 - MOUNTING SCREWS (4)
REMOVAL 2 - FLUID COOLER
3 - ELECTRIC COOLING FAN
(1) Siphon as much power steering fluid as possi- 4 - A/C CONDENSOR
ble out of the reservoir.
(2) Remove the grille (Refer to 23 - BODY/EXTE- INSTALLATION
RIOR/GRILLE - REMOVAL). (1) Install the cooler tube to the vehicle.
(3) Remove the left headlight assembly. (2) Install the cooler tube mounting screws (Fig.
(4) Disconnect the return lines from the cooler 2).
tube. (3) Install the condenser air dam shield.
(5) Remove the radiator clips (2). (4) Install the condenser upper mounting screws
(6) Remove the heat shield bolt for the turbo at (Fig. 2).
the core support.
(7) Remove the right headlight assembly.
VA PUMP 19 - 15
FLUID COOLER TUBE (Continued)
(5) Install the fan bracket bolts to the radiator (3) Remove the grille (Refer to 23 - BODY/EXTE-
(Fig. 2). RIOR/GRILLE - REMOVAL).
(6) Install the core support bolts and reconnect the (4) Remove the left headlight assembly.
hood latch cable. (5) Disconnect the return line at the cooler tube.
(7) Install the right headlight assembly. (6) Remove the return line from the vehicle.
(8) Install the bolt for the turbo shield at the core
support.
(9) Install the radiator clips. INSTALLATION
(10) Install the return lines to the cooler tube.
(11) Install the left headlight assembly. INSTALLATION - PRESSURE HOSE
(12) Install the grille assembly (Refer to 23 - (1) Install the pressure hose to the vehicle.
BODY/EXTERIOR/GRILLE - INSTALLATION). (2) Reconnect the pressure hose at the steering
(13) Fill the power steering fluid (Refer to 19 - gear. Tighten to 37 N·m (27 ft.lbs.).
STEERING/PUMP/FLUID - STANDARD PROCE- (3) Install the pressure hose mounting bracket to
DURE). the steering gear.
(4) Reconnect the pressure hose at the power
steering pump. Tighten to 38 N·m (28 ft.lbs.).
HOSES (5) Fill the power steering fluid (Refer to 19 -
STEERING/PUMP/FLUID - STANDARD PROCE-
DURE).
REMOVAL
INSTALLATION - RETURN LINE FROM PUMP
REMOVAL - PRESSURE HOSE TO COOLER TUBE
(1) Siphon as much power steering fluid as possi-
(1) Install the return line to the vehicle.
ble out of the reservoir.
(2) Reconnect the return line at the cooler tube.
(2) Disconnect the pressure hose at the pump.
(3) Install the left headlight assembly.
(3) Disconnect the pressure hose at the steering
(4) Install the grille assembly (Refer to 23 - BODY/
gear.
EXTERIOR/GRILLE - INSTALLATION).
(4) Remove the pressure hose mounting bracket
(5) Reconnect the return line at the power steering
from the gear.
pump.
(5) Remove the pressure hose from the vehicle.
(6) Fill the power steering fluid (Refer to 19 -
STEERING/PUMP/FLUID - STANDARD PROCE-
REMOVAL - RETURN LINE FROM PUMP TO DURE).
COOLER TUBE
(1) Siphon as much power steering fluid as possi- INSTALLATION - RETURN HOSE FROM GEAR
ble out of the reservoir. TO COOLER TUBE
(2) Disconnect the return line at the pump. (1) Install the return line to the vehicle.
(3) Remove the grille (Refer to 23 - BODY/EXTE- (2) Reconnect the return line at the cooler tube.
RIOR/GRILLE - REMOVAL). (3) Install the left headlight assembly.
(4) Remove the left headlight assembly. (4) Install the grille assembly (Refer to 23 - BODY/
(5) Disconnect the return line at the cooler tube. EXTERIOR/GRILLE - INSTALLATION).
(6) Remove the return line from the vehicle. (5) Reconnect the return line at the power steering
gear.
REMOVAL - RETURN HOSE FROM GEAR TO (6) Fill the power steering fluid (Refer to 19 -
COOLER TUBE STEERING/PUMP/FLUID - STANDARD
(1) Siphon as much power steering fluid as possi- PROCEDURE).
ble out of the reservoir.
(2) Disconnect the return hose from the gear.
VA TRANSMISSION 21 - 1

TRANSMISSION

AUTOMATIC TRANSMISSION NAG1 - SERVICE


INFORMATION

TABLE OF CONTENTS
page page

AUTOMATIC TRANSMISSION NAG1 - SERVICE DIAGNOSIS AND TESTING


INFORMATION EFFECTS OF INCORRECT FLUID LEVEL . . 112
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2 CAUSES OF BURNT FLUID . . . . . . . . . . . . . 112
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 FLUID CONTAMINATION . . . . . . . . . . . . . . . 113
DIAGNOSIS AND TESTING STANDARD PROCEDURE
AUTOMATIC TRANSMISSION . . . . . . . . . . . . 30 CHECK OIL LEVEL . . . . . . . . . . . . . . . . . . . 113
PRELIMINARY . . . . . . . . . . . . . . . . . . . . . . . . 30 TRANSMISSION FILL . . . . . . . . . . . . . . . . . . 114
ROAD TESTING . . . . . . . . . . . . . . . . . . . . . . 30 FLUID/FILTER SERVICE . . . . . . . . . . . . . . . 115
AUTOMATIC TRANSMISSION . . . . . . . . . . . . 31 FREEWHEELING CLUTCH
STANDARD PROCEDURE - ALUMINUM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 116
THREAD REPAIR . . . . . . . . . . . . . . . . . . . . . . 34 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 116
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 117
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 37 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 GEARSHIFT CABLE
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 49 DIAGNOSIS AND TESTING
SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . 54 GEARSHIFT CABLE . . . . . . . . . . . . . . . . . . . 119
SPECIFICATIONS - NAG1 AUTOMATIC REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . 75 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 120
SPECIAL TOOLS - AUTOMATIC HOLDING CLUTCHES
TRANSMISSION - NAG1 . . . . . . . . . . . . . . . . 77 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 121
INPUT CLUTCHES OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 122
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 79 HOLDING CLUTCH B1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 123
INPUT CLUTCH K1 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 81 HOLDING CLUTCH B2
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 127
INPUT CLUTCH K2 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 84 INPUT SPEED SENSORS
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 132
INPUT CLUTCH K3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 133
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 88 OIL PUMP
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 133
ELECTROHYDRAULIC UNIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 133
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 92 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 134
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 OUTPUT SHAFT BEARING
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 104 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 136
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 110 OUTPUT SHAFT SEAL
FLUID AND FILTER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 112 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 137
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 112
21 - 2 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA

PARK LOCK CABLE OPERATION ...................... . . 151


REMOVAL ........ . . . . . . . . . . . . . . . . . . 138 TEMPERATURE SENSOR/PARK-NEUTRAL
INSTALLATION ..... . . . . . . . . . . . . . . . . . . 139 CONTACT
PISTONS DESCRIPTION
DESCRIPTION ..... . . . . . . . . . . . . . . . . . . 141 PARK/NEUTRAL CONTACT ......... . . 153
OPERATION ...... . . . . . . . . . . . . . . . . . . 141 TRANSMISSION TEMPERATURE SENSOR . 153
PLANETARY GEARTRAIN OPERATION
DESCRIPTION ..... . . . . . . . . . . . . . . . . . . 143 PARK/NEUTRAL CONTACT ......... . . 154
OPERATION ...... . . . . . . . . . . . . . . . . . . 143 TRANSMISSION TEMPERATURE SENSOR . 154
DISASSEMBLY .... . . . . . . . . . . . . . . . . . . 143 TORQUE CONVERTER
ASSEMBLY ....... . . . . . . . . . . . . . . . . . . 144 DESCRIPTION ..................... . . 155
SHIFT MECHANISM OPERATION ...................... . . 159
DESCRIPTION ..... . . . . . . . . . . . . . . . . . . 145 REMOVAL ........................ . . 160
OPERATION ...... . . . . . . . . . . . . . . . . . . 145 INSTALLATION ..................... . . 160
REMOVAL ........ . . . . . . . . . . . . . . . . . . 146 TORQUE CONVERTER HUB SEAL
INSTALLATION ..... . . . . . . . . . . . . . . . . . . 148 REMOVAL ........................ . . 161
SOLENOID INSTALLATION ..................... . . 161
DESCRIPTION ..... . . . . . . . . . . . . . . . . . . 149

AUTOMATIC TRANSMISSION Electronic transmission control enables precise


adaptation of pressures to the respective operating
NAG1 - SERVICE conditions and to the engine output during the shift
INFORMATION phase which results in a significant improvement in
shift quality.
DESCRIPTION Furthermore, it offers the advantage of a flexible
The NAG1 automatic transmission (Fig. 1) is an adaptation to various vehicle and engines.
electronically controlled 5-speed transmission with a Basically, the automatic transmission with elec-
lock-up clutch in the torque converter. The ratios for tronic control offers the following advantages:
the gear stages are obtained by 3 planetary gear sets. • Reduces fuel consumption.
Fifth gear is designed as an overdrive with a high- • Improved shift comfort.
speed ratio. • More favourable step-up through the five gears.
NAG1 identifies a family of transmissions and • Increased service life and reliability.
means “N”ew “A”utomatic “G”earbox, generation 1. • Lower maintenance costs.
Various marketing names are associated with the
NAG1 family of transmissions, depending on the TRANSMISSION IDENTIFICATION
transmisson variation being used in a specific vehi- The transmission can be generically identified
cle. Some examples of the marketing names are: visually by the presence of a round 13-way connector
W5A300, W5A380, and W5A580. The marketing located near the front corner of the transmission oil
name can be interpreted as follows: pan, on the right side. Specific transmission informa-
• W = A transmission using a hydraulic torque tion can be found stamped into a pad on the left side
converter. of the transmission, above the oil pan rail.
• 5 = 5 forward gears.
• A = Automatic Transmission. TRANSMISSION GEAR RATIOS
• 580 = Maximum input torque capacity in New- The gear ratios for the NAG1 automatic transmis-
ton meters. sion are as follows:
The gears are actuated electronically/hydraulically.
The gears are shifted by means of an appropriate 1st Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.59:1
combination of three multi-disc holding clutches, 2nd Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19:1
three multi-disc driving clutches, and two freewheel- 3rd Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.41:1
ing clutches. 4th Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00:1
5th Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.83:1
Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16:1
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 3
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)

Fig. 1 NAG1 Automatic Transmission


1 - TORQUE CONVERTER 11 - PARKING LOCK GEAR
2 - OIL PUMP 12 - INTERMEDIATE SHAFT
3 - DRIVESHAFT 13 - FREEWHEEL F2
4 - MULTI-DISC HOLDING CLUTCH B1 14 - REAR PLANETARY GEAR SET
5 - DRIVING CLUTCH K1 15 - CENTER PLANETARY GEAR SET
6 - DRIVING CLUTCH K2 16 - ELECTROHYDRAULIC CONTROL UNIT
7 - MULTI-DISC HOLDING CLUTCH B3 17 - FRONT PLANETARY GEAR SET
8 - DRIVING CLUTCH K3 18 - FREEWHEEL F1
9 - MULTI-DISC HOLDING CLUTCH B2 19 - STATOR SHAFT
10 - OUTPUT SHAFT 20 - TORQUE CONVERTER LOCK-UP CLUTCH
21 - 4 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)
TRANSMISSION HOUSING described as a shift group. Each shift group contains
The converter housing and transmission are made a command valve, a holding pressure shift valve, a
from a light alloy. These are bolted together and cen- shift pressure shift valve, overlap regulating valve,
tered via the outer multi-disc carrier of multi-disc and a solenoid.
holding clutch, B1. A coated intermediate plate pro- The hydraulic system contains three shift groups:
vides the sealing. The oil pump and the outer multi- 1-2/4-5, 2-3, and 3-4. Each shift group can also be
disc carrier of the multi-disc holding clutch, B1, are described as being in one of two possible states. The
bolted to the converter housing. The stator shaft is active shift group is described as being in the shift
pressed into it and prevented from rotating by phase when it is actively engaging/disengaging a
splines. The electrohydraulic unit is bolted to the clutch combination. The 1-2/4-5 shift group control
transmission housing from underneath. A sheet the B1 and K1 clutches. The 2-3 shift group controls
metal steel oil pan forms the closure. the K2 and K3 clutches. The 3-4 shift group controls
the K3 and B2 clutches.
MECHANICAL SECTION
The mechanical section consists of a input shaft, OPERATION
output shaft, a sun gear shaft, and three planetary The transmission control is divided into the elec-
gear sets which are coupled to each other. The plan- tronic and hydraulic transmission control functions.
etary gear sets each have four planetary pinion While the electronic transmission control is responsi-
gears. The oil pressure for the torque converter ble for gear selection and for matching the pressures
lock-up clutch and clutch K2 is supplied through to the torque to be transmitted, the transmission’s
bores in the input shaft. The oil pressure to clutch power supply control occurs via hydraulic elements
K3 is transmitted through the output shaft. The in the electrohydraulic control module. The oil supply
lubricating oil is distributed through additional bores to the hydraulic elements, such as the hydrodynamic
in both shafts. All the bearing points of the gear sets, torque converter, the shift elements and the hydrau-
as well as the freewheeling clutches and actuators, lic transmission control, is provided by way of an oil
are supplied with lubricating oil. The parking lock pump connected with the torque converter.
gear is connected to the output shaft via splines. The Transmission Control Module (TCM) allows for
Freewheeling clutches F1 and F2 are used to opti- the precise adaptation of pressures to the correspond-
mize the shifts. The front freewheel, F1, is supported ing operating conditions and to the engine output
on the extension of the stator shaft on the transmis- during the gearshift phase, resulting in a noticeable
sion side and, in the locking direction, connects the improvement in shift quality. The engine speed limit
sun gear of the front planetary gear set to the trans- can be reached in the individual gears at full throttle
mission housing. In the locking direction, the rear and kickdown. The shift range can be changed in the
freewheeling clutch, F2, connects the sun gear of the forward gears while driving, but the TCM employs a
center planetary gear set to the sun gear of the rear downshift safeguard to prevent over-revving the
planetary gear set. engine. The system offers the additional advantage of
flexible adaptation to different vehicle and engine
ELECTROHYDRAULIC CONTROL UNIT variants.
The electrohydraulic control unit comprises the
shift plate made from light alloy for the hydraulic EMERGENCY RUNNING FUNCTION
control and an electrical control unit. The electrical In order to ensure a safe driving state and to pre-
control unit comprises of a supporting body made of vent damage to the automatic transmission, the TCM
plastic, into which the electrical components are control module switches to limp-home mode in the
assembled. The supporting body is mounted on the event of critical faults. A diagnostic trouble code
shift plate and screwed to it. (DTC) assigned to the fault is stored in memory. All
Strip conductors inserted into the supporting body solenoid and regulating valves are thus de-energized.
make the connection between the electrical compo- The net effect is:
nents and a plug connector. The connection to the • The last engaged gear remains engaged.
wiring harness on the vehicle and the transmission • The modulating pressure and shift pressures
control module (TCM) is produced via this 13-pin rise to the maximum levels.
plug connector with a bayonet lock. • The torque converter lockup clutch is deacti-
vated.
SHIFT GROUPS In order to preserve the operability of the vehicle
The hydraulic control components (including actua- to some extent, the hydraulic control can be used to
tors) which are responsible for the pressure distribu- engage 2nd gear or reverse using the following pro-
tion before, during, and after a gear change are cedure:
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 5
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)
• Stop the vehicle. The limp-home function remains active until the
• Switch off engine. DTC is rectified or the stored DTC is erased with the
• Move selector lever to 9P9. appropriate scan tool. Sporadic faults can be reset
• Wait at least 10 seconds. via ignition OFF/ON.
• Start engine.
• Move selector lever to D: 2nd gear. CLUTCH APPLICATION
• Move selector lever to R: Reverse gear. Refer to CLUTCH APPLICATION for which shift
elements are applied in each gear position.

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

Fig. 2 First Gear Powerflow


1 - TORQUE CONVERTER LOCK-UP CLUTCH 14 - CENTER PLANETARY CARRIER
2 - TORQUE CONVERTER TURBINE 15 - REAR PLANETARY CARRIER
3 - TORQUE CONVERTER IMPELLER 16 - TORQUE CONVERTER STATOR
4 - HOLDING CLUTCH B1 17 - FRONT PLANETARY PINION GEARS
5 - HOLDING CLUTCH B3 18 - CENTER PLANETARY PINION GEARS
6 - HOLDING CLUTCH B2 19 - REAR PLANETARY PINION GEARS
7 - DRIVING CLUTCH K1 20 - FREEWHEELING CLUTCH F1
8 - FRONT PLANETARY ANNULUS GEAR 21 - FRONT PLANETARY SUN GEAR
9 - DRIVING CLUTCH K2 22 - CENTER PLANETARY SUN GEAR
10 - CENTER PLANETARY ANNULUS GEAR 23 - REAR PLANETARY SUN GEAR
11 - REAR PLANETARY ANNULUS GEAR 24 - FREEWHEELING CLUTCH F2
12 - DRIVING CLUTCH K3 25 - INPUT SHAFT
13 - FRONT PLANETARY CARRIER 26 - OUTPUT SHAFT
A - ENGINE SPEED D - SECOND GEAR RATIO
B - TRANSMISSION INPUT SPEED E - THIRD GEAR RATIO
C - FIRST GEAR RATIO F - FIXED PARTS

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)

Fig. 3 First Gear Powerflow


1 - TORQUE CONVERTER LOCK-UP CLUTCH 14 - CENTER PLANETARY CARRIER
2 - TORQUE CONVERTER TURBINE 15 - REAR PLANETARY CARRIER
3 - TORQUE CONVERTER IMPELLER 16 - TORQUE CONVERTER STATOR
4 - HOLDING CLUTCH B1 17 - FRONT PLANETARY PINION GEARS
5 - HOLDING CLUTCH B3 18 - CENTER PLANETARY PINION GEARS
6 - HOLDING CLUTCH B2 19 - REAR PLANETARY PINION GEARS
7 - DRIVING CLUTCH K1 20 - FREEWHEELING CLUTCH F1
8 - FRONT PLANETARY ANNULUS GEAR 21 - FRONT PLANETARY SUN GEAR
9 - DRIVING CLUTCH K2 22 - CENTER PLANETARY SUN GEAR
10 - CENTER PLANETARY ANNULUS GEAR 23 - REAR PLANETARY SUN GEAR
11 - REAR PLANETARY ANNULUS GEAR 24 - FREEWHEELING CLUTCH F2
12 - DRIVING CLUTCH K3 25 - INPUT SHAFT
13 - FRONT PLANETARY CARRIER 26 - OUTPUT SHAFT
A - ENGINE SPEED D - SECOND GEAR RATIO
B - TRANSMISSION INPUT SPEED E - THIRD GEAR RATIO
C - FIRST GEAR RATIO F - FIXED PARTS

Rear Planetary Gear Set Center Planetary Gear Set


The annulus gear (11) turns at a reduced speed The annulus gear (10) is driven at the same speed
due to the mechanical connection to the front plane- as the rear planetary carrier (15) as a result of a
tary carrier (15). The sun gear (23) is held against mechanical connection. The sun gear (22) is held
the housing by the engaged multiple-disc holding against the housing by the multiple-disc holding
clutch B2 (6), by the locked freewheel F2 (24) during clutch B2 (6). The planetary pinion gears (18) turn
acceleration and by the engaged multiple-disc clutch on the fixed sun gear (22) and increase the torque
K3 (12) during deceleration. The planetary gears (19) from the annulus gear (10) to the planetary carrier
turn on the fixed sun gear (23) and increase the (14). The output shaft (26) connected to the planetary
torque from the annulus gear (11) to the planetary carrier (14) turns at a reduced speed in the running
carrier (15). The planetary carrier (15) moves at a direction of the engine.
reduced speed in the running direction of the engine.
21 - 8 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)
SECOND GEAR POWERFLOW

Fig. 4 Second Gear Powerflow


1 - TORQUE CONVERTER LOCK-UP CLUTCH 14 - CENTER PLANETARY CARRIER
2 - TORQUE CONVERTER TURBINE 15 - REAR PLANETARY CARRIER
3 - TORQUE CONVERTER IMPELLER 16 - TORQUE CONVERTER STATOR
4 - HOLDING CLUTCH B1 17 - FRONT PLANETARY PINION GEARS
5 - HOLDING CLUTCH B3 18 - CENTER PLANETARY PINION GEARS
6 - HOLDING CLUTCH B2 19 - REAR PLANETARY PINION GEARS
7 - DRIVING CLUTCH K1 20 - FREEWHEELING CLUTCH F1
8 - FRONT PLANETARY ANNULUS GEAR 21 - FRONT PLANETARY SUN GEAR
9 - DRIVING CLUTCH K2 22 - CENTER PLANETARY SUN GEAR
10 - CENTER PLANETARY ANNULUS GEAR 23 - REAR PLANETARY SUN GEAR
11 - REAR PLANETARY ANNULUS GEAR 24 - FREEWHEELING CLUTCH F2
12 - DRIVING CLUTCH K3 25 - INPUT SHAFT
13 - FRONT PLANETARY CARRIER 26 - OUTPUT SHAFT
A - ENGINE SPEED D - SECOND GEAR RATIO
B - TRANSMISSION INPUT SPEED E - FIXED PARTS
C - FIRST GEAR RATIO

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)

Fig. 5 Second Gear Powerflow


1 - TORQUE CONVERTER LOCK-UP CLUTCH 14 - CENTER PLANETARY CARRIER
2 - TORQUE CONVERTER TURBINE 15 - REAR PLANETARY CARRIER
3 - TORQUE CONVERTER IMPELLER 16 - TORQUE CONVERTER STATOR
4 - HOLDING CLUTCH B1 17 - FRONT PLANETARY PINION GEARS
5 - HOLDING CLUTCH B3 18 - CENTER PLANETARY PINION GEARS
6 - HOLDING CLUTCH B2 19 - REAR PLANETARY PINION GEARS
7 - DRIVING CLUTCH K1 20 - FREEWHEELING CLUTCH F1
8 - FRONT PLANETARY ANNULUS GEAR 21 - FRONT PLANETARY SUN GEAR
9 - DRIVING CLUTCH K2 22 - CENTER PLANETARY SUN GEAR
10 - CENTER PLANETARY ANNULUS GEAR 23 - REAR PLANETARY SUN GEAR
11 - REAR PLANETARY ANNULUS GEAR 24 - FREEWHEELING CLUTCH F2
12 - DRIVING CLUTCH K3 25 - INPUT SHAFT
13 - FRONT PLANETARY CARRIER 26 - OUTPUT SHAFT
A - ENGINE SPEED D - SECOND GEAR RATIO
B - TRANSMISSION INPUT SPEED E - FIXED PARTS
C - FIRST GEAR RATIO

Rear Planetary Gear Set Center Planetary Gear Set


The annulus gear (11) turns at the input speed as The annulus gear (10) is driven at the same speed
a result of the mechanical connection to the front as the rear planetary carrier (15) as a result of a
planetary carrier (13). The sun gear (23) is held mechanical connection. The sun gear (22) is held
against the housing by the engaged multiple-disc against the housing by the multiple-disc holding
holding clutch B2 (6), by the locked freewheel F2 (24) clutch B2 (6). The planetary pinion gears (18) turn
during acceleration and by the engaged multiple-disc on the fixed sun gear (22) and increase the torque
clutch K3 (12) during deceleration. The planetary from the annulus gear (10) to the planetary carrier
pinion gears (19) turn on the fixed sun gear (23) and (14). The output shaft (5) connected to the planetary
increase the torque from the annulus gear (11) to the carrier (14) turns at a reduced speed in the running
planetary carrier (15). The planetary carrier (15) direction of the engine.
moves at a reduced speed in the running direction of
the engine.
21 - 10 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)
THIRD GEAR POWERFLOW

Fig. 6 Third Gear Powerflow


1 - TORQUE CONVERTER LOCK-UP CLUTCH 14 - CENTER PLANETARY CARRIER
2 - TORQUE CONVERTER TURBINE 15 - REAR PLANETARY CARRIER
3 - TORQUE CONVERTER IMPELLER 16 - TORQUE CONVERTER STATOR
4 - HOLDING CLUTCH B1 17 - FRONT PLANETARY PINION GEARS
5 - HOLDING CLUTCH B3 18 - CENTER PLANETARY PINION GEARS
6 - HOLDING CLUTCH B2 19 - REAR PLANETARY PINION GEARS
7 - DRIVING CLUTCH K1 20 - FREEWHEELING CLUTCH F1
8 - FRONT PLANETARY ANNULUS GEAR 21 - FRONT PLANETARY SUN GEAR
9 - DRIVING CLUTCH K2 22 - CENTER PLANETARY SUN GEAR
10 - CENTER PLANETARY ANNULUS GEAR 23 - REAR PLANETARY SUN GEAR
11 - REAR PLANETARY ANNULUS GEAR 24 - FREEWHEELING CLUTCH F2
12 - DRIVING CLUTCH K3 25 - INPUT SHAFT
13 - FRONT PLANETARY CARRIER 26 - OUTPUT SHAFT
A - ENGINE SPEED C - FIRST GEAR RATIO
B - TRANSMISSION INPUT SPEED D - FIXED PARTS

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)

Fig. 7 Third Gear Powerflow


1 - TORQUE CONVERTER LOCK-UP CLUTCH 14 - CENTER PLANETARY CARRIER
2 - TORQUE CONVERTER TURBINE 15 - REAR PLANETARY CARRIER
3 - TORQUE CONVERTER IMPELLER 16 - TORQUE CONVERTER STATOR
4 - HOLDING CLUTCH B1 17 - FRONT PLANETARY PINION GEARS
5 - HOLDING CLUTCH B3 18 - CENTER PLANETARY PINION GEARS
6 - HOLDING CLUTCH B2 19 - REAR PLANETARY PINION GEARS
7 - DRIVING CLUTCH K1 20 - FREEWHEELING CLUTCH F1
8 - FRONT PLANETARY ANNULUS GEAR 21 - FRONT PLANETARY SUN GEAR
9 - DRIVING CLUTCH K2 22 - CENTER PLANETARY SUN GEAR
10 - CENTER PLANETARY ANNULUS GEAR 23 - REAR PLANETARY SUN GEAR
11 - REAR PLANETARY ANNULUS GEAR 24 - FREEWHEELING CLUTCH F2
12 - DRIVING CLUTCH K3 25 - INPUT SHAFT
13 - FRONT PLANETARY CARRIER 26 - OUTPUT SHAFT
A - ENGINE SPEED C - FIRST GEAR RATIO
B - TRANSMISSION INPUT SPEED D - FIXED PARTS

Rear Planetary Gear Set Center Planetary Gear Set


The multiple-disc clutch K2 (9) is engaged and The annulus gear (10) turns at the input speed as
transfers the input speed of the input shaft (25) to a result of the engaged multiple-disc clutch K2 (9).
the planetary carrier (15) via the annulus gear (10). The sun gear (22) is held against the housing by the
The annulus gear (11) turns in the same way as the multiple-disc holding clutch B2 (6). The planetary
planetary carrier (15) due to the mechanical connec- pinion gears (18) turn on the fixed sun gear (22) and
tion with the locked front planetary gearset. This increase the torque from the annulus gear (10) to the
planetary gearset is therefore locked and turns as a planetary carrier (14). The output shaft (26) con-
closed unit. nected to the planetary carrier (14) turns at a
reduced speed in the running direction of the engine.
21 - 12 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)
FOURTH GEAR POWERFLOW

Fig. 8 Fourth Gear Powerflow


1 - TORQUE CONVERTER LOCK-UP CLUTCH 14 - CENTER PLANETARY CARRIER
2 - TORQUE CONVERTER TURBINE 15 - REAR PLANETARY CARRIER
3 - TORQUE CONVERTER IMPELLER 16 - TORQUE CONVERTER STATOR
4 - HOLDING CLUTCH B1 17 - FRONT PLANETARY PINION GEARS
5 - HOLDING CLUTCH B3 18 - CENTER PLANETARY PINION GEARS
6 - HOLDING CLUTCH B2 19 - REAR PLANETARY PINION GEARS
7 - DRIVING CLUTCH K1 20 - FREEWHEELING CLUTCH F1
8 - FRONT PLANETARY ANNULUS GEAR 21 - FRONT PLANETARY SUN GEAR
9 - DRIVING CLUTCH K2 22 - CENTER PLANETARY SUN GEAR
10 - CENTER PLANETARY ANNULUS GEAR 23 - REAR PLANETARY SUN GEAR
11 - REAR PLANETARY ANNULUS GEAR 24 - FREEWHEELING CLUTCH F2
12 - DRIVING CLUTCH K3 25 - INPUT SHAFT
13 - FRONT PLANETARY CARRIER 26 - OUTPUT SHAFT
A - ENGINE SPEED B - TRANSMISSION INPUT SPEED

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)

Fig. 9 Fourth Gear Powerflow


1 - TORQUE CONVERTER LOCK-UP CLUTCH 14 - CENTER PLANETARY CARRIER
2 - TORQUE CONVERTER TURBINE 15 - REAR PLANETARY CARRIER
3 - TORQUE CONVERTER IMPELLER 16 - TORQUE CONVERTER STATOR
4 - HOLDING CLUTCH B1 17 - FRONT PLANETARY PINION GEARS
5 - HOLDING CLUTCH B3 18 - CENTER PLANETARY PINION GEARS
6 - HOLDING CLUTCH B2 19 - REAR PLANETARY PINION GEARS
7 - DRIVING CLUTCH K1 20 - FREEWHEELING CLUTCH F1
8 - FRONT PLANETARY ANNULUS GEAR 21 - FRONT PLANETARY SUN GEAR
9 - DRIVING CLUTCH K2 22 - CENTER PLANETARY SUN GEAR
10 - CENTER PLANETARY ANNULUS GEAR 23 - REAR PLANETARY SUN GEAR
11 - REAR PLANETARY ANNULUS GEAR 24 - FREEWHEELING CLUTCH F2
12 - DRIVING CLUTCH K3 25 - INPUT SHAFT
13 - FRONT PLANETARY CARRIER 26 - OUTPUT SHAFT
A - ENGINE SPEED B - TRANSMISSION INPUT SPEED

Rear Planetary Gear Set Center Planetary Gear Set


The multiple-disc clutch K2 (9) is engaged and The annulus gear (10) turns at the input speed as
transfers the input speed of the input shaft (25) to a result of the engaged multiple-disc clutch K2 (9).
the planetary carrier (15) via the annulus gear (10). The multiple-disc clutch K3 (12) connects the sun
The annulus gear (11) turns in the same way as the gears (22) and (23) of the rear and center planetary
planetary carrier (15) due to the mechanical connec- gearset. The planetary gearset is locked by the same
tion with the locked front planetary gearset. The speeds of the annulus gear (10) and the sun gear (22)
planetary gearset is therefore locked and turns as a and it turns as a closed unit.
closed unit.
21 - 14 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)
FIFTH GEAR POWERFLOW

Fig. 10 Fifth Gear Powerflow


1 - TORQUE CONVERTER LOCK-UP CLUTCH 14 - CENTER PLANETARY CARRIER
2 - TORQUE CONVERTER TURBINE 15 - REAR PLANETARY CARRIER
3 - TORQUE CONVERTER IMPELLER 16 - TORQUE CONVERTER STATOR
4 - HOLDING CLUTCH B1 17 - FRONT PLANETARY PINION GEARS
5 - HOLDING CLUTCH B3 18 - CENTER PLANETARY PINION GEARS
6 - HOLDING CLUTCH B2 19 - REAR PLANETARY PINION GEARS
7 - DRIVING CLUTCH K1 20 - FREEWHEELING CLUTCH F1
8 - FRONT PLANETARY ANNULUS GEAR 21 - FRONT PLANETARY SUN GEAR
9 - DRIVING CLUTCH K2 22 - CENTER PLANETARY SUN GEAR
10 - CENTER PLANETARY ANNULUS GEAR 23 - REAR PLANETARY SUN GEAR
11 - REAR PLANETARY ANNULUS GEAR 24 - FREEWHEELING CLUTCH F2
12 - DRIVING CLUTCH K3 25 - INPUT SHAFT
13 - FRONT PLANETARY CARRIER 26 - OUTPUT SHAFT
A - ENGINE SPEED D - SECOND GEAR RATIO
B - TRANSMISSION INPUT SPEED E - THIRD GEAR RATIO
C - FIRST GEAR RATIO F - FIXED PARTS

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)

Fig. 11 Fifth Gear Powerflow


1 - TORQUE CONVERTER LOCK-UP CLUTCH 14 - CENTER PLANETARY CARRIER
2 - TORQUE CONVERTER TURBINE 15 - REAR PLANETARY CARRIER
3 - TORQUE CONVERTER IMPELLER 16 - TORQUE CONVERTER STATOR
4 - HOLDING CLUTCH B1 17 - FRONT PLANETARY PINION GEARS
5 - HOLDING CLUTCH B3 18 - CENTER PLANETARY PINION GEARS
6 - HOLDING CLUTCH B2 19 - REAR PLANETARY PINION GEARS
7 - DRIVING CLUTCH K1 20 - FREEWHEELING CLUTCH F1
8 - FRONT PLANETARY ANNULUS GEAR 21 - FRONT PLANETARY SUN GEAR
9 - DRIVING CLUTCH K2 22 - CENTER PLANETARY SUN GEAR
10 - CENTER PLANETARY ANNULUS GEAR 23 - REAR PLANETARY SUN GEAR
11 - REAR PLANETARY ANNULUS GEAR 24 - FREEWHEELING CLUTCH F2
12 - DRIVING CLUTCH K3 25 - INPUT SHAFT
13 - FRONT PLANETARY CARRIER 26 - OUTPUT SHAFT
A - ENGINE SPEED D - SECOND GEAR RATIO
B - TRANSMISSION INPUT SPEED E - THIRD GEAR RATIO
C - FIRST GEAR RATIO F - FIXED PARTS

Rear Planetary Gear Set Center Planetary Gear Set


The multiple-disc clutch K2 (9) is engaged and The annulus gear (10) turns at the input speed as
transfers the input speed of the input shaft (25) to a result of the engaged multiple-disc clutch K2 (9).
the planetary carrier (15) via the annulus gear (10). The multiple-disc clutch K3 (12) transfers an
The annulus gear (11) turns at a reduced speed due increased speed to the sun gear (22) due to the con-
to the mechanical connection with the front plane- nection with the sun gear (23). The planetary pinion
tary carrier (13). The planetary pinion gears (19) gears (18) turn between the annulus gear (10) and
turn between the annulus gear (11) and the sun gear the sun gear (22). The speed of the planetary carrier
(23). The sun gear (23) moves at an increased speed (14) and the output shaft connected to the planetary
in the running direction of the engine. carrier (5) lies between that of the annulus gear (10)
and the sun gear (22). This provides a step-up ratio.
21 - 16 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)
REVERSE GEAR POWERFLOW

Fig. 12 Reverse Gear Powerflow


1 - TORQUE CONVERTER LOCK-UP CLUTCH 14 - CENTER PLANETARY CARRIER
2 - TORQUE CONVERTER TURBINE 15 - REAR PLANETARY CARRIER
3 - TORQUE CONVERTER IMPELLER 16 - TORQUE CONVERTER STATOR
4 - HOLDING CLUTCH B1 17 - FRONT PLANETARY PINION GEARS
5 - HOLDING CLUTCH B3 18 - CENTER PLANETARY PINION GEARS
6 - HOLDING CLUTCH B2 19 - REAR PLANETARY PINION GEARS
7 - DRIVING CLUTCH K1 20 - FREEWHEELING CLUTCH F1
8 - FRONT PLANETARY ANNULUS GEAR 21 - FRONT PLANETARY SUN GEAR
9 - DRIVING CLUTCH K2 22 - CENTER PLANETARY SUN GEAR
10 - CENTER PLANETARY ANNULUS GEAR 23 - REAR PLANETARY SUN GEAR
11 - REAR PLANETARY ANNULUS GEAR 24 - FREEWHEELING CLUTCH F2
12 - DRIVING CLUTCH K3 25 - INPUT SHAFT
13 - FRONT PLANETARY CARRIER 26 - OUTPUT SHAFT
A - ENGINE SPEED D - SECOND GEAR RATIO
B - TRANSMISSION INPUT SPEED E - THIRD GEAR RATIO
C - FIRST GEAR RATIO F - FIXED PARTS

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)

Fig. 13 Reverse Gear Powerflow


1 - TORQUE CONVERTER LOCK-UP CLUTCH 14 - CENTER PLANETARY CARRIER
2 - TORQUE CONVERTER TURBINE 15 - REAR PLANETARY CARRIER
3 - TORQUE CONVERTER IMPELLER 16 - TORQUE CONVERTER STATOR
4 - HOLDING CLUTCH B1 17 - FRONT PLANETARY PINION GEARS
5 - HOLDING CLUTCH B3 18 - CENTER PLANETARY PINION GEARS
6 - HOLDING CLUTCH B2 19 - REAR PLANETARY PINION GEARS
7 - DRIVING CLUTCH K1 20 - FREEWHEELING CLUTCH F1
8 - FRONT PLANETARY ANNULUS GEAR 21 - FRONT PLANETARY SUN GEAR
9 - DRIVING CLUTCH K2 22 - CENTER PLANETARY SUN GEAR
10 - CENTER PLANETARY ANNULUS GEAR 23 - REAR PLANETARY SUN GEAR
11 - REAR PLANETARY ANNULUS GEAR 24 - FREEWHEELING CLUTCH F2
12 - DRIVING CLUTCH K3 25 - INPUT SHAFT
13 - FRONT PLANETARY CARRIER 26 - OUTPUT SHAFT
A - ENGINE SPEED D - SECOND GEAR RATIO
B - TRANSMISSION INPUT SPEED E - THIRD GEAR RATIO
C - FIRST GEAR RATIO F - FIXED PARTS

Rear Planetary Gear Set Center Planetary Gear Set


The planetary carrier (15) is held against the hous- The annulus gear (10) is held against the housing
ing by the engaged multiple-disc holding clutch B3 by the multiple-disc holding clutch B3 (5) via the
(5). The annulus gear (11) turns at a reduced speed mechanical connection to the planetary carrier (15).
due to the mechanical connection to the front plane- The sun gear (22) turns backwards due to the
tary carrier (13). The planetary gears (19) turn engaged multiple-disc clutch K3 (12). The planetary
between the annulus gear (11) and the sun gear (23). gears (18) turn on the fixed annulus gear (10) and
The direction is reversed by the held planetary car- increase the torque from the sun gear (22) to the
rier (15) so that the sun gear (23) turns in the oppo- planetary carrier (14). The output shaft (26) con-
site direction to the running direction of the engine. nected to the planetary carrier (14) turns at a
reduced speed in the opposite direction to the run-
ning direction of the engine.
21 - 18 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)
SHIFT GROUPS/ SHIFT SEQUENCE 4-5 shift (1). Because of the holding pressure shift
valve (4), the working pressure (p-A) is present at
1-2 Shift - First Gear Engaged the multiple-disc holding clutch B1 (7). Clutch K1 (6)
The end face of the command valve (5) (Fig. 14) is is unpressurized.
kept unpressurized via the solenoid valve for 1-2 and

Fig. 14 First Gear Engaged


1 - 1-2/4-5 SHIFT SOLENOID 5 - 1-2/4-5 COMMAND VALVE
2 - 1-2/4-5 OVERLAP VALVE 6 - DRIVING CLUTCH K1
3 - 1-2/4-5 SHIFT PRESSURE SHIFT VALVE 7 - HOLDING CLUTCH B1
4 - 1-2/4-5 HOLDING PRESSURE SHIFT VALVE
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 19
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)
Shift Phase - 1-2 Shift Phase 1

Fig. 15 Shift Phase - 1-2 Shift Phase 1


1 - 1-2/4-5 SHIFT SOLENOID 5 - 1-2/4-5 COMMAND VALVE
2 - 1-2/4-5 OVERLAP VALVE 6 - DRIVING CLUTCH K1
3 - 1-2/4-5 SHIFT PRESSURE SHIFT VALVE 7 - HOLDING CLUTCH B1
4 - 1-2/4-5 HOLDING PRESSURE SHIFT VALVE

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)

Fig. 16 Shift Phase - 1-2 Shift Phase 2


1 - 1-2/4-5 SHIFT SOLENOID 5 - 1-2/4-5 COMMAND VALVE
2 - 1-2/4-5 OVERLAP VALVE 6 - DRIVING CLUTCH K1
3 - 1-2/4-5 SHIFT PRESSURE SHIFT VALVE 7 - HOLDING CLUTCH B1
4 - 1-2/4-5 HOLDING PRESSURE SHIFT VALVE
21 - 22 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)
Second Gear Engaged

Fig. 17 Second Gear Engaged


1 - 1-2/4-5 SHIFT SOLENOID 5 - 1-2/4-5 COMMAND VALVE
2 - 1-2/4-5 OVERLAP VALVE 6 - DRIVING CLUTCH K1
3 - 1-2/4-5 SHIFT PRESSURE SHIFT VALVE 7 - HOLDING CLUTCH B1
4 - 1-2/4-5 HOLDING PRESSURE SHIFT VALVE

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

Fig. 18 Shift Phase - 2-1 Shift Phase 1


1 - 1-2/4-5 SHIFT SOLENOID 5 - 1-2/4-5 COMMAND VALVE
2 - 1-2/4-5 OVERLAP VALVE 6 - DRIVING CLUTCH K1
3 - 1-2/4-5 SHIFT PRESSURE SHIFT VALVE 7 - HOLDING CLUTCH B1
4 - 1-2/4-5 HOLDING PRESSURE SHIFT VALVE
21 - 24 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)
The 1-2/4-5 shift solenoid (1) (Fig. 18) is turned ON Simultaneously, the pressure in the releasing
to apply shift pressure (p-S) to the end face of the clutch, K1 (6), is regulated at the 1-2/4-5 overlap
1-2/4-5 command valve (5). This allows the command valve (2). The pressure in the K1 clutch as it disen-
valve to up-shift and the shift pressure coming from gages is controlled during the shift phase depending
the 1-2/4-5 shift valve (3) is routed to the holding on engine load, via the modulating pressure
clutch B1 (7) via the command valve. (p-MOD), and the shift pressure in clutch B1 (7). The
increasing shift pressure in clutch B1, which also
acts on the end face of the overlap valve, reduces the
overlap pressure.
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 25
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)
Shift Phase - 2-1 Shift Phase 2

Fig. 19 Shift Phase - 2-1 Shift Phase 2


1 - 1-2/4-5 SHIFT SOLENOID 5 - 1-2/4-5 COMMAND VALVE
2 - 1-2/4-5 OVERLAP VALVE 6 - DRIVING CLUTCH K1
3 - 1-2/4-5 SHIFT PRESSURE SHIFT VALVE 7 - HOLDING CLUTCH B1
4 - 1-2/4-5 HOLDING PRESSURE SHIFT VALVE

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

Fig. 20 First Gear Engaged


1 - 1-2/4-5 SHIFT SOLENOID 5 - 1-2/4-5 COMMAND VALVE
2 - 1-2/4-5 OVERLAP VALVE 6 - DRIVING CLUTCH K1
3 - 1-2/4-5 SHIFT PRESSURE SHIFT VALVE 7 - HOLDING CLUTCH B1
4 - 1-2/4-5 HOLDING PRESSURE SHIFT VALVE

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

Fig. 21 Engine Started


1 - HOLDING CLUTCH B1 11 - PRESSURE HOLDING VALVE
2 - DRIVING CLUTCH K1 12 - 3-4 HOLDING PRESSURE SHIFT VALVE
3 - HOLDING CLUTCH B3 13 - 3-4 COMMAND VALVE
4 - DRIVING CLUTCH K3 14 - 3-4 SHIFT PRESSURE SHIFT VALVE
5 - HOLDING CLUTCH B2 PISTON 15 - 3-4 OVERLAP REGULATING VALVE
6 - HOLDING CLUTCH B2 PISTON OPPOSING FACE 16 - BALL VALVE
7 - SHIFT PRESSURE REGULATING SOLENOID 17 - 1-2/4-5 COMMAND VALVE
8 - SHIFT PRESSURE REGULATING VALVE 18 - 1-2/4-5 COMMAND VALVE
9 - SHIFT VALVE B2 19 - BALL VALVE
10 - 3-4 SHIFT SOLENOID

With the engine started (Fig. 21) and the gearshift


lever in the NEUTRAL or PARK positions, holding
clutch B1 (1) and driving clutch K3 (4) are applied
and the various valves in the 1-2/4-5 shift group are
positioned to apply pressure to the holding clutch B2.
21 - 28 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)
Activation Sequence

Fig. 22 Activation Sequence


1 - HOLDING CLUTCH B1 11 - PRESSURE HOLDING VALVE
2 - DRIVING CLUTCH K1 12 - 3-4 HOLDING PRESSURE SHIFT VALVE
3 - HOLDING CLUTCH B3 13 - 3-4 COMMAND VALVE
4 - DRIVING CLUTCH K3 14 - 3-4 SHIFT PRESSURE SHIFT VALVE
5 - HOLDING CLUTCH B2 PISTON 15 - 3-4 OVERLAP REGULATING VALVE
6 - HOLDING CLUTCH B2 PISTON OPPOSING FACE 16 - BALL VALVE
7 - SHIFT PRESSURE REGULATING SOLENOID 17 - 1-2/4-5 COMMAND VALVE
8 - SHIFT PRESSURE REGULATING VALVE 18 - 1-2/4-5 COMMAND VALVE
9 - SHIFT VALVE B2 19 - BALL VALVE
10 - 3-4 SHIFT SOLENOID

The selector valve (Fig. 22) opens the shift pres-


sure (p-S) feed connection from the ball valve (19)
with the shift valve B2 (9). With the shift valve B2
(9) in the upper position, shift pressure (p-S) travels
behind the piston B2 (5) and simultaneously to the
opposing face of the piston B2 (6). The multiple-disc
holding clutch B2 begins to close.
The pressure on the opposing face of the piston B2
(6) ensures a soft activation of the multiple-disc hold-
ing clutch B2.
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 29
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)
First Gear Engaged

Fig. 23 First Gear Engaged


1 - HOLDING CLUTCH B1 11 - PRESSURE HOLDING VALVE
2 - DRIVING CLUTCH K1 12 - 3-4 HOLDING PRESSURE SHIFT VALVE
3 - HOLDING CLUTCH B3 13 - 3-4 COMMAND VALVE
4 - DRIVING CLUTCH K3 14 - 3-4 SHIFT PRESSURE SHIFT VALVE
5 - HOLDING CLUTCH B2 PISTON 15 - 3-4 OVERLAP REGULATING VALVE
6 - HOLDING CLUTCH B2 PISTON OPPOSING FACE 16 - BALL VALVE
7 - SHIFT PRESSURE REGULATING SOLENOID 17 - 1-2/4-5 COMMAND VALVE
8 - SHIFT PRESSURE REGULATING VALVE 18 - 1-2/4-5 COMMAND VALVE
9 - SHIFT VALVE B2 19 - BALL VALVE
10 - 3-4 SHIFT SOLENOID

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)

DIAGNOSIS AND TESTING (2) Check for broken or disconnected gearshift


cable.
AUTOMATIC TRANSMISSION (3) Check for cracked, leaking cooler lines, or loose
or missing pressure-port plugs.
CAUTION: Before attempting any repair on a NAG1 (4) Raise and support vehicle on safety stands,
automatic transmission, check for Diagnostic Trou- start engine, shift transmission into gear, and note
ble Codes with the appropriate scan tool. following:
(a) If propeller shaft turns but wheels do not,
Transmission malfunctions may be caused by these problem is with differential or axle shafts.
general conditions: (b) If propeller shaft does not turn and transmis-
• Poor engine performance. sion is noisy, stop engine. Remove oil pan, and
• Improper adjustments. check for debris. If pan is clear, remove transmis-
• Hydraulic malfunctions. sion and check for damaged driveplate, converter,
• Mechanical malfunctions. oil pump, or input shaft.
• Electronic malfunctions. (c) If propeller shaft does not turn and transmis-
• Transfer case performance (if equipped). sion is not noisy, perform hydraulic-pressure test to
Diagnosis of these problems should always begin determine if problem is hydraulic or mechanical.
by checking the easily accessible variables: fluid level
and condition, gearshift cable adjustment. Then per- ROAD TESTING
form a road test to determine if the problem has been Before road testing, be sure the fluid level and con-
corrected or if more diagnosis is necessary. trol cable adjustments have been checked and
adjusted if necessary. Verify that all diagnostic trou-
PRELIMINARY ble codes have been resolved.
Two basic procedures are required. One procedure Observe engine performance during the road test.
for vehicles that are drivable and an alternate proce- A poorly tuned engine will not allow accurate analy-
dure for disabled vehicles (will not back up or move sis of transmission operation.
forward). Operate the transmission in all gear ranges. Check
for shift variations and engine flare which indicates
VEHICLE IS DRIVABLE slippage. Note if shifts are harsh, spongy, delayed,
(1) Check for transmission fault codes using the early, or if part throttle downshifts are sensitive.
appropriate scan tool. Slippage indicated by engine flare, usually means
(2) Check fluid level and condition. clutch, overrunning clutch, or line pressure problems.
(3) Adjust gearshift cable if complaint was based A slipping clutch can often be determined by com-
on delayed, erratic, or harsh shifts. paring which internal units are applied in the vari-
(4) Road test and note how transmission upshifts, ous gear ranges. The Clutch Application chart
downshifts, and engages. CLUTCH APPLICATION provides a basis for analyz-
ing road test results.
VEHICLE IS DISABLED
(1) Check fluid level and condition.

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

CONDITION POSSIBLE CAUSES CORRECTION


MAXIMUM SPEED 30 km/h 1. Speed Control 30 Actuated. 1. Instruct Customer.
ENGINE DIES WHEN 1. PWM Valve Blocked. 1. Replace Valve.
TRANSMISSION IS
SHIFTED INTO GEAR, 2. Torque Converter Lock Up Control 2. Enable Movement of Valve,
ALSO NOISES IN N Valve Locked. Remove Particle.
AND/OR P
LEVER IN 9P9 POSITION 1. No Vacuum Brake Booster After 1. Check Vacuum/ Tightness of
BLOCKED (BRAKE Long Immobilization, Brake Pedal Brake Booster.
ACTIVATED) Not Fully Applied/Hard Pedal.
2. No Stoplamp Switch Signal (no 2. Check Contact to Stoplamp
DTC IN ECM). Switch. Replace Switch if
Necessary.
GRUMBLING, DRONING, 1. Slip Speed TCC to Low. 1. Switch Off Torque Converter
JERKING WHEN TCC IS Lock Up Using DRBT. If
ENGAGED Complaint Is Not Reproduced
Afterwards, Replace PWM
Valve, Set Adaption Values to
Zero.
HOWLING, HUMMING 1. Oil Filter Blocked. 1. Replace Oil Filter.
ABOVE 4000 RPM IN
EACH GEAR 2. Oil Pump. 2. Replace Oil Pump.
WHINING, SINGING 1. Gear Set Noises in 1st, 2nd, 5th 1. Replace Transmission..
Gear.
2. Intermediate Bearing Of The Drive 2. Replace Intermediate
Shaft At 0 km/h, Only When Cold. Bearing of the Drive Shaft.
9CLACK9 NOISE FROM 1. Park Lock Solenoid. 1. Replace Shift Lever
CENTER SHIFT AREA Assembly.
WHEN STOPPING OR
STARTING
CRACKING NOISE WHEN 1. Stick - Slip Between Joint Flange 1. Install Zinc Coated Collar Nut
LOAD CYCLE and Collar Nut. Together With Washer.
CHATTERING IN CENTER 1. Bushing Shift Shaft Has Too Much 1. Replace Shifter Lever and
CONSOLE SHIFT WHILE Clearance. Cover Plate.
ACCELERATING
HARD 2-3 UPSHIFT WHEN 1. Response Characteristic Control 1. Install K2 Disc Spring.
STEPPING OFF THE Loop.
ACCELERATOR PEDAL
UPSHIFT 2-3, 3-4 1. Spring of Regulating Valve 1. Replace Spring.
SLIPPING Pressure control Valve Broken.
HARD 2-1 DOWNSHIFT 1. Transmission (2-1 downshift) Not 1. Re-adapt Transmission.
WHEN COMING TO A Adapted.
STOP 2. TCM Software Data. 2. Flash TCM.
3. Free Wheeling Clutch F1 Replace Free Wheeling Clutch
Defective. F1.
21 - 32 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)

CONDITION POSSIBLE CAUSES CORRECTION


HARD 3-2 DOWNSHIFT 1. K3 Idles. 1. Install TCM And/Or
WHEN DECELERATION Electrohydraulic Control Unit.
EVEN AFTER
READAPTION
NO RESP. DELAYED 1. Different Tire Sizes Are Mounted 1. Mount Uniform Tire Sizes On
UPSHIFT, NO DTC On The Front Axle. The Front Axle.
NO UPSHIFT 3-4, 4-5 1. Upshift Prevention To Realize 1. Instruct Customer.
AFTER FAST OFF Dynamical Drivestyle.
(ACCELERATOR)
NO UPSHIFT OF 1ST 1. Gear Recognition Switch. 1. Replace Gear Recognition
GEAR BELOW 5000 RPM Switch.
NO UPSHIFT INTO 5TH 1. The Upshift 4-5 At Full Throttle or 1. Instruct Customer.
GEAR WHEN FULL Kick Down Never Occurs Until
THROTTLE OR KICK Reaching Cut Off Speed. Under
DOWN ACTIVATION These Conditions, The High
Powered Vehicle Will Never Shift
Into 5th Gear Below 250 km/h.
NO KICK DOWN 1. Accelerator Pedal Value < 95%. 1. Check Engine Control. Adjust
SHIFTING As Necessary.
Engine Turns Up While 2-3 1. Oil Level Too Low. 1. Check Oil Level. Add if
Upshift and/or Hard 3-2 Necessary.
Downshift 2. Oil Filter Not Installed. 2. Install Oil Filter.
3. Free Wheeling Clutch F2 3. Replace Free Wheeling
Defective. Clutch F2, Hollow Shaft, and
Rear Sun Gear/Inner Disc
Carrier K3.
GRABBING 2-3 COASTING 1. Oil Level Too Low. 1. Check Oil Level. Add if
UPSHIFT AND/OR BRAKE Necessary.
DOWNSHIFT 2. Oil Filter Not Installed. 2. Install Oil Filter.
3. Control shift or Command Valve 3. Check Each Slide Valve For
Blocked. Base Position and Ease Of
Movement, Remove Particle.
4. K3 Disc Burnt, Hot Spots or 4. Replace Inner and Outer
Rubbed Down. Disc Carrier K3 And Control
Valve.
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 33
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)

CONDITION POSSIBLE CAUSES CORRECTION


DELAYED ENGAGEMENT, 1. Oil Level Too Low. 1. Check Oil Level. Add if
NO TRANSFER OF Necessary.
POWER IN R AND/OR D, 2. Recognition Switch - Selector 2. Replace Recognition Switch
ALSO AT TIMES Lever Position. Only When Intermediate
Position or Fault is Indicated.
3. Oil Filter Not Installed. 3. Install Oil Filter.
4. AEV, Delayed Pressure Build Up 4. Install New Shifting
On Piston B2/B3. Procedure (TCM,
electrohydraulic control unit or
repair set).
5. Wrong Combination TCM/ 5. Check Combination
Electrohydraulic Control Unit. TCM/Electrohydraulic Control
Unit. Replace TCM Resp.
Electrohydraulic Control Unit, if
necessary.
NO UPSHIFT OF 1ST 1. Connector Ballast Unit. Output 1. Check Connectors, Replace
GEAR AT TIMES Speed Sensor Loose, Incorrectly Output Speed sensor If
Contacted. Necessary.
2. Output Speed Sensor Defective 2. Replace Output Speed
Sensor.
LEAKAGE AT THE AREA 1. Deformation O-Rings. 1. Replace O-Rings.
OF THE ELECTRICAL 2. Deformation Adapter. 2.Replace Adaptor.
PLUG TO THE
3. The Conductor Plate Is Not Fitted 3. Remove Nose Of Conductor
CONDUCTOR PLATE
Surface To Surface On The Valve Plate.
Body In One Corner, The Plug Is Not
Centered In The Socket And The
O-ring Will Not Seal.
4. Contacting At The Conductor Plate 4. Replace Conductor Plate.
Leaky. Oil In Harness, Sometimes In
The Control Module.
LEAKAGE AT THE AREA 1. Bolts (Torx M6) Outer Disc Carrier 1. Clean Thread and Install the
OF BELL HOUSING/ B1. Bolts Using Sealer.
TORQUE CONVERTER
OIL LEAKS 1. 6 Lower Bolts (TorxM8) Converter 1. Clean Thread and Install the
Housing. Bolts Using Sealer.
2. Oil Drain Plug Converter Loose 2. Install Drain Plug Correctly.
Resp. No Seal Ring Installed.
3. Weld Seam Of Torque Converter 3. Replace Torque Converter.
Leaky.
4. Radial Sealing Ring Oil Pump 4. Replace Sealing Ring.
Defective.
5. O-Ring Oil Pump Defective Or Not 5. Install O-Ring.
Installed.
6. Bushing Of Oil Pump Loose, 6. Install Fit Bolt If Necessary.
caused By Missing Fit Bolt At
Transmission/Engine Flange.
21 - 34 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)

STANDARD PROCEDURE - ALUMINUM


THREAD REPAIR
Damaged or worn threads in the aluminum trans-
mission case and valve body can be repaired by the
use of Heli-Coils™, or equivalent. This repair con-
sists of drilling out the worn-out damaged threads.
Then tap the hole with a special Heli-Coil™ tap, or
equivalent, and installing a Heli-Coil™ insert, or
equivalent, into the hole. This brings the hole back to
its original thread size.
Heli-Coil™, or equivalent, tools and inserts are
readily available from most automotive parts suppli-
ers.

REMOVAL
(1) Disconnect the negative (ground) battery cable.

CAUTION: Isolate ground lead to prevent accidental


contact.

(2) Apply parking brake.


(3) Move gear selector lever to position 9N9.
(4) Remove oil drain plug (2) (Fig. 24) and drain Fig. 25 test Fill Tube
automatic transmission oil into a clean container. 1 - FILL TUBE
2 - BOLTS TO CYLINDER HEAD AND TRANSMISSION HOUSING
3 - BOLT TO TRANSMISSION FLANGE

PROPELLER SHAFT/PROPELLER SHAFT -


REMOVAL). Move propeller shaft to the right and tie
up.

Fig. 24 Drain Transmission


1 - SEAL
2 - DRAIN PLUG

(5) Remove oil filler pipe.


(a) Remove bolts (2) (Fig. 25) to cylinder head.
Fig. 26 Propeller Shaft and Heat Shield
(b) Remove bolt (3) (Fig. 25) to transmission
flange and bolt (2) to transmission housing. 1 - PROPELLER SHAFT
2 - BOLT
(c) Pull lower connection of oil filler pipe (1) (Fig. 3 - BOLT
25) out of the fill hole in the side of the transmis- 4 - RETAINING BRACKET
sion housing. 5 - HEAT SHIELD
6 - WASHER
(d) Guide oil filler pipe (1) (Fig. 25) up and out. 7 - BOLT
(6) Remove exhaust heat shield (5) (Fig. 26).
(7) Remove retaining bracket (4) (Fig. 26). (9) Remove the cooler lines at transmission.
(8) Detach propeller shaft (1) (Fig. 26) at transmis- (a) Remove bracket for the oil cooler feed and
sion (Refer to 3 - DIFFERENTIAL & DRIVELINE/ return lines (1) (Fig. 27) from engine oil pan
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 35
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)
flange. Detail shows right side of motor. Position is
mirrored for the left side of engine.
(b) Detach bracket of cable retainer (4) (Fig. 28)
from the threaded shank of a engine oil pan bolt
(5).
(c) Press cable retainer (4) (Fig. 28) down and
out.
(d) Remove the bolts holding the oil cooler lines
(6) (Fig. 29) to the left and right sides of transmis-
sion and hang the lines to the side.

Fig. 29 Driver’s Side Cooler Line


1 - COOLER LINE

(10) Disconnect the transmission electrical connec-


tor (2) (Fig. 30) from transmission and hang to the
side. Turn sealing ring (3) counterclockwise and dis-
connect plug connection (2).
(11) Detach shift cable at transmission.
(a) Unlatch ball socket latch (Fig. 31) of cable.
(b) Unclip shift cable retainer from retainer
Fig. 27 Cooler Line Supports bracket. When pulling out cable, press together
hooks of shift cable retainer at the points shown
1 - COOLER LINES
(arrows).
(c) Pull shift cable out of ball socket. Ball socket
can remain on transmission lever.

Fig. 28 Cable Support


1 - CABLE
2 - BOLT Fig. 30 Transmission Electrical Connector and
Cooler Line
1 - COOLER LINE
2 - TRANSMISSION ELECTRICAL CONNECTOR
3 - SEALING RING
21 - 36 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)

Fig. 31 Shift Cable at Transmission


1 - SHIFT CABLE
2 - TRANSMISSION SHIFT LEVER

(12) Remove the torque converter bolts.


(a) Remove the steering gear (1) (Fig. 32) from
the chassis crossmember. Fig. 33 Torque Converter Access Cover
(b) Lower the steering gear (1) (Fig. 32) down-
1 - TORQUE CONVERTER ACCESS COVER
wards. 2 - BOLT
(c) Remove the plastic torque converter access
cover (1) (Fig. 33) at back of engine flange.
(d) Rotate engine by hand until bolts (2) (Fig.
33) are in front of opening. Rotate engine forwards
at crankshaft.
(e) To remove bolts, position a ratchet with long
extension and joint nut as shown (Fig. 34).
(f) Remove the two bolts (2) (Fig. 33) at each of
the three locations at circumference of driving
plate.

Fig. 34 Torque Converter Bolts Access


1 - BOLT
2 - STABILIZER BAR
3 - REINFORCEMENT PLATE
4 - OPENING
5 - CHASSIS CROSSMEMBER
6 - STEERING GEAR

(13) Support engine. Insert wooden block between


oil pan and front chassis crossmember beam.
(14) Remove vent hose bracket and tie back to one
Fig. 32 Steering Gear side.
1 - STEERING GEAR (15) Disconnect ground strap and tie back to one
2 - BRACKET
side.
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 37
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)
(16) Remove bolts (A) (Fig. 35) on underside of DISASSEMBLY
transmission. Two bolts (A) on top of transmission
must remain in the housing.
(17) Place hydraulic transmission jack under
transmission and raise slightly. Secure transmission
on hydraulic jack with a strap or ask an assistant to
hold it.
(18) Remove rear engine cross member (4) (Fig.
35). First remove the nuts (5) at the outside ends of
the engine crossmember. Then remove the bolts (1) of
the transmission mount.

Fig. 36 Remove Torque Converter


1 - TORQUE CONVERTER
2 - CONVERTER HOUSING

(1) Remove the torque converter (1) (Fig. 36).

Fig. 35 Support Transmission and Remove Bolts


1 - BOLT, TRANSMISSION MOUNT
2 - UPPER SHELL FOR TRANSMISSION MOUNT
3 - TRANSMISSION MOUNT
4 - CROSSMEMBER
5 - NUT, ENGINE CROSSMEMBER
6 - NUT, TRANSMISSION SUPPORT

(19) Remove the last bolts (A, B) (Fig. 35) on the


top of the transmission.
(20) Remove the transmission towards the rear
and lower. Ensure that the converter remains in the
transmission housing when the transmission is
removed.
(21) Remove the torque converter.

Fig. 37 Checking Input Shaft End Play


1 - TOOL 8266-8
2 - TOOL 8266-18
3 - TOOL C-3339

(2) Place transmission in a vertical position.


21 - 38 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)
(3) Measure input shaft end play as follows: (Fig.
37)
(a) Attach Adapter 8266-18 (2) to Handle 8266-8
(1).
(b) Attach dial indicator C-3339 (3) to Handle
8266-8 (1).
(c) Install the assembled tool onto the input
shaft of the transmission and tighten the retaining
screw on Adapter 8266-18 (2) to secure it to the
input shaft.
(d) Position the dial indicator plunger against a
flat spot on the oil pump and zero the dial indica-
tor.
(e) Move the input shaft in and out. Record the
maximum travel for assembly reference.

Fig. 39 Remove Rear Output Shaft Retaining Ring


1 - RETAINING RING
2 - OUTPUT SHAFT BEARING

(9) Remove the nut holding the propeller shaft


flange to the output shaft and remove the flange.
(10) Remove the transmission rear oil seal with a
suitable slide hammer and screw.
(11) Remove the transmission output shaft washer.
Be sure to tag the washer since it is very similar to
the geartrain end-play shim and they must not be
interchanged.
(12) Remove the transmission rear output shaft
bearing retaining ring (1) (Fig. 39).

Fig. 38 Remove Electrohydraulic Unit


1 - HEAT SHIELD
2 - ELECTROHYDRAULIC UNIT
3 - BOLT
4 - OIL FILTER
5 - OIL PAN
6 - CLAMPING ELEMENT
7 - BOLT
8 - DRAIN PLUG
9 - DRAIN PLUG GASKET
10 - 13-PIN PLUG CONNECTOR
11 - BOLT
12 - GUIDE BUSHING

(4) Loosen guide bushing (12) (Fig. 38) and remove


from transmission housing.
(5) Detach oil pan (5) (Fig. 38).
(6) Remove oil filter (4) (Fig. 38).
Fig. 40 Position Remover 9082 On Bearing
(7) Unscrew Torx socket bolts (3) and remove elec-
trohydraulic unit (2). 1 - BEARING REMOVER 9082
2 - TRANSMISSION CASE
(8) Place the transmission in PARK to prepare for 3 - OUTPUT SHAFT BEARING
the removal of the output shaft nut.
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 39
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)
(13) Position Bearing Remover 9082 (1) (Fig. 40)
over the inner race of the output shaft bearing (3).

Fig. 42 Remove Output Shaft Bearing


1 - BEARING REMOVER 9082
2 - TRANSMISSION CASE
Fig. 41 Slide Remover 9082 Collar Downward 3 - OUTPUT SHAFT BEARING
1 - BEARING REMOVER 9082
2 - TRANSMISSION CASE (15) Remove the output shaft bearing (3) (Fig. 42).
3 - COLLAR
4 - FINGERS (16) Remove the geartrain end-play shim from the
output shaft. Be sure to tag the shim since it is very
(14) Slide the collar (3) (Fig. 41) on the Bearing similar to the output shaft washer and they must not
Remover 9082 (1) downward over the fingers (4) of be interchanged.
the tool.
21 - 40 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)
(17) Remove the bolts holding the transmission (24) Remove clutch K1 (1).
housing to the converter housing from inside the con- (25) Unscrew Torx socket bolts (4) (Fig. 44) and
verter housing. remove oil pump (6). Screw two opposed bolts into
(18) Stand the transmission upright on the con- the oil pump housing and press the oil pump out of
verter housing. Be sure to use suitable spacers the converter housing by applying light blows with a
between the bench surface and the converter housing plastic hammer.
since the input shaft protrudes past the front surface (26) Remove and discard the torque converter hub
of the housing. seal and the oil pump outer o-ring seal from the oil
(19) Remove the remaining bolts holding the pump.
transmission housing to the converter housing. (27) Unscrew Torx socket bolts (1) (Fig. 44) and
(20) Remove the transmission housing from the remove multiple-disc holding clutch B1 (5) from con-
converter housing. verter housing. Screw two opposed bolts into the
(21) Remove output shaft with center and rear multiple-disc holding clutch B1 (5) and separate from
gear set and clutch K3 (3) (Fig. 43). the converter housing by applying light blows with a
(22) Remove thrust needle bearing (4) and thrust plastic hammer.
washer (5) (Fig. 43). (28) Detach intermediate plate (3) (Fig. 44) from
(23) Remove input shaft with clutch K2 and front converter housing (2).
gear set (6).

Fig. 43 Remove K1, K2, and K3 Clutches


1 - DRIVING CLUTCH K1 5 - THRUST WASHER
2 - SUN GEAR OF FRONT PLANETARY GEAR SET 6 - FRONT PLANETARY GEAR SET, DRIVING CLUTCH K2, AND
INPUT SHAFT
3 - DRIVING CLUTCH K3, OUTPUT SHAFT , AND CENTER AND 7 - SEALING RINGS
REAR PLANETARY GEAR SETS
4 - THRUST NEEDLE BEARING
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 41
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)

Fig. 44 Remove Holding Clutch B1 and Oil Pump


1 - BOLTS - M6X32 4 - BOLTS - M8X35
2 - CONVERTER HOUSING 5 - HOLDING CLUTCH B1
3 - INTERMEDIATE PLATE 6 - OIL PUMP
21 - 42 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)

Fig. 45 Remove B2, B3, and Parking Gear


1 - SNAP-RING 5 - PARK GEAR
2 - HOLDING CLUTCH B3 DISCS 6 - TRANSMISSION HOUSING
3 - SPRING WASHER 7 - BOLTS - M8X60
4 - HOLDING CLUTCH B2

(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

Fig. 46 Install B2, B3, and Parking Gear


1 - SNAP-RING 5 - PARK GEAR
2 - HOLDING CLUTCH B3 DISCS 6 - TRANSMISSION HOUSING
3 - SPRING WASHER 7 - BOLTS - M8X60
4 - HOLDING CLUTCH B2

(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. 49 Install Holding Clutch B1 and Oil Pump


1 - BOLTS - M6X32 4 - BOLTS - M8X35
2 - CONVERTER HOUSING 5 - HOLDING CLUTCH B1
3 - INTERMEDIATE PLATE 6 - OIL PUMP

Fig. 50 Install New Oil Pump Seals


1 - INNER OIL SEAL
2 - OUTER OIL SEAL
21 - 46 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)

Fig. 51 Install K1, K2, and K3 Clutches


1 - DRIVING CLUTCH K1 5 - THRUST WASHER
2 - SUN GEAR OF FRONT PLANETARY GEAR SET 6 - FRONT PLANETARY GEAR SET, DRIVING CLUTCH K2, AND
INPUT SHAFT
3 - DRIVING CLUTCH K3, OUTPUT SHAFT , AND CENTER AND 7 - SEALING RINGS
REAR PLANETARY GEAR SETS
4 - THRUST NEEDLE BEARING

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.).

Fig. 54 Install Output Shaft Bearing


1 - BEARING INSTALLER 9287
2 - BEARING
3 - TRANSMISSION CASE

(26) Screw in Torx socket bolts through the con-


verter housing into the transmission housing.
Tighten the bolts to 20 N·m (177 in.lbs.).
(27) Install output shaft bearing (2) in rear trans-
mission housing. Using Bearing Installer 9287 (1)
(Fig. 54), install the output shaft bearing (2) into the
transmission housing. The closed side of the plas-
Fig. 56 Checking Input Shaft End Play
tic cage must point towards the parking lock
gear. 1 - TOOL 8266-8
2 - TOOL 8266-18
3 - TOOL C-3339

(31) Rotate the transmission so that the bellhous-


ing is pointed upward and ensuring that the output
shaft is allowed to move freely.
(32) Measure input shaft end-play (Fig. 56).

NOTE: If end-play is incorrect, transmission is


incorrectly assembled, or the geartrain end-play
shim is incorrect. The geartrain end-play shim is
selective.

(a) Attach Adapter 8266-18 (2) to Handle 8266-8


(1).
(b) Attach dial indicator C-3339 (3) to Handle
8266-8 (1).
(c) Install the assembled tool onto the input
Fig. 55 Install Rear Output Shaft Retaining Ring shaft of the transmission and tighten the retaining
1 - RETAINING RING screw on Adapter 8266-18 to secure it to the input
2 - OUTPUT SHAFT BEARING
shaft.
21 - 48 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)
(d) Position the dial indicator plunger against a (35) Place the transmission in PARK to prepare for
flat spot on the oil pump and zero the dial indica- the installation of the output shaft nut.
tor. (36) Install the propeller shaft flange onto the out-
(e) Move input shaft in and out and record read- put shaft and install an new flange nut. Tighten the
ing. End play should be 0.3-0.5 mm (0.012-0.020 flange nut to 120 N·m (88.5 ft.lbs.).
in.). Adjust as necessary. (37) Place the Staking Tool 9078 (2) and Driver
Handle C-4171 onto the output shaft.
(38) Rotate the Staking Tool 9078 (2) until the
alignment pin (3) engages the output shaft notch (4)
(Fig. 58).

Fig. 57 Install Output Shaft Seal


1 - SEAL INSTALLER 8902A
2 - TRANSMISSION CASE

(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).

Fig. 58 Align Staking Tool 9078


1 - PROPELLER SHAFT FLANGE
2 - STAKING TOOL 9078
3 - ALIGNMENT PIN
4 - OUTPUT SHAFT NOTCH
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 49
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)

Fig. 60 Install Electrohydraulic Unit Fig. 61 Install Torque Converter


1 - HEAT SHIELD 1 - TORQUE CONVERTER
2 - ELECTROHYDRAULIC UNIT 2 - CONVERTER HOUSING
3 - BOLT
4 - OIL FILTER
5 - OIL PAN
6 - CLAMPING ELEMENT
7 - BOLT
8 - DRAIN PLUG
9 - DRAIN PLUG GASKET
10 - 13-PIN PLUG CONNECTOR
11 - BOLT
12 - GUIDE BUSHING

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.).

Fig. 63 Position Torque Converter as Shown


1 - TORQUE CONVERTER
2 - INSPECTION OPENING

Fig. 65 Support Transmission and Install Bolts


1 - BOLT, TRANSMISSION MOUNT
2 - UPPER SHELL FOR TRANSMISSION MOUNT
3 - TRANSMISSION MOUNT
4 - CROSSMEMBER
Fig. 64 Position Driveplate as Shown 5 - NUT, ENGINE CROSSMEMBER
1 - DRIVEPLATE 6 - NUT, TRANSMISSION SUPPORT

(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

Fig. 66 Torque Converter Bolts


1 - BOLT
2 - STABILIZER BAR
3 - REINFORCEMENT PLATE Fig. 68 Install Steering Gear
4 - OPENING 1 - STEERING GEAR
5 - CHASSIS CROSSMEMBER 2 - BRACKET
6 - STEERING GEAR
21 - 52 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)
(14) Install the transmission electrical connector (b) Attach the bracket for the cable retainer (4)
(2) (Fig. 69) from transmission and hang to the side. (Fig. 72) to the threaded shank of a engine oil pan
Turn sealing ring (3) clockwise and connect plug con- bolt (5).
nection (2). (c) Install the bolts to hold the oil cooler lines (6)
(15) Install the shift cable (Fig. 70) to the trans- to the left (Fig. 73) and right sides of transmission.
mission. Torque the bolts to 34 N·m (254 ft.lbs.).
(a) Push shift cable onto the transmission shift
lever ball socket.
(b) Latch ball socket latch of cable.
(c) Clip shift cable retainer into retainer bracket.

Fig. 71 Cooler Line Supports


1 - COOLER LINES

Fig. 69 Transmission Electrical Connector and


Cooler Line
1 - COOLER LINE
2 - TRANSMISSION ELECTRICAL CONNECTOR
3 - SEALING RING

Fig. 72 Cable Support


1 - CABLE
2 - BOLT

(17) Install exhaust heat shield (5) (Fig. 74).


(18) Install retaining bracket (4) (Fig. 74). Bracket
is asymmetric. The slanted side must be installed on
Fig. 70 Shift Cable at Transmission the left side in the direction of travel.
1 - SHIFT CABLE (19) Attach propeller shaft (1) (Fig. 74) to the
2 - TRANSMISSION SHIFT LEVER
transmission (Refer to 3 - DIFFERENTIAL & DRIV-
ELINE/PROPELLER SHAFT/PROPELLER SHAFT -
(16) Install the cooler lines to the transmission.
INSTALLATION).
(a) Install the brackets for the oil cooler feed and
(20) Install oil filler pipe.
return lines (1) (Fig. 71) onto the engine oil pan
(a) Guide oil filler pipe (1) (Fig. 75) down and
flange. Detail shows right side of motor. Position is
into position.
mirrored for the left side of engine.
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 53
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)

Fig. 73 Driver’s Side Cooler Line


1 - COOLER LINE

Fig. 75 Fill Tube


1 - FILL TUBE
2 - BOLTS TO CYLINDER HEAD AND TRANSMISSION HOUSING
3 - BOLT TO TRANSMISSION FLANGE

Fig. 74 Propeller Shaft and Heat Shield


1 - PROPELLER SHAFT
2 - BOLT
3 - BOLT
4 - RETAINING BRACKET
5 - HEAT SHIELD
6 - WASHER
7 - 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)

SCHEMATICS AND DIAGRAMS

HYDRAULIC FLOW IN PARK


VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 55
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)

HYDRAULIC FLOW IN REVERSE - FAILSAFE


21 - 56 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)

HYDRAULIC FLOW IN REVERSE


VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 57
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)

HYDRAULIC FLOW IN NEUTRAL - DEFAULT


21 - 58 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)

HYDRAULIC FLOW IN NEUTRAL


VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 59
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)

HYDRAULIC FLOW IN NEUTRAL TO DRIVE TRANSITION


21 - 60 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)

HYDRAULIC FLOW IN DRIVE - FAILSAFE


VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 61
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)

HYDRAULIC FLOW IN DRIVE - FIRST GEAR


21 - 62 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)

HYDRAULIC FLOW IN DRIVE - FIRST TO SECOND GEAR TRANSITION


VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 63
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)

HYDRAULIC FLOW IN DRIVE - SECOND GEAR


21 - 64 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)

HYDRAULIC FLOW IN DRIVE - SECOND TO THIRD GEAR TRANSITION


VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 65
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)

HYDRAULIC FLOW IN DRIVE - THIRD GEAR


21 - 66 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)

HYDRAULIC FLOW IN DRIVE - THIRD TO FOURTH GEAR TRANSITION


VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 67
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)

HYDRAULIC FLOW IN DRIVE - FOURTH GEAR


21 - 68 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)

HYDRAULIC FLOW IN DRIVE - FOURTH TO FIFTH GEAR TRANSITION


VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 69
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)

HYDRAULIC FLOW IN DRIVE - FIFTH GEAR


21 - 70 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)

HYDRAULIC FLOW IN DRIVE - FIFTH GEAR - EMCC


VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 71
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)

HYDRAULIC FLOW IN DRIVE - FIFTH TO FOURTH GEAR TRANSITION


21 - 72 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)

HYDRAULIC FLOW IN DRIVE - FOURTH TO THIRD GEAR TRANSITION


VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 73
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)

HYDRAULIC FLOW IN DRIVE - THIRD TO SECOND GEAR TRANSITION


21 - 74 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)

HYDRAULIC FLOW IN DRIVE - SECOND TO FIRST GEAR TRANSITION


VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 75
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)

SPECIFICATIONS - NAG1 AUTOMATIC COMPONENT METRIC INCH (in.)


TRANSMISSION (mm)
GEAR RATIOS B2 Clutch Snap-rings 2.9, 3.2, 0.114,
3.5, 3.8, 0.126,
1ST 3.59:1 and 4.1 0.138,
0.150,
2ND 2.19:1
0.162
3RD 1.41:1
B3 Clutch Clearance 1.0-1.4 0.039-
4TH 1.00:1 0.055
5TH 0.83:1 B3 Clutch Snap-rings 3.2, 3.5, 0.126,
REVERSE 3.16:1 3.8, 4.1, 0.138,
4.4, and 0.150,
4.7 0.162,
SPECIFICATIONS
0.173,
0.185
COMPONENT METRIC INCH (in.)
K1 Clutch 3 Disc 2.7-3.1 0.106-
(mm)
Clearance - 0.122
Geartrain End-play 0.3-0.5 0.012- Double 4 Disc 3.0-3.4 0.118-0.134
0.020 Sided
5 Disc 3.3-3.7 0.13-0.146
Geartrain End-play Shim 0.2, 0.3, 0.008, Friction
0.4, and 0.012, Discs 6 Disc 3.6-4.0 0.142-
0.5 0.016, 0.158
0.020 K1 Clutch 6 Disc 2.4-2.8 0.095-0.110
Rear Planetary Gear Set 0.15-0.6 0.006- Clearance -
8 Disc 2.6-3.0 0.102-0.118
End-play 0.024 Single
Sided 10 Disc 2.8-3.2 0.110-0.126
Rear Planetary Gear Set 3.0, 3.4, 0.118,
Friction
Snap-rings and 3.7 0.134, 12 Disc 2.9-3.3 0.114-0.130
Discs
0.146
K1 Clutch Snap-rings 2.6, 2.9, 0.102,
B1 Clutch 2 Disc 2.3-2.7 0.091-
3.2, 3.5, 0.114,
Clearance - 0.106
3.8, and 0.126,
Double
3 Disc 2.7-3.1 0.106- 4.1 0.138,
Sided
0.122 0.150,
Friction
0.162
Discs 4 Disc 3.0-3.4 0.118-0.134
K2 Clutch 3 Disc 2.3-2.7 0.091-
B1 Clutch 4 Disc 2.2-2.6 0.087-
Clearance 0.106
Clearance - 0.102
Single 4 Disc 2.4-2.8 0.095-0.110
Sided 6 Disc 2.4-2.8 0.095-0.110 5 Disc 2.5-2.9 0.099-0.114
Friction 6 Disc 2.7-3.1 0.106-
8 Disc 2.6-3.0 0.102-0.118
Discs 0.122
B1 Clutch Snap-rings 2.6, 2.9, 0.102, K2 Clutch Snap-rings 2.3, 2.6, 0.091,
3.2, 3.5, 0.114, 2.9, 3.2, 0.102,
3.8, and 0.126, 3.5, and 0.114,
4.1 0.138, 3.8 0.126,
0.150, 0.138,
0.162 0.150
B2 Clutch 4 Disc 1.9-2.3 0.075- K3 Clutch 3 Disc 2.3-2.7 0.091-
Clearance 0.091 Clearance - 0.106
5 Disc 2.0-2.4 0.079- Double
0.095 Sided 4 Disc 2.4-2.8 0.095-0.110
Friction
5 Disc 2.5-2.9 0.099-0.114
Discs
21 - 76 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)

COMPONENT METRIC INCH (in.) COMPONENT METRIC INCH (in.)


(mm) (mm)
K3 Clutch 6 Disc 2.3-2.7 0.091- K3 Clutch Snap-rings 2.0, 2.3, 0.079,
Clearance - 0.106 2.6, 2.9, 0.091,
Single 3.2, and 0.102,
Sided 8 Disc 2.4-2.8 0.095-0.110 3.5 0.114,
Friction 0.126,
10 Disc 2.5-2.9 0.099-0.114
Discs 0.138

TORQUE SPECIFICATIONS

DESCRIPTION N·m Ft. Lbs. In. Lbs.


Bolt, B2 Clutch Carrier 16 - 141
Bolt, B1 Carrier to 10 - 88.5
Converter Housing
Nut, Propeller Flange 120 88.5 -
Bolt, Electrohydraulic Unit 8 - 71
Bolt, Transmission 20 - 177
Housing to Converter
Housing
Bolts, Oil Pan 8 - 71
Screws, Valve Body/ 4 - 35
Housing Side Cover
Bolt, Shift Plate 8 - 71
Bolt, Solenoid Leaf Spring 8 - 71
Plug, Oil Pan Drain 20 - 177
Nut, Shifter Mechanism to 7 - 65
Floor Pan
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 77
AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION (Continued)

SPECIAL TOOLS - AUTOMATIC TRANSMISSION


- NAG1
SPECIAL TOOL CROSS REFERENCE CHART

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

Dial Indicator - C-3339

Adapter, Geartrain End-play - 8266-18

Handle, Universal - C-4171

Dipstick - 8863B
21 - 78 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
INPUT CLUTCHES (Continued)

Tool, Staking - 9078

Compressor, Multi-use Spring - 8900

Remover, Bearing - 9082

Tool, Pressing - 8901

Installer, Bearing - 9287

Installer, Seal - 8902A


VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 79

INPUT CLUTCHES
DESCRIPTION

Fig. 77 Input Clutches


1 - K1 CLUTCH 12 - CENTER PLANETARY GEARSET SUN GEAR
2 - K2 CLUTCH 13 - K2 CLUTCH EXTERNALLY TOOTHED DISC CARRIER
3 - EXTERNALLY TOOTHED DISC 14 - K2 CLUTCH PISTON
4 - INTERNALLY TOOTHED DISC 15 - FRONT PLANETARY GEARSET PLANETARY CARRIER
5 - K3 CLUTCH 16 - FRONT PLANETARY GEARSET ANNULUS GEAR
6 - K3 CLUTCH EXTERNALLY TOOTHED DISC CARRIER 17 - FRONT PLANETARY GEARSET SUN GEAR
7 - K3 CLUTCH PISTON 18 - K1 CLUTCH INTERNALLY TOOTHED DISC CARRIER
8 - K3 CLUTCH INTERNALLY TOOTHED DISC CARRIER 19 - K1 CLUTCH EXTERNALLY TOOTHED DISC CARRIER
9 - REAR PLANETARY GEARSET SUN GEAR 20 - K1 CLUTCH PISTON
10 - CENTER PLANETARY GEARSET PLANETARY CARRIER 21 - DRIVE SHAFT
11 - CENTER PLANETARY GEARSET ANNULUS GEAR

Three multi-plate input clutches (1, 2, 5) (Fig. 77),


the front, middle and rear multi-plate clutches K1
(1), K2 (2), and K3 (5), are located in the planetary
gear sets in the transmission housing.
A multi-plate input clutch consists of a number of
internally toothed discs (4) on an internally toothed
disc carrier and externally toothed discs (3) on an
externally toothed disc carrier.
21 - 80 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
INPUT CLUTCHES (Continued)

OPERATION

Fig. 78 Input Clutches


1 - K1 CLUTCH 12 - CENTER PLANETARY GEARSET SUN GEAR
2 - K2 CLUTCH 13 - K2 CLUTCH EXTERNALLY TOOTHED DISC CARRIER
3 - EXTERNALLY TOOTHED DISC 14 - K2 CLUTCH PISTON
4 - INTERNALLY TOOTHED DISC 15 - FRONT PLANETARY GEARSET PLANETARY CARRIER
5 - K3 CLUTCH 16 - FRONT PLANETARY GEARSET ANNULUS GEAR
6 - K3 CLUTCH EXTERNALLY TOOTHED DISC CARRIER 17 - FRONT PLANETARY GEARSET SUN GEAR
7 - K3 CLUTCH PISTON 18 - K1 CLUTCH INTERNALLY TOOTHED DISC CARRIER
8 - K3 CLUTCH INTERNALLY TOOTHED DISC CARRIER 19 - K1 CLUTCH EXTERNALLY TOOTHED DISC CARRIER
9 - REAR PLANETARY GEARSET SUN GEAR 20 - K1 CLUTCH PISTON
10 - CENTER PLANETARY GEARSET PLANETARY CARRIER 21 - DRIVE SHAFT
11 - CENTER PLANETARY GEARSET ANNULUS GEAR

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

Fig. 79 Input Clutch K1 Components


1 - K1 OUTER DISC CARRIER 7 - DISC SPRING
2 - FREEWHEELING CLUTCH F1 8 - SPRING PLATE
3 - SNAP-RING 9 - SPRING PLATE SEALING RING
4 - OUTER DISC CARRIER SEALING RING 10 - SNAP-RING
5 - PISTON SEALING RING 11 - SNAP-RING
6 - PISTON 12 - MULTIPLE DISC PACK - REFER TO TEXT FOR CORRECT
ASSEMBLY ORDER

(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.

CAUTION: When working with double sided friction


discs, an externally lugged steel plate is installed
first, followed by a friction disc, and continuing on
until all the required discs are installed. When work-
ing with single sided friction discs, an externally
lugged disc is installed first, followed by an inter-
nally lugged disc, and continuing on until all the
Fig. 80 Compress the Disc Spring required discs are installed. All single sided discs
1 - SNAP-RING are installed with the friction side up.
2 - MULTI-USE SPRING COMPRESSOR 8900

Fig. 81 Input Clutch K1 Components


1 - K1 OUTER DISC CARRIER 7 - DISC SPRING
2 - FREEWHEELING CLUTCH F1 8 - SPRING PLATE
3 - SNAP-RING 9 - SPRING PLATE SEALING RING
4 - OUTER DISC CARRIER SEALING RING 10 - SNAP-RING
5 - PISTON SEALING RING 11 - SNAP-RING
6 - PISTON 12 - MULTIPLE DISC PACK - REFER TO TEXT FOR CORRECT
ASSEMBLY ORDER
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 83
INPUT CLUTCH K1 (Continued)
(6) Insert multiple-disc pack (12) in the outer mul-
tiple-disc carrier.
(7) Insert snap-ring (11).
(8) Measure the K1 clutch pack clearance by
mounting Pressing Tool 8901 (1) (Fig. 83) on outer
multiple disc.
(9) Using a lever press, compress pressing tool as
far as the stop (then the marking ring is still visible,
see small arrow).

Fig. 82 Compress the Disc Spring


1 - SNAP-RING
2 - MULTI-USE SPRING COMPRESSOR 8900

Fig. 84 Input Clutch K1 Stack-up - Double Sided


Discs
1 - OUTER MULTIPLE DISC - 1.8MM (0.071 IN.)
2 - OUTER MULTIPLE DISC - 2.8MM (0.110 IN.)
3 - OUTER MULTIPLE DISC - 4.0MM (0.158 IN.)
4 - K1 OUTER DISC CARRIER
5 - SNAP-RING
6 - FRICTION DISCS
7 - DISC SPRING
8 - PISTON

(10) For transmissions using double sided friction


discs, use a feeler gauge to determine the play 9L9
(Fig. 84) at three points between the snap-ring (5)
and outer multiple-disc (3).
(11) During the measurement the snap-ring (5)
must contact the upper bearing surface of the groove
in the outer multiple-disc carrier (4).
(12) The correct clutch clearance for transmissions
with double sided friction discs is 2.7-3.1 mm (0.106-
0.122 in.) for three friction disc versions, 3.0-3.4 mm
Fig. 83 Measure K1 Clutch Clearance (0.118-0.134 in.) for four disc versions, 3.3-3.7 mm
1 - PRESSING TOOL 8901 (0.130-0.146 in.) for five disc versions, and 3.6-4.0
2 - K1 OUTER DISC CARRIER mm (0.142-0.158 in.) for six disc versions.
(13) Adjust with snap-ring (5), if necessary. Snap-
NOTE: Pay attention to the sequence of discs. If the rings are available in thicknesses of 2.6 mm (0.102
original clutch discs are reused, be sure to return in.), 2.9 mm (0.114 in.), 3.2 mm (0.126 in.), 3.5 mm
the disc identified on disassembly as belonging on (0.138 in.), 3.8 mm (0.150 in.), and 4.1 mm (0.162
top of the spring plate (8) to its original location. in.).
(14) Insert front freewheeling clutch F1 (2) and fit
snap-ring (3). The freewheeling clutch F1 (2) must be
NOTE: Place new friction multiple-discs in ATF fluid
installed in the direction of the arrow.
for one hour before installing.
21 - 84 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
INPUT CLUTCH K1 (Continued)

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.

(15) For transmissions using single sided friction


discs, use a feeler gauge to determine the play 9L9
(Fig. 85) at three points between the snap-ring (4)
and outer multiple-disc (2).
(16) During the measurement the snap-ring (4)
must contact the upper bearing surface of the groove
in the outer multiple-disc carrier (3).
(17) The correct clutch clearance for transmissions
with single sided friction discs is 2.4-2.8 mm (0.095-
0.110 in.) for six friction disc versions, 2.6-3.0 mm
(0.102-0.118 in.) for eight disc versions, 2.8-3.2 mm
(0.110-0.126 in.) for ten disc versions, and 2.9-3.3 mm
(0.114-0.130 in.) for twelve disc versions.
(18) Adjust with snap-ring (4), if necessary. Snap-
rings are available in thicknesses of 2.6 mm (0.102
in.), 2.9 mm (0.114 in.), 3.2 mm (0.126 in.), 3.5 mm
(0.138 in.), 3.8 mm (0.150 in.), and 4.1 mm (0.162
in.).
(19) Insert front freewheeling clutch F1 (2) and fit
snap-ring (3). The freewheeling clutch F1 (2) must be
installed in the direction of the arrow.
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 85
INPUT CLUTCH K2 (Continued)

Fig. 86 Input Clutch K2 Components


1 - NEEDLE ROLLER BEARING 11 - SPRING RETAINER SEALING - O-RING
2 - K1 INNER DISC CARRIER WITH INTEGRATED FRONT GEAR 12 - SPRING RETAINER
SET
3 - THRUST BEARING 13 - SNAP-RING
4 - TORLON SEAL RINGS 14 - DISC SPRING
5 - INPUT SHAFT AND K2 CLUTCH 15 - EXTERNALLY TOOTHED PLATE - 1.8 MM (0.071 IN.)
6 - PISTON OUTER SEAL RING - O-RING 16 - MULTIPLE DISC PACK
7 - PISTON INNER SEAL RING 17 - SNAP-RING
8 - THRUST WASHER 18 - HOLLOW GEAR
9 - PISTON 19 - SNAP-RING
10 - DISC SPRING
21 - 86 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
INPUT CLUTCH K2 (Continued)
NOTE: Pay attention to the sequence of discs. If the
original clutch discs are reused, be sure to return
the disc identified on disassembly as belonging on
top of the disc spring (14) to its original location.

(6) Insert multiple-disk set (16) into outer multi-


ple-disk carrier.
(7) Fit snap-ring (17).
(8) Measure K2 clutch clearance by mounting
Pressing Tool 8901 (1) (Fig. 90) on outer multiple
disc.
(9) Using a lever press, compress pressing tool as
far as the stop (then the marking ring is still visible,
see small arrow).
(10) Using a feeler gauge, determine the play 9L9
(Fig. 91) at three points between the snap-ring (6)
and outer multiple-disc (4).
(11) During the measurement the snap-ring (6)
must contact the upper bearing surface of the groove
in the outer multiple-disc carrier.
(12) The correct clutch clearance is 2.3-2.7 mm
(0.091-0.106 in.) for three friction disc versions, 2.4-
Fig. 87 Compress K2 Clutch Spring 2.8 mm (0.095-0.110 in.) for four disc versions, 2.5-2.9
1 - MULTI-USE SPRING COMPRESSOR 8900
mm (0.099-0.114 in.) for five disc versions, and 2.7-
2 - SNAP-RING 3.1 mm (0.106-0.122 in.) for six disc versions.
(13) Adjust with snap-ring (6), if necessary. Snap-
ASSEMBLY rings are available in thicknesses of 2.3 mm (0.091
(1) Install piston (9) (Fig. 88) in outer multiple- in.), 2.6 mm (0.102 in.), 2.9 mm (0.114 in.), 3.2 mm
disc carrier. Inspect seals (6 and 7), replace if neces- (0.126 in.), 3.5 mm (0.138 in.), and 3.8 mm (0.150
sary. The rounded edges of the inner piston seal (7) in.).
must point to the outside. (14) Insert axial needle bearing (3) into K1 inner
(2) Insert disk spring (10) and spring retainer (12). multiple-disk carrier. Insert axial needle bearing (3)
Insert disk spring (10) with curved side pointing with a little grease to prevent it slipping.
toward spring retainer (12). Inspect seal (11) (Fig. (15) Install input shaft in K1 inner multiple-disc
88), replace if necessary. carrier with integrated front gear set (2).
(3) Place Multi-use Spring Compressor 8900 (1) (16) Fit internally-geared wheel (18) and install
(Fig. 89) on spring plate and press until the groove snap-ring (19). Pay attention to installation position.
(2) of the snap-ring is exposed.
(4) Insert snap-ring.
(5) Insert disk spring (14).
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 87
INPUT CLUTCH K3 (Continued)

Fig. 88 Input Clutch K2 Components


1 - NEEDLE ROLLER BEARING 11 - SPRING RETAINER SEALING - O-RING
2 - K1 INNER DISC CARRIER WITH INTEGRATED FRONT GEAR 12 - SPRING RETAINER
SET
3 - THRUST BEARING 13 - SNAP-RING
4 - TORLON SEAL RINGS 14 - DISC SPRING
5 - INPUT SHAFT AND K2 CLUTCH 15 - EXTERNALLY TOOTHED PLATE - 1.8 MM (0.071 IN.)
6 - PISTON OUTER SEAL RING - O-RING 16 - MULTIPLE DISC PACK
7 - PISTON INNER SEAL RING 17 - SNAP-RING
8 - THRUST WASHER 18 - HOLLOW GEAR
9 - PISTON 19 - SNAP-RING
10 - DISC SPRING
21 - 88 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
INPUT CLUTCH K3 (Continued)

Fig. 91 Input Clutch K2 Stack-up


1 - DISC SPRING
2 - OUTER MULTIPLE DISC - 1.8 MM (0.071 IN.)
3 - OUTER MULTIPLE DISC - 3.5 MM (0.138 IN.)
4 - OUTER MULTIPLE DISC - 4.0 MM (0.158 IN.)
5 - K2 OUTER DISC CARRIER
6 - SNAP-RING
7 - FRICTION DISCS
Fig. 89 Compress K2 Clutch Spring 8 - PISTON
1 - MULTI-USE SPRING COMPRESSOR 8900
2 - SNAP-RING
INPUT CLUTCH K3
DISASSEMBLY
(1) Remove snap-ring (1) (Fig. 92) from outer mul-
tiple-disc carrier.
(2) Remove multiple-disc pack (2) and disk spring
(3) from outer multiple-disc carrier. Note which
clutch disc is removed just prior to the spring plate
(3) for re-assembly. If the clutch discs are re-used,
this disc must be returned to its original position on
top of the spring plate.
(3) Place Multi-use Spring Compressor 8900 (9)
(Fig. 92) on disc spring (5) and compress the spring
until the snap-ring (4) is exposed.
(4) Remove snap-ring (4).
(5) Remove spring plate (5) and piston (6) from
outer multiple-disc carrier.

Fig. 90 Measure K2 Clutch Clearance


1 - PRESSING TOOL 8901
2 - K1 INNER DISC CARRIER
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 89
INPUT CLUTCH K3 (Continued)

Fig. 92 Input Clutch K3 Components


1 - SNAP-RING 6 - PISTON
2 - MULTIPLE DISC PACK 7 - SEALING RING
3 - DISC SPRING 8 - OUTER DISC CARRIER
4 - SNAP-RING 9 - MULTI-USE SPRING COMPRESSOR 8900
5 - SPRING PLATE
21 - 90 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
INPUT CLUTCH K3 (Continued)

ASSEMBLY

Fig. 93 Input Clutch K3 Components


1 - SNAP-RING 6 - PISTON
2 - MULTIPLE DISC PACK 7 - SEALING RING
3 - DISC SPRING 8 - OUTER DISC CARRIER
4 - SNAP-RING 9 - MULTI-USE SPRING COMPRESSOR 8900
5 - SPRING PLATE

(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.).

Fig. 94 Measure K3 Clutch Clearance


1 - PRESSING TOOL 8901
2 - OUTER DISC CARRIER

Fig. 96 Input Clutch K3 Stack-up - Single Sided


Discs
1 - OUTER DISC CARRIER
2 - OUTER MULTIPLE DISC - 4.0 MM (0.158 IN.)
3 - OUTER MULTIPLE DISCS
4 - DISC SPRING
5 - PISTON
6 - INNER MULTIPLE DISCS
7 - SNAP-RING

(13) For transmissions using single sided friction


discs, use a feeler gauge to determine the play 9L9
(Fig. 96) at three points between the snap-ring (7)
and outer multiple-disc (2).
(14) During the measurement the snap-ring (7)
must contact the upper bearing surface of the groove
Fig. 95 Input Clutch K3 Stack-up - Double Sided in the outer multiple-disc carrier.
Discs (15) The correct clutch clearance for transmissions
1 - OUTER DISC CARRIER with single sided friction discs is 2.3-2.7 mm (0.091-
2 - OUTER MULTIPLE DISC - 4.0 MM (0.158 IN.) 0.106 in.) for six friction disc versions, 2.4-2.8 mm
3 - OUTER MULTIPLE DISC - 2.8 MM (0.110 IN.)
4 - OUTER MULTIPLE DISC - 1.8 MM (0.079 IN.)
(0.095-0.110 in.) for eight disc versions, and 2.5-2.9
5 - DISC SPRING mm (0.099-0.114 in.) for ten disc versions.
6 - PISTON (16) Adjust with snap-ring (7), if necessary. Snap-
7 - FRICTION DISCS - 2.1 MM (0.083 IN.)
8 - SNAP-RING
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
(10) During the measurement the snap-ring (8) (0.114 in.), 3.2 mm (0.126 in.), and 3.5 mm (0.138
must contact the upper bearing surface of the groove in.).
in the outer multiple-disc carrier.
(11) The correct clutch clearance for transmissions
with double sided friction discs is 2.3-2.7 mm (0.091-
21 - 92 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA

ELECTROHYDRAULIC UNIT
DESCRIPTION

Fig. 98 Electrical Control Unit


1 - N3 SPEED SENSOR
2 - PLUG CONNECTOR
3 - MODULATING PRESSURE REGULATING SOLENOID
4 - SHIFT PRESSURE REGULATING SOLENOID
Fig. 97 Electrical Unit Components 5 - 1-2/4-5 SHIFT SOLENOID
1 - SOLENOID CAP 6 - 3-4 SHIFT SOLENOID
2 - SOLENOID CAP 7 - ELECTRICAL CONTROL UNIT
3 - BOLT - M6X32 8 - TRANSMISSION TEMPERATURE SENSOR
4 - BOLT - M6X30 9 - STARTER INTERLOCK CONTACT
5 - LEAF SPRING 10 - 2-3 SHIFT SOLENOID
6 - MODULATING PRESSURE REGULATING SOLENOID VALVE 11 - TORQUE CONVERTER LOCK-UP SOLENOID
7 - SHIFT PRESSURE REGULATING SOLENOID 12 - N2 SPEED SENSOR
8 - 3-4 SHIFT SOLENOID
9 - TORQUE CONVERTER LOCK-UP SOLENOID valves (5, 6, 10), the TCC solenoid valve (11), the
10 - 1-2/4-5 SHIFT SOLENOID
11 - 2-3 SHIFT SOLENOID park/neutral contact (9), and the transmission oil
12 - ELECTRICHYDRAULIC CONTROL MODULE temperature sensor (8). Conductor tracks integrated
13 - SHIFT PLATE into the shell connect the electric components to a
plug connection (2). This 13-pin plug connection (2)
The electrohydraulic control unit (Fig. 97) com-
establishes the connection to the vehicle-side cable
prises the shift plate (13) made from light alloy for
harness and to the transmission control module
the hydraulic control and an electrical control unit
(TCM). With the exception of the solenoid valves, all
(12). The electrical control unit (12) comprises of a
other electric components are fixed to the conductor
supporting body made of plastic, into which the elec-
tracks.
trical components (1 - 11) are assembled. The sup-
porting body is mounted on the shift plate (13) and HYDRAULIC CONTROL UNIT
screwed to it.
Strip conductors inserted into the supporting body Working Pressure (Line Pressure or Operating Pressure)
make the connection between the electrical compo- (p-A)
nents and a plug connector. The connection to the The working pressure provides the pressure supply
wiring harness on the vehicle and the transmission to the hydraulic control and the transmission shift
control module (TCM) is produced via this 13-pin elements. It is the highest hydraulic pressure in the
plug connector with a bayonet lock. entire hydraulic system. The working pressure is reg-
ulated at the working pressure regulating valve in
ELECTRICAL CONTROL UNIT relation to the load and gear. All other pressures
The electric valve control unit (7) (Fig. 98) consists required for the transmission control are derived
of a plastic shell which houses the RPM sensors from the working pressure.
(1,12), regulating solenoid valves (3, 4), solenoid
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 93
ELECTROHYDRAULIC UNIT (Continued)
Lubrication Pressure (p-Sm) Overlap Pressure (p-Ü)
At the working pressure regulating valve surplus The overlap pressure controls the shift component
oil is diverted to the lubrication pressure regulating pressure reduction during a shift phase. The pres-
valve, from where it is used in regulated amounts to sure in a shift element as it disengages is controlled
lubricate and cool the mechanical transmission com- during the shift phase depending on engine load
ponents and the torque converter. Furthermore, the (modulating pressure) and the pressure in the shift
lubrication pressure (p-Sm) is also used to limit the element as it engages. The adjusted pressure is
pressure in the torque converter. inversely proportional to the transmission capability
of the shift element being engaged (controlled over-
Shift Pressure (p-S) lap).
The shift pressure is determined by the shift pres-
sure regulating solenoid valve and the shift pressure Working Pressure Regulating Valve (Operating Pressure)
regulating valve. The shift pressure:
• Regulates the pressure in the activating shift
element during the shift phase.
• Determines together with the modulating pres-
sure the pressure reduction at the deactivating shift
element as regulated by the overlap regulating valve.
• Initializes 2nd gear in limp-home mode.

Modulating Pressure (p-Mod)


The modulating pressure influences the size of the
working pressure and determines together with the
shift pressure the pressure regulated at the overlap
regulating valve. The modulating pressure is regu-
lated at the modulating pressure regulating solenoid
valve, which is under regulating valve pressure. The
modulating pressure is variable and relative to the
engine load. Fig. 99 Working Pressure Regulating Valve
1 - PRESSURE FROM K1/K2
Regulating Valve/Control Valve Pressure (p-RV) 2 - END FACE
The regulating valve pressure is regulated at the 3 - TO TORQUE CONVERTER REGULATING VALVE
regulating valve pressure regulating valve in relation 4 - WORKING PRESSURE REGULATING VALVE
to the working pressure (p-A) up to a maximum pres-
sure of 8 bar (116 psi). It supplies the modulating The working pressure regulating valve (4) (Fig. 99)
pressure regulating solenoid valve, the shift pressure is located in the valve housing of the shift plate. It
regulating solenoid valve and the shift valve pressure regulates the primary pressure of the hydraulic sys-
regulating valve. tem.

Shift Valve Pressure (p-SV)


The shift valve pressure (p-SV) is derived from the
regulating valve pressure (p-RV), is regulated at the
shift valve pressure regulating valve and is then
present at the:
• 1-2 and 4-5 shift solenoid valve.
• 3-4 shift solenoid valve.
• 2-3 shift solenoid valve.
• Torque converter lockup solenoid valve.
• 3-4 and 2-3 shift pressure shift valve.
The shift valve pressure (p-SV) controls the com-
mand valves via the upshift/downshift solenoid
valves.
21 - 94 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
ELECTROHYDRAULIC UNIT (Continued)
Torque Converter Lockup Clutch Regulating Valve

Fig. 100 Torque Converter Lockup Clutch Regulating Valve


1 - TORQUE CONVERTER LOCK-UP CLUTCH 6 - TORQUE CONVERTER LOCK-UP CLUTCH REGULATING
2 - TORQUE CONVERTER OUTPUT VALVE
3 - TORQUE CONVERTER INPUT 7 - OIL COOLER
4 - LUBRICATION 8 - LINE PRESSURE REGULATING VALVE
5 - TORQUE CONVERTER LOCK-UP SOLENOID 9 - OIL PUMP

The torque converter lock-up clutch regulating


valve (6) (Fig. 100) is located in the valve housing of
the electrohydraulic control module. The valve is
responsible for the hydraulic control of the torque
converter lockup clutch and distribution of the lubri-
cating oil.
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 95
ELECTROHYDRAULIC UNIT (Continued)
Overlap Regulating Valve Each shift group is assigned one overlap regulating
valve (1) (Fig. 101). The 1-2 / 4-5 overlap regulating
valve is installed in the shift valve housing; the 2-3
and 3-4 overlap regulating valves are installed in the
valve housing. The overlap regulating valve regulates
the pressure reduction during a shift phase.

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.

Fig. 101 Overlap Regulating Valve


1 - OVERLAP REGULATING VALVE
2 - ANNULAR SURFACE ON OVERLAP REGULATING VALVE

Fig. 102 Command Valve


1 - HOLDING CLUTCH B1 3 - 1-2/4-5 COMMAND VALVE
2 - DRIVING CLUTCH K1
21 - 96 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
ELECTROHYDRAULIC UNIT (Continued)
Holding Pressure Shift Valve

Fig. 103 Holding Pressure Shift Valve


1 - HOLDING PRESSURE SHIFT VALVE

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

Fig. 104 Shift Pressure Shift Valve


1 - 1-2/4-5 COMMAND VALVE 3 - HOLDING CLUTCH B1
2 - DRIVING CLUTCH K1 4 - 1-2/4-5 SHIFT PRESSURE SHIFT VALVE
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 97
ELECTROHYDRAULIC UNIT (Continued)
Lubrication Pressure Regulating Valve

Fig. 107 Regulating Valve Pressure Regulating


Fig. 105 Lubrication Pressure Regulating Valve Valve
1 - REGULATING VALVE PRESSURE REGULATING VALVE
1 - LUBRICATION PRESSURE REGULATING 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 Regulating Valve

Fig. 108 Shift Valve Pressure Regulating Valve


1 - SHIFT VALVE PRESSURE REGULATING VALVE

The shift valve pressure regulating valve (1) (Fig.


108) is located in the valve housing of the electrohy-
draulic control module. It regulates the shift valve
pressure (p-SV).
Fig. 106 Shift Pressure Regulating Valve
1 - SHIFT PRESSURE REGULATING VALVE OPERATION
The shift pressure regulating valve (1) (Fig. 106) is ELECTRICAL CONTROL UNIT
located in the valve housing of the shift plate. It reg- Signals from the transmission control module
ulates the shift pressure (p-S). (TCM) are converted into hydraulic functions in the
electric valve control unit (7) (Fig. 109). The RPM
Regulating Valve Pressure Regulating Valve sensors (1, 12), starter interlock contact (9), and
The regulating valve pressure regulating valve (1) transmission oil temperature sensor (8) of the electric
(Fig. 107) is located in the valve housing of the elec- valve control unit (7) supply the TCM with input sig-
trohydraulic control module. It regulates the regulat- nals. The solenoid valves are controlled by the TCM
ing valve/control valve pressure (p-RV). and trigger the hydraulic functions.
21 - 98 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
ELECTROHYDRAULIC UNIT (Continued)

Fig. 110 Working Pressure Regulating Valve


1 - PRESSURE FROM K1/K2
2 - END FACE
3 - ANNULAR SURFACE
4 - WORKING PRESSURE REGULATING VALVE

Torque Converter Lockup Clutch Regulating Valve


Fig. 109 Electrical Control Unit The torque converter lockup clutch regulating
1 - N3 SPEED SENSOR valve (6) (Fig. 111) regulates the torque converter
2 - PLUG CONNECTOR
3 - MODULATING PRESSURE REGULATING SOLENOID lock-up clutch working pressure (p-TCC) in relation
4 - SHIFT PRESSURE REGULATING SOLENOID to the torque converter clutch control pressure (p-S/
5 - 1-2/4-5 SHIFT SOLENOID TCC). According to the size of the working pressure
6 - 3-4 SHIFT SOLENOID
7 - ELECTRICAL CONTROL UNIT (p-A), the torque converter lockup clutch is either
8 - TRANSMISSION TEMPERATURE SENSOR Engaged, Disengaged, or Slipping. When the regulat-
9 - STARTER INTERLOCK CONTACT ing valve (6) is in the lower position, lubricating oil
10 - 2-3 SHIFT SOLENOID
11 - TORQUE CONVERTER LOCK-UP SOLENOID flows through the torque converter and oil cooler (8)
12 - N2 SPEED SENSOR into the transmission (torque converter lockup clutch
unpressurized). In its regulating position (slipping,
HYDRAULIC CONTROL UNIT torque converter lockup clutch pressurized), a
reduced volume of lubricating oil flows through the
Working Pressure Regulating Valve (Line Pressure or annular passage (7) bypassing the torque converter
Operating Pressure) and passing direct through the oil cooler into the
The working pressure (p-A) is regulated at the transmission. The rest of the lubricating oil is
working pressure regulating valve (4) (Fig. 110) in directed via the throttle 9a9 into the torque converter
relation to load (modulating pressure, p-Mod) and in order to cool the torque converter lockup clutch.
gear (K1 or K2 pressure) (1). The spring in the work-
ing pressure regulating valve sets a minimum pres-
sure level (basic pressure).
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 99
ELECTROHYDRAULIC UNIT (Continued)

Fig. 111 Torque Converter Lockup Clutch Regulating Valve


1 - TORQUE CONVERTER LOCK-UP CLUTCH 6 - TORQUE CONVERTER LOCK-UP CLUTCH REGULATING
2 - TORQUE CONVERTER OUTPUT VALVE
3 - TORQUE CONVERTER INPUT 7 - OIL COOLER
4 - LUBRICATION 8 - LINE PRESSURE REGULATING VALVE
5 - TORQUE CONVERTER LOCK-UP SOLENOID 9 - OIL PUMP
21 - 100 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
ELECTROHYDRAULIC UNIT (Continued)
Overlap Regulating Valve Command Valve
When the end face is unpressurized (stationary
phase), the working pressure (p-A) is directed to the
actuated shift element. If the end face of the com-
mand valve (Fig. 113) is subjected to the shift valve
pressure (p-SV) (shift phase), then the shift pressure
(p-S) is switched to the activating element and the
overlap pressure (p-Ü) is switched to the deactivating
element.

Shift Valve Holding Pressure


The holding pressure shift valve (1) (Fig. 114) is
actuated by the pressures present at the end face in
the actuators and a spring. It assigns the working
pressure (p-A) to the actuator with the higher pres-
sure (taking into account the spring force and the
effective surface area). The other element of the shift
Fig. 112 Overlap Regulating Valve group is then unpressurized. The valve switches over
only during the shift phase and only at a certain
1 - OVERLAP REGULATING VALVE
2 - ANNULAR SURFACE ON OVERLAP REGULATING VALVE pressure ratio between the overlap pressure (p-Ü)
and the shift pressure (p-S).
During the shift phase the pressure (Fig. 112) in
the deactivating shift actuator is regulated in rela-
tion to the engine load (modulating pressure, p-Mod)
and the pressure in the activating actuator. The reg-
ulated pressure is inversely proportional to the trans-
fer capacity of the activating shift actuator (regulated
overlap).

Fig. 113 Command Valve


1 - HOLDING CLUTCH B1 3 - 1-2/4-5 COMMAND VALVE
2 - DRIVING CLUTCH K1
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 101
ELECTROHYDRAULIC UNIT (Continued)

Fig. 114 Shift Valve Holding Pressure


1 - HOLDING PRESSURE SHIFT VALVE

Shift Pressure Shift Valve clutch K1 (2) is activated, the end face of the shift

Fig. 115 Shift Pressure Shift Valve


1 - 1-2/4-5 COMMAND VALVE 3 - HOLDING CLUTCH B1
2 - DRIVING CLUTCH K1 4 - 1-2/4-5 SHIFT PRESSURE SHIFT VALVE

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

Shift Pressure Regulating Valve

Fig. 119 Shift Valve Pressure Regulating Valve


1 - SHIFT VALVE PRESSURE REGULATING VALVE
Fig. 117 Shift Pressure Regulating Valve
1 - SHIFT PRESSURE REGULATING VALVE The non-constant regulating valve pressure (p-RV)
is regulated to a constant shift valve pressure (p-SV)
The shift pressure is determined by the shift pres- at the shift valve pressure regulating valve (1) (Fig.
sure regulating solenoid valve and the shift pressure 119) and is used to supply the 1-2 and 4-5 / 3-4 / 2-3
regulating valve (3) (Fig. 117). In addition, pressure solenoid valves and the torque converter lockup
from the clutch K2 (1) is also present at the annular clutch PWM solenoid valve.
surface (2) of the shift pressure regulating valve (3).
This reduces the shift pressure in 2nd gear.
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 103
ELECTROHYDRAULIC UNIT (Continued)

REMOVAL

Fig. 121 Remove Heat Shield


1 - SCREW
2 - HEAT SHIELD
3 - BOLT

Fig. 120 Remove Electrohydraulic Unit


1 - HEAT SHIELD
2 - ELECTROHYDRAULIC UNIT
3 - BOLT
4 - OIL FILTER
5 - OIL PAN
6 - CLAMPING ELEMENT
7 - BOLT
8 - DRAIN PLUG
9 - DRAIN PLUG GASKET
10 - 13-PIN PLUG CONNECTOR
11 - BOLT
12 - GUIDE BUSHING

(1) Drain transmission oil by unscrewing oil drain


plug (8) (Fig. 120).
Fig. 122 Remove Wiring Connector Plug
NOTE: If the transmission fluid is burnt or contains 1 - PLUG CONNECTOR
abraded particles, the oil cooler lines and oil cooler 2 - GUIDE BUSHING
must be flushed out.
(6) Loosen guide bushing (2) and remove from
(2) Move selector lever to position 9P9. transmission housing.
(3) Raise vehicle. (7) Detach oil pan (5) (Fig. 123).
(4) Remove bolt (3) (Fig. 121) and screw (1) hold- (8) Remove oil filter (4).
ing the heat shield (2) to the transmission. (9) Unscrew Torx socket bolts (3) and remove elec-
(5) Disconnect 13-pin plug connector (1) (Fig. 122). trohydraulic control module (2).
Turn bayonet lock of guide bushing (2) anti-clock-
wise.
21 - 104 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
ELECTROHYDRAULIC UNIT (Continued)

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. 128 Converter Lock-up Solenoid Valve Strainer


Location
1 - CONVERTER LOCK-UP SOLENOID STRAINER

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.

NOTE: The sleeves and pistons of the overlap reg-


ulating valves must not be mixed up.

(18) Remove all valves and springs from the valve


housing (2) (Fig. 131). Check all valves for ease of
movement and shavings.
(19) Remove the pressure supply valve (1) (Fig.
132) from the valve body.

Fig. 129 Check Balls and Strainer Location


1 - STEEL CHECK BALLS
2 - CENTRAL STRAINER
3 - STEEL CHECK BALLS
4 - PLASTIC CHECK BALLS
5 - PLAIN DOWEL PIN

Fig. 130 Valve Body Components


1 - VALVE BODY 8 - SHIFT VALVE PRESSURE REGULATING VALVE
2 - 1-2/4-5 COMMAND VALVE 9 - B2 SHIFT VALVE
3 - 1-2/4-5 HOLDING PRESSURE SHIFT VALVE 10 - 2-3 HOLDING PRESSURE SHIFT VALVE
4 - 1-2/4-5 SHIFT PRESSURE SHIFT VALVE 11 - 2-3 COMMAND VALVE
5 - 1-2/4-5 OVERLAP REGULATING VALVE, SLEEVE, AND PISTON 12 - 2-3 SHIFT PRESSURE SHIFT VALVE
6 - SHIFT PRESSURE REGULATING VALVE 13 - TCC LOCK-UP REGULATING VALVE
7 - REGULATING VALVE PRESSURE REGULATING VALVE 14 - TCC DAMPER VALVE - if equipped
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 107
ELECTROHYDRAULIC UNIT (Continued)

Fig. 131 Valve Housing Components


1 - 2-3 OVERLAP REGULATING VALVE, SLEEVE, AND PISTON 6 - 3-4 SHIFT PRESSURE SHIFT VALVE
2 - VALVE HOUSING 7 - 3-4 OVERLAP REGULATING VALVE, SLEEVE, AND PISTON
3 - SELECTOR VALVE 8 - OPERATING PRESSURE REGULATING VALVE
4 - 3-4 HOLDING PRESSURE SHIFT VALVE 9 - LUBRICATING PRESSURE REGULATING VALVE
5 - 3-4 COMMAND VALVE

Fig. 132 Pressure Feed Valve Location Fig. 133 Pressure Feed Valve Location
1 - PRESSURE FEED VALVE 1 - PRESSURE FEED VALVE

ASSEMBLY with compressed-air, noting that parts may be


blown away.
NOTE: Pay great attention to cleanliness for all (1) Install the pressure supply valve (1) (Fig. 133)
work on the shift plate. Fluffy cloths must not be into the valve body.
used. Leather cloths are particularly good. After dis-
mantling, all parts must be washed and blown out
21 - 108 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
ELECTROHYDRAULIC UNIT (Continued)

Fig. 134 Valve Body Components


1 - VALVE BODY 8 - SHIFT VALVE PRESSURE REGULATING VALVE
2 - 1-2/4-5 COMMAND VALVE 9 - B2 SHIFT VALVE
3 - 1-2/4-5 HOLDING PRESSURE SHIFT VALVE 10 - 2-3 HOLDING PRESSURE SHIFT VALVE
4 - 1-2/4-5 SHIFT PRESSURE SHIFT VALVE 11 - 2-3 COMMAND VALVE
5 - 1-2/4-5 OVERLAP REGULATING VALVE, SLEEVE, AND PISTON 12 - 2-3 SHIFT PRESSURE SHIFT VALVE
6 - SHIFT PRESSURE REGULATING VALVE 13 - TCC LOCK-UP REGULATING VALVE
7 - REGULATING VALVE PRESSURE REGULATING VALVE 14 - TCC DAMPER VALVE - if equipped

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. 135 Valve Housing Components


1 - 2-3 OVERLAP REGULATING VALVE, SLEEVE, AND PISTON 6 - 3-4 SHIFT PRESSURE SHIFT VALVE
2 - VALVE HOUSING 7 - 3-4 OVERLAP REGULATING VALVE, SLEEVE, AND PISTON
3 - SELECTOR VALVE 8 - OPERATING PRESSURE REGULATING VALVE
4 - 3-4 HOLDING PRESSURE SHIFT VALVE 9 - LUBRICATING PRESSURE REGULATING VALVE
5 - 3-4 COMMAND VALVE

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)

Fig. 138 Shift Plate Components


1 - BOLTS - 29
2 - VALVE HOUSING
3 - SEALING PLATE
4 - VALVE BODY
5 - LEAF SPRING

Fig. 140 Electrical Unit Components


1 - SOLENOID CAP
2 - SOLENOID CAP
3 - BOLT - M6X32
4 - BOLT - M6X30
5 - LEAF SPRING
6 - MODULATING PRESSURE REGULATING SOLENOID VALVE
7 - SHIFT PRESSURE REGULATING SOLENOID
8 - 3-4 SHIFT SOLENOID
9 - TORQUE CONVERTER LOCK-UP SOLENOID
10 - 1-2/4-5 SHIFT SOLENOID
11 - 2-3 SHIFT SOLENOID
12 - ELECTRICHYDRAULIC CONTROL MODULE
13 - SHIFT PLATE

(18) Install the solenoid caps (1, 2).


(19) Install the electrohydraulic unit into the vehi-
cle.

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. 141 Connect The Selector Valve To The Detent


Plate
1 - SELECTOR VALVE Fig. 143 Install Wiring Connector Plug
2 - DETENT PLATE
1 - PLUG CONNECTOR
2 - GUIDE BUSHING

(8) Check O-ring on plug connector (1) (Fig. 143),


and replace if necessary.
(9) Install the plug connector (1) into the guide
bushing (2). Turn bayonet lock of guide bushing (2)
clockwise to connect plug connector (1).

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 AND FILTER


DESCRIPTION

Fig. 146 Fluid Level Control


1 - GEARSET CHAMBER
2 - OIL GALLERY
3 - SHELL OF ELECTROHYDRAULIC UNIT
4 - ELECTROHYDRAULIC UNIT
Fig. 145 Fluid Level Control 5 - FLOAT
1 - GEARSET CHAMBER 6 - OPENING
2 - OIL GALLERY
3 - SHELL OF ELECTROHYDRAULIC UNIT
4 - ELECTROHYDRAULIC UNIT DIAGNOSIS AND TESTING
5 - FLOAT
6 - OPENING EFFECTS OF INCORRECT FLUID LEVEL
A low fluid level allows the pump to take in air
The oil level control (Fig. 145) is located on the
along with the fluid. Air in the fluid will cause fluid
electrohydraulic unit (4) and consists of the float (5)
pressures to be low and develop slower than normal.
which is integrated into the electrohydraulic unit.
If the transmission is overfilled, the gears churn the
The float is positioned to plug the opening (6)
fluid into foam. This aerates the fluid and causing
between the oil gallery (2) and gearset chamber (1) so
the same conditions occurring with a low level. In
that the rotating gearsets do not splash about in oil
either case, air bubbles cause fluid overheating, oxi-
as the oil level rises. The oil level control reduces
dation, and varnish buildup which interferes with
power loss and prevents oil from being thrown out of
valve and clutch operation. Foaming also causes fluid
the transmission housing at high oil temperatures.
expansion which can result in fluid overflow from the
transmission vent or fill tube. Fluid overflow can eas-
OPERATION ily be mistaken for a leak if inspection is not careful.
With low oil levels, the lubricating oil which flows
constantly out of the gearset, flows back to oil gallery
(2) though the opening (6). (Fig. 146) If the oil level
CAUSES OF BURNT FLUID
Burnt, discolored fluid is a result of overheating
rises, the oil presses the float (5) against the housing
which has three primary causes.
opening (6). The float (5) therefore separates the oil
1. Internal clutch slippage, usually caused by low
gallery (2) from the gearset chamber (1). The lubri-
line pressure, inadequate clutch apply pressure, or
cating oil which continues to flow out of the gearsets
clutch seal failure.
is thrown against the housing wall, incorporated by
2. A result of restricted fluid flow through the
the rotating parts and flows back into the oil gallery
main and/or auxiliary cooler. This condition is usu-
(2) through the upper opening (arrow).
ally the result of a faulty or improperly installed
drainback valve, a damaged oil cooler, or severe
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 113
FLUID AND FILTER (Continued)
restrictions in the coolers and lines caused by debris
or kinked lines.
3. Heavy duty operation with a vehicle not prop-
erly equipped for this type of operation. Trailer tow-
ing or similar high load operation will overheat the
transmission fluid if the vehicle is improperly
equipped. Such vehicles should have an auxiliary
transmission fluid cooler, a heavy duty cooling sys-
tem, and the engine/axle ratio combination needed to
handle heavy loads.

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)

Fig. 148 NAG1 Transmission Fill Graph


TRANSMISSION FILL

Fig. 149 Dipstick Tube Cap Components


1 - LOCKING PIN
2 - TUBE CAP
Fig. 150 Remove Dipstick Tube Cap Lock
3 - DIPSTICK TUBE 1 - LOCKING PIN
2 - TUBE CAP
(10) Once the oil level is correct, install a new dip- 3 - DIPSTICK TUBE
stick tube cap (2) (Fig. 149) and lock pin (1).
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 115
FLUID AND FILTER (Continued)
To avoid overfilling transmission after a fluid (4) Rotate the engine clockwise until the torque
change or overhaul, perform the following procedure: converter drain plug (8) (Fig. 151) is aligned with the
(1) Verify that the vehicle is parked on a level sur- access hole.
face.
(2) Remove locking pin (1) (Fig. 150). Remove the NOTE: Clean the area around the drain plug to pre-
plate of the locking pin with a suitable tool and press vent dirt from entering the torque converter.
out the pin remaining in the cap downwards.
(3) Remove cap (2). (5) Using a suitable drain pan to catch the fluid,
(4) Add following initial quantity of required fluid remove the torque converter drain plug (8) and allow
(Refer to LUBRICATION & MAINTENANCE/FLUID the torque converter to drain completely.
TYPES - DESCRIPTION) to transmission: (6) Inspect the torque converter drain plug seal (9)
(a) If only fluid and filter were changed, add 7.4 (Fig. 151). Replace the seal if necessary.
L (14.8 pts.) of transmission fluid to transmission. (7) Install the torque converter drain plug (8).
(b) If transmission was completely overhauled, Tighten the drain plug to 14 N·m (10 ft.lbs.).
torque converter was replaced or drained, and (8) Install the torque converter drain plug access
cooler was flushed, add 7.7 L (16.3 pts.) of trans- plug into the bottom of the torque converter housing.
mission fluid to transmission. (9) Using a suitable drain pan to catch the fluid,
(5) Check the transmission fluid (Refer to 21 - remove the transmission oil pan drain plug (6) (Fig.
TRANSMISSION/AUTOMATIC - NAG1/FLUID AND 151) and allow the oil pan to drain completely.
FLUID - STANDARD PROCEDURE - CHECK OIL (10) Inspect the transmission oil pan drain plug
LEVEL) and adjust as required. seal (7). Replace the seal if necessary.
(11) Install the transmission oil pan drain plug (6).
FLUID/FILTER SERVICE Tighten the drain plug to 20 N·m (15 ft.lbs.).
(12) Remove the bolts (5) and retainers (4) (Fig.
151) holding the oil pan to the transmission.
(13) Remove the transmission oil pan (3) and gas-
ket (2) from the transmission.
(14) Remove the transmission oil filter (1) and
o-ring from the electrohydraulic control unit.
(15) Clean the inside of the oil pan (3) of any
debris. Inspect the oil pan gasket (2) and replace if
necessary.
(16) Install a new oil filter (1) and o-ring into the
electrohydraulic control unit.
(17) Install the oil pan (3) and gasket (2) onto the
transmission.
(18) Install the oil pan bolts (5) and retainers (4).
Torque the bolts to 8 N·m (70 in.lbs.).
(19) Lower the vehicle and add 7.0 L (7.4 qts.) of
transmission fluid to the transmission.
Fig. 151 Fluid/Filter Service Points (20) Check the oil level (Refer to 21 - TRANSMIS-
1 - OIL FILTER SION/AUTOMATIC - NAG1/FLUID AND FILTER -
2 - OIL PAN GASKET
3 - OIL PAN
STANDARD PROCEDURE - CHECK OIL LEVEL).
4 - RETAINER
5 - BOLT
6 - OIL PAN DRAIN PLUG
7 - SEAL
8 - TORQUE CONVERTER DRAIN PLUG
9 - SEAL

(1) Run the engine until the transmission oil


reaches operating temperature.
(2) Raise and support vehicle.
(3) Remove the torque converter drain plug access
plug from the bottom of the torque converter hous-
ing.
21 - 116 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA

FREEWHEELING CLUTCH OPERATION

DESCRIPTION

Fig. 153 Freewheeling Clutch


1 - ROTATION DIRECTION 9A9
2 - ROTATION DIRECTION 9B9
Fig. 152 Freewheeling Clutch 3 - LOCKING ELEMENTS
1 - ROTATION DIRECTION 9A9 4 - OUTER RACE
2 - ROTATION DIRECTION 9B9 5 - FRONT OR REAR SUN GEAR
3 - LOCKING ELEMENTS 6 - LOCKING ELEMENT CAGE
4 - OUTER RACE 7 - INNER RACE
5 - FRONT OR REAR SUN GEAR
6 - LOCKING ELEMENT CAGE The freewheeling clutch (Fig. 153) optimizes indi-
7 - INNER RACE
vidual gearshifts. They lock individual elements of a
Freewheeling clutches (Fig. 152) are installed in planetary gear set together or against the transmis-
the front planetary gear set between the sun gear sion housing in one direction of rotation to allow the
and the stator shaft, and in the rear planetary gear torque to be transmitted.
set between the sun gear and the intermediate shaft. If the inner race (7) of the freewheeling clutch is
The freewheel consists of an outer race (4), an locked and the outer race (4) turns counter-clockwise
inner race (7), a number of locking elements (3) and (1), the locking elements (3) adopt a diagonal position
a cage (6) for these locking elements. on account of their special contours, allowing the
freewheel function. The inner race (4) slides under
the locking elements (3) with minimal friction. If the
rotation of the outer race (4) changes to clockwise (2),
the locking elements (3) stand up and lock the outer
and inner races (4, 7) together.
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 117
FREEWHEELING CLUTCH (Continued)

DISASSEMBLY

Fig. 154 Freewheeling Clutch F2


1 - HOLLOW SHAFT 4 - K3 INNER DISC CARRIER AND REAR PLANETARY SUN GEAR
2 - F2 CLUTCH SNAP-RING 5 - RETAINING RING
3 - FREEWHEELING CLUTCH F2 6 - O-RINGS

(1) Remove retaining ring (5) (Fig. 154) from hol-


low shaft (1).
(2) Remove rear sun gear (4) with the K3 inter-
nally toothed disk carrier and rear freewheeling
clutch F2 (3).
(3) Remove snap-ring (2) (Fig. 154) for freewheel.
(4) Press freewheeling clutch (3) out of sun gear.
(5) Check O-rings (6), replace if necessary.
(6) Check the anti-friction bearing (2) (Fig. 155) in
the rear planetary sun gear for damage. Replace as
necessary.
21 - 118 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
FREEWHEELING CLUTCH (Continued)

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).

(1) Press freewheeling clutch F2 (3) (Fig. 156) into


sun gear (4).
(2) Install snap-ring (2) for freewheeling clutch.
(3) Check O-rings (6) (Fig. 156) on hollow shaft,
replace if necessary.
(4) Install rear sun gear (4) with K3 internally
toothed disc carrier and rear freewheeling clutch (3)
onto the hollow shaft.
(5) Verify proper operation of the freewheeling
clutch F2. When the assembly is held with the F2
clutch snap-ring upward, it should be possible to
rotate the hollow shaft counter-clockwise.
(6) Install retaining ring (5) onto hollow shaft (1).

Fig. 155 Freewheeling Clutch F2 Anti-Friction


Bearing
1 - K3 INNER DISC CARRIER AND REAR PLANETARY SUN
GEAR
2 - ANTI-FRICTION BEARING
3 - FREEWHEELING CLUTCH F2
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 119
GEARSHIFT CABLE (Continued)

Fig. 156 Freewheeling Clutch F2


1 - HOLLOW SHAFT 4 - K3 INNER DISC CARRIER AND REAR PLANETARY SUN GEAR
2 - F2 CLUTCH SNAP-RING 5 - RETAINING RING
3 - FREEWHEELING CLUTCH F2 6 - O-RINGS

GEARSHIFT CABLE (a) PARK position - Apply forward force on cen-


ter of handle and remove pressure. Engine starts
must be possible.
DIAGNOSIS AND TESTING (b) PARK position - Apply rearward force on cen-
ter of handle and remove pressure. Engine starts
GEARSHIFT CABLE must be possible.
(1) The floor shifter lever and gate positions (c) NEUTRAL position - Normal position. Engine
should be in alignment with all transmission PARK, starts must be possible.
NEUTRAL, and gear detent positions. (d) NEUTRAL position - Engine running and
(2) Engine starts must be possible with floor shift brakes applied, apply forward force on center of
lever in PARK or NEUTRAL gate positions only. shift handle. Transmission shall not be able to shift
Engine starts must not be possible in any other gear from NEUTRAL to REVERSE.
position.
(3) With floor shift lever handle push-button not
depressed and lever in:
21 - 120 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
GEARSHIFT CABLE (Continued)

REMOVAL

Fig. 158 Remove Bottom Section Of Center


Fig. 157 Remove Top Section Of Center Instrument Instrument Panel
Panel 1 - SCREW
2 - BOTTOM CENTER PART OF INSTRUMENT PANEL
1 - SHIFT LEVER ASSEMBLY FRAME TRIM
2 - STORAGE COMPARTMENT
3 - TOP CENTER PART OF INSTRUMENT PANEL
4 - SCREW
5 - PLUG CONNECTIONS
6 - ASHTRAY

(1) Move selector lever to position 9D9.


(2) Remove top (3) (Fig. 157) of the center section
of instrument panel.
(3) Remove bottom (2) (Fig. 158) of the center sec-
tion of instrument panel.
(4) Pry ball socket of transmission shift cable off
ball knob at the shift lever assembly (SLA). Use a
suitable slotted screwdriver.
(5) Raise and support vehicle.
(6) Detach shift cable (1) at transmission.
(a) Unlatch ball socket latch (Fig. 159) of cable.
(b) Unclip shift cable retainer from retainer
bracket. When pulling out cable, press together Fig. 159 Remove Shift Cable From Transmission
hooks of shift cable retainer at the points shown 1 - SHIFT CABLE
2 - TRANSMISSION SHIFT LEVER
(arrows).
(c) Pull shift cable out of ball socket. Ball socket (2) Install the shift cable (1) (Fig. 160) to the
can remain on transmission lever (2). transmission.
(7) Remove the shift cable grommet from the dash (a) Push shift cable onto the transmission shift
panel. lever (2) ball socket.
(8) Remove the shift cable from the vehicle. (b) Latch ball socket latch of cable.
(c) Clip shift cable retainer into retainer bracket.
INSTALLATION (3) Lower vehicle.
(1) Pass the shift cable through the opening in the (4) Install the transmission shift cable onto the
dash panel and seat the shift cable grommet into the ball knob at the SLA.
hole.
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 121
GEARSHIFT CABLE (Continued)

Fig. 160 Install Shift Cable Onto Transmission


1 - SHIFT CABLE
2 - TRANSMISSION SHIFT LEVER

Fig. 162 Install Top Section Of Center Instrument


Panel
1 - SHIFT LEVER ASSEMBLY FRAME TRIM
2 - STORAGE COMPARTMENT
3 - TOP CENTER PART OF INSTRUMENT PANEL
4 - SCREW
5 - PLUG CONNECTIONS
6 - ASHTRAY

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

(5) Install the bottom section (2) (Fig. 161) of the


center section of instrument panel.
(6) Install the top section (3) (Fig. 162) of the cen-
ter section of instrument panel.
(7) Verify repair.
21 - 122 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
HOLDING CLUTCHES (Continued)

Fig. 163 Holding Clutches


1 - B1 CLUTCH 10 - CENTER PLANETARY GEARSET ANNULUS GEAR
2 - EXTERNALLY TOOTHED DISC 11 - CENTER PLANETARY GEARSET PINION GEARS
3 - INTERNALLY TOOTHED DISC 12 - CENTER PLANETARY GEARSET SUN GEAR
4 - B3 CLUTCH 13 - FRONT PLANETARY GEARSET PINION GEARS
5 - B2 CLUTCH 14 - FRONT PLANETARY GEARSET SUN GEAR
6 - B3 CLUTCH PISTON 15 - B1 CLUTCH INTERNALLY TOOTHED DISC CARRIER
7 - B2 CLUTCH PISTON 16 - B1 CLUTCH PISTON
8 - B2 CLUTCH INTERNALLY TOOTHED DISC CARRIER 17 - B1 CLUTCH EXTERNALLY TOOTHED DISC CARRIER
9 - REAR PLANETARY GEARSET PLANETARY CARRIER

OPERATION If the multiple-disc holding clutch B2 (5) is actu-


The holding clutches (Fig. 164) connect the annu- ated via the piston (7), the piston compresses the disc
lus gear, sun gear, or planetary carrier of a planetary set. The internally toothed disc carrier (8) locks the
gear set against the transmission housing in order to sun gear (12) against the housing. The planetary pin-
transmit the drive torque. ion gears (11) turn on the sun gear (12).
If the piston (16) on multiple-disc holding clutch If the multiple-disc holding clutch B3 (4) is actu-
B1 (1) is subjected to oil pressure, it presses the ated via the piston (6), the planetary carrier (9) and
internal (3) and external discs (2) of the disc set the annulus gear (10) are locked. When the multiple-
together. The internally toothed disc carrier (15) disc brake B3 (4) is actuated, the direction of rotation
locks the sun gear (14) against the housing. The is reversed.
planetary pinion gears (13) turn on the sun gear (14).
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 123
HOLDING CLUTCH B1 (Continued)

Fig. 164 Holding Clutches


1 - B1 CLUTCH 10 - CENTER PLANETARY GEARSET ANNULUS GEAR
2 - EXTERNALLY TOOTHED DISC 11 - CENTER PLANETARY GEARSET PINION GEARS
3 - INTERNALLY TOOTHED DISC 12 - CENTER PLANETARY GEARSET SUN GEAR
4 - B3 CLUTCH 13 - FRONT PLANETARY GEARSET PINION GEARS
5 - B2 CLUTCH 14 - FRONT PLANETARY GEARSET SUN GEAR
6 - B3 CLUTCH PISTON 15 - B1 CLUTCH INTERNALLY TOOTHED DISC CARRIER
7 - B2 CLUTCH PISTON 16 - B1 CLUTCH PISTON
8 - B2 CLUTCH INTERNALLY TOOTHED DISC CARRIER 17 - B1 CLUTCH EXTERNALLY TOOTHED DISC CARRIER
9 - REAR PLANETARY GEARSET PLANETARY CARRIER

HOLDING CLUTCH B1 (4) Place the Multi-use Spring Compressor 8900


(8) (Fig. 166) on disc spring (3) and compress the
spring until the snap-ring (4) is exposed.
DISASSEMBLY
(5) Remove snap-ring (4).
(1) Remove the teflon rings (1) (Fig. 165) from the
(6) Remove piston (2) from the outer multiple-disc
B1 plate carrier hub (2).
carrier by carefully blowing compressed air into the
(2) Remove snap-ring (7) (Fig. 166).
bore (A).
(3) Remove multiple-disc pack (6) and disc spring
(5) from outer multiple-disc carrier. Note which
clutch disc is removed just prior to the disc spring (5)
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.
21 - 124 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
HOLDING CLUTCH B1 (Continued)

ASSEMBLY
NOTE: Check vulcanized gasket, replace if neces-
sary.

(1) Install piston (2) (Fig. 167) in outer multiple-


disc carrier (1).
(2) Place compressor (8) on disc spring (3) and
compress until the groove of the snap-ring is exposed.

NOTE: The collar of the snap-ring must point


towards the multiple-disc pack. After installing,
check snap-ring for correct seat.

(3) Insert snap-ring (4) (Fig. 167).


(4) Insert disc spring (2) (Fig. 168) in the outer
multiple-disc carrier. Observe the disc spring (2)
installation position. The lugs of the disc spring (2)
washer must align with the 3 raised pads (arrow) of
Fig. 165 Remove the Teflon Rings the B1 multiple-disc carrier (1). The cone of the
spring washer must point downwards.
1 - TEFLON RINGS
2 - PLATE CARRIER HUB

Fig. 166 Holding Clutch B1


1 - HOLDING CLUTCH B1 OUTER CARRIER 5 - DISC SPRING
2 - PISTON 6 - MULTIPLE DISC PACK
3 - DISC SPRING 7 - SNAP-RING
4 - SNAP-RING 8 - MULTI-USE SPRING COMPRESSOR 8900
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 125
HOLDING CLUTCH B1 (Continued)

Fig. 167 Holding Clutch B1


1 - HOLDING CLUTCH B1 OUTER CARRIER 5 - DISC SPRING
2 - PISTON 6 - MULTIPLE DISC PACK
3 - DISC SPRING 7 - SNAP-RING
4 - SNAP-RING 8 - MULTI-USE SPRING COMPRESSOR 8900

Fig. 168 Install the Disc Spring


1 - B1 MULTIPLE-DISC CARRIER
2 - DISC SPRING
Fig. 169 Measure B1 Clutch Clearance
1 - PRESSING TOOL 8901
2 - B1 CLUTCH OUTER CARRIER
21 - 126 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
HOLDING CLUTCH B1 (Continued)
(5) Insert the multiple-disc pack (6) in the outer (8) For transmissions using double sided friction
multiple-disc carrier and measure the clutch clear- discs, use a feeler gauge to determine the play 9L9
ance. (Fig. 170) at three points between the snap-ring (6)
and outer multiple-disc (4). During the measurement,
NOTE: Pay attention to the sequence of discs. If the the snap-ring (6) must contact the upper bearing sur-
original clutch discs are reused, be sure to return face of the groove in the outer multiple-disc carrier
the disc identified on disassembly as belonging on (5). The correct clearance for transmissions using
top of the disc spring (5) to its original location. double sided friction discs is 2.3-2.7 mm (0.091-0.106
in.) for two friction disc versions, 2.7-3.1 mm (0.106-
0.122 in.) for three disc versions, and 3.0-3.4 mm
CAUTION: When working with double sided friction
(0.118-0.134 in.) for four disc versions.
discs, an externally lugged steel plate is installed
(9) Adjust with snap-ring (6), if necessary. Snap-
first, followed by a friction disc, and continuing on
rings are available in thicknesses of 2.6 mm (0.102
until all the required discs are installed. When work-
in.), 2.9 mm (0.114 in.), 3.2 mm (0.126 in.), 3.5 mm
ing with single sided friction discs, an externally
(0.138 in.), 3.8 mm (0.150 in.), and 4.1 mm (0.162
lugged disc is installed first, followed by an inter-
in.).
nally lugged disc, and continuing on until all the
required discs are installed. All single sided discs
are installed with the friction side up.

NOTE: Place new friction multiple-discs in ATF fluid


for one hour before installing.

(6) Measure B1 clutch clearance by mounting


Pressing Tool 8901 (1) (Fig. 169) on outer multiple
disc.
(7) Using a lever press (Fig. 169), compress press-
ing tool as far as the stop (then the marking ring is
still visible, see small arrow).

Fig. 171 B1 Clutch Stack-up - Single Sided Discs


1 - DISC SPRING
2 - OUTER MULTIPLE DISC
3 - OUTER MULTIPLE DISC - 4.0 mm (0.158 IN.)
4 - B1 OUTER CARRIER
5 - SNAP-RING
6 - INNER MULTIPLE DISCS
7 - PISTON

(10) For transmissions using single sided friction


discs, use a feeler gauge to determine the play 9L9
(Fig. 171) at three points between the snap-ring (5)
and outer multiple-disc (3). During the measurement,
the snap-ring (5) must contact the upper bearing sur-
face of the groove in the outer multiple-disc carrier
Fig. 170 B1 Clutch Stack-up - Double Sided Discs (4). The correct clearance is 2.2-2.6 mm (0.087-0.102
1 - DISC SPRING in.) for four friction disc versions, 2.4-2.8 mm (0.095-
2 - OUTER MULTIPLE DISC - 1.8 mm (0.071 IN.)
3 - OUTER MULTIPLE DISC - 2.8 mm (0.110 IN.) 0.110 in.) for six disc versions, and 2.6-3.0 mm
4 - OUTER MULTIPLE DISC - 4.0 mm (0.158 IN.) (0.102-0.118 in.) for eight disc versions.
5 - B1 OUTER CARRIER (11) Adjust with snap-ring (5), if necessary. Snap-
6 - SNAP-RING
7 - INNER MULTIPLE DISCS rings are available in thicknesses of 2.6 mm (0.102
8 - PISTON in.), 2.9 mm (0.114 in.), 3.2 mm (0.126 in.), 3.5 mm
(0.138 in.), 3.8 mm (0.150 in.), and 4.1 mm (0.162
in.).
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 127
HOLDING CLUTCH B1 (Continued)

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)

Fig. 173 Holding Clutch B2


1 - SNAP-RING 9 - B2 PISTON SEALING RING
2 - MULTIPLE DISC PACK 10 - B2 PISTON
3 - DISC SPRING 11 - PISTON GUIDE SEALING RING
4 - B2 AND B3 PISTON GUIDE 12 - PISTON GUIDE SEALING RING
5 - O-RING 13 - PISTON GUIDE RING
6 - B3 PISTON SEALING RING 14 - PISTON BACK PRESSURE DISC SPRING
7 - B3 PISTON SEALING RING 15 - SPRING PLATE
8 - B3 PISTON/B2 OUTER DISC CARRIER 16 - SNAP-RING
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 129
HOLDING CLUTCH B2 (Continued)
NOTE: Pay attention to sequence of discs. If the
original clutch discs are reused, be sure to return
the disc identified on disassembly as belonging on
top of the disc spring (3) to its original location.
Place new friction multiple-discs in ATF fluid for
one hour before installing.

(8) Insert disc spring (3) and multiple-disc pack (2)


in the B2 outer multiple-disc carrier.
(9) Insert snap-ring (1).

NOTE: During the measurement the snap-ring (8)


must contact the upper bearing surface of the
groove in the outer multiple-disc carrier.

(10) Measure the B2 clutch pack clearance by


mounting the Pressing Tool 8901 (1) (Fig. 178) on
Fig. 174 B2 Clutch Oil Supply Locations
outer multiple disc.
A - B3 PISTON (11) Using a lever press, compress the pressing
B - B2 PISTON GUIDE RING SIDE
C - K3 CLUTCH FEED tool as far as the stop (then the marking ring is still
D - B2 PISTON SHIFT SIDE visible, see small arrow).
(12) Using a feeler gauge, determine the play 9L9
ASSEMBLY (Fig. 179) at three points between the snap-ring (8)
(1) Check all sealing rings (2-4, 6) (Fig. 175), and outer multiple-disc (7).
replace if necessary. The rounded off edges on the (13) The correct clutch clearance is 1.9-2.3 mm
sealing rings (2, 4, 6) must point outwards. (0.075-0.091 in.) for the four friction disc versions
(2) Assemble piston guide (4) (Fig. 176) and B3 and 2.0-2.4 mm (0.079-0.095 in.) for the five disc ver-
piston (8) in the correct position. Verify that the sions.
missing tooth in the B3 piston/B2 outer disc carrier (14) Adjust with snap-ring (8), if necessary. Snap-
(8) is aligned with the centerline of the two threaded rings are available in thicknesses of 2.9 mm (0.114
holes in the B2 and B3 piston guide (4). in.), 3.2 mm (0.126 in.), 3.5 mm (0.138 in.), 3.8 mm
(3) Insert B2 piston (10) (Fig. 176) in B3 piston (8). (0.150 in.), and 4.1 mm (0.162 in.).
(4) Insert piston guide ring (2) (Fig. 177). The
valve (1) in the piston guide ring must be on top.
(5) Insert disc spring (14) (Fig. 176) and spring
plate (15). Insert disc spring with the curvature
towards the spring plate
(6) Place Multi-use Spring Compressor 8900 on the
disc spring (14) and compress the spring until the
groove for the snap-ring is exposed.
(7) Insert snap-ring (16).
21 - 130 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
INPUT SPEED SENSORS (Continued)

Fig. 175 Holding Clutch B2/B3 Seals


1 - PISTON GUIDE RING 4 - B2 PISTON SEALING RING
2 - PISTON GUIDE RING SEALING RING 5 - B3 PISTON/B2 OUTER DISC CARRIER
3 - PISTON GUIDE RING SEALING RING 6 - B3 PISTON SEALING RING
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 131
INPUT SPEED SENSORS (Continued)

Fig. 176 Holding Clutch B2


1 - SNAP-RING 9 - B2 PISTON SEALING RING
2 - MULTIPLE DISC PACK 10 - B2 PISTON
3 - DISC SPRING 11 - PISTON GUIDE SEALING RING
4 - B2 AND B3 PISTON GUIDE 12 - PISTON GUIDE SEALING RING
5 - O-RING 13 - PISTON GUIDE RING
6 - B3 PISTON SEALING RING 14 - PISTON BACK PRESSURE DISC SPRING
7 - B3 PISTON SEALING RING 15 - SPRING PLATE
8 - B3 PISTON/B2 OUTER DISC CARRIER 16 - SNAP-RING
21 - 132 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
INPUT SPEED SENSORS (Continued)

Fig. 179 B2 Clutch Stack-up


1 - B2 OUTER DISC CARRIER
2 - FRICTION DISCS
3 - DISC SPRING
4 - B2 PISTON
5 - OUTER MULTIPLE DISC - 1.8 MM (0.071 IN.)
6 - OUTER MULTIPLE DISC - 1.8 MM (0.071 IN.)
7 - OUTER MULTIPLE DISC - 6.5 MM (0.256 IN.)
Fig. 177 B2 Piston and Piston Guide Ring 8 - SNAP-RING
1 - VALVE
2 - PISTON GUIDE RING
3 - B2 PISTON INPUT SPEED SENSORS
DESCRIPTION

Fig. 180 Speed Sensors


1 - DRIVING CLUTCH K1
2 - TRANSMISSION HOUSING
3 - DRIVING CLUTCH K1 INTERNALLY TOOTHED DISC
4 - EXCITER RING
5 - VALVE HOUSING OF SHIFT PLATE
Fig. 178 Measure B2 Clutch Clearance 6 - N2 INPUT SPEED SENSOR
1 - PRESSING TOOL 8901 7 - SPRING
2 - B3 PISTON/B2 OUTER DISC CARRIER 8 - N3 INPUT SPEED SENSOR
9 - EXCITER RING
10 - DRIVING CLUTCH K1 EXTERNALLY TOOTHED DISC
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 133
INPUT SPEED SENSORS (Continued)
The input speed sensors (6, 8) (Fig. 180) are fixed
to the shell of the control unit via contact blades. The
speed sensors are pressed against the transmission
housing (2) by a spring (7) which is held against the
valve housing of the shift plate (5). This ensures a
defined distance between the speed sensors and the
exciter ring (4).

OPERATION

Fig. 182 Oil Pump


1 - CRESCENT
2 - OIL PUMP
3 - EXTERNAL GEAR
4 - INTERNAL GEAR
5 - INLET CHAMBER
6 - PRESSURE CHAMBER

OPERATION

Fig. 181 Input Speed Sensors


1 - DRIVING CLUTCH K1
2 - TRANSMISSION HOUSING
3 - DRIVING CLUTCH K1 INTERNALLY TOOTHED DISC
4 - EXCITER RING
5 - VALVE HOUSING OF SHIFT PLATE
6 - N2 INPUT SPEED SENSOR
7 - SPRING
8 - N3 INPUT SPEED SENSOR
9 - EXCITER RING
10 - DRIVING CLUTCH K1 EXTERNALLY TOOTHED DISC

Signals from the input speed sensors (6, 8) (Fig.


181) are recorded in the transmission control module
(TCM) together with the wheel and engine speeds
and other information and are processed into an
input signal for electronic control.
Input speed sensor N2 (6) records the speed of the Fig. 183 Oil Pump
front sun gear via the externally toothed disc carrier 1 - CRESCENT
of the multiple-disc clutch K1 (10) and input speed 2 - OIL PUMP
sensor N3 (8) records the speed of the front planet 3 - EXTERNAL GEAR
4 - INTERNAL GEAR
carrier via the internally toothed disc carrier of mul- 5 - INLET CHAMBER
tiple-disc clutch K1 (3). 6 - PRESSURE CHAMBER

When the engine is running, the oil (Fig. 183) is


OIL PUMP pumped through the inlet chamber (5) along the
upper and lower side of the crescent (1) to the pres-
DESCRIPTION sure chamber (6) of the housing. The meshing of the
The oil pump (2) (Fig. 182) (crescent-type pump) is teeth prevents oil flowing from the delivery side to
installed in the bellhousing behind the torque con- the intake side. An external gear (3) is eccentrically
verter and is driven by the drive flange of the torque mounted in the pump housing. The external gear is
converter. The pump creates the oil pressure required driven by the internal gear (4) which is connected to
for the hydraulic procedures. the torque converter hub.
21 - 134 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
OIL PUMP (Continued)

DISASSEMBLY

Fig. 186 Install New Oil Pump Seals


1 - INNER OIL SEAL
Fig. 184 Oil Pump Gears 2 - OUTER OIL SEAL
1 - OUTER PUMP ROTOR
2 - INNER PUMP ROTOR

(1) Remove pump gears (1 and 2) (Fig. 184) from


pump housing.

Fig. 187 Oil Pump Gears


1 - OUTER PUMP ROTOR
2 - INNER PUMP ROTOR

Fig. 185 Remove Oil Pump Seals OUTPUT SHAFT BEARING


1 - INNER OIL SEAL
2 - OUTER OIL SEAL
REMOVAL
(1) Raise and support vehicle.
(2) Remove the inner oil pump seal (1) (Fig. 185).
(2) Remove the propeller shaft (Refer to 3 - DIF-
(3) Replace the outer oil pump O-ring (2) (Fig.
FERENTIAL & DRIVELINE/PROPELLER SHAFT/
185).
PROPELLER SHAFT - REMOVAL).
(3) Verify that the transmission is in PARK in
ASSEMBLY
order to prepare for the removal of the output shaft
(1) Install new inner oil pump seal (1) (Fig. 186)
nut.
with Seal Installer 8902-A.
(4) Remove the nut holding the propeller shaft
(2) Replace O-ring (2) (Fig. 186).
flange to the output shaft and remove the flange.
(3) Lubricate pump gears and place in the pump
(5) Remove the transmission rear oil seal with a
housing. Insert pump gear (1) (Fig. 187) so that the
suitable slide hammer and screw.
chamfer (arrow) points towards the pump housing.
(6) Remove the transmission output shaft washer.
Be sure to tag the washer since it is very similar to
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 135
OUTPUT SHAFT BEARING (Continued)

Fig. 188 Remove Rear Output Shaft Retaining Ring


1 - RETAINING RING
2 - OUTPUT SHAFT BEARING

the geartrain end-play shim and they must not be


interchanged.
(7) Remove the transmission rear output shaft Fig. 190 Slide Remover 9082 Collar Downward
bearing retaining ring (1) (Fig. 188).
1 - BEARING REMOVER 9082
2 - TRANSMISSION CASE
3 - COLLAR
4 - FINGERS

Fig. 189 Position Remover 9082 On Bearing


1 - BEARING REMOVER 9082
2 - TRANSMISSION CASE
3 - OUTPUT SHAFT BEARING
Fig. 191 Remove Output Shaft Bearing
(8) Position Bearing Remover 9082 (1) (Fig. 189) 1 - BEARING REMOVER 9082
2 - TRANSMISSION CASE
over the inner race of the output shaft bearing. 3 - OUTPUT SHAFT BEARING
(9) Slide the collar (3) (Fig. 190) on the Bearing
Remover 9082 (1) downward over the fingers (3) of
the tool.
21 - 136 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
OUTPUT SHAFT BEARING (Continued)
CAUTION: Verify that the geartrain end-play shim
has remained on the output shaft and against the
park gear. The shim may be adhered to the bearing
inner race. Retrieve the shim from the bearing and
install over the output shaft and against the park
gear.

(10) Remove the output shaft bearing (3) (Fig.


191).

INSTALLATION

Fig. 193 Install Rear Output Shaft Retaining Ring


1 - RETAINING RING
2 - OUTPUT SHAFT BEARING

Fig. 192 Install Output Shaft Bearing


1 - BEARING INSTALLER 9287
2 - BEARING
3 - TRANSMISSION CASE

CAUTION: Verify that the geartrain end-play shim is


properly installed over the output shaft and against
the park gear.

(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)

OUTPUT SHAFT SEAL


REMOVAL
(1) Remove the propeller shaft (Refer to 3 - DIF-
FERENTIAL & DRIVELINE/PROPELLER SHAFT/
PROPELLER SHAFT - REMOVAL). Move propeller
shaft to the right and tie up.
(2) Verify that the transmission is in PARK in
order to prepare for the removal of the output shaft
nut.
(3) Remove the nut holding the propeller shaft
flange to the output shaft and remove the flange.
(4) Remove the output shaft seal with suitable
screw and slide hammer.

Fig. 195 Align Staking Tool 9078


INSTALLATION
1 - PROPELLER SHAFT FLANGE
2 - STAKING TOOL 9078
3 - ALIGNMENT PIN
4 - OUTPUT SHAFT NOTCH

Fig. 197 Install the Output Shaft Seal


1 - SEAL INSTALLER 8902A
2 - TRANSMISSION CASE

(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)

PARK LOCK CABLE


REMOVAL
(1) Disconnect battery.
(2) Move selector lever to position 9D9.
(3) Remove top section (3) (Fig. 200) of the center
section of instrument panel.
(4) Remove bottom section (2) (Fig. 201) of the cen-
ter section of instrument panel.

Fig. 198 Align Staking Tool 9078


1 - PROPELLER SHAFT FLANGE
2 - STAKING TOOL 9078
3 - ALIGNMENT PIN
4 - OUTPUT SHAFT NOTCH

Fig. 200 Remove Top Section Of Center Instrument


Panel
1 - SHIFT LEVER ASSEMBLY FRAME TRIM
2 - STORAGE COMPARTMENT
3 - TOP CENTER PART OF INSTRUMENT PANEL
4 - SCREW
Fig. 199 Stake Output Shaft Nut 5 - PLUG CONNECTIONS
6 - ASHTRAY
1 - STAKING TOOL 9078
2 - PROPELLER FLANGE
3 - STAKING PIN (5) Disconnect the park lock cable coupling (1)
(Fig. 202) from the shift lever assembly (SLA). Press
(8) Strike the Driver handle C-4171 with a suit- locking tab (2) together and push coupling (1) against
able hammer until the output shaft nut is securely the spring force into the SLA, twist through 90°
staked to the output shaft. (right or left) and pull off.
(9) Install the propeller shaft (Refer to 3 - DIF- (6) Remove the lower steering column shroud.
FERENTIAL & DRIVELINE/PROPELLER SHAFT/ (7) Loosen the park lock cable (2) (Fig. 203) from
PROPELLER SHAFT - INSTALLATION). the ignition switch.
(8) Remove the park lock cable (2) (Fig. 204) from
the ignition switch.
(9) Remove the park lock cable from the vehicle.
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 139
PARK LOCK CABLE (Continued)

Fig. 203 Loosen Park Lock Cable From Ignition


Switch
1 - IGNITION SWITCH
2 - PARK LOCK CABLE

Fig. 201 Remove Bottom Section Of Center


Instrument Panel
1 - SCREW
2 - BOTTOM CENTER PART OF INSTRUMENT PANEL

Fig. 204 Remove Park Lock Cable From Ignition


Switch
1 - IGNITION SWITCH
2 - PARK LOCK CABLE

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)

Fig. 205 Install Park Lock Cable to Ignition Switch


1 - IGNITION SWITCH
2 - PARK LOCK CABLE

Fig. 207 Engage Park Lock Cable to SLA


1 - PARK LOCK CABLE COUPLING
2 - LOCK TAB
3 - BOLT
4 - SHIFT LEVER ASSEMBLY (SLA)
5 - CONNECTOR

Fig. 206 Tighten Park Lock Cable to Ignition Switch


1 - IGNITION SWITCH
2 - PARK LOCK CABLE

(6) Install the bottom section (2) (Fig. 208) of the


center section of instrument panel.
(7) Install the top section (3) (Fig. 209) of the cen-
ter section of instrument panel.
(8) Connect battery.
(9) Verify repair.

Fig. 208 Install Bottom Section Of Center


Instrument Panel
1 - SCREW
2 - BOTTOM CENTER PART OF INSTRUMENT PANEL
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 141
PISTONS (Continued)
lbs. 100 in or 1 pound per square inch, or PSI as it is
commonly referred to.

Fig. 209 Install Top Section Of Center Instrument


Panel
1 - SHIFT LEVER ASSEMBLY FRAME TRIM Fig. 210 Force and Pressure Relationship
2 - STORAGE COMPARTMENT
3 - TOP CENTER PART OF INSTRUMENT PANEL PRESSURE ON A CONFINED FLUID
4 - SCREW
5 - PLUG CONNECTIONS Pressure is exerted on a confined fluid (Fig. 211) by
6 - ASHTRAY applying a force to some given area in contact with
the fluid. A good example of this is a cylinder filled
PISTONS with fluid and equipped with a piston that is closely
fitted to the cylinder wall. If a force is applied to the
DESCRIPTION piston, pressure will be developed in the fluid. Of
There are several sizes and types of pistons used in course, no pressure will be created if the fluid is not
an automatic transmission. Some pistons are used to confined. It will simply “leak” past the piston. There
apply clutches. They all have in common the fact must be a resistance to flow in order to create pres-
that they are round or circular in shape, located sure. Piston sealing is extremely important in
within a smooth walled cylinder, which is closed at hydraulic operation. Several kinds of seals are used
one end and converts fluid pressure into mechanical to accomplish this within a transmission. These
movement. The fluid pressure exerted on the piston include but are not limited to O-rings, D-rings, lip
is contained within the system through the use of seals, sealing rings, or extremely close tolerances
piston rings or seals. between the piston and the cylinder wall. The force
exerted is downward (gravity), however, the principle
OPERATION remains the same no matter which direction is taken.
The principal which makes this operation possible The pressure created in the fluid is equal to the force
is known as Pascal’s Law. Pascal’s Law can be stated applied, divided by the piston area. If the force is 100
as: “Pressure on a confined fluid is transmitted lbs., and the piston area is 10 sq. in., then the pres-
equally in all directions and acts with equal force on sure created equals 10 PSI. Another interpretation of
equal areas.” Pascal’s Law is that regardless of container shape or
size, the pressure will be maintained throughout, as
PRESSURE long as the fluid is confined. In other words, the
Pressure (Fig. 210) is nothing more than force pressure in the fluid is the same everywhere within
(lbs.) divided by area (in or ft.), or force per unit the container.
area. Given a 100 lb. block and an area of 100 sq. in.
on the floor, the pressure exerted by the block is: 100
21 - 142 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
PISTONS (Continued)
PISTON TRAVEL
The relationship between hydraulic lever and a
mechanical lever is the same. With a mechanical
lever it’s a weight-to-distance output rather than a
pressure-to-area output. Using the same forces and
areas as in the previous example, the smaller piston
(Fig. 213) has to move ten times the distance
required to move the larger piston one inch. There-
fore, for every inch the larger piston moves, the
smaller piston moves ten inches. This principle is
true in other instances also. A common garage floor
jack is a good example. To raise a car weighing 2000
lbs., an effort of only 100 lbs. may be required. For
every inch the car moves upward, the input piston at
the jack handle must move 20 inches downward.

Fig. 211 Pressure on a Confined Fluid


FORCE MULTIPLICATION
Using the 10 PSI example used in the illustration
(Fig. 212), a force of 1000 lbs. can be moved with a
force of only 100 lbs. The secret of force multiplica-
tion in hydraulic systems is the total fluid contact
area employed. The illustration, (Fig. 212), shows an
area that is ten times larger than the original area.
The pressure created with the smaller 100 lb. input
is 10 PSI. The concept “pressure is the same every-
where” means that the pressure underneath the
larger piston is also 10 PSI. Pressure is equal to the
force applied divided by the contact area. Therefore,
by means of simple algebra, the output force may be
found. This concept is extremely important, as it is
also used in the design and operation of all shift
valves and limiting valves in the valve body, as well
as the pistons, of the transmission, which activate
the clutches and bands. It is nothing more than
using a difference of area to create a difference in
pressure to move an object.
Fig. 213 Piston Travel

Fig. 212 Force Multiplication


VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 143

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. 215 Planetary Geartrain


1 - ANNULUS GEAR
2 - PLANETARY PINION GEARS
3 - SUN GEAR
4 - PLANETARY CARRIER
21 - 144 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
PLANETARY GEARTRAIN (Continued)

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

ASSEMBLY NOTE: During the test, apply a contact force by


(1) Mount thrust washer (4) (Fig. 217) with the hand to K3 in the direction of the arrow.
collar pointing towards the planet carrier.
(8) Inspect axial play (Fig. 218) between shim (10)
(2) Mount the rear gear set (5) on the rear hollow
and retaining ring (11). Check axial play 9S9 between
shaft (6).
shim (10) and retaining ring (1) using a feeler gauge.
(3) Using grease, install lower three Teflon rings
Clearance should be 0.15-0.6 mm (0.006-0.024 in.).
(1) (Fig. 217) in the groove so that the joint stays
Shims are available in thicknesses of 3.0 mm (0.118
together
in.), 3.4 mm (0.134 in.), and 3.7 mm (0.146 in.).
(4) Put rear hollow shaft/freewheeling clutch F2
Adjust as necessary
(6) with rear gear set (5) onto output shaft.
(5) Install clutch K3 (7).
(6) Mount retaining ring, shim, thrust needle bear-
ing and thrust washer (8 - 11) (Fig. 217).
(7) Using grease, insert the upper two Teflon rings
(1) in the groove so that the joint remains together.
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 145
SHIFT MECHANISM (Continued)

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

SHIFT MECHANISM is in position 9P9. A park lock cable is used to perform


this function.
• Park lock: The selector lever is not released
DESCRIPTION
from postion 9P9 until the brake pedal has been
The automatic transmission is operated with the
applied and the ignition key is in driving position.
help of a shift lever assembly (SLA) located in the
Shift lock is controlled by the brake light switch in
center console. There are four positions to which the
conjunction with a locking solenoid in the SLA. As
selection lever can be shifted: P, R, N, D. In addition,
soon as the brake pedal is applied firmly, the locking
the selector lever can be moved sideways (+/-) in posi-
solenoid is retracted to unlock the selector lever. If
tion 9D9 to adjust the shift range.
the selector lever cannot be moved out of position 9P9
All selector lever positions, as well as selected shift
due to a malfunction, the shift lock function can be
ranges in position 9D9, are identified by the SLA. The
overriden (see operator’s manual).
information is then sent to the transmission control
• Reverse inhibitor: As soon as the vehicle
module (TCM) via a hardwire connection. At the
speed exceeds approx. 4 mph, it is no longer possible
same time, the selector lever positions 9P9, 9R9, 9N9
to move the selector lever from position 9N9 to posi-
and 9D9 are transmitted by a shift cable to the selec-
tion 9R9.
tor shaft in the transmission.
The SLA is comprised of the following functions:
• Key lock: Depending on the selector lever posi-
OPERATION
tion, the ignition lock is locked/unlocked, i.e., the With the selector lever in position 9D9, the trans-
ignition key can be removed only if the selector lever mission control module (TCM) automatically shifts
the gears that are best-suited to the current operat-
21 - 146 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
SHIFT MECHANISM (Continued)
when in position 9D9. If the shift range is limited, the
display in the instrument cluster indicates the
selected shift range and not the currently engaged
gear.
Tipping the shift lever will have the following
results:
• Tipping the selector lever toward (-( one
time after another: The shift range is reduced in
descending sequence by one gear each time, i.e., from
D - 4 - 3 - 2 - 1. If the selected limitation of the shift
range would result in a downshift causing excessive
engine speed, the shifting is not executed and the
engaged gear as well as the shift range remain
unchanged. This is to prevent the engine from over-
speeding. Engine retardation is low with the selector
lever in position 9D9. To make use of the full braking
power of the engine, 9manual9 downshifting by tip-
ping the lever towards the left-hand side is recom-
mended. If this has been done, subsequent upshifting
must be carried out manually as well.
• Tipping the selector lever toward (-( and
holding it in this position: The currently engaged
Fig. 218 Check Center and Rear Planetary End-Play gear in range 9D9 is indicated in the instrument clus-
1 - DRIVING CLUTCH K3 ter display and the shift range is limited to this gear.
2 - THRUST WASHER • Tipping the selector lever toward (+( one
3 - SHIM time after another: The shift range is increased by
4 - AXIAL NEEDLE BEARING
5 - RETAINING RING one gear each time and the increased shift range is
6 - OUTPUT SHAFT WITH CENTER PLANETARY CARRIER displayed in the instrument cluster; possibly, the
transmission upshifts to a faster gear.
ing situation. This means that shifting of gears is • Tipping the selector lever toward (+( sev-
continuously adjusted to current driving and operat- eral times: The shift range is increased by one gear
ing conditions in line with the selected shift range each time the lever is tipped until the shift range
and the accelerator pedal position. Starting off is ends up in 9D9.
always performed in 1st gear. • Tipping the selector lever toward (+( and
The selector lever positions are determined by the holding it in this position: The shift range is
slider position of a potentiometer in the shift lever extended immediately to 9D9, shift ranges are indi-
assembly (SLA). The shift pattern diagram (position cated in ascending sequence; possibly, the transmis-
display) and the program selector are illuminated by sion upshifts to a faster gear due to the extension of
the LEDs. the shift range.
The current selector lever position or, if the shift
range has been limited, the current shift range is REMOVAL
indicated in the LCD display in the instrument clus- (1) Move selector lever to position 9D9.
ter. (2) Remove top section (3) (Fig. 219) of the center
The permissible shifter positions and transmission section of instrument panel.
operating ranges are: (3) Remove bottom section (2) (Fig. 220) of the cen-
• P = Parking lock and engine starting. ter section of instrument panel.
• R = Reverse. (4) Disconnect the park lock cable coupling (1)
• N = Neutral and engine starting (no power is (Fig. 221) from the shift lever assembly (SLA). Press
transmitted to the axles). locking tab (2) together and push coupling (1) against
• D = The shift range includes all forward gears. the spring force into the SLA, twist through 90°
• 4= Shift range is limited to gears 1 to 4. (right or left) and pull off.
• 3= Shift range is limited to gears 1 to 3. (5) Disconnect connector plug (5) from SLA. When
• 2= Shift range is limited to gears 1 to 2. disconnecting plug, press together at points shown
• 1= Shift range is limited to the 1st gear. (arrows).
The shift range can be adjusted to the current
operating conditions by tipping the selector lever to
the left-hand side (9-9) or the right-hand side (9+9)
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 147
SHIFT MECHANISM (Continued)

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.

Fig. 222 Remove SLA


1 - BOLT
Fig. 220 Remove Bottom Section Of Center 2 - SLA
Instrument Panel 3 - SHIFT CABLE
1 - SCREW
2 - BOTTOM CENTER PART OF INSTRUMENT PANEL
21 - 148 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
SHIFT MECHANISM (Continued)

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. 224 Install Bottom Section Of Center


Instrument Panel
1 - SCREW
2 - BOTTOM CENTER PART OF INSTRUMENT PANEL

Fig. 223 Engage Park Lock Cable to SLA


1 - PARK LOCK CABLE COUPLING
2 - LOCK TAB
3 - BOLT
4 - SHIFT LEVER ASSEMBLY (SLA)
5 - CONNECTOR

(5) Turn on ignition and apply brakes. Move selec-


tor lever back to position 9D9.
(6) Install the transmission shift cable onto the
ball knob at the SLA.
(7) Install the bottom (2) (Fig. 224) of the center
section of instrument panel.
(8) Install the top (3) (Fig. 225) of the center sec-
tion of instrument panel.
(9) Verify repair.

Fig. 225 Install Top Section Of Center Instrument


Panel
1 - SHIFT LEVER ASSEMBLY FRAME TRIM
2 - STORAGE COMPARTMENT
3 - TOP CENTER PART OF INSTRUMENT PANEL
4 - SCREW
5 - PLUG CONNECTIONS
6 - ASHTRAY
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 149

SOLENOID across the solenoid to allow either full flow or no flow


through the solenoid’s valve.
DESCRIPTION UPSHIFT/DOWNSHIFT SOLENOID VALVES
The typical electrical solenoid used in automotive
applications is a linear actuator. It is a device that
produces motion in a straight line. This straight line
motion can be either forward or backward in direc-
tion, and short or long distance.
A solenoid is an electromechanical device that uses
a magnetic force to perform work. It consists of a coil
of wire, wrapped around a magnetic core made from
steel or iron, and a spring loaded, movable plunger,
which performs the work, or straight line motion.
The solenoids used in transmission applications
are attached to valves which can be classified as nor-
mally open or normally closed. The normally
open solenoid valve is defined as a valve which
allows hydraulic flow when no current or voltage is
applied to the solenoid. The normally closed sole-
noid valve is defined as a valve which does not allow
hydraulic flow when no current or voltage is applied
to the solenoid. These valves perform hydraulic con-
trol functions for the transmission and must there-
fore be durable and tolerant of dirt particles. For
these reasons, the valves have hardened steel pop-
pets and ball valves. The solenoids operate the valves
directly, which means that the solenoids must have Fig. 226 Upshift/Downshift Solenoid Valves
very high outputs to close the valves against the siz- 1 - UPSHIFT/DOWNSHIFT SOLENOID VALVE
able flow areas and line pressures found in current 2 - CONTACT SPRING
3 - CONDUCTOR TRACK
transmissions. Fast response time is also necessary 4 - O-RING
to ensure accurate control of the transmission. 5 - VALVE HOUSING OF SHIFT PLATE
The strength of the magnetic field is the primary 6 - O-RING
7 - CONDUCTOR TRACK
force that determines the speed of operation in a par- 8 - CONTACT SPRING
ticular solenoid design. A stronger magnetic field will
cause the plunger to move at a greater speed than a The solenoid valves (1) for upshifts and downshifts
weaker one. There are basically two ways to increase (Fig. 226) are located in the shell of the electric con-
the force of the magnetic field: trol unit and pressed against the shift plate with a
1. Increase the amount of current applied to the spring.
coil or The solenoid valves (1) initiate the upshift and
2. Increase the number of turns of wire in the coil. downshift procedures in the shift plate.
The most common practice is to increase the num- The solenoid valves (1) are sealed off from the
ber of turns by using thin wire that can completely valve housing of the shift plate (5) by two O-rings (4,
fill the available space within the solenoid housing. 6). The contact springs (8) at the solenoid valve
The strength of the spring and the length of the engage in a slot in the conductor tracks (7). The force
plunger also contribute to the response speed possi- of the contact spring (8) ensures safe contacts.
ble by a particular solenoid design.
A solenoid can also be described by the method by MODULATING PRESSURE CONTROL SOLENOID
which it is controlled. Some of the possibilities VALVE
include variable force, pulse-width modulated, con- The modulating pressure control solenoid valve (1)
stant ON, or duty cycle. The variable force and pulse- (Fig. 227) is located in the shell of the electric valve
width modulated versions utilize similar methods to control unit and pressed against the shift plate by a
control the current flow through the solenoid to posi- spring.
tion the solenoid plunger at a desired position some- Its purpose is control the modulating pressure
where between full ON and full OFF. The constant depending on the continuously changing operating
ON and duty cycled versions control the voltage conditions, such as load and gear change.
21 - 150 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
SOLENOID (Continued)

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. 229 Shift Pressure Control Solenoid Valve


1 - SHIFT PRESSURE CONTROL SOLENOID VALVE Fig. 230 Upshift/Downshift Solenoid Valves
2 - CONTACT SPRING
3 - CONDUCTOR TRACK 1 - UPSHIFT/DOWNSHIFT SOLENOID VALVE
4 - VALVE HOUSING SHIFT PLATE 2 - CONTACT SPRING
5 - CONDUCTOR TRACK 3 - CONDUCTOR TRACK
6 - CONTACT SPRING 4 - O-RING
5 - VALVE HOUSING OF SHIFT PLATE
6 - O-RING
OPERATION 7 - CONDUCTOR TRACK
When an electrical current is applied to the sole- 8 - CONTACT SPRING
noid coil, a magnetic field is created which produces
an attraction to the plunger, causing the plunger to If a solenoid valve (1) (Fig. 230) is actuated by the
move and work against the spring pressure and the TCM, it opens and guides the control pressure (p-SV)
load applied by the fluid the valve is controlling. The to the assigned command valve. The solenoid valve
plunger is normally directly attached to the valve remains actuated and therefore open until the shift-
which it is to operate. When the current is removed ing process is complete. The shift pressure (p-SV) to
from the coil, the attraction is removed and the the command valve is reduced to zero as soon as the
plunger will return to its original position due to power supply to the solenoid valve is interrupted.
spring pressure.
The plunger is made of a conductive material and
accomplishes this movement by providing a path for
the magnetic field to flow. By keeping the air gap
between the plunger and the coil to the minimum
necessary to allow free movement of the plunger, the
magnetic field is maximized.
21 - 152 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
SOLENOID (Continued)
MODULATING PRESSURE CONTROL SOLENOID TORQUE CONVERTER LOCKUP CLUTCH PWM
VALVE SOLENOID VALVE

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

Fig. 234 Park/Neutral Contact


1 - SHELL OF ELECTRIC CONTROL MODULE
2 - PLUNGER
3 - PERMANENT MAGNET
4 - DRY-REED CONTACT

TRANSMISSION TEMPERATURE SENSOR


Fig. 233 Shift Pressure Control Solenoid Valve
1 - SHIFT PRESSURE CONTROL SOLENOID VALVE
2 - CONTACT SPRING
3 - CONDUCTOR TRACK
4 - VALVE HOUSING SHIFT PLATE
5 - CONDUCTOR TRACK
6 - CONTACT SPRING

The shift pressure regulating solenoid valve (1)


(Fig. 233) assigns a proportional pressure to the cur-
rent which is controlled by the TCM according to the
load.

TEMPERATURE SENSOR/
PARK-NEUTRAL CONTACT
Fig. 235 Transmission Temperature Sensor
DESCRIPTION 1 - TRANSMISSION TEMPERATURE SENSOR

The transmission oil temperature sensor (1) (Fig.


PARK/NEUTRAL CONTACT 235) is located in the shell of the electric valve con-
The park/neutral contact (4) (Fig. 234) is located in
trol unit and is fixed to the conductor tracks.
the shell of the electric control unit and is fixed to
Its purpose is to measure the temperature of the
the conductor tracks.
transmission oil and pass the temperature to the
Its purpose is to recognize selector valve and selec-
TCM as an input signal. It is a temperature-depen-
tor lever positions 9P9 and 9N9. The park/neutral con-
dent resistor (PTC).
tact consists of:
• the plunger (2).
• the permanent magnet (3).
• the dry-reed contact (4).
21 - 154 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
TEMPERATURE SENSOR/PARK-NEUTRAL CONTACT (Continued)

OPERATION shift quality. By measuring the oil temperature, shift


operations can be optimized in all temperature
PARK/NEUTRAL CONTACT ranges. The transmission oil temperature sensor (1)
(Fig. 237) is switched in series with the park/neutral
contact. The temperature signal is transferred to the
TCM only when the dry-reed contact of the park/neu-
tral contact is closed in REVERSE or a forward gear
position.

Fig. 236 Park/Neutral Contact


1 - SHELL OF ELECTRIC CONTROL MODULE
2 - PLUNGER
3 - PERMANENT MAGNET
4 - DRY-REED CONTACT

In selector lever positions 9P9 and 9N9 the park/


neutral contact (4) (Fig. 236) is actuated by a cam
track which is located on the detent plate. The per-
manent magnet (3) is moved away from the dry-reed
contact (4). The dry-reed contact (4) is opened. The
TCM receives an electric signal. The circuit to the
starter in the selector lever positions 9P9 and 9N9 is
closed.

TRANSMISSION TEMPERATURE SENSOR

Fig. 238 Transmission Temperature Sensor


Specifications
Refer to the Transmission Temperature Sensor
Specifications table (Fig. 238) for the relationship
Fig. 237 Transmission Temperature Sensor between transmission temperature, sensor voltage,
1 - TRANSMISSION TEMPERATURE SENSOR and sensor resistance.

The temperature of the transmission oil has a con-


siderable effect on the shifting time and therefore the
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 155

TORQUE CONVERTER CAUTION: The torque converter must be replaced if


a transmission failure resulted in large amounts of
metal or fiber contamination in the fluid.
DESCRIPTION
The torque converter (Fig. 239) is a hydraulic
device that couples the engine crankshaft to the
transmission. The torque converter consists of an
outer shell with an internal turbine (1), a stator (3),
an overrunning clutch, an impeller (2), and an elec-
tronically applied converter clutch. The converter
clutch provides reduced engine speed and greater
fuel economy when engaged. Clutch engagement also
provides reduced transmission fluid temperatures.
The converter clutch engages in third through fifth
gears. The torque converter hub drives the transmis-
sion oil (fluid) pump.
A turbine damper (6) has been added for some
applications to help improve vehicle noise, vibration,
and harshness (NVH) characteristics.
The torque converter is a sealed, welded unit that
is not repairable and is serviced as an assembly.

Fig. 239 Torque Converter


1 - TURBINE
2 - IMPELLER
3 - STATOR
4 - INPUT SHAFT
5 - STATOR SHAFT
6 - TURBINE DAMPER
21 - 156 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
TORQUE CONVERTER (Continued)
IMPELLER

Fig. 240 Impeller


1 - ENGINE FLEXPLATE 4 - ENGINE ROTATION
2 - OIL FLOW FROM IMPELLER SECTION INTO TURBINE 5 - ENGINE ROTATION
SECTION
3 - IMPELLER VANES AND COVER ARE INTEGRAL

The impeller (3) (Fig. 240) is an integral part of


the converter housing. The impeller consists of
curved blades placed radially along the inside of the
housing on the transmission side of the converter. As
the converter housing is rotated by the engine, so is
the impeller, because they are one and the same and
are the driving members of the system.
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 157
TORQUE CONVERTER (Continued)
TURBINE

Fig. 241 Turbine


1 - TURBINE VANE 4 - PORTION OF TORQUE CONVERTER COVER
2 - ENGINE ROTATION 5 - ENGINE ROTATION
3 - INPUT SHAFT 6 - OIL FLOW WITHIN TURBINE SECTION

The turbine (1) (Fig. 241) is the output, or driven,


member of the converter. The turbine is mounted
within the housing opposite the impeller, but is not
attached to the housing. The input shaft is inserted
through the center of the impeller and splined into
the turbine. The design of the turbine is similar to
the impeller, except the blades of the turbine are
curved in the opposite direction.
21 - 158 AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION VA
TORQUE CONVERTER (Continued)
STATOR The stator (1) is located between the impeller (2)
and turbine (4) within the torque converter case (Fig.
243). The stator contains a freewheeling clutch,
which allows the stator to rotate only in a clockwise
direction. When the stator is locked against the free-
wheeling clutch, the torque multiplication feature of
the torque converter is operational.

TORQUE CONVERTER CLUTCH (TCC)

Fig. 242 Stator Components


1 - CAM (OUTER RACE)
2 - ROLLER
3 - SPRING
4 - INNER RACE

The stator assembly (1-4) (Fig. 242) is mounted on


a stationary shaft which is an integral part of the oil
pump.

Fig. 244 Torque Converter Lock-up Clutch


1 - TURBINE
2 - IMPELLER
3 - STATOR
4 - INPUT SHAFT
5 - STATOR SHAFT
6 - PISTON
7 - COVER SHELL
8 - INTERNALLY TOOTHED DISC CARRIER
9 - CLUTCH PLATE SET
10 - EXTERNALLY TOOTHED DISC CARRIER
11 - TURBINE DAMPER

The TCC (9) (Fig. 244) was installed to improve


the efficiency of the torque converter that is lost to
the slippage of the fluid coupling. Although the fluid
coupling provides smooth, shock-free power transfer,
it is natural for all fluid couplings to slip. If the
impeller and turbine were mechanically locked
Fig. 243 Stator Location together, a zero slippage condition could be obtained.
1 - STATOR
A hydraulic piston with friction material was added
2 - IMPELLER to the turbine assembly to provide this mechanical
3 - FLUID FLOW lock-up.
4 - TURBINE
In order to reduce heat build-up in the transmis-
sion and buffer the powertrain against torsional
vibrations, the TCM can duty cycle the torque con-
verter lock-up solenoid to achieve a smooth applica-
tion of the torque converter clutch. This function,
VA AUTOMATIC TRANSMISSION NAG1 - SERVICE INFORMATION 21 - 159
TORQUE CONVERTER (Continued)
referred to as Electronically Modulated Converter ing the trailing edges of the turbine’s blades it con-
Clutch (EMCC) can occur at various times depending tinues in a “hindering” direction back toward the
on the following variables: impeller. If the fluid is not redirected before it strikes
• Shift lever position the impeller, it will strike the impeller in such a
• Current gear range direction that it would tend to slow it down.
• Transmission fluid temperature
• Engine coolant temperature STATOR
• Input speed
• Throttle angle
• Engine speed

OPERATION

Fig. 246 Stator Operation


1 - DIRECTION STATOR WILL FREE WHEEL DUE TO OIL
PUSHING ON BACKSIDE OF VANES
2 - FRONT OF ENGINE
3 - INCREASED ANGLE AS OIL STRIKES VANES
4 - DIRECTION STATOR IS LOCKED UP DUE TO OIL PUSHING
AGAINST STATOR VANES

Torque multiplication is achieved by locking the


stator’s over-running clutch to its shaft. (Fig. 246)
Under stall conditions (the turbine is stationary), the
oil leaving the turbine blades strikes the face of the
stator blades and tries to rotate them in a counter-
Fig. 245 Torque Converter clockwise direction. When this happens the over-run-
1 - TURBINE ning clutch of the stator locks and holds the stator
2 - IMPELLER from rotating. With the stator locked, the oil strikes
3 - STATOR
4 - INPUT SHAFT the stator blades and is redirected into a “helping”
5 - STATOR SHAFT direction before it enters the impeller. This circula-
6 - TURBINE DAMPER tion of oil from impeller to turbine, turbine to stator,
and stator to impeller, can produce a maximum
The converter impeller (driving member) (2) (Fig. torque multiplication of about 2.0:1. As the turbine
245), which is integral to the converter housing and begins to match the speed of the impeller, the fluid
bolted to the engine drive plate, rotates at engine that was hitting the stator in such as way as to
speed. The converter turbine (driven member) (1), cause it to lock-up is no longer doing so. In this con-
which reacts from fluid pressure generated by the dition of operation, the stator begins to free wheel
impeller, rotates and turns the transmission input and the converter acts as a fluid coupling.
shaft (4).

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

Fig. 248 Torque Converter Installation Depth


1 - TORQUE CONVERTER
2 - TRANSMISSION HOUSING
Fig. 249 Position Torque Converter Hub Seal
1 - TORQUE CONVERTER HUB SEAL
(2) Place torque converter in position on transmis- 2 - INPUT SHAFT
sion.
(1) Position the torque converter hub seal (1) (Fig.
CAUTION: Do not damage oil pump seal or con- 249) over the input shaft and against the transmis-
verter hub while inserting torque converter into the sion oil pump.
front of the transmission.

(3) Align torque converter to oil pump seal open-


ing.
(4) Insert torque converter hub into oil pump.
(5) While pushing torque converter inward, rotate
converter until converter is fully seated in the oil
pump gears.
(6) Check converter seating with a scale and
straightedge (Fig. 248). Surface of converter lugs
should be at least 19 mm (3/4 in.) to rear of straight-
edge when converter is fully seated.
(7) If necessary, temporarily secure converter with
C-clamp attached to the converter housing.
(8) Install the transmission in the vehicle.
(9) Fill the transmission with the recommended
fluid. Fig. 250 Install Torque Converter Hub Seal
1 - OIL PUMP
2 - SEAL INSTALLER 8902A
TORQUE CONVERTER HUB
SEAL (2) Using Seal Installer 8902A (2) (Fig. 250),
install a new torque converter hub seal.
REMOVAL (3) Install the torque converter (Refer to 21 -
(1) Remove the torque converter (Refer to 21 - TRANSMISSION/AUTOMATIC - NAG1/TORQUE
TRANSMISSION/AUTOMATIC - NAG1/TORQUE CONVERTER - INSTALLATION).
CONVERTER - REMOVAL).
(2) Remove the torque converter hub seal with
suitable screw and slide hammer.
VA TIRES/WHEELS 22 - 1

TIRES/WHEELS
TABLE OF CONTENTS

page page

TIRES/WHEELS DIAGNOSIS AND TESTING - TIRE WEAR


DIAGNOSIS AND TESTING - TIRE AND PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
WHEEL RUNOUT .................... ..1 DIAGNOSIS AND TESTING - TIRE/VEHICLE
STANDARD PROCEDURE LEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
STANDARD PROCEDURE - MATCH STANDARD PROCEDURE - REPAIRING
MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . ..2 LEAKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
STANDARD PROCEDURE - TIRE AND CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
WHEEL BALANCE . . . . . . . . . . . . . . . . . . . . ..3 SPECIFICATIONS
STANDARD PROCEDURE - TIRE ROTATION .5 TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SPECIFICATIONS SPARE TIRE CARRIER
TORQUE CHART .................... ..5 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
TIRES INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10
DESCRIPTION WHEELS
DESCRIPTION - TIRES . . . . . . . . . . . . . . . . ..6 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11
DESCRIPTION - RADIAL – PLY TIRES .... ..6 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DESCRIPTION - TIRE PRESSURE FOR DIAGNOSIS AND TESTING
HIGH SPEEDS. . . . . . . . . . . . . . . . . . . . . . . ..6 WHEEL INSPECTION . . . . . . . . . . . . . . . . . . 11
DESCRIPTION - REPLACEMENT TIRES . . . ..7 STANDARD PROCEDURE
DESCRIPTION - TIRE INFLATION STANDARD PROCEDURE - WHEEL
PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . ..7 REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . 11
DIAGNOSIS AND TESTING STANDARD PROCEDURE - DUAL REAR
DIAGNOSIS AND TESTING - PRESSURE WHEEL INSTALLATION . . . . . . . . . . . . . . . . . 12
GAUGES . . . . . . . . . . . . . . . . . . . . . . . . . . . ..8 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
DIAGNOSIS AND TESTING - TIRE NOISE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13
OR VIBRATION . . . . . . . . . . . . . . . . . . . . . . ..8
DIAGNOSIS AND TESTING - TREAD WEAR
INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . ..8

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.

METHOD 2 (RELOCATE TIRE ON WHEEL)


NOTE: Rotating the tire on wheel is particularly
effective when there is runout in both tire and Fig. 3 Lateral Runout
wheel. 1 - MOUNTING CONE
2 - SPINDLE SHAFT
(1) Remove tire from wheel and mount wheel on 3 - WING NUT
4 - PLASTIC CUP
service dynamic balance machine. 5 - DIAL INDICATOR
(2) Check wheel radial runout (Fig. 2) and lateral 6 - WHEEL
runout (Fig. 3). 7 - DIAL INDICATOR
• STEEL WHEELS: Radial runout 0.031 in., Lat-
eral runout 0.031 in. (maximum) STANDARD PROCEDURE
• ALUMINUM WHEELS: Radial runout 0.020 in.,
Lateral runout 0.025 in. (maximum) STANDARD PROCEDURE - MATCH MOUNTING
(3) If point of greatest wheel lateral runout is near Wheels and tires are match mounted at the factory.
original chalk mark, remount tire 180 degrees. This means that the high spot of the tire is matched
Recheck runout, Refer to match mounting procedure. to the low spot on the wheel rim. Each are marked
with a bright colored temporary label on the out-
board surface for alignment. The wheel is also
marked permanently on the inside of the rim in the
tire well. This permanent mark may be a paint dot
or line, a permanent label or a stamped impression
such as an X. An optional location mark is a small
spherical indentation on the vertical face of the out-
board flange on some non styled base steel wheels.
The tire must be removed to locate the permanent
mark on the inside of the wheel.
Before dismounting a tire from its wheel, a refer-
ence mark should be placed on the tire at the valve
stem location. This reference will ensure that it is
remounted in the original position on the wheel.
(1) Remove the tire and wheel assembly from the
vehicle and mount on a service dynamic balance
machine.
(2) Measure the total runout on the center of the
Fig. 2 Radial Runout
tire tread rib with a dial indicator. Record the indi-
1 - MOUNTING CONE
2 - SPINDLE SHAFT
cator reading. Mark the tire to indicate the high spot.
3 - WING NUT Place a mark on the tire at the valve stem location
4 - PLASTIC CUP (Fig. 4).
5 - DIAL INDICATOR
6 - WHEEL
(3) Break down the tire and remount it 180
7 - DIAL INDICATOR degrees on the rim (Fig. 5).
(4) Measure the total indicator runout again. Mark
the tire to indicate the high spot.
VA TIRES/WHEELS 22 - 3
TIRES/WHEELS (Continued)
(5) If runout is still excessive, the following proce-
dures must be done.
• If the high spot is within 101.6 mm (4.0 in.) of
the first spot and is still excessive, replace the tire.
• If the high spot is within 101.6 mm (4.0 in.) of
the first spot on the wheel, the wheel may be out of
specifications. Refer to Wheel and Tire Runout.
• If the high spot is NOT within 101.6 mm (4.0
in.) of either high spot, draw an arrow on the tread
from second high spot to first. Break down the tire
and remount it 90 degrees on rim in that direction
(Fig. 6). This procedure will normally reduce the
runout to an acceptable amount, if not replace the
rim.

Fig. 4 First Measurement On Tire


1 - REFERENCE MARK
2 - 1ST MEASUREMENT HIGH SPOT MARK TIRE AND RIM
3 - WHEEL
4 - VALVE STEM

Fig. 6 Remount Tire 90 Degrees In Direction of


Arrow
1 - 2ND HIGH SPOT ON TIRE
2 - 1ST HIGH SPOT ON TIRE

STANDARD PROCEDURE - TIRE AND WHEEL


BALANCE
It is recommended that a two plane service
dynamic balancer be used when a tire and wheel
assembly require balancing. Refer to balancer opera-
tion instructions for proper cone mounting proce-
dures. Typically use front cone mounting method for
steel wheels. For aluminum wheel use back cone
Fig. 5 Remount Tire 180 Degrees mounting method without cone spring.
1 - VALVE STEM
2 - REFERENCE MARK
NOTE: Static should be used only when a two plane
balancer is not available.
22 - 4 TIRES/WHEELS VA
TIRES/WHEELS (Continued)
NOTE: Cast aluminum and forged aluminum wheels directly opposite the heavy spot. Determine weight
require coated balance weights and special align- required to counter balance the area of imbalance.
ment equipment. Place half of this weight on the inner rim flange and
the other half on the outer rim flange (Fig. 7).
Wheel balancing can be accomplished with either For dynamic balancing, the balancing equipment is
on or off vehicle equipment. When using on-vehicle designed to locate the amount of weight to be applied
balancing equipment, remove the opposite wheel/tire. to both the inner and outer rim flange (Fig. 8).
Off-vehicle balancing is recommended.
For static balancing, find the location of the heavy
spot causing the imbalance. Counter balance wheel

Fig. 7 Static Unbalance & Balance


1 - HEAVY SPOT 4 - CORRECTIVE WEIGHT LOCATION
2 - CENTER LINE OF SPINDLE 5 - TIRE OR WHEEL TRAMP, OR WHEEL HOP
3 - ADD BALANCE WEIGHTS HERE

Fig. 8 Dynamic Unbalance & Balance


1 - CENTER LINE OF SPINDLE 3 - CORRECTIVE WEIGHT LOCATION
2 - ADD BALANCE WEIGHTS HERE 4 - HEAVY SPOT WHEEL SHIMMY AND VIBRATION
VA TIRES/WHEELS 22 - 5
TIRES/WHEELS (Continued)

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.

Fig. 10 TIRE ROTATION PATTERN - DUAL REAR


WHEELS (DRW)

Fig. 9 TIRE ROTATION PATTERN - SINGLE REAR


WHEEL (SRW)

SPECIFICATIONS

TORQUE CHART
TORQUE SPECIFICATIONS

DESCRIPTION N·m Ft. Lbs. In. Lbs.


Models 190 +10 140 +10 –
690.6,901,902,903,904,905, WD2YD441,YD541
Models 240 +10 177 +10 –
WD5.WD141,WD241,WD341,WD2.YD141,YD241,YD341
22 - 6 TIRES/WHEELS VA

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.

TIRE CHAINS DESCRIPTION - TIRE PRESSURE FOR HIGH


Tire snow chains may be used on certain models. SPEEDS
Refer to the Owner’s Manual for more information. Where speed limits allow the vehicle to be driven
at high speeds, correct tire inflation pressure is very
important. For speeds up to and including 120 km/h
(75 mph), tires must be inflated to the pressures
VA TIRES/WHEELS 22 - 7
TIRES (Continued)
shown on the tire placard. For continuous speeds in
excess of 120 km/h (75 mph), tires must be inflated
to the maximum pressure specified on the tire side-
wall.
Vehicles loaded to the maximum capacity should
not be driven at continuous speeds above 75 mph
(120 km/h).
For emergency vehicles that are driven at speeds
over 90 mph (144 km/h), special high speed tires
must be used. Consult tire manufacturer for correct
inflation pressure recommendations.

DESCRIPTION - REPLACEMENT TIRES


The original equipment tires provide a proper bal-
ance of many characteristics such as:
• Ride
• Noise Fig. 12 Under Inflation Wear
• Handling 1 - THIN TIRE THREAD AREAS
• Durability
• Tread life
• Traction
• Rolling resistance
• Speed capability
It is recommended that tires equivalent to the orig-
inal equipment tires be used when replacement is
needed.
Failure to use equivalent replacement tires may
adversely affect the safety and handling of the vehi-
cle.
The use of oversize tires may cause interference
with vehicle components. Under extremes of suspen-
sion and steering travel, interference with vehicle
components may cause tire damage.

WARNING: FAILURE TO EQUIP THE VEHICLE WITH


Fig. 13 Over Inflation Wear
TIRES HAVING ADEQUATE SPEED CAPABILITY
1 - THIN TIRE THREAD AREA
CAN RESULT IN SUDDEN TIRE FAILURE.
Tire pressures have been chosen to provide safe
operation, vehicle stability, and a smooth ride. Tire
DESCRIPTION - TIRE INFLATION PRESSURES
pressure should be checked cold once a month. Tire
Under inflation will cause rapid shoulder wear, tire
pressure decreases as the ambient temperature
flexing, and possible tire failure (Fig. 12).
drops. Check tire pressure frequently when ambient
Over inflation will cause rapid center wear and
temperature varies widely.
loss of the tire’s ability to cushion shocks (Fig. 13).
Tire inflation pressures are cold inflation pressure.
Improper inflation can cause:
The vehicle must sit for at least 3 hours to obtain the
• Uneven wear patterns
correct cold inflation pressure reading. Or be driven
• Reduced tread life
less than one mile after sitting for 3 hours. Tire
• Reduced fuel economy
inflation pressures may increase from 2 to 6 pounds
• Unsatisfactory ride
per square inch (psi) during operation. Do not reduce
• Vehicle drift
this normal pressure build-up.
For proper tire pressure specification refer to the
Tire Inflation Pressure Chart provided with the vehi- WARNING: OVER OR UNDER INFLATED TIRES CAN
cles Owners Manual. A Certification Label on the AFFECT VEHICLE HANDLING AND TREAD WEAR.
drivers side door pillar provides the minimum tire THIS MAY CAUSE THE TIRE TO FAIL SUDDENLY,
and rim size for the vehicle. The label also list the RESULTING IN LOSS OF VEHICLE CONTROL.
cold inflation pressure for these tires at full load
operation
22 - 8 TIRES/WHEELS VA
TIRES (Continued)

DIAGNOSIS AND TESTING


DIAGNOSIS AND TESTING - PRESSURE
GAUGES
A quality air pressure gauge is recommended to
check tire pressure. After checking the air pressure,
replace valve cap finger tight.

DIAGNOSIS AND TESTING - TIRE NOISE OR


VIBRATION
Radial-ply tires are sensitive to force impulses
caused by improper mounting, vibration, wheel
defects, or possibly tire imbalance.
To find out if tires are causing the noise or vibra-
tion, drive the vehicle over a smooth road at varying
speeds. Note the noise level during acceleration and
deceleration. The engine, differential and exhaust
noises will change as speed varies, while the tire
noise will usually remain constant.
Fig. 14 Tread Wear Indicators
DIAGNOSIS AND TESTING - TREAD WEAR
1 - TREAD ACCEPTABLE
INDICATORS 2 - TREAD UNACCEPTABLE
Tread wear indicators are molded into the bottom 3 - WEAR INDICATOR
of the tread grooves. When tread depth is 1.6 mm
Excessive camber causes the tire to run at an
(1/16 in.), the tread wear indicators will appear as a
angle to the road. One side of tread is then worn
13 mm (1/2 in.) band (Fig. 14).
more than the other (Fig. 15).
Tire replacement is necessary when indicators
Excessive toe-in or toe-out causes wear on the
appear in two or more grooves or if localized balding
tread edges and a feathered effect across the tread
occurs.
(Fig. 15).
DIAGNOSIS AND TESTING - TIRE WEAR
DIAGNOSIS AND TESTING - TIRE/VEHICLE
PATTERNS
Under inflation will cause wear on the shoulders of
LEAD
Use the following Vehicle Lead Diagnosis And Cor-
tire. Over inflation will cause wear at the center of
rection Chart to diagnose and correct a vehicle lead
tire.
or drift problem (Fig. 16).

Fig. 15 Tire Wear Patterns


VA TIRES/WHEELS 22 - 9
TIRES (Continued)

Fig. 16 VEHICLE LEAD DIAGNOSIS AND CORRECTION CHART


22 - 10 TIRES/WHEELS VA
TIRES (Continued)

STANDARD PROCEDURE - REPAIRING LEAKS SPECIFICATIONS


For proper repairing, a radial tire must be removed
from the wheel. Repairs should only be made if the TIRES
defect, or puncture, is in the tread area (Fig. 17). The SPECIFICATIONS
tire should be replaced if the puncture is located in
the sidewall. DESCRIPTION SPECIFICATION
Deflate tire completely before removing the tire
from the wheel. Use lubrication such as a mild soap TIRE P225/70R15C
solution when dismounting or mounting tire. Use LR D
tools free of burrs or sharp edges which could dam- TIRE LT225/75R16
age the tire or wheel rim. LR E
Before mounting tire on wheel, make sure all rust TIRE P
is removed from the rim bead and repaint if neces-
sary.
Install wheel on vehicle, and tighten to proper SPARE TIRE CARRIER
torque specification, (Refer to 22 - TIRES/WHEELS/
WHEELS - SPECIFICATIONS). REMOVAL
(1) Open the back doors.
(2) Loosen the bolts for the spare tire hold down
(Fig. 18).
(3) Push up on the spare tire carrier and push the
hold downs to the side and lower (Fig. 18).
(4) Remove the spare tire.

Fig. 17 TIRE REPAIR AREA


1 - TIRE REPAIR AREA

CLEANING Fig. 18 SPARE TIRE


Remove the protective coating on the tires before 1 - HOLD DOWNS
delivery of a vehicle. This coating may cause deteri- 2 - SPARE TIRE
3 - SPARE TIRE CARRIER
oration of the tires.
To remove the protective coating, apply warm
water and let it soak for a few minutes. Afterwards, INSTALLATION
scrub the coating away with a soft bristle brush. (1) Install the spare tire to the spare tire carrier
Steam cleaning may also be used to remove the coat- (Fig. 18).
ing. (2) Raise the tire and wheel assmbly and hook on
the hold downs (Fig. 18).
NOTE: DO NOT use gasoline, mineral oil, oil-based (3) Then tighten the hold downs to secure the
solvent or a wire brush for cleaning. spare tire in place and then close the doors.
VA TIRES/WHEELS 22 - 11

WHEELS replacement wheels, they should be equivalent in


load carrying capacity. The diameter, width, offset,
pilot hole and bolt circle of the wheel should be the
DESCRIPTION
same as the original wheel.
Original equipment wheels are designed for the
specified Maximum Vehicle Capacity. WARNING: FAILURE TO USE EQUIVALENT REPLACE-
All models use steel or aluminum wheels. MENT WHEELS MAY ADVERSELY AFFECT THE
Aluminum wheels require special balance weights SAFETY AND HANDLING OF THE VEHICLE. USED
and alignment equipment. WHEELS ARE NOT RECOMMENDED. THE SERVICE
(1) On vehicles equipped with dual rear wheels, HISTORY OF THE WHEEL MAY HAVE INCLUDED
The slots in the wheel must be aligned to provide SEVERE TREATMENT OR VERY HIGH MILEAGE. THE
access to the valve stem. RIM COULD FAIL WITHOUT WARNING.

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).

Fig. 22 (DRW) WHEEL CONE WASHERS


1 - CONE WASHER
2 - LUG STUD

• Tighten the wheel lug nuts in the numbered


sequential pattern until they are snug tight. Then
tighten lug nuts to specified torque following same
number sequence, (Refer to 22 - TIRES/WHEELS/
Fig. 20 WHEEL RING FLANGE CONE WASHERS WHEELS - SPECIFICATIONS).
1 - WHEEL STUD • Tighten lug nuts in same numbered sequence a
2 - CONE WASHER second time to the specified torque. This will ensure
that the wheels are thoroughly mated.
The dual rear wheel lug nuts should be tightened
• Check lug nut specified torque after 100 miles
according to the following procedure:
(160 kilometers). Also after 500 miles (800 kilome-
• Install the inner wheel to the hub assembly.
ters) of vehicle operation.
• Install the outer wheel Make sure the valve
stems line up with each when aligning the NOTE: Wheel lug nuts should be tightened to spec-
wheels (Fig. 21). ified torque at every maintenance interval thereafter.

Fig. 21 DUAL REAR WHEEL


1 - VALVE STEMS
2 - LUG NUTS
VA TIRES/WHEELS 22 - 13
WHEELS (Continued)

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).

Fig. 24 WHEEL REMOVAL / INSTALLATION


1 - VEHICLE
2 - LUG/STUD
3 - TIRE & WHEEL ASSEMBLY

- SPECIFICATIONS) See specification table for


model variations.
(3) Install the hub cap to the wheel then install
Fig. 23 FRONT TIRE (DRW) snugly the lug nuts to hold the hub cap to the wheel
1 - HUB CAP (DRW) (Fig. 23).
2 - LUG NUT WITH HUB CAP HOLD DOWNS (4) Install the wheel lug nuts (DRW) and tighten
to specification(Refer to 22 - TIRES/WHEELS -
(4) Remove the wheel and tire assembly. SPECIFICATIONS) See specification table for model
variations.
INSTALLATION (5) Lower the vehicle.
(1) Install the wheel and tire assembly to the vehi-
cle.
(2) Install the wheel lug studs (SRW) (Fig. 24) and
tighten to specification(Refer to 22 - TIRES/WHEELS
VA BODY 23 - 1

BODY
TABLE OF CONTENTS

page page

BODY DOOR - FRONT ..... .. . . . . . . . . . . . . . . . . . . 13


WARNING DOORS - REAR ..... .. . . . . . . . . . . . . . . . . . . 24
SAFETY PRECAUTIONS AND WARNINGS . . . 1 DOORS - SLIDING ... .. . . . . . . . . . . . . . . . . . . 36
DIAGNOSIS AND TESTING EXTERIOR ......... .. . . . . . . . . . . . . . . . . . . 47
DIAGNOSIS AND TESTING - WATER LEAKS .1 HOOD . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . 50
DIAGNOSIS AND TESTING - WIND NOISE . . . 2 INSTRUMENT PANEL . .. . . . . . . . . . . . . . . . . . . 53
STANDARD PROCEDURE INTERIOR . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . 67
STANDARD PROCEDURE - PLASTIC BODY PAINT . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . 74
PANEL REPAIR . . . . . . . . . . . . . . . . . . . . . . . . 3 SEATS ............ .. . . . . . . . . . . . . . . . . . . 76
STANDARD PROCEDURE - BUZZ, SQUEAK STATIONARY GLASS . .. . . . . . . . . . . . . . . . . . . 81
& RATTLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 WEATHERSTRIP/SEALS . . . . . . . . . . . . . . . . . . . 87
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 12 BODY STRUCTURE .. .. . . . . . . . . . . . . . . . . . . 88

BODY • Do not use harsh alkaline based cleaning sol-


vents on painted or upholstered surfaces. Damage
to finish or color can result.
WARNING • Do not hammer or pound on plastic trim panel
when servicing interior trim. Plastic panels can
SAFETY PRECAUTIONS AND WARNINGS break.

WARNING: USE AN OSHA APPROVED BREATHING


FILTER WHEN SPRAYING PAINT OR SOLVENTS IN DIAGNOSIS AND TESTING
A CONFINED AREA. PERSONAL INJURY CAN
RESULT. DIAGNOSIS AND TESTING - WATER LEAKS
• AVOID PROLONGED SKIN CONTACT WITH Water leaks can be caused by poor sealing,
PETROLEUM OR ALCOHOL – BASED CLEANING improper body component alignment, body seam
SOLVENTS. PERSONAL INJURY CAN RESULT. porosity, missing plugs, or blocked drain holes. Cen-
• DO NOT STAND UNDER A HOISTED VEHICLE trifugal and gravitational force can cause water to
THAT IS NOT PROPERLY SUPPORTED ON SAFETY drip from a location away from the actual leak point,
STANDS. PERSONAL INJURY CAN RESULT. making leak detection difficult. All body sealing
points should be water tight in normal wet-driving
conditions. Water flowing downward from the front of
CAUTION: When holes must be drilled or punched the vehicle should not enter the passenger or luggage
in an inner body panel, verify depth of space to the compartment. Moving sealing surfaces will not
outer body panel, electrical wiring, or other compo- always seal water tight under all conditions. At
nents. Damage to vehicle can result. times, side glass or door seals will allow water to
• Do not weld exterior panels unless combustible enter the passenger compartment during high pres-
material on the interior of vehicle is removed from sure washing or hard driving rain (severe) condi-
the repair area. Fire or hazardous conditions, can tions. Overcompensating on door or glass
result. adjustments to stop a water leak that occurs under
• Always have a fire extinguisher ready for use severe conditions can cause premature seal wear and
when welding. excessive closing or latching effort. After completing
• Disconnect the negative (-) cable clamp from a repair, water test vehicle to verify leak has stopped
the battery when servicing electrical components before returning vehicle to use.
that are live when the ignition is OFF. Damage to
electrical system can result.
• Do not use abrasive chemicals or compounds
on painted surfaces. Damage to finish can result.
23 - 2 BODY VA
BODY (Continued)
VISUAL INSPECTION BEFORE WATER LEAK TESTS MIRROR INSPECTION METHOD
Verify that floor and body plugs are in place, body When a leak point area is visually obstructed, use
drains are clear, and body components are properly a suitable mirror to gain visual access. A mirror can
aligned and sealed. If component alignment or seal- also be used to deflect light to a limited-access area
ing is necessary, refer to the appropriate section of to assist in locating a leak point.
this group for proper procedures.
BRIGHT LIGHT LEAK TEST METHOD
WATER LEAK TESTS Some water leaks in the luggage compartment can
be detected without water testing. Position the vehi-
WARNING: DO NOT USE ELECTRIC SHOP LIGHTS cle in a brightly lit area. From inside the darkened
OR TOOLS IN WATER TEST AREA. PERSONAL luggage compartment inspect around seals and body
INJURY CAN RESULT. seams. If necessary, have a helper direct a drop light
over the suspected leak areas around the luggage
When the conditions causing a water leak have compartment. If light is visible through a normally
been determined, simulate the conditions as closely sealed location, water could enter through the open-
as possible. ing.
• If a leak occurs with the vehicle parked in a
steady light rain, flood the leak area with an open- PRESSURIZED LEAK TEST METHOD
ended garden hose. When a water leak into the passenger compart-
• If a leak occurs while driving at highway speeds ment cannot be detected by water testing, pressurize
in a steady rain, test the leak area with a reasonable the passenger compartment and soap test exterior of
velocity stream or fan spray of water. Direct the the vehicle. To pressurize the passenger compart-
spray in a direction comparable to actual conditions. ment, close all doors and windows, start engine, and
• If a leak occurs when the vehicle is parked on an set heater control to high blower in HEAT position. If
incline, hoist the end or side of the vehicle to simu- engine can not be started, connect a charger to the
late this condition. This method can be used when battery to ensure adequate voltage to the blower.
the leak occurs when the vehicle accelerates, stops or With interior pressurized, apply dish detergent solu-
turns. If the leak occurs on acceleration, hoist the tion to suspected leak area on the exterior of the
front of the vehicle. If the leak occurs when braking, vehicle. Apply detergent solution with spray device or
hoist the back of the vehicle. If the leak occurs on left soft bristle brush. If soap bubbles occur at a body
turns, hoist the left side of the vehicle. If the leak seam, joint, seal or gasket, the leak entry point could
occurs on right turns, hoist the right side of the vehi- be at that location.
cle. For hoisting recommendations (Refer to LUBRI-
CATION & MAINTENANCE/HOISTING - DIAGNOSIS AND TESTING - WIND NOISE
STANDARD PROCEDURE). Wind noise is the result of most air leaks. Air leaks
can be caused by poor sealing, improper body compo-
WATER LEAK DETECTION nent alignment, body seam porosity, or missing plugs
To detect a water leak point-of-entry, do a water in the engine compartment or door hinge pillar areas.
test and watch for water tracks or droplets forming All body sealing points should be airtight in normal
on the inside of the vehicle. If necessary, remove inte- driving conditions. Moving sealing surfaces will not
rior trim covers or panels to gain visual access to the always seal airtight under all conditions. At times,
leak area. If the hose cannot be positioned without side glass or door seals will allow wind noise to be
being held, have someone help do the water test. noticed in the passenger compartment during high
Some water leaks must be tested for a considerable cross winds. Over compensating on door or glass
length of time to become apparent. When a leak adjustments to stop wind noise that occurs under
appears, find the highest point of the water track or severe conditions can cause premature seal wear and
drop. The highest point usually will show the point of excessive closing or latching effort. After a repair pro-
entry. After leak point has been found, repair the cedure has been performed, test vehicle to verify
leak and water test to verify that the leak has noise has stopped before returning vehicle to use.
stopped.
Locating the entry point of water that is leaking VISUAL INSPECTION BEFORE TESTS
into a cavity between panels can be difficult. The Verify that floor and body plugs are in place and
trapped water may splash or run from the cavity, body components are aligned and sealed. If compo-
often at a distance from the entry point. Most water nent alignment or sealing is necessary, refer to the
leaks of this type become apparent after accelerating, appropriate section of this group for proper proce-
stopping, turning, or when on an incline. dures.
VA BODY 23 - 3
BODY (Continued)
ROAD TESTING WIND NOISE Repair Procedure:
(1) Drive the vehicle to verify the general location The repair procedure for all three categories of
of the wind noise. plastics is basically the same. The one difference is
(2) Apply 50 mm (2 in.) masking tape in 150 mm the material used for the repair. The materials must
(6 in.) lengths along weatherstrips, weld seams or be specific for each substrate, rigid repair material
moldings. After each length is applied, drive the vehi- for rigid plastic repair, semi-rigid repair material for
cle. If noise goes away after a piece of tape is applied, semi-rigid plastic repair and flexible repair material
remove tape, locate, and repair defect. for flexible plastic repair.

POSSIBLE CAUSE OF WIND NOISE Adhesion Promoter/Surface Modifier:


• Moldings standing away from body surface can Adhesion Promoters/Surface Modifiers are required
catch wind and whistle. for certain plastics. All three categories may have
• Gaps in sealed areas behind overhanging body plastics that require the use of adhesion promoter/
flanges can cause wind-rushing sounds. surface modifiers. Always follow repair material man-
• Misaligned movable components. ufacturer’s plastic identification and repair
• Missing or improperly installed plugs in pillars. procedures.
• Weld burn through holes.
SAFETY PRECAUTION AND WARNINGS
STANDARD PROCEDURE WARNING:
• EYE PROTECTION SHOULD BE USED WHEN
STANDARD PROCEDURE - PLASTIC BODY SERVICING COMPONENTS. PERSONAL INJURY
PANEL REPAIR CAN RESULT.
There are many different types of plastics used in • USE AN OSHA APPROVED BREATHING MASK
today’s automotive environment. We group plastics in WHEN MIXING EPOXY, GRINDING, AND SPRAYING
three different categories: Rigid, Semi-Rigid, and PAINT OR SOLVENTS IN A CONFINED AREA. PER-
Flexible. Any of these plastics may require the use of SONAL INJURY CAN RESULT.
an adhesion promoter for repair. These types of plas- • AVOID PROLONGED SKIN CONTACT WITH
tic are used extensively on DaimlerChrysler Motors RESIN, PETROLEUM, OR ALCOHOL BASED SOL-
vehicles. Always follow repair material manufactur- VENTS. PERSONAL INJURY CAN RESULT.
er’s plastic identification and repair procedures. • DO NOT VENTURE UNDER A HOISTED VEHI-
CLE THAT IS NOT PROPERLY SUPPORTED ON
Rigid Plastics: SAFETY STANDS. PERSONAL INJURY CAN
Examples of rigid plastic use: Fascias, Hoods, RESULT.
Doors, and other Body Panels, which include SMC,
ABS, and Polycarbonates.
NOTE:
• When holes must be drilled or cut in body pan-
Semi-Rigid Plastics:
els, verify locations of internal body components
Examples of semi-rigid plastic use: Interior Panels,
and electrical wiring. Damage to vehicle can result.
Under Hood Panels, and other Body Trim Panels.
• Do not use abrasive chemicals or compounds
on undamaged painted surfaces around repair
Flexible Plastics:
areas. Damage to finish can result.
Examples of flexible plastic use: Fascias, Body
Moldings, and upper and lower Fascia Covers.
23 - 4 BODY VA
BODY (Continued)
RIGID, SEMI-RIGID, AND FLEXIBLE PLASTIC
PARTS TYPES

CODE FAMILY NAME COMMON TRADE NAME TYPICAL APPLICATION


ASA ACRYLONITRILE STYRENE LURAN S CONSOLES, GRILLES
ACRYLITE
ABS ACRYLONITRILE TERLURAN 9A9 PILLARS, CONSOLES,
BUTADIENE STYRENE GRILLES
ABS/PC ABS/PC ALLOY PULSE, PROLOY, BAYBLEND DOORS, INSTRUMENT
PANELS
ABS/PVC ABS/PV ALLOY PROLOY, PULSE, LUSTRAN, DOOR PANELS, GRILLES,
CYCLOVIN TRIM
BMC BULK MOLDING BMC FENDER EXTENSIONS
COMPOUND
EMA EHTYLENE METHYL SURLYN, EMA, IONOMER BUMPER GUARDS, PADS
ACRYLATE/IONOMER
METTON METTON METTON GRILLES, KICK PANELS,
RUNNING BOARDS
MPPO MODIFIED MPPO SPOILER ASSEMBLY
POLYPHENYLENE OXIDE
PA POLYAMID ZYTEL, VYDYNE, PA, FENDERS, QUARTER
MINLON PANELS
PET THERMOPLASTIC RYNITE TRIM
POLYESTER
PBT/PPO PBT/PPO ALLOY GERMAX CLADDINGS
PBTP POLYBUTYLENE PBT, PBTP, POCAN, VALOX WHEEL COVERS, FENDERS,
THEREPTHALATE GRILLES
PBTP/EEBC POLYBUTYLENE BEXLOY, 9M9, PBTP/EEBC FASCIAS, ROCKER PANEL,
THEREPTHALATE/EEBC MOLDINGS
ALLOY
PC POLYCARBONATE LEXAN, MERLON, CALIBRE, TAIL LIGHT LENSES, IP TRIM,
MAKROLON PC VALANCE PANELS
PC/ABS PC/ABS ALLOY GERMAX, BAY BLENDS, DOORS, INSTRUMENT
PULSE PANELS
PPO POLYPHENYLENE OXIDE AZDEL, HOSTALEN, INTERIOR TRIM, DOOR
MARLEX, PRFAX, NORYL, PANELS, SPLASH SHIELDS,
GTX, PPO STEERING COLUMN
SHROUD
PPO/PA POLYPHENYLENE/ PPO/PA, GTX 910 FENDERS, QUARTER
POLYAMID PANELS
PR/FV FIBERGLASS REINFORCED FIBERGLASS, FV, PR/FV BODY PANELS
PLASTIC
PS POLYSTYRENE LUSTREX, STYRON, PS DOOR PANELS, DASH
PANELS
RTM RESIN TRANSFER RTM BODY PANELS
MOLDING COMPOUND
SMC SHEET MOLDED SMC BODY PANELS
COMPOUND
VA BODY 23 - 5
BODY (Continued)

CODE FAMILY NAME COMMON TRADE NAME TYPICAL APPLICATION


TMC TRANSFER MOLDING TMC GRILLES
COMPOUND
UP UNSATURATED SMC, BMC, TMC, ZMC, IMC, GRILLE OPENING PANEL,
POLYESTER XSMC, UP LIFTGATES, FLARESIDE
(THERMOSETTING) FENDERS, FENDER
EXTENSIONS
EEBC ETHER/ESTER BLOCKED EEBC BUMPERS
CO-POLYMER
EEBC/PBTP EEBC/POLYBUTYLENE EEBC, PBTP, BEXLOY BUMPER, ROCKER PANELS
TEREPTHALATE
EMPP ETHYLENE MODIFIED EMPP BUMPER COVERS
POLYPROPYLENE
EPDM ETHYLENE/ EPDM, NORDEL, VISTALON BUMPERS
PROPROPYLENE DIENE
MONOMER
EPM ETHYLENE/ EPM FENDERS
PROPROPYLENE CO-
POLYMER
MPU FOAM POLYURETHANE MPU SPOILERS
PE POLYETHYLENE ALATHON, DYLAN, -
LUPOLEN, MARLEX
PP POLYPROPYLENE NORYL, AZDEL, MARLOX, INNER FENDER, SPOILERS,
(BLENDS) DYLON, PRAVEX KICK PANELS
PP/EPDM PP/EPDM ALLOY PP/EPDM SPOILERS, GRILLES
PUR POLYURETHANE COLONELS, PUR, PU FASCIAS, BUMPERS
PUR/PC PUR/PC ALLOY TEXIN BUMPERS
PVC POLYVINYL CHLORIDE APEX, GEON, VINYLITE BODY MOLDINGS, WIRE
INSULATION, STEERING
WHEELS
RIM REACTION INJECTED RIM, BAYFLEX FRONT FASCIAS, MODULAR
MOLDED POLYURETHANE WINDOWS
RRIM REINFORCED REACTION PUR, RRIM FASCIAS, BODY PANELS,
INJECTED MOLDED BODY TRIMS
TPE THERMO POLYETHYLENE TPE, HYTREL, BEXLOY-V FASCIAS, BUMPERS,
CLADDINGS
TPO THERMOPOLYOLEFIN POLYTROPE, RENFLEX, BUMPERS, END CAPS,
SANTOPRENE, VISAFLEX, TELCAR, RUBBER, STRIPS,
ETA, APEX, TPO, SHIELDS, SIGHT, INTERIOR B POST
CLADDINGS
TPP THERMO-POLYPROPYLENE TPP BUMPERS
TPU THERMOPOLYURETHANE, TPU, HYTREL, TEXIN, BUMPERS, BODY SIDE,
POLYESTER ESTANE MOLDINGS, FENDERS,
FASCIAS
23 - 6 BODY VA
BODY (Continued)
PANEL SECTIONING applications of glass cloth saturated with structural
If it is required to section a large panel for a plas- adhesive. Semi-rigid or flexible repair materials
tic repair, it will be necessary to reinforce the panel should be used for semi-rigid or flexible backing rein-
(Fig. 1). To bond two plastic panels together, a rein- forcement (Fig. 2) and (Fig. 3). Open meshed fiber-
forcement must overlap both panels. The panels glass dry wall tape can be used to form a
must be “V’d” at a 20 degree angle. The area to be reinforcement. The dry wall tape allows the resin to
reinforced should be washed, then sanded. Be sure to penetrate through and make a good bond between
wipe off any excess soap and water when finished. the panel and the adhesive. Structurally, the more
Lightly sand or abrade the plastic with an abrasive dry wall tape used, the stronger the repair.
pad or sandpaper. Blow off any dust with compressed Another kind of repair that can be done to repair
air or wipe with a clean dry rag. large cracks and holes is to use a scrap piece of sim-
ilar plastic and bond with structural adhesive. The
reinforcement should cover the entire break and
should have a generous amount of overlap on either
side of the cracked or broken area.
When repairing plastic, the damaged area is first
“V’d” out, or beveled. Large bonding areas are desir-
able when repairing plastic because small repairs are
less likely to hold permanently. Beveling the area
around a crack at a 20 degree angle will increase the
bonding surface for a repair (Fig. 4). It is recom-
mended that sharp edges be avoided because the
joint may show through after the panel is refinished.

Fig. 1 PANEL SECTIONING


1 - EXISTING PANEL
2 - NEW PANEL
3 - PANEL ADHESIVE
4 - BONDING STRIP

When bonding plastic panels, Follow repair mate-


rial manufacturers recommendations. Be sure that
enough adhesive has been applied to allow squeeze Fig. 2 SOFTENED EDGES
out and to fill the full bond line. Once the pieces 1 - SOFTENED EDGES
have been brought together, do not move them until 2 - PANEL ADHESIVE
the adhesive is cured. The assembly can be held 3 - BONDING STRIP
together with clamps, rivets, etc. A faster cure can be
obtained by heating with a heat lamp or heat gun.
After the parts have been bonded and have had time
to cure, rough sand the seam and apply the final
adhesive filler to the area being repaired. Smooth the
filler with a spreader, wooden tongue depressor, or
squeegee. For fine texturing, a small amount of
water can be applied to the filler surface while
smoothing. The cured filler can be sanded as neces-
sary and, as a final step, cleanup can be done with
soapy water. Wipe the surface clean with a dry cloth Fig. 3 PANEL REINFORCEMENT
allowing time for the panel to dry before moving on 1 - PANEL ADHESIVE
with the repair. 2 - REINFORCEMENT

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)

Fig. 4 BEVELING ANGLE - 20 DEGREE


• The technician should first decide what needs to
be done when working on any type of body panel.
One should determine if it is possible to return the Fig. 6 DAMAGE COMPONENT
damage part to its original strength and appearance 1 - PUNCTURE
without exceeding the value of the replacement part.
• When plastic repairs are required, it is recom- be stopped or removed. To stop a running crack in a
mended that the part be left on the vehicle when panel, drill a 6 mm (0.250 in.) hole at the end of the
every possible. That will save time, and the panel crack farthest away from the damage. If spider web
will remain stationary during the repair. Misalign- cracks can not be stopped, the panel would require
ment can cause stress in the repair areas and can replacement. The surfaces around the damaged area
result in future failure. should be stripped of paint and freed from wax and
oil. Scuff surfaces around repair area with 360 grit
wet/dry sandpaper, or equivalent, to assure adhesion
of repair materials.

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.

Fig. 8 FABRICATED PANEL Fig. 9 SECURE SUPPORT SQUARES TO BODY


1 - STRUCTURAL ADHESIVE PANEL
2 - FIBERGLASS CLOTH OR FIBERGLASS MESH TAPE 1 - SUPPORT SQUARES
3 - WIDTH OF V-GROOVE 2 - SCREWS
4 - WAXED PAPER 3 - DAMAGED BODY PANEL
VA BODY 23 - 9
BODY (Continued)
(12) Position patch in cutout against support (15) Install screws to hold the patch to support
squares and adjust patch until the gap is equal along squares (Fig. 12). Tighten screws until patch surface
all sides (Fig. 10). is flush with panel surface.
(13) Drill 3 mm (0.125 in.) holes in the support (16) Allow adhesive to cure, and remove all screws.
squares through the pre-drilled holes in the patch. (17) Using a 125 mm (5 in.) 24 grit disc grinder,
(14) Apply a coat of adhesive to the exposed ends grind a 50 mm (2 in.) to 75 mm (3 in.) wide and 2
of the support squares (Fig. 11). mm (0.080 in.) deep path across the gaps around the
patch (Fig. 13). With compressed air, blow dust from
around patch.

Fig. 10 POSITION PATCH IN CUTOUT AND ALIGN


1 - CUTOUT Fig. 12 INSTALL SCREWS
2 - SUPPORT SQUARES
1 - PATCH
2 - GAP

Fig. 11 APPLY ADHESIVE TO SUPPORT SQUARES


1 - APPLICATOR
Fig. 13 GRIND SURFACE
2 - SUPPORT SQUARES 1 - PATCH
3 - ADHESIVE 2 - GAP
3 - DISC GRINDER
23 - 10 BODY VA
BODY (Continued)
(18) Apply adhesive backed nylon mesh (dry wall PATCHED PANEL SURFACING
tape) over gaps around patch (Fig. 14). After patch panel is installed, the patch area can
(19) Mix enough adhesive to cover the entire patch be finished using the same methods as finishing
area. other types of body panels. If mesh material is
(20) Apply adhesive over the mesh around patch, exposed in the patched area, grind surface down, and
and smooth epoxy with a wide spreader to reduce fin- apply a coat of high quality rigid plastic body filler.
ish grinding. Use two to three layers of mesh and Prime, block sand, and paint as required.
adhesive to create a stronger repair (Fig. 15).
STANDARD PROCEDURE - BUZZ, SQUEAK &
RATTLE
Buzz, Squeak & Rattles (BSR) may be caused by
any one or more of the following and may be cor-
rected as indicated:
• Loose fasteners should be tightened to specifica-
tions.
• Damaged or missing clips should be replaced.
• Damaged trim panels should be replaced.
• Incorrectly installed trim panels should be rein-
stalled properly.
Many BSR complaints such as loose trim, can be
serviced using the Mopart Parts BSR Noise Reduc-
tion Kit. This kit contains various tapes including
foam, flock and anti-squeak used to eliminate noises
Fig. 14 COVER GAPS WITH MESH caused by metal, plastic and vinyl components. Long
life lubricants and greases can also be used on a vari-
1 - GROUND DOWN AREA
2 - PATCH ety of components. Refer to the Buzz, Squeak & Rat-
3 - MESH tle Kit table for material contents and usage.

Fig. 15 COVER MESH WITH ADHESIVE


1 - ADHESIVE
2 - MESH
3 - PATCH
4 - SPREADER
VA BODY 23 - 11
BODY (Continued)
BUZZ, SQUEAK & RATTLE KIT

ITEM FEATURES APPLICATIONS SERVICE TEMP


Itch And Squeak An abrasion resistant material Between metal and metal, -40° to 225°
Tape thin enough to conform to most metal and plastic, metal and Fahrenheit
irregular surfaces. Stops most vinyl, vinyl and plastic. Interior. (-40° to 107°
itches and squeaks. Examples: Trim panels and Celsius)
bezels.
Black Nylon Flock Nylon Flock with an aggressive Between metal and metal, -40° to 180°
acrylic adhesive. Provides for metal and plastic, vinyl and Fahrenheit
cushioning and compression fit, plastic. (-40° to 82° Celsius)
also isolates components. Examples: Pull cups, bezels,
Water-resistant. clips, ducts, top cover to glass,
cowl panel.
High Density Tear resistant, highly resilient Between metal and metal, -40° to 180°
Urethane Foam and durable. metal and plastic. Water- Fahrenheit
resistant. (-40° to 82° Celsius)
Examples: I/P, heavy metal
rattles, isolating brackets.
Open Cell Foam Soft foam conforms to irregular Wire harness and connector -40° to 180°
Tape surfaces. wrap. Fahrenheit
Examples: Seals, gasket, (-40° to 82° Celsius)
wiring, heat ducts.
Closed Cell Low Soft, conformable. Water- Wherever bulk is needed. -40° to 180°
Density Foam Tape resistant. Prevents closing flutters and Fahrenheit
rattles when applied to door (-40° to 82° Celsius)
watershield.
Examples: Door, I/P.
NYET Grease 880 Long life. Suspensions. -40° to 390°
Examples: Strut busings, sway Fahrenheit
bars. (-40° to 200°
Celsius)
KrytoxT Oil Long life. Will not dry out or When access is not possible, oil -30° to 400°
harm plastics or rubber. will migrate to condition. Vinyl, Fahrenheit
rubber, plastic, metal. (-34° to 205°
Examples: Convertible top Celsius)
bushings, pull cups trim panel
inserts.
KrytoxT Grease Long life. Will not dry out or Vinyl, rubber, plastic, metal, -30° to 400°
harm plastics or rubber. glass. Fahrenheit
Examples: Weather-strips, (-34° to 205°
backlite and windshield Celsius)
moldings.
23 - 12 BODY VA
BODY (Continued)

SPECIFICATIONS
TORQUE SPECIFICATIONS

DESCRIPTION N·m Ft. Lbs. In. Lbs.


Front door check bracket bolt/nut 6 — 53
Front door check to a-pillar M6 bolts 10 — 89
Front door check to a-pillar M8 bolts 35 26 —
Front door check to door fasteners 10 — 89
Front door exterior handle 10 — 89
Front door hinge bolts 25 18 —
Front door latch assembly bolts 10 — 89
Front door latch striker bolts 28 18 —
Front door regulator carrier plate bolts 10 — 89
Front door reinforcement bolts 21 15 —
Front door striker bolts 25 18 —
Front seat back mounting bolts 20 15 —
Front seat back stop bolt 20 15 —
Front seat mounting bolts 25 18 —
Hood hinge bolts/nuts 23 17 —
Lower seat belt anchor bolt 35 26 —
Radiator crossmember bolts 14 10 —
Rear door check bolts 10 — 89
Rear door exterior handle bolts 10 — 89
Rear door hinge bolts 25 18 —
Rear door upper closing wedge screws 10 — 89
Side view mirror bolts 25 18 —
Sliding door center guide rail end piece screws 10 — 89
Sliding door center roller arm bolt 45 33 —
Sliding door center track bolts/nuts 10 — 89
Sliding door inside handle screw 10 — 89
Sliding door latch screws 10 — 89
Sliding door latch/lock control bolts 10 — 89
Sliding door lower roller arm to door screws 25 18 —
Sliding door reinforcement bolts 21 15 —
Sliding door stabilizer screws 10 — 89
Sliding door stop bumper screws 10 — 89
Sliding door striker 25 18 —
Sliding door upper roller arm to door screws 25 18 —
Steering column support bolts 25 18 —
VA DOOR - FRONT 23 - 13

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

CHECK (4) Remove the bolt/nut and remove check bracket.


(Fig. 2)
(5) Remove the door fasteners and remove check
REMOVAL
from door.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove trim panel. (Refer to 23 - BODY/DOOR
INSTALLATION
- FRONT/TRIM PANEL - REMOVAL) (1) Install check through door opening and install
(3) Remove a-pillar bolts. (Fig. 1) the fasteners.

Fig. 2 FRONT DOOR CHECK - DOOR


Fig. 1 FRONT DOOR CHECK - BODY 1 - DOOR FASTENERS
1 - DOOR 2 - CHECK BRACKET NUT
2 - A-PILLAR BOLTS 3 - CHECK BRACKET
3 - DOOR CHECK 4 - DOOR OPENING
23 - 14 DOOR - FRONT VA
CHECK (Continued)
(2) Tighten door fasteners to 10 N·m (89 in. lbs.).
(3) Install bracket onto check and install bracket
bolt/nut.
(4) Tighten bracket bolt/nut to 6 N·m (53 in. lbs.).
(5) Install check bracket onto a-pillar.
(6) Apply Loctitet 243 sealant check strap bolts
and install bolts.
(7) Tighten the M8 bolts to 35 N·m (26 ft. lbs.) or
tighten the M6 bolts to 10 N·m (89 in. lbs.).
(8) Install trim panel. (Refer to 23 - BODY/DOOR -
FRONT/TRIM PANEL - INSTALLATION)
(9) Connect battery negative cable.

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)

Fig. 5 FRONT DOOR


1 - UPPER CHECK BOLT
Fig. 3 ELECTRICAL CONNECTORS 2 - DOOR CHECK
1 - ELECTRICAL CONNECTORS 3 - UPPER HINGE SET SCREW
2 - BOOT 4 - LOWER HINGE SET SCREW
3 - DOOR 5 - HINGE RECEIVERS
6 - DOOR
7 - LOWER CHECK BOLT
(4) Remove the bolts and disconnect the door check
from the a-pillar. (Fig. 4) (5) Tighten the M8 bolts to 35 N·m (26 ft. lbs.) or
(5) Support door with a suitable device. tighten the M6 bolts to 10 N·m (89 in. lbs.).
(6) Loosen the hinge set screws. (Fig. 5) (6) Connect all door electrical connectors and posi-
(7) Remove door by lifting off hinge pins. tion boot back.
(7) Install mirror. (Refer to 23 - BODY/EXTERI-
INSTALLATION OR/SIDE VIEW MIRROR - INSTALLATION)
(1) Slide door into hinges. (8) Adjust door if required. (Refer to 23 - BODY/
(2) Install set screws. DOOR - FRONT/DOOR - ADJUSTMENTS)
(3) Install check bracket onto a-pillar. (9) Connect battery negative cable.
(4) Apply Loctitet 243 sealant check strap bolts
and install bolts.
VA DOOR - FRONT 23 - 15
DOOR (Continued)

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.

(1) Check door alignment. (Refer to 23 - BODY/


BODY STRUCTURE/GAP AND FLUSH - SPECIFI-
CATIONS)
(2) If adjustment is required, remove latch striker.
(Refer to 23 - BODY/DOOR - FRONT/LATCH
STRIKER - REMOVAL)
(3) Remove side view mirror. (Refer to 23 - BODY/ Fig. 6 FRONT DOOR GLASS
EXTERIOR/SIDE VIEW MIRROR - REMOVAL) 1 - DOOR RUN CHANNEL
(4) Loosen hinge bolts and adjust door gap and 2 - DOOR GLASS
align ridge pattern as necessary. 3 - REINFORCEMENT BOLTS
(5) Tighten hinge bolts to 25 N·m (18 ft. lbs.).
(6) Install latch striker and adjust flush measure-
ment as necessary. (Refer to 23 - BODY/DOOR -
FRONT/LATCH STRIKER - INSTALLATION)
(7) Install side view mirror. (Refer to 23 - BODY/
EXTERIOR/SIDE VIEW MIRROR - INSTALLA-
TION)

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

EXTERIOR HANDLE INSTALLATION


(1) Position front of handle into front slot in door.
REMOVAL (Fig. 10)
(1) Remove handle bolt. (Fig. 8)

Fig. 10 EXTERIOR HANDLE INSTALLATION


1 - DOOR LATCH OPENING
2 - LOCK ACTUATION LEVER
Fig. 8 LATCH/HANDLE FASTENERS 3 - LATCH ACTUATION LEVER
4 - EXTERIOR HANDLE
1 - EXTERIOR HANDLE BOLT
2 - LATCH
3 - LATCH BOLTS (3) (2) Position rear of handle into latch opening and
engage lock and latch actuation levers with the latch
(2) Slide handle assembly towards front of door. levers. (Fig. 11)
(Fig. 9)

Fig. 11 LATCH LEVERS


Fig. 9 EXTERIOR HANDLE 1 - LATCH LEVER
1 - EXTERIOR HANDLE 2 - LATCH OPENING
2 - DOOR 3 - LOCK LEVER

(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)

Fig. 13 FRONT DOOR


1 - UPPER CHECK BOLT
2 - DOOR CHECK
3 - UPPER HINGE SET SCREW
4 - LOWER HINGE SET SCREW
5 - HINGE RECEIVERS
Fig. 12 EXTERIOR HANDLE 6 - DOOR
7 - LOWER CHECK BOLT
1 - EXTERIOR HANDLE BOLT
2 - LATCH
3 - LATCH BOLTS (3)

(4) Tighten bolt to 10 N·m (89 in. lbs.).

HINGE
REMOVAL
NOTE: It is not necessary to remove the door to
replace the hinges if they are replaced one at a
time.

(1) Using a grease pencil or equivalent, mark the


position of the hinge on the door.
(2) Remove side view mirror. (Refer to 23 - BODY/
EXTERIOR/SIDE VIEW MIRROR - REMOVAL)
(3) Loosen hinge set bolts. (Fig. 13)
(4) Remove hinge bolts and remove hinge. (Fig. 14) Fig. 14 HINGE
1 - HINGE BOLTS
2 - DOOR HINGE
INSTALLATION
(1) Install hinge and install bolts.
(2) Tighten bolts to 25 N·m (18 ft. lbs.).
(3) Tighten hinge set bolts.
(4) Install side view mirror. (Refer to 23 - BODY/
EXTERIOR/SIDE VIEW MIRROR - INSTALLA-
TION)
(5) Adjust door if necessary. (Refer to 23 - BODY/
DOOR - FRONT/DOOR - ADJUSTMENTS)
23 - 18 DOOR - FRONT VA

LATCH LATCH STRIKER


REMOVAL REMOVAL
(1) Remove trim panel. (Refer to 23 - BODY/DOOR (1) Using a grease pencil or equivalent, mark the
- FRONT/TRIM PANEL - REMOVAL) position of the striker to aid installation.
(2) Remove exterior handle. (Refer to 23 - BODY/ (2) Remove the bolts and remove the striker. (Fig.
DOOR - FRONT/EXTERIOR HANDLE - REMOVAL) 16)
(3) Remove screws and remove latch assembly.
(4) Disconnect electrical connector and control
cable. (Fig. 15)

Fig. 16 LATCH STRIKER


1 - BOLTS
2 - STRIKER
Fig. 15 FRONT DOOR LATCH
1 - CONTROL CABLE INSTALLATION
2 - LATCH LEVER (1) Install striker and install bolts.
3 - LATCH BOLTS (3) (2) Tighten bolts to 25 N·m (18 ft. lbs.).
4 - WIRE HARNESS
5 - LATCH ASSEMBLY (3) Check door for flush and adjust the striker hor-
izontally if necessary. (Refer to 23 - BODY/BODY
INSTALLATION STRUCTURE/GAP AND FLUSH - SPECIFICA-
(1) Connect electrical connectors and control cable. TIONS)
(2) Install latch and install bolts.
(3) Tighten bolts to 10 N·m (89 in. lbs.).
(4) Install exterior handle. (Refer to 23 - BODY/
LOCK CYLINDER
DOOR - FRONT/EXTERIOR HANDLE - INSTALLA-
TION) REMOVAL
(5) Install trim panel. (Refer to 23 - BODY/DOOR - (1) Remove exterior door handle. (Refer to 23 -
FRONT/TRIM PANEL - INSTALLATION) BODY/DOOR - FRONT/EXTERIOR HANDLE -
REMOVAL)
(2) Remove lock cylinder from handle.

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

TRIM PANEL (5) Remove mounting ring and remove window


crank, if equipped.
(6) Open pocket door. (Fig. 19)
REMOVAL
(1) Disconnect and isolate battery negative cable.
(2) Using a small flat bladed tool or equivalent,
press retaining clip upward through cutout in handle
cover and remove cover. (Fig. 17)

Fig. 17 TRIM PANEL HANDLE


1 - SWITCH BEZEL
2 - HANDLE COVER

(3) Remove switch bezel and disconnect electrical


connectors. Fig. 19 TRIM PANEL
(4) Remove the screws. (Fig. 18) 1 - TRIM PANEL
2 - DOOR POCKET

Fig. 18 TRIM PANEL FASTENERS


1 - UPPER SCREW
2 - WINDOW CRANK MOUNTING RING
3 - WINDOW CRANK
4 - LOWER SCREW
23 - 20 DOOR - FRONT VA
TRIM PANEL (Continued)
(7) Using a trim stick C-4755 or equivalent, sepa- INSTALLATION
rate window frame molding from door. (Fig. 20) (1) Position trim panel and connect control cable.
(2) Install trim panel.
(3) Position window frame molding and seat clips
fully.
(4) Close pocket door.
(5) Install window crank and mounting ring, if
equipped.
(6) Install handle screws.
(7) Connect electrical connectors and install switch
bezel.
(8) Install handle cover.
(9) Connect battery negative cable.

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

(8) Slightly pull door trim upward and swing away


slightly.
(9) Unlock retainer clip and disconnect control
cable. (Fig. 21)

Fig. 22 ELECTRICAL CONNECTOR


1 - ELECTRICAL CONNECTOR
2 - REGULATOR MOTOR
3 - WIRE TIE

Fig. 21 CONTROL CABLE


1 - RETAINER CLIP
2 - CONTROL CABLE MOUNTING

(10) Remove trim panel.


VA DOOR - FRONT 23 - 21
WINDOW REGULATOR - POWER (Continued)
(5) Using wood wedge, tape or equivalent, secure (7) Remove carrier plate bolts.
glass in the up position. (Fig. 23) (8) Disengage lift arm from glass guide rail and
remove regulator assembly. (Fig. 25)

Fig. 23 GLASS SUPPORT


1 - WOOD WEDGE (or equivalent) Fig. 25 REGULATOR ASSEMBLY
2 - WINDOW GLASS 1 - GUIDE RAIL
2 - REGULATOR
(6) Remove tape securing wire harness to regula- 3 - CARRIER PLATE
4 - RIVETS (4)
tor assembly. (Fig. 24) 5 - CARRIER PLATE BOLTS (3)
6 - WINDOW GLASS

(9) Remove four rivets attaching regulator to car-


rier plate and remove 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)

Fig. 27 MANUAL REGULATOR ASSEMBLY


1 - DOOR
2 - CARRIER PLATE BOLTS
3 - CARRIER PLATE
4 - REGULATOR ASSEMBLY
5 - SEALING STRIP
6 - REGULATOR RIVETS (4)
7 - WINDOW CRANK/TRIM RING
8 - TRIM PANEL
9 - CLIPS
10 - WINDOW FRAME MOLDING
Fig. 26 GLASS SUPPORT 11 - REGULATOR
1 - WOOD WEDGE (or equivalent)
2 - WINDOW GLASS

(4) Remove carrier plate bolts. (Fig. 27)


(5) Disengage lift arm from glass guide rail and
remove regulator assembly. (Fig. 28)
(6) Remove four rivets attaching regulator to car-
rier plate and remove regulator. (Fig. 29)

Fig. 28 LIFT ARM


1 - GLASS GUIDE RAIL
2 - LIFT ARM
VA DOOR - FRONT 23 - 23
WINDOW REGULATOR - MANUAL (Continued)

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)

Fig. 29 MANUAL REGULATOR FASTENERS


1 - RIVETS (4)
2 - REGULATOR
3 - CARRIER PLATE
23 - 24 DOORS - REAR VA

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.

Fig. 1 DOOR CHECK


1 - RECEIVER
2 - DOOR CHECK
3 - SCREWS
VA DOORS - REAR 23 - 25

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)

Fig. 3 DOOR HINGES


1 - DOOR
2 - TORX BOLTS (2 PER HINGE)
3 - ALLEN BOLTS (1 PER HINGE)

Fig. 2 CHECK STRAP


1 - RECEIVER
2 - DOOR CHECK
23 - 26 DOORS - REAR VA
DOOR (Continued)

DISASSEMBLY (6) Remove rivets (15) and remove closing wedge


(16).
RIGHT DOOR (7) Remove bolts (2) and remove top closing wedge
(1) Remove door. (Refer to 23 - BODY/DOORS - (1).
REAR/DOOR - REMOVAL) (8) Remove bolts (9) and remove door check (10).
(2) Remove trim panel (20) (Fig. 4). (Refer to 23 - (Refer to 23 - BODY/DOORS - REAR/CHECK -
BODY/DOORS - REAR/TRIM PANEL - REMOVAL) REMOVAL)
(3) Remove latch assembly (14). (Refer to 23 - (9) Remove the bolts (3) and remove the door
BODY/DOORS - REAR/LATCH - REMOVAL) hinges (4). (Refer to 23 - BODY/DOORS - REAR/
(4) Remove screws (21) from door handle (20). HINGE - INSTALLATION)
(5) Slide door handle (20) to right and remove.

Fig. 4 RIGHT DOOR


1 - TOP CLOSING WEDGE 12 - DOOR LOCK LINKAGE
2 - BOLTS 13 - BOLTS (3)
3 - BOLTS (2) 14 - LATCH ASSEMBLY
4 - DOOR HINGE 15 - RIVETS (2)
5 - PANEL 16 - BOTTOM CLOSING WEDGE
6 - SCREW 17 - LOCKING ROD
7 - INNER ACTION 18 - GROMMET
8 - PANELING 19 - LOCKING KNOB
9 - BOLTS (2) 20 - EXTERIOR DOOR HANDLE
10 - DOOR CHECK 21 - SCREW
11 - THREADED PLATE
VA DOORS - REAR 23 - 27
DOOR (Continued)
LEFT DOOR (7) Remove door hinge (6). (Refer to 23 - BODY/
(1) Remove door. (Refer to 23 - BODY/DOORS - DOORS - REAR/HINGE - REMOVAL)
REAR/DOOR - REMOVAL) (8) Remove closing wedge (4).
(2) Remove trim panel (20) (Fig. 5). (Refer to 23 - (9) Remove rivets (22) and remove bottom closing
BODY/DOORS - REAR/TRIM PANEL - REMOVAL) wedge (21).
(3) Disconnect electrical connectors and remove (10) Remove rear door seal (8).
license plate lighting (18, 19). (11) Remove the four screws (9, 14) from the lock
(4) Pull out switch and disconnect electrical con- rod actuator.
nector (17). (12) Using locking pliers, hold upper lock rod (2)
(5) Remove and discard roll pin (12) and remove and remove lock rod actuator.
lock rod handle (11). (13) Remove clips (15).
(6) Remove door check (23). (Refer to 23 - BODY/ (14) Pull out lock rod guides (1, 16) and remove
DOORS - REAR/CHECK - REMOVAL) lock rods (2, 13).

Fig. 5 LEFT DOOR


1 - UPPER LOCK ROD GUIDE 15 - CLIPS (2)
2 - UPPER LOCK ROD 16 - BOTTOM LOCK ROD GUIDE
3 - LEFT REAR DOOR 17 - SWITCHES
4 - TOP CLOSING WEDGE 18 - ELECTRICAL CONNECTOR
5 - BOLTS (2) 19 - LICENSE PLATE LIGHTING
6 - HINGE 20 - TRIM PANEL
7 - BOLTS (2) 21 - BOTTOM CLOSING WEDGE
8 - REAR DOOR SEAL 22 - RIVETS (2)
9 - SCREWS (2) 23 - DOOR CHECK
10 - LOCK ROD ACTUATOR 24 - BOLTS (2)
11 - LOCK ROD HANDLE 25 - FELT STRIP
12 - ROLL PIN 26 - O-RINGS (2)
13 - BOTTOM LOCK ROD 27 - THREADED PLATE
14 - SCREWS (2)
23 - 28 DOORS - REAR VA
DOOR (Continued)

ASSEMBLY (5) Install the exterior handle (20). (Refer to 23 -


BODY/DOORS - REAR/EXTERIOR HANDLE -
RIGHT DOOR INSTALLATION)
(1) Install the door hinges (4) and bolts (3) (Fig. 6). (6) Install the latch assembly (14). (Refer to 23 -
(Refer to 23 - BODY/DOORS - REAR/HINGE - BODY/DOORS - REAR/LATCH - INSTALLATION)
INSTALLATION) (7) Install trim panel (20). (Refer to 23 - BODY/
(2) Install the door check (10) and bolts (9). (Refer DOORS - REAR/TRIM PANEL - INSTALLATION)
to 23 - BODY/DOORS - REAR/CHECK - INSTALLA- (8) Install door. (Refer to 23 - BODY/DOORS -
TION) REAR/DOOR - INSTALLATION)
(3) Install the top closing wedge (1) and bolts (2).
(4) Install the bottom closing wedge (16) and
replace rivets (15).

Fig. 6 RIGHT DOOR


1 - TOP CLOSING WEDGE 12 - DOOR LOCK LINKAGE
2 - BOLTS 13 - BOLTS (3)
3 - BOLTS (2) 14 - LATCH ASSEMBLY
4 - DOOR HINGE 15 - RIVETS (2)
5 - PANEL 16 - BOTTOM CLOSING WEDGE
6 - SCREW 17 - LOCKING ROD
7 - INNER ACTION 18 - GROMMET
8 - PANELING 19 - LOCKING KNOB
9 - BOLTS (2) 20 - EXTERIOR DOOR HANDLE
10 - DOOR CHECK 21 - SCREW
11 - THREADED PLATE
VA DOORS - REAR 23 - 29
DOOR (Continued)
LEFT DOOR (9) Install door check (23). (Refer to 23 - BODY/
(1) Install lock rods (2, 13) and install lock rod DOORS - REAR/CHECK - INSTALLATION)
guides (1, 16). (Fig. 7) (10) Install lock rod handle (11) and replace roll
(2) Using locking pliers, hold upper lock rod (2) in pin (12).
place. (11) Connect the electrical connector and install
(3) Install clips (15). switches (17).
(4) Install the lock rod actuator (10). The bolts (12) Connect electrical connectors and install
should reach into the holes (arrows) of the lock rods license plate lighting (18, 19).
(2, 13). Place and o-ring (dia. 6 mm) on each of the (13) Install trim panel (20). (Refer to 23 - BODY/
lock rod actuator bolts to prevent the lock rods from DOORS - REAR/TRIM PANEL - INSTALLATION)
chattering against the lock. (14) Install door. (Refer to 23 - BODY/DOORS -
(5) Install rear door seal. REAR/DOOR - INSTALLATION)
(6) Install bottom closing wedge (21) and replace
rivets (22).
(7) Install closing wedge (4).
(8) Install door hinge (6). (Refer to 23 - BODY/
DOORS - REAR/HINGE - INSTALLATION)

Fig. 7 LEFT DOOR


1 - UPPER LOCK ROD GUIDE 15 - CLIPS (2)
2 - UPPER LOCK ROD 16 - BOTTOM LOCK ROD GUIDE
3 - LEFT REAR DOOR 17 - SWITCHES
4 - TOP CLOSING WEDGE 18 - ELECTRICAL CONNECTOR
5 - BOLTS (2) 19 - LICENSE PLATE LIGHTING
6 - HINGE 20 - TRIM PANEL
7 - BOLTS (2) 21 - BOTTOM CLOSING WEDGE
8 - REAR DOOR SEAL 22 - RIVETS (2)
9 - SCREWS (2) 23 - DOOR CHECK
10 - LOCK ROD ACTUATOR 24 - BOLTS (2)
11 - LOCK ROD HANDLE 25 - FELT STRIP
12 - ROLL PIN 26 - O-RINGS (2)
13 - BOTTOM LOCK ROD 27 - THREADED PLATE
14 - SCREWS (2)
23 - 30 DOORS - REAR VA
DOOR (Continued)

INSTALLATION
CAUTION: If the door is being replaced a suitable
seam sealer must be used prior to painting.

(1) Support the door with a suitable lifting device,


install door and install the hinge bolts.
(2) Tighten bolts to 25 N·m (18 ft. lbs.).
(3) Engage check arm into receiver.
(4) Adjust the door as necessary. (Refer to 23 -
BODY/DOORS - REAR/DOOR - ADJUSTMENTS)

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)

NOTE: Striker should engage in latch at center.


Door should not be lifted or pushed downward with
striker.

(8) Tighten striker.

Fig. 8 HINGE BOLTS


1 - HINGE
2 - BODY
3 - TORX BOLTS

NOTE: Close and adjust each door individually.

(3) Close the door and check gap measurement.


(4) Loosen allen screw through hole in hinge. (Fig. 9)

NOTE: Adjust so that bottom closing wedges make


Fig. 10 STRIKER ADJUSTMENT
contact and door gaps are uniform all the way around. 1 - STRIKER
2 - LOCK ROD HANDLE ASSEMBLY
3 - LEFT DOOR
(5) Adjust rear door and tighten allen screw to 25
N·m (18 ft. lbs.).
VA DOORS - REAR 23 - 31
DOOR (Continued)
CAUTION: Since the rear doors are components
with static functions it is very important that they
are fastened while driving. This prevents excessive
torsion of the vehicle and leaky rear doors. The rear
doors are fastened by adjusting the closing
wedges.

(9) Closing wedges at bottom must be resting free


of play on plastic closing plates when rear doors are
closed. To adjust, loosen door hinges and raise or
lower complete doors.
(10) Loosen upper closing wedge screws and move
top closing wedge up against plastic closing plate free
of play with rear door closed and tighten screws to 10 Fig. 11 REAR HINGE ADJUSTMENT
N·m (89 in. lbs.). 1 - ADJUSTMENT SCREW
(11) Check and adjust the hinges. On rear doors, 2 - ADJUSTMENT SCREW
the retaining magnets should run up to the middle of 3 - ADJUSTMENT SCREW
4 - CONTROL ARM
the mating plate at the side wall. If this is not the
case, correct as listed. (Fig. 11)
DOOR GLASS
CAUTION: Adjustment range of screw (3) maximum
1 turn (risk of control cam breaking, 4) REMOVAL
(1) Position an assistant on one side of the door to
• Retaining magnet is too far forward relative to receive the glass and weatherstrip seal.
mating plate. Turn in adjustment screw (2) at top (2) Start at an inside, upper corner. Separate the
and bottom hinge. seal from the window opening. Push the glass and
• Retaining magnet is too far back relative to mat- seal outward from the window opening. Remove the
ing plate. Turn out adjustment screw (2) at top and glass and seal.
bottom hinge. (3) Clean the window opening.
• Retaining magnet is too deep relative to mating
plate. Turn in adjustment screw (2) at top hinge, INSTALLATION
turn out adjustment screw (2) at bottom hinge. (1) Install the weatherstrip seal on the window
• Retaining magnet is too high relative to mating glass. Verify that the glass is seated in the groove
plate. Turn out adjustment screw (2) at top hinge, around the edge of the seal.
turn in adjustment screw (2) at bottom hinge. (2) Insert an installation cord in the weatherstrip
• Retaining magnet strikes too hard against mat- seal inner groove.
ing plate. Turn in adjustment screw (1) at top and
bottom hinge. NOTE: Use mineral spirits as a lubricant to aid seal
• Retaining magnet does not make contact with installation in the window opening.
mating plate. Turn out adjustment screw (1) at top
and bottom hinge. (3) Position the glass and seal in the window open-
• Door projects at corner paneling when closed. ing.
Turn out adjustment screw (3) at hinge. (4) Pull the installation cord outward and force the
• Door is too far recessed at corner paneling when seal lip over the panel flange around the edge of the
closed. Turn in adjustment screw (3) at hinge. opening.
(5) Seat the seal inner lip on the panel flange.
Press against the lip around the edge of the seal.
23 - 32 DOORS - REAR VA
DOOR GLASS (Continued)
NOTE: Remove any mineral spirits with a clean
cloth after glass installation.

(6) Verify that the seal is seated in the window


opening (Fig. 12).
(7) Test the window for water leaks. (Refer to 23 -
BODY - DIAGNOSIS AND TESTING - WATER
LEAKS)

Fig. 13 EXTERIOR HANDLE


1 - EXTERIOR HANDLE BOLT
2 - LATCH
3 - LATCH BOLTS (3)

Fig. 12 Glass & Weatherstrip Seal Installation


1 - BODY PANEL
2 - WEATHERSTRIP SEAL
3 - INSTALLATION CORD
4 - WINDOW OPENING

EXTERIOR HANDLE
REMOVAL
(1) Remove handle bolt. (Fig. 13)

NOTE: Front door shown, rear door similar.

(2) Slide handle assembly towards front of door.


(Fig. 14) Fig. 14 LATCH/HANDLE FASTENERS
1 - EXTERIOR HANDLE
NOTE: Front door shown, rear door similar. 2 - DOOR

(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)

INSTALLATION (3) Slide exterior handle towards rear of door and


(1) Position front of handle into front slot in door. install bolt. (Fig. 17)
(Fig. 15)
NOTE: Front door shown, rear door similar.
NOTE: Front door shown, rear door similar.

Fig. 15 EXTERIOR HANDLE INSTALLATION Fig. 17 EXTERIOR HANDLE


1 - DOOR LATCH OPENING 1 - EXTERIOR HANDLE BOLT
2 - LOCK ACTUATION LEVER 2 - LATCH
3 - LATCH ACTUATION LEVER 3 - LATCH BOLTS (3)
4 - EXTERIOR HANDLE

(4) Tighten bolt to 10 N·m (89 in. lbs.).


(2) Position rear of handle into latch opening and
engage lock and latch actuation levers with the latch
levers. (Fig. 16)

NOTE: Front door shown, rear door similar.

Fig. 16 LATCH LEVERS


1 - LATCH LEVER
2 - LATCH OPENING
3 - LOCK LEVER
23 - 34 DOORS - REAR VA

HINGE
REMOVAL
NOTE: It is not necessary to remove the door to
replace the hinges if they are replaced one at a time.

(1) Using a grease pencil or equivalent, mark the


position of the hinge on the door.
(2) Remove the bolts and remove the hinge. (Fig. 18)

Fig. 19 TRIM PANEL


1 - TRIM
2 - INSIDE HANDLE ACTUATOR
3 - TRIM PANEL
4 - CONTROL CABLE

(3) Disconnect lock rod. (Fig. 20)


Fig. 18 REAR DOOR HINGE (4) Remove the screws and pull out latch from door.
1 - TORX BOLTS BODY SIDE (5) Disconnect cable and electrical connectors.
2 - TORX BOLTS DOOR SIDE
3 - HINGE
4 - ALLEN BOLT

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)

INSIDE HANDLE ACTUATOR


REMOVAL
(1) Remove the handle trim cover. (Fig. 19)
(2) Remove the screws and handle.
(3) Disconnect the latch cable.

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.

Fig. 21 TRIM PANEL


1 - TRIM
2 - INSIDE HANDLE ACTUATOR
3 - TRIM PANEL
4 - CONTROL CABLE
23 - 36 DOORS - SLIDING VA

DOORS - SLIDING
TABLE OF CONTENTS
page page

EXTERIOR HANDLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 40


REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 REAR LATCH STRIKER
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 36 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
INSIDE HANDLE ACTUATOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 41
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 SLIDING DOOR
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
UPPER ROLLER ARM DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 42
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 44
CENTER ROLLER ARM ADJUSTMENTS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 44
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 38 STABILIZER
LOWER ROLLER ARM REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 45
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 38 TRIM PANEL
CENTER TRACK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 46
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 39 DOOR GLASS
LATCH / LOCK CONTROL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 46
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 40
REAR LATCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

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.

Fig. 1 EXTERIOR HANDLE


1 - EXTERIOR HANDLE
2 - CATCH POINTS
3 - BOLT
4 - TRIM CAP
VA DOORS - SLIDING 23 - 37

INSIDE HANDLE ACTUATOR


REMOVAL
(1) Remove the trim plug. (Fig. 2)
(2) Remove screw and remove handle.

Fig. 3 UPPER ROLLER ARM


1 - ROLLER ARM
2 - BOLTS

(2) Remove trim panel if necessary. (Refer to 23 -


Fig. 2 INTERIOR HANDLE BODY/DOORS - SLIDING/TRIM PANEL -
1 - HANDLE REMOVAL)
2 - SCREW
3 - TRIM PLUG
(3) Remove rubber cover.
(4) Using a grease pencil or equivalent, mark the
INSTALLATION horizontal position of the arm at the arrow.
(5) Support door with suitable lifting device.
(1) Install the handle and screw.
(6) Remove bolt and remove roller arm from door.
(2) Tighten screw to 10 N·m (89 in. lbs.).
(7) Remove roller arm from center guide track.
(3) Install trim plug.

UPPER ROLLER ARM


REMOVAL
(1) Using a grease pencil or equivalent, mark posi-
tion of roller arm to aid installation.
(2) Support door with suitable device.
(3) Remove the bolts. (Fig. 3)
(4) Slide roller arm towards rear of vehicle and
remove from back of track.

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.

LOWER ROLLER ARM


Fig. 6 SLIDING DOOR LOWER ROLLER ARM
REMOVAL 1 - SCREWS
(1) Remove trim plugs and screws and remove 2 - ROLLER ARM
stepwell scuff pad. (Fig. 5)
(2) Remove the door screws and remove the roller CENTER TRACK
arm. (Fig. 6)
REMOVAL
(1) Remove center roller arm. (Refer to 23 - BODY/
DOORS - SLIDING/CENTER ROLLER ARM -
REMOVAL)
(2) Remove quarter trim panel. (Refer to 23 -
BODY/INTERIOR/QUARTER TRIM PANEL -
REMOVAL)
(3) Remove the nuts. (Fig. 7)
(4) Remove the front bolts.

Fig. 5 SLIDING DOOR SCUFF PAD


1 - TRIM PLUGS
2 - SCREWS (5)
3 - SCUFF PAD

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)

Fig. 7 SLIDING DOOR CENTER TRACK


1 - NUTS
2 - QUARTER TRIM PANEL
3 - BOLT
4 - BOLT
5 - CENTER TRACK
VA DOORS - SLIDING 23 - 39
CENTER TRACK (Continued)
(5) Remove the screws and remove the center LATCH / LOCK CONTROL
track end piece. (Fig. 8)
(6) Using a heat gun or equivalent, heat track up
REMOVAL
to approximately 60° C (140° F).
(1) Disconnect and isolate battery negative cable.
(7) Remove center track.
(2) Remove trim panel. (Refer to 23 - BODY/
DOORS - SLIDING/TRIM PANEL - REMOVAL)
(3) Disconnect electrical connectors. (Fig. 9)
(4) Remove bolts and remove control assembly.
(Fig. 10)

Fig. 9 ELECTRICAL CONNECTORS


Fig. 8 SLIDING DOOR 1 - CONNECTOR
1 - STOP BUMPER 2 - CONNECTOR
2 - SCREWS (2) 3 - CONNECTOR
3 - SCREWS (2)
4 - LOWER ROLLER ARM
5 - END PIECE
6 - SCREWS (2)

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.

Fig. 11 LOCK ASSEMBLY


1 - LATCH/LOCK CONTROL ASSEMBLY
2 - LOCK ROD
3 - LOCK KNOB
4 - LATCH CONTROL CABLE
5 - ELECTRICAL CONNECTOR
6 - ELECTRICAL CONNECTOR
7 - INTERIOR HANDLE ACTUATOR
8 - STOP BUMPER
9 - TRIM PANEL

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)

Fig. 13 REAR LATCH


1 - LATCH OPENING
2 - SCREWS
3 - LATCH ASSEMBLY
4 - CONTROL CABLE

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

REAR LATCH STRIKER SLIDING DOOR


REMOVAL REMOVAL
(1) Open door. (1) Disconnect and isolate battery negative cable.
(2) Remove bolts and remove striker. (Fig. 14) (2) Remove the screws and remove the center
track end piece. (Fig. 15)
(3) Remove the screws and remove the stop
bumper.
(4) Remove the screws attaching the lower roller
arm to door.
(5) Support door with a suitable lifting device and
roll off the upper and center tracks towards the rear
of vehicle.

Fig. 14 LATCH STRIKER


1 - STRIKER
2 - BOLTS

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)

Fig. 15 SLIDING DOOR


1 - STOP BUMPER
2 - SCREWS (2)
3 - SCREWS (2)
4 - LOWER ROLLER ARM
5 - END PIECE
6 - SCREWS (2)
23 - 42 DOORS - SLIDING VA
SLIDING DOOR (Continued)

DISASSEMBLY (9) Remove exterior handle (10). (Refer to 23 -


(1) Remove door.(Refer to 23 - BODY/DOORS - BODY/DOORS - SLIDING/EXTERIOR HANDLE -
SLIDING/REAR LATCH STRIKER - REMOVAL) REMOVAL)
(2) Remove inside door handle actuator (7). (Refer (10) Remove center roller arm (20). (Refer to 23 -
to 23 - BODY/DOORS - SLIDING/INSIDE HANDLE BODY/DOORS - SLIDING/LOWER ROLLER ARM -
ACTUATOR - REMOVAL) REMOVAL)
(3) Remove center roller arm cover (23). (Fig. 16) (11) Remove stabilizer wedges (6). (Refer to 23 -
(4) Remove trim panel (24). (Refer to 23 - BODY/ BODY/DOORS - SLIDING/STABILIZER -
DOORS - SLIDING/TRIM PANEL - REMOVAL) REMOVAL)
(5) Remove lock knob (27). (12) Remove upper roller arm (2). (Refer to 23 -
(6) Disconnect lock rod (25) and remove. BODY/DOORS - SLIDING/UPPER ROLLER -
(7) Remove rear latch (22). (Refer to 23 - BODY/ REMOVAL)
DOORS - SLIDING/REAR LATCH - REMOVAL) (13) Remove bolts (28) and remove crash reinforce-
(8) Remove latch/lock control (14). (Refer to 23 - ment (29).
BODY/DOORS - SLIDING/LATCH / LOCK CON-
TROL - REMOVAL)

Fig. 16 SLIDING DOOR ASSEMBLY


1 - SLIDING DOOR 16 - BOLT
2 - UPPER ROLLER ARM 17 - RELEASE CABLE
3 - BOLTS (2) 18 - WASHER
4 - TRIM PLUG 19 - BOLT
5 - BOLTS (2) 20 - CENTER ROLLER ARM
6 - STABILIZER PIN 21 - RUBBER COVER
7 - INSIDE HANDLE ACTUATOR 22 - REAR LATCH
8 - SCREWS 23 - COVER
9 - TRIM PLUG 24 - TRIM PANEL
10 - EXTERIOR HANDLE 25 - CONNECTOR ROD
11 - TRIM PLUG 26 - GROMMET
12 - BOLT (1) 27 - LOCK KNOB
13 - NUT 28 - SCREWS
14 - LATCH/LOCK CONTROL 29 - CRASH REINFORCEMENT
15 - BOLT
VA DOORS - SLIDING 23 - 43
SLIDING DOOR (Continued)

ASSEMBLY (7) Install the latch/lock control (14). (Refer to 23 -


(1) Install the crash reinforcement (29). (Fig. 17) BODY/DOORS - SLIDING/LATCH / LOCK CON-
(2) Install the bolts (28) and tighten to 21 N·m (15 TROL - INSTALLATION)
ft. lbs.). (8) Install the rear latch (22). (Refer to 23 - BODY/
(3) Install upper roller arm (2). (Refer to 23 - DOORS - SLIDING/REAR LATCH - INSTALLATION)
BODY/DOORS - SLIDING/UPPER ROLLER - (9) Install lock rod (25) and connect to latch/lock
INSTALLATION) control.
(4) Install stabilizer wedges (6). (Refer to 23 - (10) Install the lock knob (27).
BODY/DOORS - SLIDING/STABILIZER - INSTAL- (11) Install the trim panel (24). (Refer to 23 -
LATION) BODY/DOORS - SLIDING/TRIM PANEL - INSTAL-
(5) Install center roller arm (20). (Refer to 23 - LATION)
BODY/DOORS - SLIDING/LOWER ROLLER ARM - (12) Install inside handle actuator (7). (Refer to 23
INSTALLATION) - BODY/DOORS - SLIDING/INSIDE HANDLE
(6) Install exterior handle (10). (Refer to 23 - ACTUATOR - INSTALLATION)
BODY/DOORS - SLIDING/EXTERIOR HANDLE - (13) Install the center roller arm cover (23).
INSTALLATION) (14) Install the door. (Refer to 23 - BODY/DOORS
- SLIDING/SLIDING DOOR - INSTALLATION)

Fig. 17 SLIDING DOOR ASSEMBLY


1 - SLIDING DOOR 16 - BOLT
2 - UPPER ROLLER ARM 17 - RELEASE CABLE
3 - BOLTS (2) 18 - WASHER
4 - TRIM PLUG 19 - BOLT
5 - BOLTS (2) 20 - CENTER ROLLER ARM
6 - STABILIZER PIN 21 - RUBBER COVER
7 - INSIDE HANDLE ACTUATOR 22 - REAR LATCH
8 - SCREWS 23 - COVER
9 - TRIM PLUG 24 - TRIM PANEL
10 - EXTERIOR HANDLE 25 - CONNECTOR ROD
11 - TRIM PLUG 26 - GROMMET
12 - BOLT (1) 27 - LOCK KNOB
13 - NUT 28 - SCREWS
14 - LATCH/LOCK CONTROL 29 - CRASH REINFORCEMENT
15 - BOLT
23 - 44 DOORS - SLIDING VA
SLIDING DOOR (Continued)

INSTALLATION (3) Loosen guide wedge screws.


(1) Install the door by inserting the center and
upper rollers into the tracks and sliding the door for- Gaps and Ridge Adjustment
ward to the front of each track. (1) Loosen screw and adjust rear ridge pattern by
(2) Connect the lower roller arm and install the lifting and lowering sliding door at center roller arm.
screws. (Fig. 19)
(3) Tighten the screws to 25 N·m (18 ft. lbs.).
(4) Install door stop and screws.
(5) Tighten the screws to 10 N·m (89 in. lbs.).
(6) Install the center track end piece and install
the screw.
(7) Tighten the screw to 10 N·m (89 in. lbs.).
(8) Check and adjust door if necessary. (Refer to 23
- BODY/DOORS - SLIDING/SLIDING DOOR -
ADJUSTMENTS)
(9) Connect battery negative cable.

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.

Fig. 18 LATCH STRIKER


1 - STRIKER
2 - BOLTS

(2) Check gaps and ridge pattern on door all the


way around. (Refer to 23 - BODY/BODY STRUC-
Fig. 20 UP/DOWN ADJUST
TURE/GAP AND FLUSH - SPECIFICATIONS)
1 - SCREWS (2) UPPER ROLLER ARM
2 - SCREWS (2) LOWER ROLLER ARM
NOTE: It must be possible to move the guide wedge
during the entire adjusting procedure. In order to
(6) Tighten upper and lower roller arm bolts to 25
close the door during adjustment move guide
N·m (18 ft. lbs.).
wedge if necessary.
VA DOORS - SLIDING 23 - 45
SLIDING DOOR (Continued)
(7) Loosen center roller bolt and adjust the front
and rear gaps.
(8) Check rear ridge pattern alignment and
tighten bolt to 45 N·m (33 ft. lbs.).

Flush Adjustment
(1) Loosen upper roller arm screw. (Fig. 21)
(2) Loosen lower roller arm screws.

Fig. 22 SLIDING DOOR STABILIZER


1 - SCREWS
2 - GUIDE WEDGES (2)
3 - SCREWS
4 - RECEIVERS (2)

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

(3) Adjust front of door flushness by altering posi-


tion of top and bottom roller arms.
(4) Tighten upper and lower roller arm adjustment
screws.
(5) Install door striker and hand tighten the bolts.
(6) Adjust door striker in and out to adjust rear
door flushness.
(7) Tighten striker bolts to 25 N·m (18 ft. lbs.).
(Fig. 18)
(8) Loosen stabilizer closing wedge screws. (Fig.
22)
(9) Close sliding door to adjust closing wedge.
(10) Open door and tighten screws to 10 N·m (89
in. lbs.).
Fig. 23 SLIDING DOOR STABILIZER
Door Stop Bumper Adjust 1 - SCREWS
2 - GUIDE WEDGES (2)
(1) Loosen door stop bumper bolts. 3 - SCREWS
(2) Open sliding door and hold tight in end posi- 4 - RECEIVERS (2)
tion.
(3) Hold stop bumper tight against c-pillar and INSTALLATION
tighten bolts to 10 N·m (89 in. lbs.). (1) Install receiver and install screws.
(2) Tighten screws to 10 N·m (89 in. lbs.).
(3) Install wedge and install screws.
(4) Close sliding door to adjust closing wedge.
(5) Open door and tighten screws to 10 N·m (89 in.
lbs.).
23 - 46 DOORS - SLIDING VA

TRIM PANEL DOOR GLASS


REMOVAL REMOVAL
(1) Position an assistant on one side of the door to
Upper receive the glass and weatherstrip seal.
(1) Remove rivets and remove panel. (2) Start at an inside, upper corner. Separate the
seal from the window opening. Push the glass and
Lower seal outward from the window opening. Remove the
(1) Remove the bolts and remove the stop bumper. glass and seal.
(Fig. 24) (3) Clean the window opening.
(2) Remove the inside handle actuator. (Refer to 23
INSTALLATION
- BODY/DOORS - SLIDING/INSIDE HANDLE
(1) Install the weatherstrip seal on the window
ACTUATOR - REMOVAL)
glass. Verify that the glass is seated in the groove
(3) Remove the push pin fasteners and remove the
around the edge of the seal.
trim panel.
(2) Insert an installation cord in the weatherstrip
seal inner groove.
NOTE: Use mineral spirits as a lubricant to aid seal
installation in the window opening.
(3) Position the glass and seal in the window opening.
(4) Pull the installation cord outward and force the
seal lip over the panel flange around the edge of the
opening.
(5) Seat the seal inner lip on the panel flange.
Press against the lip around the edge of the seal.
NOTE: Remove any mineral spirits with a clean
cloth after glass installation.
(6) Verify that the seal is seated in the window
opening (Fig. 25).
(7) Test the window for water leaks. (Refer to 23 -
Fig. 24 LOCK ASSEMBLY
BODY - DIAGNOSIS AND TESTING - WATER LEAKS)
1 - LATCH/LOCK CONTROL ASSEMBLY
2 - LOCK ROD
3 - LOCK KNOB
4 - LATCH CONTROL CABLE
5 - ELECTRICAL CONNECTOR
6 - ELECTRICAL CONNECTOR
7 - INTERIOR HANDLE ACTUATOR
8 - STOP BUMPER
9 - TRIM PANEL

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

FUEL FILL DOOR RADIATOR CROSSMEMBER


REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 47 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 48
GRILLE SIDE VIEW MIRROR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 47 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 48
LICENSE PLATE BRACKET SIDE VIEW MIRROR - GLASS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 47 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 49

FUEL FILL DOOR


REMOVAL
(1) Open passenger compartment door.
(2) Open fuel fill door.
(3) Using a trim stick C-4755 or equivalent, dis-
connect the filler cap tether.
(4) Remove two bolts and remove filler door.

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.

Fig. 3 DRIVERS SIDE MIRROR


1 - ELECTRICAL CONNECTOR
2 - MIRROR
Fig. 2 RADIATOR CROSSMEMBER 3 - EXTERIOR BOLTS
1 - HEAT SHIELD 4 - INNER BOLT
2 - HOOD CABLE 5 - TRIM PLUG
3 - CROSSMEMBER 6 - TAPE
4 - RUBBER MOUNTS
5 - RETAINING CLAMP Passenger Side
(1) Disconnect and isolate battery negative cable.
INSTALLATION (2) Remove trim plug. (Fig. 4)
(1) Connect hood release cable and install cross-
member. NOTE: If the vehicle is not equipped with power
(2) Install crossmember bolts and tighten to 14 mirrors, skip to step 5.
N·m (10 ft. lbs.).
(3) Install rubber mounts and retaining clamps. (3) Separate dust boot from a-pillar.
(4) Install heat shield. (4) Disconnect the electrical connector.
(5) Install headlamps. (Refer to 8 - ELECTRICAL/ (5) Remove bolts and remove mirror.
LAMPS/LIGHTING - EXTERIOR/FRONT LAMP (6) If equipped, pull wire harness through.
UNIT - INSTALLATION)
(6) Install grille. (Refer to 23 - BODY/EXTERIOR/ INSTALLATION
GRILLE - INSTALLATION)
Driver’s Side
(1) If equipped, pull wire harness through door.
SIDE VIEW MIRROR (2) Install mirror and bolts.
(3) Tighten the bolts to 25 N·m (18 ft. lbs.).
REMOVAL
NOTE: If vehicle is not equipped with power mir-
Driver’s Side rors, skip to step 6.
(1) Disconnect and isolate battery negative cable.
(2) Remove trim plug. (Fig. 3) (4) Connect electrical connector and replace tape.
(5) Install trim panel. (Refer to 23 - BODY/DOOR -
NOTE: If the vehicle is not equipped with power FRONT/TRIM PANEL - INSTALLATION)
mirrors, skip to step 5. (6) Install trim plug.
(7) Connect battery negative cable.
(3) Remove trim panel. (Refer to 23 - BODY/DOOR
- FRONT/TRIM PANEL - REMOVAL)
(4) Remove tape, expose electrical connector and
disconnect. (Fig. 3)
(5) Remove bolts and remove mirror.
(6) If equipped, Pull wire harness through.
VA EXTERIOR 23 - 49
SIDE VIEW MIRROR (Continued)

SIDE VIEW MIRROR - GLASS


REMOVAL
(1) Disconnect and isolate battery negative cable.
(2) Press mirror glass in at bottom.
(3) Pull mirror glass up and out of the guides.
(Fig. 5)
(4) Disconnect the electrical connectors, if
equipped.

Fig. 4 PASSENGER SIDE MIRROR


1 - OUTER BOLTS
2 - INNER BOLT
3 - TRIM PLUG
4 - MIRROR
5 - ELECTRICAL CONNECTOR
6 - DUST BOOT

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

(4) Connect the electrical connector.


(5) Connect dust boot to a-pillar.
INSTALLATION
(1) Connect the electrical connectors, if equipped.
(6) Install trim plug.
(2) Push mirror glass down into the guides.
(7) Connect battery negative cable.
(3) Straighten mirror glass.
(4) Connect battery negative cable.
23 - 50 HOOD VA

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

HINGE (5) Remove nuts attaching hinges to hood.


(6) With the aid of a helper, remove hood from
vehicle.
REMOVAL
NOTE: It is not necessary to remove the hood to
replace one or both hinges. The hinges can be
replaced one at a time.

(1) Open hood and support as needed.


(2) Using a grease pencil or equivalent, mark the
position of the hinge on the hood and cowl.
(3) Remove the two hood nuts.
(4) Remove the two cowl bolts and remove hinge.

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

(1) Check hood to fender gap. Refer to the SPECI-


FICATIONS table.
(2) Loosen hinge to cowl bolts and adjust hood side
to side, if necessary.
(3) Tighten bolts to 23 N·m (17 ft. lbs.).
(4) Check hood to fender flushness. Refer to the Fig. 3 HOOD LATCH
SPECIFICATIONS table.
1 - BOLTS
(5) Loosen hinge to hood nuts and adjust hood up 2 - LATCH CABLE
and down, if necessary. 3 - LATCH
(6) Tighten nuts to 23 N·m (17 ft. lbs.).
(7) Loosen safety latch bolts. (Fig. 2) INSTALLATION
(1) Connect latch cable and install latch.
(2) Install the bolts and tighten.

LATCH RELEASE CABLE


REMOVAL
(1) Remove the release handle screws and release
handle.
(2) Disconnect the cable from the handle.
(3) Remove the latch. (Refer to 23 - BODY/HOOD/
LATCH - REMOVAL)
(4) Route cable through cowl panel and remove
from engine compartment.

Fig. 2 SAFETY LATCH INSTALLATION


1 - SAFETY LATCH
(1) Route cable through engine compartment and
2 - BOLTS into passenger compartment as necessary.
(2) Install latch. (Refer to 23 - BODY/HOOD/
(8) Adjust latch to align with hood latch, if neces- LATCH - INSTALLATION)
sary. (3) Connect cable to release handle.
(9) Tighten safety latch bolts. (4) Install release handle and install the screws.
(10) Loosen safety latch striker pin lock nut and
adjust striker pin up and down to adjust front of
hood to fender flushness. Refer to the SPECIFICA-
TIONS table.
(11) Tighten lock nut fully.
(12) Adjust hood slam bumpers up or down if nec-
essary.
23 - 52 HOOD VA

LATCH RELEASE HANDLE


REMOVAL
(1) Remove the screws and remove the release
handle.
(2) Disconnect the cable from handle.

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)

Fig. 5 Washer Reservoir Mounting


1 - RIGHT INNER FENDER
2 - STUD NUT
3 - DASH PANEL
4 - RIGHT FRONT WHEEL HOUSE
5 - GROMMET (2)
6 - HOOD PROP

(3) Remove the bolts and remove the latch. (Fig. 6)

Fig. 4 Washer Reservoir Remove/Install


1 - RIGHT INNER FENDER
2 - WASHER RESERVOIR
3 - NUT & WASHER
4 - ROUTING CLIP

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 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 56


REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 INSTRUMENT PANEL ASSEMBLY
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 54 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
ACCESSORY SWITCH BEZEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 61
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 TOP COVER - CLUSTER
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 54 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
INSTRUMENT PANEL CENTER BEZEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 62
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 TOP COVER - TRAY
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 55 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
ASH RECEIVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 64
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 TOP COVER
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 55 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
CUP HOLDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 65
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 STEERING COLUMN OPENING COVER
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 56 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
GLOVE BOX INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 66
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

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.

(1) Connect the electrical connectors.


(2) Position cluster bezel into place and seat clips
fully.
(3) Install screws.
(4) Connect battery negative cable.
Fig. 2 ACCESSORY SWITCH BEZEL
1 - SHIFT LEVER ASSEMBLY FRAME TRIM
ACCESSORY SWITCH BEZEL 2 - STORAGE COMPARTMENT
3 - ACCESSORY SWITCH BEZEL
4 - SCREW
REMOVAL 5 - PLUG CONNECTIONS
6 - ASHTRAY
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE INSTALLATION
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU- WARNING: ON VEHICLES EQUIPPED WITH AIR-
MENT PANEL COMPONENT DIAGNOSIS OR SER- BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
VICE. DISCONNECT AND ISOLATE THE BATTERY ATTEMPTING ANY STEERING WHEEL, STEERING
NEGATIVE (GROUND) CABLE, THEN WAIT TWO COLUMN, SEAT BELT TENSIONER, OR INSTRU-
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR MENT PANEL COMPONENT DIAGNOSIS OR SER-
TO DISCHARGE BEFORE PERFORMING FURTHER VICE. DISCONNECT AND ISOLATE THE BATTERY
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE NEGATIVE (GROUND) CABLE, THEN WAIT TWO
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
TO TAKE THE PROPER PRECAUTIONS COULD TO DISCHARGE BEFORE PERFORMING FURTHER
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
AND POSSIBLE PERSONAL INJURY. WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
(1) Move selector lever to position 9D9. RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
(2) Using a trim stick C-4755 or equivalent, AND POSSIBLE PERSONAL INJURY.
remove shift lever frame trim. (Fig. 2)
(3) Using a trim stick C-4755 or equivalent, (1) Position bezel and seat clips fully.
remove storage compartment. (2) Install screw.
(4) Remove ashtray. (3) Install ashtray.
(5) Remove screw and using a trim stick C-4755 or (4) Install storage compartment.
equivalent, remove bezel. (5) Install shift lever trim.
VA INSTRUMENT PANEL 23 - 55

INSTRUMENT PANEL CENTER INSTALLATION


BEZEL WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
REMOVAL ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, SEAT BELT TENSIONER, OR INSTRU-
WARNING: ON VEHICLES EQUIPPED WITH AIR- MENT PANEL COMPONENT DIAGNOSIS OR SER-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE VICE. DISCONNECT AND ISOLATE THE BATTERY
ATTEMPTING ANY STEERING WHEEL, STEERING NEGATIVE (GROUND) CABLE, THEN WAIT TWO
COLUMN, SEAT BELT TENSIONER, OR INSTRU- MINUTES FOR THE AIRBAG SYSTEM CAPACITOR
MENT PANEL COMPONENT DIAGNOSIS OR SER- TO DISCHARGE BEFORE PERFORMING FURTHER
VICE. DISCONNECT AND ISOLATE THE BATTERY DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
NEGATIVE (GROUND) CABLE, THEN WAIT TWO WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO TAKE THE PROPER PRECAUTIONS COULD
TO DISCHARGE BEFORE PERFORMING FURTHER RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE AND POSSIBLE PERSONAL INJURY.
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD (1) Install the bezel and install the screws.
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT (2) Install the accessory switch bezel. (Refer to 23 -
AND POSSIBLE PERSONAL INJURY. BODY/INSTRUMENT PANEL/ACCESSORY
SWITCH BEZEL - INSTALLATION)
(1) Remove accessory switch bezel. (Refer to 23 -
BODY/INSTRUMENT PANEL/ACCESSORY
SWITCH BEZEL - REMOVAL) ASH RECEIVER
(2) Remove the screws and using a trim stick
C-4755 or equivalent, remove bezel. REMOVAL
(1) Disconnect and isolate battery negative cable.
(2) Open ash receiver and remove two screws.
(3) Pull out ash receiver and disconnect electrical
connector.
(4) Remove ash receiver.

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.

(1) Install bottom section and install the bolts.


(2) Install vent hose.
(3) Install top section and install the screws.
Fig. 4 CUP HOLDER
(4) Install rubber mats.
1 - SCREWS
2 - CUPHOLDER

(3) Remove vent hose (1). (Fig. 5) GLOVE BOX


(4) Unscrew bolts (2) and remove cup holder bot-
tom section (3) from cab floor. REMOVAL
(1) Open glove box and remove the screws. (Fig. 6)
(2) Remove glove box and disconnect electrical con-
nector.

Fig. 5 CUP HOLDER BOTTOM


1 - VENT HOSE
2 - BOLTS (4)
3 - BOTTOM SECTION

Fig. 6 GLOVE BOX


1 - SCREWS (3)
2 - GLOVE BOX DOOR

INSTALLATION
(1) Connect electrical connector and install glove box.
(2) Install three screws.
VA INSTRUMENT PANEL 23 - 57

INSTRUMENT PANEL (6) Remove passenger airbag. (Refer to 8 - ELEC-


TRICAL/RESTRAINTS/PASSENGER AIRBAG -
ASSEMBLY REMOVAL)
(7) Remove right and left speakers. (Refer to 8 -
REMOVAL ELECTRICAL/AUDIO/SPEAKER - REMOVAL)
(8) Remove center bezel. (Refer to 23 - BODY/IN-
WARNING: ON VEHICLES EQUIPPED WITH AIR- STRUMENT PANEL/INSTRUMENT PANEL CEN-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE TER BEZEL - REMOVAL)
ATTEMPTING ANY STEERING WHEEL, STEERING (9) Remove air conditioning push-button control
COLUMN, SEAT BELT TENSIONER, OR INSTRU- module. (Fig. 7)
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-
BER GLOVES, EYE PROTECTION, AND A LONG-
SLEEVED SHIRT SHOULD BE WORN. THERE MAY
BE DEPOSITS ON THE AIRBAG UNIT AND OTHER
INTERIOR SURFACES. IN LARGE DOSES, THESE
DEPOSITS MAY CAUSE IRRITATION TO THE SKIN
AND EYES.
• USE EXTREME CARE TO PREVENT ANY FOR-
EIGN MATERIAL FROM ENTERING THE PASSEN-
GER AIRBAG, OR BECOMING ENTRAPPED
BETWEEN THE PASSENGER AIRBAG CUSHION Fig. 7 HVAC CONTROL MODULE
AND THE PASSENGER AIRBAG DOOR. FAILURE TO 1 - CONTROL CABLES
2 - ELECTRICAL CONNECTORS
OBSERVE THIS WARNING COULD RESULT IN 3 - MODULE
OCCUPANT INJURIES UPON AIRBAG DEPLOY- 4 - SCREWS
MENT.
• THE PASSENGER AIRBAG DOOR MUST (10) Twist cover lock 1/4 turn and remove Power
NEVER BE PAINTED. REPLACEMENT PASSENGER Distribution Center (PDC) cover. (Fig. 8)
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-
URE TO OBSERVE THIS WARNING COULD RESULT
IN OCCUPANT INJURIES UPON AIRBAG DEPLOY-
MENT.

(1) Disconnect and isolate the battery negative


cable.
(2) Remove radio. (Refer to 8 - ELECTRICAL/AU-
DIO/RADIO - REMOVAL)
(3) Remove glove compartment. (Refer to 23 -
BODY/INSTRUMENT PANEL/GLOVE BOX -
REMOVAL)
(4) Remove cup holder. (Refer to 23 - BODY/IN-
STRUMENT PANEL/CUP HOLDER - REMOVAL) Fig. 8 POWER DISTRIBUTION CENTER COVER
(5) Remove instrument cluster. (Refer to 8 - ELEC-
1 - COVER LOCK
TRICAL/INSTRUMENT CLUSTER - REMOVAL) 2 - COVER
23 - 58 INSTRUMENT PANEL VA
INSTRUMENT PANEL ASSEMBLY (Continued)
(11) Remove nut and screws and remove steering (13) Disconnect PDC electrical connectors and
column shroud. (Fig. 9) remove. (Fig. 11)

Fig. 9 STEERING COLUMN SHROUD


1 - SHROUD
2 - SCREWS (2)
3 - NUT Fig. 11 POWER DISTRIBUTION CENTER
CONNECTORS
(12) Remove PDC bolt, nut and nut for ground
1 - ELECTRICAL CONNECTORS (5)
wire. (Fig. 10) 2 - POWER DISTRIBUTION CENTER

(14) Remove screws and remove passenger side air


nozzle cover. (Fig. 12)

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)

Fig. 13 SIDE COVERS & NOZZLES


1 - LEFT SIDE COVER
2 - RIGHT SIDE COVER
3 - BRACKET
4 - OUTER AIR NOZZLE
5 - INNER AIR NOZZLE
6 - INNER AIR NOZZLE
7 - OUTER AIR NOZZLE Fig. 15 INSTRUMENT PANEL TOP COVER
1 - SPEAKER COVERS (2)
(16) Remove left outer and inner air nozzles. 2 - CENTER NOZZLE COVER
(17) Remove right side cover. 3 - INSTRUMENT PANEL TOP COVER
(18) Remove right outer and inner air nozzles. 4 - TOP SCREWS (6)
5 - BRACKET/SCREW
(19) Remove protective matting from cluster loca- 6 - LOWER SCREWS (2)
tion. (Fig. 14)
(21) Remove vent hose. (Fig. 16)

Fig. 14 PROTECTIVE MAT


1 - CLUSTER OPENING Fig. 16 CENTER VENT HOSE
2 - PROTECTIVE MAT
1 - VENT HOSE
2 - CENTER STACK
23 - 60 INSTRUMENT PANEL VA
INSTRUMENT PANEL ASSEMBLY (Continued)
(22) Remove brake pedal spring. (Fig. 17)

Fig. 19 STEERING COLUMN BOLTS


Fig. 17 BRAKE PEDAL SPRING 1 - BOLTS (2)
2 - STEERING COLUMN
1 - STEERING COLUMN
2 - SPRING

(23) Remove ignition transponder. (Fig. 18)

Fig. 20 INSTRUMENT PANEL FASTENERS


1 - UPPER SCREWS (6)
2 - INSTRUMENT PANEL
Fig. 18 IGNITION TRANSPONDER 3 - RIGHT SCREW
4 - CENTER SCREWS (2)
1 - COLUMN LOCK 5 - LEFT SCREWS (3)
2 - IGNITION TRANSPONDER

CAUTION: The position of the steering gear must


not be altered again for the entire duration of the
work procedure.

(24) Turn the steering wheel and lock the steering


wheel in the straight ahead position.
(25) Remove steering column support bolts. (Fig.
19)
(26) Remove the screws and remove instrument
panel. (Fig. 20)
VA INSTRUMENT PANEL 23 - 61
INSTRUMENT PANEL ASSEMBLY (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.
• 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) Remove the screws and using a trim stick


C-4755 or equivalent, remove the cover. (Fig. 23)
VA INSTRUMENT PANEL 23 - 63

TOP COVER - TRAY DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE


WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
REMOVAL
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
WARNING: ON VEHICLES EQUIPPED WITH AIR- AND POSSIBLE PERSONAL INJURY.
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE (1) Using a trim stick C-4755 or equivalent,
ATTEMPTING ANY STEERING WHEEL, STEERING remove the tray. (Fig. 24)
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

Fig. 24 Passenger Airbag Remove/Install


1 - TRAY 5 - CONNECTOR
2 - SCREW (2) 6 - PASSENGER AIRBAG
3 - UPPER CLIP (2) 7 - SCREW (3)
4 - LOWER CLIP (2)
23 - 64 INSTRUMENT PANEL VA
TOP COVER - TRAY (Continued)

INSTALLATION GER AIRBAG, OR BECOMING ENTRAPPED


BETWEEN THE PASSENGER AIRBAG CUSHION
WARNING: ON VEHICLES EQUIPPED WITH AIR- AND THE PASSENGER AIRBAG DOOR. FAILURE TO
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE OBSERVE THIS WARNING COULD RESULT IN
ATTEMPTING ANY STEERING WHEEL, STEERING OCCUPANT INJURIES UPON AIRBAG DEPLOY-
COLUMN, SEAT BELT TENSIONER, OR INSTRU- MENT.
MENT PANEL COMPONENT DIAGNOSIS OR SER- • THE PASSENGER AIRBAG DOOR MUST
VICE. DISCONNECT AND ISOLATE THE BATTERY NEVER BE PAINTED. REPLACEMENT PASSENGER
NEGATIVE (GROUND) CABLE, THEN WAIT TWO AIRBAGS ARE SERVICED WITH DOORS IN THE
MINUTES FOR THE AIRBAG SYSTEM CAPACITOR ORIGINAL COLORS. PAINT MAY CHANGE THE WAY
TO DISCHARGE BEFORE PERFORMING FURTHER IN WHICH THE MATERIAL OF THE AIRBAG DOOR
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE RESPONDS TO AN AIRBAG DEPLOYMENT. FAIL-
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE URE TO OBSERVE THIS WARNING COULD RESULT
TO TAKE THE PROPER PRECAUTIONS COULD IN OCCUPANT INJURIES UPON AIRBAG DEPLOY-
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT MENT.
AND POSSIBLE PERSONAL INJURY. (1) Disconnect and isolate the battery negative
cable.
(1) Position the tray and seat the clips fully. (2) Remove radio. (Refer to 8 - ELECTRICAL/AU-
DIO/RADIO - REMOVAL)
(3) Remove passenger airbag. (Refer to 8 - ELEC-
TOP COVER TRICAL/RESTRAINTS/PASSENGER AIRBAG -
REMOVAL)
REMOVAL (4) Remove screws and remove passenger side air
nozzle cover. (Fig. 25)
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-
BER GLOVES, EYE PROTECTION, AND A LONG-
SLEEVED SHIRT SHOULD BE WORN. THERE MAY
BE DEPOSITS ON THE AIRBAG UNIT AND OTHER Fig. 25 PASSENGER SIDE AIR NOZZLE COVER
INTERIOR SURFACES. IN LARGE DOSES, THESE 1 - FRONT SCREWS (2)
2 - BRACKET
DEPOSITS MAY CAUSE IRRITATION TO THE SKIN 3 - BRACKET SCREWS
AND EYES. 4 - NOZZLE COVER
• USE EXTREME CARE TO PREVENT ANY FOR- 5 - INSTRUMENT PANEL
EIGN MATERIAL FROM ENTERING THE PASSEN-
VA INSTRUMENT PANEL 23 - 65
TOP COVER (Continued)
(5) Remove accessory switch bezel. (Refer to 23 - RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
BODY/INSTRUMENT PANEL/ACCESSORY AND POSSIBLE PERSONAL INJURY.
SWITCH BEZEL - REMOVAL) • WHEN REMOVING A DEPLOYED AIRBAG, RUB-
(6) Remove a-pillar trim. (Refer to 23 - BODY/IN- BER GLOVES, EYE PROTECTION, AND A LONG-
TERIOR/A-PILLAR TRIM - REMOVAL) SLEEVED SHIRT SHOULD BE WORN. THERE MAY
(7) Remove speaker covers. (Fig. 26) BE DEPOSITS ON THE AIRBAG UNIT AND OTHER
(8) Remove screw and bracket. INTERIOR SURFACES. IN LARGE DOSES, THESE
(9) Remove lower screws. DEPOSITS MAY CAUSE IRRITATION TO THE SKIN
(10) Remove upper screws. AND EYES.
(11) Pull top cover toward rear and remove. • 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-
URE TO OBSERVE THIS WARNING COULD RESULT
IN OCCUPANT INJURIES UPON AIRBAG DEPLOY-
MENT.
(1) Position top cover and slide toward front of
vehicle.

NOTE: Observe cable routing for radio: The leads


should not be located above the air duct.

(2) Install upper and lower screws.


(3) Install screw and bracket.
(4) Position speaker covers and seat fully.
(5) Install a-pillar trim. (Refer to 23 - BODY/IN-
Fig. 26 INSTRUMENT PANEL TOP COVER TERIOR/A-PILLAR TRIM - INSTALLATION)
1 - SPEAKER COVERS (2) (6) Install accessory switch bezel. (Refer to 23 -
2 - CENTER NOZZLE COVER
3 - INSTRUMENT PANEL TOP COVER
BODY/INSTRUMENT PANEL/ACCESSORY
4 - TOP SCREWS (6) SWITCH BEZEL - INSTALLATION)
5 - BRACKET/SCREW (7) Install passenger side air nozzle cover and
6 - LOWER SCREWS (2)
bracket and install the screws.
(8) Install passenger airbag. (Refer to 8 - ELEC-
INSTALLATION TRICAL/RESTRAINTS/PASSENGER AIRBAG -
INSTALLATION)
WARNING: ON VEHICLES EQUIPPED WITH AIR-
(9) Install radio. (Refer to 8 - ELECTRICAL/AU-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
DIO/RADIO - INSTALLATION)
ATTEMPTING ANY STEERING WHEEL, STEERING
(10) Connect battery negative cable.
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
23 - 66 INSTRUMENT PANEL VA

STEERING COLUMN OPENING


COVER
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 Fig. 28 STEERING COLUMN SHROUD
TO TAKE THE PROPER PRECAUTIONS COULD
1 - SHROUD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT 2 - SCREWS (2)
AND POSSIBLE PERSONAL INJURY. 3 - NUT

(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.

(1) Install steering column shroud and install the


two screws and one nut.
(2) Install Power Distribution Center cover and
twist lock 1/4 turn to secure in place.
Fig. 27 ELECTRICAL CENTER COVER
1 - COVER LOCK
2 - COVER
VA INTERIOR 23 - 67

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)

Fig. 1 A-PILLAR TRIM


1 - A-PILLAR
2 - TRIM PANEL
23 - 68 INTERIOR VA
A-PILLAR TRIM (Continued)
(3) Remove the four screws and remove the foam
trim support. (Fig. 2)

Fig. 3 ASSIST HANDLE


1 - SCREWS (2)
2 - ASSIST HANDLE

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.

Fig. 4 Front Seat Belt Lower Anchor


1 - FRONT SEAT BELT
2 - COVER AND/OR SCREW
VA INTERIOR 23 - 69
B-PILLAR TRIM (Continued)

BULKHEAD TRIM PANEL


REMOVAL
(1) Remove the rivets and remove the lower panel.
(Fig. 7)
(2) Remove the rivets and remove the upper panel.

Fig. 5 B-PILLAR TRIM


1 - FRONT DOOR WEATHERSTRIP
2 - B-PILLAR
3 - B-PILLAR TRIM Fig. 7 BULKHEAD TRIM PANEL
1 - RIVETS
2 - UPPER PANEL
3 - PANEL GLASS
4 - LOWER PANEL

INSTALLATION
(1) Install the upper panel and replace rivets.
(2) Install the lower panel and replace rivets.

CARPETS AND FLOOR MATS


REMOVAL
Cargo/Passenger Van - Front
(1) Remove the stepwell scuff pads. (Refer to 23 -
BODY/INTERIOR/STEPWELL SCUFF PADS -
Fig. 6 B-PILLAR TRIM MOUNTING CLIPS REMOVAL)
1 - RETAINING CLIPS (5) (2) Remove the three bolts and tray behind drivers
2 - B-PILLAR TRIM seat.
(3) Remove cup holder. (Refer to 23 - BODY/IN-
INSTALLATION STRUMENT PANEL/CUP HOLDER - REMOVAL)
(1) Route the seat belt through the trim and (4) Remove the jack storage cover.
mount the trim panel. (5) Remove carpet/mat.
(2) Seat the mounting clips fully.
(3) Position the door opening weatherstrip back Passenger Van - Rear
along the mounting flange. (1) Remove seats. (Refer to 23 - BODY/SEATS/
(4) Install the seat belt and mounting bolt. SEAT - REAR - REMOVAL)
(5) Tighten the bolt to 35 N·m (26 ft. lbs.). (2) Remove the screws and retaining strips.
(3) Remove the seat striker assemblies.
(4) Remove carpet/mat.
23 - 70 INTERIOR VA
CARPETS AND FLOOR MATS (Continued)
Cargo Van - Rear HEADLINER
(1) Remove the screws and retaining strips.
(2) Remove carpet/mat. REMOVAL
INSTALLATION Cab Section
(1) Remove the a-pillar trim. (Refer to 23 - BODY/
Cargo/Passenger Van - Front INTERIOR/A-PILLAR TRIM - REMOVAL)
(1) Position carpet/mat in vehicle. (2) Remove the sun visors. (Refer to 23 - BODY/
(2) Install the jack storage cover. INTERIOR/SUN VISOR - REMOVAL)
(3) Install the cup holder. (Refer to 23 - BODY/IN- (3) Remove the b-pillar trim. (Refer to 23 - BODY/
STRUMENT PANEL/CUP HOLDER - INSTALLA- INTERIOR/B-PILLAR TRIM - REMOVAL)
TION) (4) Remove the assist handle. (Refer to 23 - BODY/
(4) Install the tray behind the driver’s seat and INTERIOR/ASSIST HANDLE - REMOVAL)
install the three bolts. (5) Remove the dome light. (Refer to 8 - ELECTRI-
(5) Install the stepwell scuff pads. (Refer to 23 - CAL/LAMPS/LIGHTING - INTERIOR/CARGO
BODY/INTERIOR/STEPWELL SCUFF PADS - LAMP UNIT - REMOVAL)
INSTALLATION) (6) Carefully separate the headliner and remove.

Passenger Van - Rear Number 2 Section


(1) Position carpet/mat in vehicle. (1) Disconnect and isolate battery negative cable.
(2) Install the seat striker assemblies. (2) Remove the second and third row seats. (Refer
(3) Install the retaining strips and screws. to 23 - BODY/SEATS/SEAT - REAR - REMOVAL)
(4) Install the seats. (Refer to 23 - BODY/SEATS/
SEAT - INSTALLATION) NOTE: If vehicle is not equipped with rear air con-
ditioning unit, skip to step 8.
Cargo Van - Rear
(1) Position carpet/mat in vehicle. (3) Remove the push pin fasteners and remove the
(2) Install the retaining strips and screws. rear air front duct cover.
(4) Disconnect the electrical connector at front of
cover.
COWL TRIM (5) Remove the push pin fasteners and remove the
rear air middle duct cover.
REMOVAL (6) Disconnect the electrical connector.
(1) Position door weatherstrip aside. (7) Remove the three push-pins and three screws
(2) Remove the jack storage cover, if necessary. and remove the rear air cover.
(3) Position aside carpet/mat, if necessary. (8) Remove the duct work.
(4) Using a trim stick C-4755 or equivalent, (9) Release clips at front and rear of headliner and
remove the cowl trim panel. remove.

INSTALLATION Number 3 Section


(1) Position the cowl trim panel and seat the clips (1) Disconnect and isolate battery negative cable.
fully. (2) Remove the third and fourth row seats. (Refer
(2) Install the jack storage cover, if necessary. to 23 - BODY/SEATS/SEAT - REAR - REMOVAL)
(3) Position the carpet/mat back.
(4) Position the door weatherstrips back. NOTE: If vehicle is not equipped with rear air con-
ditioning unit, skip to step 8.

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.

INSTALLATION STEPWELL SCUFF PADS


INSTALLATION
(1) Install the support bracket if necessary. (Refer
REMOVAL
to 23 - BODY/INTERIOR/REAR VIEW MIRROR - (1) Remove screws and remove seat bracket if nec-
INSTALLATION - SUPPORT BRACKET) essary.
(2) Slide mirror onto support bracket fully. (2) Remove trim plugs and screws. (Fig. 8) and
(Fig. 9)
(3) Remove stepwell scuffs.
INSTALLATION - REAR VIEW MIRROR
SUPPORT BRACKET
(1) Mark the position for the mirror bracket on the
outside of the windshield glass with a wax pencil.
(2) Clean the bracket contact area on the glass.
Use a mild powdered cleanser on a cloth saturated
with isopropyl (rubbing) alcohol. Finally, clean the
glass with a paper towel dampened with alcohol.
(3) Sand the surface on the support bracket with
fine grit-sandpaper. Wipe the bracket surface clean
with a paper towel.
(4) Apply accelerator to the surface on the bracket
according to the following instructions:
(a) Crush the vial to saturate the felt applicator.
(b) Remove the paper sleeve.
(c) Apply accelerator to the contact surface on
the bracket.
(d) Allow the accelerator to dry for five minutes. Fig. 8 STEPWELL SCUFF PADS
(e) Do not touch the bracket contact surface 1 - TRIM PLUGS
2 - STEPWELL
after the accelerator has been applied.
VA INTERIOR 23 - 73
STEPWELL SCUFF PADS (Continued)

SUN VISOR
REMOVAL
(1) Remove the support screws and remove the
visor. (Fig. 10)

Fig. 9 SLIDING DOOR SCUFF PAD


1 - TRIM PLUGS
2 - SCREWS (5)
3 - SCUFF PAD

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

PAINT STANDARD PROCEDURE - PAINT TOUCH-UP . 75


SPECIFICATIONS - PAINT CODES . . . . . . . . . . 74 FINESSE SANDING/BUFFING & POLISH
BASECOAT/CLEARCOAT FINISH DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 75
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 74
PAINT TOUCH-UP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 74

PAINT tion (E-coat), anti-chip primer, basecoat, and


clearcoat steps.
On most vehicles a two-part paint application
SPECIFICATIONS - PAINT CODES
(basecoat/clearcoat) is used. Color paint that is
EXTERIOR COLORS
applied to primer is called basecoat. The clear coat
protects the basecoat from ultraviolet light and pro-
EXTERIOR COLOR DAIMLERCHRYSLER vides a durable high-gloss finish.
CODE
Steel Blue MB 5389 CAUTION: Do not use abrasive chemicals or com-
pounds on painted surfaces. Damage to finish can
Brilliant Blue MB 5362
result.
Orchid Green MB 6464 Do not use harsh alkaline based cleaning solvents
Flame Red MB 3534 on painted surfaces. Damage to finish or color can
result.
Arctic White MB 9147
Black Blue MB 7103
Calcite Yellow MB 1234
PAINT TOUCH-UP
Piedmont Red MB 3636
Hycanith Blue MB 5376 DESCRIPTION
Black Gray MB 7103 When a painted metal surface has been scratched
Stone Gray MB 7160 or chipped, it should be touched-up as soon as possi-
ble to avoid corrosion. For best results, use MOPARt
Silver Gray MB 7708 Scratch Filler/Primer, Touch-Up Paints and Clear Top
Coat.
BASECOAT/CLEARCOAT WARNING: USE AN OSHA APPROVED RESPIRATOR
FINISH AND SAFETY GLASSES WHEN SPRAYING PAINT
OR SOLVENTS IN A CONFINED AREA. PERSONAL
DESCRIPTION INJURY CAN RESULT.
The original equipment finish is a multi step pro-
cess that involves cleaning, applying electro de-posi-
VA PAINT 23 - 75
PAINT TOUCH-UP (Continued)

STANDARD PROCEDURE - PAINT TOUCH-UP ING SOLVENTS. PERSONAL INJURY CAN


(1) Scrape loose paint and corrosion from inside RESULT.AVOID PROLONGED SKIN CONTACT WITH
scratch or chip. PETROLEUM OR ALCOHOL – BASED CLEANING
(2) Clean affected area with MOPARt Tar/Road SOLVENTS. PERSONAL INJURY CAN RESULT.
Oil Remover or equivalent, and allow to dry.
(3) Fill the inside of the scratch or chip with a coat
of filler/primer. Do not overlap primer onto good sur-
FINESSE SANDING/BUFFING &
face finish. The applicator brush should be wet POLISH
enough to puddle-fill the scratch or chip without run-
ning. Do not stroke brush applicator on body surface. DESCRIPTION
Allow the filler/primer to dry hard.
(4) Cover the filler/primer with color touch-up CAUTION: Do not remove more than .5 mils of
paint. Do not overlap touch-up color onto the original clearcoat finish, if equipped. Basecoat paint must
color coat around the scratch or chip. Butt the new retain clearcoat for durability.
color to the original color, if possible. Do not stroke Use a Paint Thickness Gauge #PR-ETG-2X or equiv-
applicator brush on body surface. Allow touch-up alent to determine film thickness before and after
paint to dry hard. the repair.
(5) On vehicles without clearcoat, the touch-up
color can be lightly finesse sanded (1500 grit) and Minor acid etching, orange peel, or smudging in
polished with rubbing compound. clearcoat or single-stage finishes can be reduced with
(6) On vehicles with clearcoat, apply clear top coat light finesse sanding, hand buffing, and polishing. If
to touch-up paint with the same technique as the finish has been finesse sanded in the past,
described in Step 4. Allow clear top coat to dry hard. it cannot be repeated. Finesse sanding opera-
If desired, Step 5 can be performed on clear top coat. tion should be performed by a trained automo-
tive paint technician.
WARNING: AVOID PROLONGED SKIN CONTACT
WITH PETROLEUM OR ALCOHOL – BASED CLEAN-
23 - 76 SEATS VA

SEATS

TABLE OF CONTENTS
page page

ARMREST SEAT ADJUSTERS - FRONT


REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 76 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 78
HEADREST SEAT - REAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 76 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 79
SEAT - FRONT REAR SEAT BACK SHIELD
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 77 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 79
SEAT BACK - FRONT SEAT BACK CUSHION/COVER - REAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 77 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 80
SEAT CUSHION - FRONT SEAT CUSHION/COVER - REAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 78 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 80

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.

Fig. 3 FRONT SEAT BACK


1 - SEAT BACK
2 - STOP BOLT
3 - LUMBAR SUPPORT HOSE
4 - GUIDE TAB
5 - RELEASE LEVER
6 - SEAT BACK BOLTS (2)

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

SEAT CUSHION - FRONT INSTALLATION


(1) Connect seat cushion electrical connectors, if
REMOVAL equipped.
(1) Disconnect and isolate battery negative cable. (2) Place seat cushion onto mounting points.
(2) Move seat to the foremost position. (3) On comfort seat equipped vehicles, slide seat
(3) On standard cushion equipped vehicles, remove cushion to the rear until the arresting mechanism
the front two screws. (Fig. 4) latches audibly.
(4) On comfort seat equipped vehicles, operate the (4) On standard cushion equipped vehicles, install
front release lever. (Fig. 5) the front two screws.
(5) Slide seat cushion forward and lift off the (5) Connect battery negative cable.
mounting points.
(6) Disconnect the electrical connectors, if
equipped.
SEAT ADJUSTERS - FRONT
REMOVAL
(1) Remove the seat. (Refer to 23 - BODY/SEATS/
SEAT - FRONT - REMOVAL)
(2) Remove the seat back. (Refer to 23 - BODY/
SEATS/SEAT BACK - FRONT - REMOVAL)
(3) Remove the seat cushion. (Refer to 23 - BODY/
SEATS/SEAT CUSHION - FRONT - REMOVAL)
(4) Remove the four bolts attaching adjust to seat
track.

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)

Fig. 5 COMFORT SEAT CUSHION


1 - SEAT CUSHION
2 - MOUNTING POINTS
3 - RELEASE LEVER
VA SEATS 23 - 79

SEAT - REAR INSTALLATION


(1) With seat facing forward, insert mounting legs
REMOVAL into the respective mounting cups.
(1) Turn all release levers on the legs of the appro- (2) Slide seat forwards with some force as far as it
priate rear seat up. (Fig. 6) and (Fig. 7) will go, until the release levers are heard to engage
(2) Lift seat up and out of the seat mounting cups. and all release levers are parallel to the vehicle floor.

REAR SEAT BACK SHIELD


REMOVAL
(1) Remove the screws and remove the panel. (Fig.
8)

Fig. 6 THREE PASSENGER BENCH


1 - RELEASE LEVERS
2 - MOUNTING LEGS
3 - RETAINING BOLT
4 - RETAINING BOLT
5 - MOUNTING CUP
6 - MOUNTING LEG

Fig. 8 REAR SEAT


1 - SCREWS (4)
2 - SCREWS (6)
3 - PANEL

INSTALLATION
(1) Install the panel and install the screws.

Fig. 7 TWO PASSENGER BENCH


1 - RESTRAINT CABLE
2 - HOOK
3 - RELEASE LEVERS
4 - RETAINING BOLT
5 - MOUNTING CUP
6 - MOUNTING LEGS
23 - 80 SEATS VA

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

BACKLITE - BULKHEAD TRIM PANEL WINDSHIELD


REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 WARNING
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 81 WINDSHIELD SAFETY PRECAUTIONS . . . . . 82
QUARTER WINDOW REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 83
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 81

BACKLITE - BULKHEAD TRIM


PANEL
REMOVAL
(1) Position an assistant opposite side of the bulk-
head trim panel to receive the glass and weatherstrip
seal.
(2) Start at an upper corner and separate the seal
from the window opening. Push the glass and seal
outward from the window opening. Remove the glass
and seal.
(3) Remove seal from glass if necessary.
(4) Clean the window 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 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.

CAUTION: Protect all painted and trimmed surfaces


from coming in contact with urethane or primers.
Be careful not to damage painted surfaces when
removing moldings or cutting urethane around
windshield.
Fig. 2 Glass & Weatherstrip Seal Installation
1 - BODY PANEL
2 - WEATHERSTRIP SEAL REMOVAL
3 - INSTALLATION CORD (1) Remove wiper arms. (Refer to 8 - ELECTRI-
4 - WINDOW OPENING CAL/WIPERS/WASHERS/WIPER ARMS -
REMOVAL)
WINDSHIELD (2) Remove headliner. (Refer to 23 - BODY/INTE-
RIOR/HEADLINER - REMOVAL)
(3) Remove rear view mirror. (Refer to 23 - BODY/
WARNING INTERIOR/REAR VIEW MIRROR - REMOVAL)

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)

Fig. 3 WINDSHIELD SEAL Fig. 5 ADHESIVE SEPARATION


1 - WINDSHIELD SEAL 1 - T-HANDLE
2 - TRIM STICK #4755 2 - WINDSHIELD ADHESIVE
3 - COUNTER SUPPORT
4 - CUTTING WIRE
CAUTION: Fabricate a protection guard from 2 mm
sheet plastic or equivalent to protect rubber instru-
(7) Carefully remove windshield.
ment panel from damage.

(5) Place protection guard between windshield and INSTALLATION


instrument panel seal. (Fig. 4)
WARNING: Allow the urethane at least 24 hours to
cure before returning the vehicle to use.

CAUTION: Roll down the left and right front door


glass and open the rear glass slider (if available)
before installing windshield to avoid pressurizing
the passenger compartment if a door is slammed
before urethane is cured. Water leaks can result.

The windshield fence should be cleaned of most of


its old urethane bonding material. A small amount of
old urethane, approximately 1 mm in height, should
remain on the fence. Do not grind off or completely
remove all old urethane from the fence, the paint fin-
ish and bonding strength will be adversely affected.

Fig. 4 INSTRUMENT PANEL SEAL


1 - WINDSHIELD
2 - SEAL PROTECTOR
3 - INSTRUMENT PANEL
4 - INSTRUMENT PANEL SEAL
23 - 84 STATIONARY GLASS VA
WINDSHIELD (Continued)
Windshield Preparation - Installing A Previously
Installed Windshield
(1) Level old bead of windshield adhesive to a
thickness of approximately 1 mm (0.04 in.) and
remove loose adhesive. (Fig. 6)

Fig. 8 WINDSHIELD POSITIONING


1 - TAPE
2 - WINDSHIELD FRAME
Fig. 6 WINDSHIELD ADHESIVE PREPARATION
1 - WINDSHIELD (5) Verify windshield gap is parallel to with wind-
2 - SCRAPER shield.
3 - OLD ADHESIVE
(6) Cut tape with a sharp knife and remove wind-
shield.
(2) Position windshield seal onto windshield start-
(7) Clean and dry area of glass to be re-glued with
ing at one corner and quickly moving up and down.
a suitable glass preparation solvent and rag.
(Fig. 7)
(8) Using a flash light, verify that glass primer is
CAUTION: Never moisten windshield seal with lubri- without damage.
cants to facilitate installation. (9) Re-prime any damaged area. If old adhesive
has been exposed for more than 12 hours, entire
adhesive area needs to be re-primed. (Fig. 9)

Fig. 7 WINDSHIELD SEAL INSTALLATION


1 - WINDSHIELD
2 - WINDSHIELD SEAL Fig. 9 WINDSHIELD PRIMER
1 - PRIMER
(3) Position windshield in center of windshield 2 - WINDSHIELD SEAL
opening.
(4) Apply adhesive tape to the locations shown to (10) Allow primer to air dry for at least 10 min-
aid with final installation. (Fig. 8) utes.
VA STATIONARY GLASS 23 - 85
WINDSHIELD (Continued)
(11) Using a flash light, verify that glass primer is (3) Clean and dry area of windshield opening to be
without damage. re-glued with a suitable glass preparation solvent
and rag.
Windshield Preparation - Installing A New (4) Re-prime any damaged area. If old adhesive
Windshield has been exposed for more than 12 hours, entire
(1) Clean and check windshield for damage. adhesive area needs to be re-primed. (Fig. 11)
(2) Position windshield seal onto windshield start-
ing at one corner and quickly moving up and down.
(Fig. 7)

CAUTION: Never moisten windshield seal with lubri-


cants to facilitate installation.

(3) Position windshield in center of windshield


opening.
(4) Apply adhesive tape to the locations shown to
aid with final installation. (Fig. 8)
(5) Verify windshield gap is parallel to with wind-
shield.
(6) Cut tape with a sharp knife and remove wind-
shield.
(7) Clean and dry area of glass to be glued with a
suitable glass preparation solvent and rag.
Fig. 11 WINDSHIELD OPENING PRIMER
(8) Apply primer to gluing surface at windshield
seal. (Fig. 9) 1 - PRIMER
2 - WINDSHIELD OPENING
(9) Allow primer to air dry for at least 10 minutes.
(10) Using a flash light, verify that glass primer is (5) Allow primer to air dry for at least 10 minutes.
without damage.
Windshield Installation
Windshield Opening Preparation (1) Apply bead of glue with a triangular nozzle
(1) Clean and vacuum windshield opening. directly to the windshield seal starting at bottom in
(2) Level old bead of windshield opening adhesive center of windshield. (Fig. 12)
to a thickness of approximately 1 mm (0.04 in.) and
remove loose adhesive. (Fig. 10) CAUTION: Always apply bead of adhesive to the
windshield. Always install the windshield within 5
minutes after applying adhesive.

Fig. 10 WINDSHIELD OPENING PREPARATION


1 - OLD ADHESIVE
2 - SCRAPER Fig. 12 WINDSHIELD ADHESIVE APPLICATION
3 - WINDSHIELD OPENING
1 - ADHESIVE BEAD
2 - WINDSHIELD SEAL
23 - 86 STATIONARY GLASS VA
WINDSHIELD (Continued)
(2) Allow end of adhesive bead to run out parallel aid installation of the windshield into the center of
to the start of the bead and smooth ends flush. (Fig. the cutout.
13) (4) Carefully lay down windshield and press on.

CAUTION: It is no longer possible to move the


windshield after installation. The windshield should
never be pressed into place by more than one per-
son, because the windshield can break if pressed
simultaneously on both sides.

CAUTION: Roll down the left and right front door


glass and open the rear glass slider (if available)
before installing windshield to avoid pressurizing
the passenger compartment if a door is slammed
before urethane is cured. Water leaks can result.

(1) Install the rear view mirror. (Refer to 23 -


BODY/INTERIOR/REAR VIEW MIRROR - INSTAL-
LATION)
Fig. 13 WINDSHIELD ADHESIVE OVERLAP (2) Install the headliner. (Refer to 23 - BODY/IN-
1 - ADHESIVE BEAD TERIOR/HEADLINER - INSTALLATION)
2 - WINDSHIELD SEAL (3) Install the wiper arms. (Refer to 8 - ELECTRI-
CAL/WIPERS/WASHERS/WIPER ARMS - INSTAL-
(3) Lift windshield into place in the center of the LATION)
windshield opening and use the tape as a guide to
VA WEATHERSTRIP/SEALS 23 - 87

WEATHERSTRIP/SEALS

TABLE OF CONTENTS
page page

FRONT DOOR INNER BELT WEATHERSTRIP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 87


REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 DOOR OPENING SEALS
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 87 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
FRONT DOOR OUTER BELT WEATHERSTRIP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 87
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

FRONT DOOR INNER BELT DOOR OPENING SEALS


WEATHERSTRIP
REMOVAL
REMOVAL (1) Open door and separate the door opening seal
(1) Remove the front door trim panel. (Refer to 23 from the door opening flange.
- BODY/DOOR - FRONT/TRIM PANEL - REMOVAL)
(2) Remove the inner belt weatherstrip. INSTALLATION
(1) Position the seal to the bottom of the door
INSTALLATION opening, with bulb facing outboard, starting the
(1) Install the inner belt weatherstrip. installation at the center of the lower flange. Press
(2) Install the trim panel. (Refer to 23 - BODY/ the seal onto the sill flange and work around the
DOOR - FRONT/TRIM PANEL - INSTALLATION) perimeter of the door opening until fully seated.
Work in one direction, smoothing the seal to avoid
puckers or wrinkles.
FRONT DOOR OUTER BELT (2) When installing a new weatherstrip on the
front door opening, remove the tear strip starting at
WEATHERSTRIP the splice and moving around the front of the door to
the back of the opening.
REMOVAL
(1) Remove door glass. (Refer to 23 - BODY/DOOR
- FRONT/DOOR GLASS - REMOVAL)
(2) Remove screws at window channel and remove
channel.
(3) Remove outer belt weatherstrip.

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

GAP AND FLUSH OPENING DIMENSIONS


SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 88 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 90

GAP AND FLUSH LOCATION GAP FLUSH


1 Door at top. 7± FLUSH
SPECIFICATIONS 0.5
GAP & FLUSH DIMENSIONS INDEX 2 Door at upper b-pillar. 7± Up to max 1 mm
0.5 recessed, at
DESCRIPTION FIGURE rear with 1 mm
FRONT DOORS 1 overlap (wind
noise)
SLIDING DOORS 2
3 Door at bottom. 8± FLUSH
REAR DOORS 3
0.5
4 Door at wheelhouse. 7± FLUSH
0.5
5 Door ridge at — FLUSH
wheelhouse and
b-pillar.
6 Door at a-pillar. 8± FLUSH
0.5

Fig. 1 FRONT DOOR

NOTE:
All measurements are in mm.
VA BODY STRUCTURE 23 - 89
GAP AND FLUSH (Continued)

Fig. 2 SLIDING DOOR Fig. 3 REAR DOOR

NOTE: NOTE:
All measurements are in mm. All measurements are in mm.

LOCATION GAP FLUSH LOCATION GAP FLUSH


1 Sliding doors at top and 7± FLUSH 1 Rear doors at top 13 ± FLUSH
bottom 0.5 0.5
2 Sliding doors at sides to body 7± FLUSH 2 Right rear door to left rear 8 ± 0.5 FLUSH
0.5 door
3 Door ridge at b-pillar and side — FLUSH 3 Rear doors (both sides) to 8 ± 0.5 FLUSH
panel without rear body
offset 4 Rear doors at bottom 8 ± 0.5 —
23 - 90 BODY STRUCTURE VA

OPENING DIMENSIONS
SPECIFICATIONS
BODY OPENING DIMENSIONS INDEX

DESCRIPTION FIGURE
WINDSHIELD OPENING 4

Fig. 4 WINDSHIELD OPENING


VA HEATING & AIR CONDITIONING 24 - 1

HEATING & AIR CONDITIONING


TABLE OF CONTENTS

page page

HEATING & AIR CONDITIONING SPECIFICATIONS


DESCRIPTION . . . . . . . . . . . . . . ............1 A/C SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 5
OPERATION . . . . . . . . . . . . . . . . ............2 FASTENER TORQUE ...................6
DIAGNOSIS AND TESTING CONTROLS .............................7
A/C PERFORMANCE TEST . . . ............3 DISTRIBUTION . . . . . . . . . . . . . . . . . . . . . . . . . . 21
HEATER PERFORMANCE TEST ...........4 PLUMBING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
ATC FUNCTION TEST . . . . . . . ............4 CABIN HEATER . . . . . . . . . . . . . . . . . . . . . . . . . 50

HEATING & AIR


CONDITIONING
DESCRIPTION
An automatic temperature control (ATC) single
zone type heating-A/C system is standard equipment
on this model.
To maintain the performance level of the heating,
ventilation and air conditioning (HVAC) system, the
engine cooling system must be properly maintained.
The use of a bug screen is not recommended. Any
obstructions in front of the radiator or A/C condenser
will reduce the performance of the A/C and engine
cooling systems.
The engine cooling system includes the radiator,
thermostat, radiator hoses and the engine coolant
pump. Refer to 7 - Cooling for more information
before opening or attempting any service to the
engine cooling system.
All vehicles are equipped with a common ventila-
tion housing (Fig. 1) located in the engine compart-
ment which includes: Fig. 1 Ventilation Housing
• Blower motor 1 - NUT (5)
• Blower motor resistor block 2 - WASHER (5)
• Recirculation door and actuator 3 - VENTILATION HOUSING
4 - HOUSING COVER
24 - 2 HEATING & AIR CONDITIONING VA
HEATING & AIR CONDITIONING (Continued)
All vehicles are also equipped with a common
heater housing (Fig. 2) mounted under the instru-
ment panel which includes:
• Heater core
• Evaporator core
• Evaporator temperature sensor
• Expansion valve
• Air outlet temperature sensor
• Mode doors

Fig. 3 Denso 10S17 A/C Compressor

Fig. 2 Heater Housing


1 - SCREW (12)
2 - UPPER HOUSING
3 - A/C EVAPORATOR
4 - EVAPORATOR O-RING SEAL (2)
4 - EVAPORATOR GASKET
6 - VENTILATION HOUSING GASKET
7 - LOWER HOUSING
8 - WIRING HARNESS
9 - BOLT (3)
10 - HEATER CORE
11 - HEATER CORE TUBE ASSEMBLY
12 - HEATER CORE TUBE GASKET
13 - HEATER CORE TUBE O-RING SEAL (2)
Fig. 4 Heater Booster
Some vehicles are equipped with an additional
Denso 10S17 A/C compressor mounted to the engine
OPERATION
which can be used for various aftermarket add-on Outside air enters the vehicle through the hood
rear A/C systems (Fig. 3). opening at the base of the windshield, and passes
A heater booster is used to aid in warming the through the ventilation housing located in the engine
engine coolant. The heater booster system can be compartment into the heater housing located behind
switched on while the vehicle is being driven to help the instrument panel. Air flow velocity is adjusted
the engine reach its normal operating temperature with the blower motor speed selector thumbwheel on
quickly and will help aid in heating up the air within the A/C-heater control. The air intake openings must
the passenger compartment quickly when requested be kept free of snow, ice, leaves, and other obstruc-
by the operator (Fig. 4). tions for the HVAC system to receive a sufficient vol-
ume of outside air.
VA HEATING & AIR CONDITIONING 24 - 3
HEATING & AIR CONDITIONING (Continued)
The automatic temperature control (ATC) system has to perform a double duty. It must lower the air
controls interior temperature by taking actual values temperature, and it must lower the temperature of
from the temperature sensors and the CAN bus and the moisture in the air that condenses on the evapo-
comparing them to the nominal value of the temper- rator fins. Condensing the moisture in the air trans-
ature control switch. The electric pulsed heater valve fers heat energy into the evaporator fins and tubing.
is then energized depending on the requested quan- This reduces the amount of heat the evaporator can
tity of heat and an electrically-operated water pump absorb from the air. High humidity greatly reduces
gives a nearly constant water flow for exact temper- the ability of the evaporator to lower the temperature
ature regulation. If the solenoid is not energized, the of the air.
coolant circuit to the heat exchanger is fully open. To However, evaporator capacity used to reduce the
control the temperature the solenoid valve is pulsed amount of moisture in the air is not wasted. Remov-
by the ATC in periods of four seconds. ing some of the moisture out of the air entering the
The mode control knob on the A/C-heater control is vehicle adds to the comfort of the passengers.
used to direct the conditioned air flow to the selected Although, an owner may expect too much from their
air outlets. The mode control knob operates the mode air conditioning system on humid days. A perfor-
doors by cables connected to the mode doors. mance test is the best way to determine whether the
When the outside air contains smoke, odors, high system is performing up to standard. This test also
humidity, or if rapid cooling is desired, interior air provides valuable clues as to the possible cause of
can by recirculated by selecting the Recirculation trouble with the air conditioning system.
Mode with the mode control knob. The mode control
knob operates the recirculation door through use of a WARNING: REFER TO THE APPLICABLE WARN-
vacuum actuator. When the Recirculation Mode is INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
selected, the recirculation door is closed to prevent PERFORMING THE FOLLOWING OPERATION (Refer
outside air from entering the passenger compart- to 24 - HEATING & AIR CONDITIONING/PLUMBING -
ment. WARNING) and (Refer to 24 - HEATING & AIR CON-
To maintain minimum evaporator temperature and DITIONING/PLUMBING - CAUTION).
prevent evaporator freezing, an evaporator tempera-
ture sensor is used.
NOTE: Very specific instructions and conditions
The A/C system is designed for the use of non-CFC,
pertain to this procedure which are significantly dif-
R-134a refrigerant only and uses an expansion valve
ferent than procedures used in other vehicle appli-
to meter refrigerant flow to the evaporator.
cations. Follow each step in the order they are
presented. Do not skip steps or change conditions
DIAGNOSIS AND TESTING from those stated or results will be adversely
affected and invalid.
A/C PERFORMANCE TEST
The compressor clutch is de-energized under any of
The air conditioning system is designed to provide
the following conditions:
the passenger compartment with low temperature
• Blocked compressor (thermal fuse in the pulley)
and low specific humidity air. The evaporator, located
• Low pressure in the system
in the heater housing on the dash panel below the
• Low evaporator temperature
instrument panel, is cooled to temperatures near the
• Hard acceleration (WOT)
freezing point. As warm damp air passes through the
• High coolant temperatures
cooled evaporator, the air transfers its heat to the
(1) Place the vehicle in the shade with all widows
refrigerant in the evaporator and the moisture in the
open.
air condenses on the evaporator fins. During periods
(2) Turn the temperature control to cold.
of high heat and humidity, an air conditioning sys-
(3) Select Fresh Air, not Recirculate and open all
tem will be more effective in the Recirculation Mode.
air conditioning duct louvers.
With the system in the Recirculation Mode, only air
(4) Start the vehicle and allow it to idle.
from the passenger compartment passes through the
(5) Turn the blower switch to the maximum blower
evaporator. As the passenger compartment air dehu-
speed setting and allow to operate for a short period
midifies, the air conditioning system performance
of time before proceeding.
levels improve.
(6) Perform an outlet temperature test as follows:
Humidity has an important bearing on the temper-
a. Turn the blower switch to the lowest blower
ature of the air delivered to the interior of the vehi-
speed setting.
cle. It is important to understand the effect that
b. Insert a thermometer into a center duct for at
humidity has on the performance of the air condition-
least five minutes.
ing system. When humidity is high, the evaporator
24 - 4 HEATING & AIR CONDITIONING VA
HEATING & AIR CONDITIONING (Continued)
c. With the engine running, duct temperature Cooling for the procedures to check the radiator cool-
should not be less than 2° C (35° F) or than 12° C ant level, serpentine drive belt tension, radiator air
(54° F). flow and the radiator fan operation.
(7) If the compressor has not cycled off and the
duct temperature is less than 2° C (35° F) , check the MAXIMUM HEATER OUTPUT
evaporator temperature sensor and circuit by per- Engine coolant is provided to the heater core
forming the ATC Function Test (Refer to 24 - HEAT- through a heater valve and heater hose. With the
ING & AIR CONDITIONING - DIAGNOSIS AND engine idling at normal operating temperature, set
TESTING). the heater-A/C controls as follows:
(8) If duct output temperature is not within speci- • Temperature control in the full hot position
fications, check the refrigerant system for leaks and • Mode control in the floor heat position
proper refrigerant charge (Refer to 24 - HEATING & • Blower motor control in the highest speed posi-
AIR CONDITIONING/PLUMBING - DIAGNOSIS tion
AND TESTING) and (Refer to 24 - HEATING & AIR Using a test thermometer, check the temperature
CONDITIONING/PLUMBING - STANDARD PRO- of the air being discharged at the floor outlets. Com-
CEDURE). pare the test thermometer reading to the Tempera-
ture Reference chart.
HEATER PERFORMANCE TEST
Before performing the following tests, perform the
ATC Function Test using the DRBIIIt and refer to

TEMPERATURE REFERENCE CHART

Ambient Temperature Minimum Floor Outlet Temperature


Celsius Fahreheit Celsius Fahreheit
15.5° 60° 62.2° 144°
21.1° 70° 63.8° 147°
26.6° 80° 65.5° 150°
32.2° 90° 67.2° 153°

If the floor outlet air temperature is insufficient, POSSIBLE LOCATIONS OR CAUSE OF


check for a faulty heater valve (perform ATC Func- INSUFFICIENT HEAT
tion Test) and verify that the cooling system is oper- • An obstructed cowl air intake.
ating to specifications (Refer to 7 - COOLING/ • Obstructed heater system outlets.
ENGINE/COOLANT - DIAGNOSIS AND TESTING). • Heater water valve not functioning properly.
Both of the heater hoses should be HOT to the touch
(the coolant return heater hose should be slightly TEMPERATURE CONTROL
cooler than the supply hose. If the coolant return If outlet air temperature cannot be adjusted with
hose is much cooler than the supply hose, locate and the A/C-heater temperature control, one of the follow-
repair the engine coolant flow obstruction in the ing could require service:
heater system. • Faulty A/C-heater control switch.
• Faulty temperature sensor.
POSSIBLE LOCATIONS OR CAUSE OF • Faulty A/C-heater control cable or actuator.
OBSTRUCTED COOLANT FLOW • Faulty A/C-heater control module.
• Pinched or kinked heater hoses.
• Improper heater hose routing. ATC FUNCTION TEST
• Plugged heater hoses or supply and return ports The automatic temperature control (ATC) system can
at the cooling system connections. perform an self-test, which can be activated by the
• Inoperative or stuck heater water valve. DRBIIIt scan tool to confirm that the A/C system is per-
• Plugged heater core. forming satisfactorily. This test provides a quick confir-
If proper coolant flow is verified, and heater floor mation of heating and A/C system performance to the
outlet air temperature is insufficient, a mechanical service technician. Refer to Body Diagnostic Procedures
problem may exist. for the appropriate diagnostic information.
VA HEATING & AIR CONDITIONING 24 - 5
HEATING & AIR CONDITIONING (Continued)

SPECIFICATIONS Item Description Notes


Refrigerant R-134a
A/C SYSTEM Type
Refrigerant Refer to the
Item Description Notes Capacity Underhood
Compressor Denso 7SBU16C ND-8 PAG oil Specification
(front A/C system) Label in the
Denso 10S17 engine
(add-on rear A/C) compartment
Freeze-up Evaporator HVAC housing Compressor 7SBU16C —
Control temperature mounted - Clutch Coil 2.0-3.7 amps @
sensor input to Draw 12V ± 0.5V @
A/C-heater 21° C (70° F)
control 10S17 — 3.3
Low psi Control A/C Pressure Liquid line amps @ 12V ±
Transducer mounted - 0.5V @ 21° C
input to PCM - (70° F)
opens below Compressor 7SBU16C — 0.5
152 kPa (22 Clutch Air Gap - 0.88 mm (0.020
psi) - resets - 0.035 in.)
above 234 - 10S17 — 0.35 -
262 (34-38 0.60 mm (0.014 -
psi) 0.024 in.)
High psi Control High Pressure Compressor
Relief Valve mounted -
opens at a
discharge
pressure over
3445-4135
kPa (500 -
600 psi)
24 - 6 HEATING & AIR CONDITIONING VA
HEATING & AIR CONDITIONING (Continued)

FASTENER TORQUE

Description N·m Ft. Lbs. In. Lbs.


A/C Compressor bolts 20 15 —
A/C Compressor Shaft Bolt 17.5 — 155
Air Nozzle Reinforcing Plate Screws 2 — 17
Air Outlet Screws 2 — 17
Auxiliary Fan Bracket Screws 5 — 45
Auxiliary Fan Bracket Nuts 5 — 45
Blower Motor Screws 2 — 17
Condenser Screws 2 — 17
Defroster Duct Screws 2 — 17
Discharge Line to Compressor Bolt 23 17 —
Discharge Line to Condenser Nut 33 24 —
A/C-Heater Control Screws 2 — 17
Heater Core Tube to Heater Core Bolts 5 — 45
Heater Housing Cover Screws 2 — 17
Heater Housing to Dash Panel Screws 4.5 — 40
Electric Coolant Pump Bracket Bolts 5 — 45
Expansion Valve to Evaporator Tube Tapping Plate 5 — 45
Bolts
Floor Duct Screws 2 — 17
Heater Core Tube Bolts 5 — 45
Heater Water Valve Bracket Bolts 5 — 45
Instrument Panel Duct Screws 2 — 17
Instrument Panel End Cover Screws 2 — 17
Intermediate Suction Line to Front Suction Line 10 — 89
Tapping Plate Bolt
Liquid Line to Condenser Nut 33 24 —
Liquid Line to Reciever-Drier Bolt 7 — 62
Recirculation Door Actuator Screws 2 — 17
Suction Line Routing Clip Nut 5 — 45
Suction Line to Compressor Bolt 23 17 —
Suction Line to Expansion Valve Nut 10 — 89
Supplemental Heater Air Intake Pipe Screws 7 — 62
Supplemental Heater M6 Fasteners 7 — 62
Supplemental Heater M8 Fasteners 23 17 —
Supplemental Heater Seat to Mounting Flange Nut 60 44 —
Terminal Block to Evaporator Bolts 5 — 45
Ventilation Housing to Dash Panel Nuts 5 — 45
VA CONTROLS 24 - 7

CONTROLS

TABLE OF CONTENTS
page page

A/C COMPRESSOR CLUTCH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15


DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 BLOWER MOTOR RESISTOR BLOCK
STANDARD PROCEDURE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 16
A/C COMPRESSOR CLUTCH AIR GAP . . . . . . 8 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
A/C COMPRESSOR CLUTCH BREAK-IN . . . . . 8 DIAGNOSIS AND TESTING
REMOVAL .............................8 BLOWER MOTOR RESISTOR BLOCK . . . . . . 16
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16
A/C COMPRESSOR CLUTCH COIL BLOWER MOTOR SWITCH
DIAGNOSIS AND TESTING DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 17
A/C COMPRESSOR CLUTCH COIL . . . . . . . . 11 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
A/C HEATER CONTROL DIAGNOSIS AND TESTING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11 BLOWER MOTOR SWITCH . . . . . . . . . . . . . . 17
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 EVAPORATOR TEMPERATURE SENSOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
A/C PRESSURE TRANSDUCER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 12 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 IN-CAR TEMPERATURE SENSOR
DIAGNOSIS AND TESTING DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 18
A/C PRESSURE TRANSDUCER . . . . . . . . . . 13 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 DIAGNOSIS AND TESTING
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14 IN-CAR TEMPERATURE SENSOR . . . . . . . . . 19
AIR OUTLET TEMPERATURE SENSOR MODE DOOR CABLES
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 14 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 RECIRCULATION DOOR ACTUATOR
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 20
AMBIENT TEMPERATURE SENSOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 15 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20

A/C COMPRESSOR CLUTCH OPERATION


The compressor clutch components provide the
DESCRIPTION means to engage and disengage the compressor from
The A/C compressor clutch assembly consists of a the engine serpentine accessory drive belt. When the
stationary electromagnetic field coil, a hub bearing clutch coil is energized, it magnetically draws the
and pulley assembly, and a clutch plate (Fig. 1). The clutch into contact with the pulley and drives the
field coil and the hub bearing and pulley assembly compressor shaft. When the coil is not energized, the
are each retained on the nose of the compressor front pulley freewheels on the clutch hub bearing, which is
housing with snap rings. The clutch plate is splined part of the pulley.
to the compressor shaft and secured with a bolt. The compressor clutch engagement is controlled by
The compressor clutch plate and pulley and the several components:
clutch field coil are available for service replacement. • A/C switch on the A/C-heater control panel
• Evaporator temperature sensor
24 - 8 CONTROLS VA
A/C COMPRESSOR CLUTCH (Continued)
air gap is still correct. Spin the clutch pulley before
making the final air gap check.

A/C COMPRESSOR CLUTCH BREAK-IN


After a new compressor clutch has been installed,
cycle the compressor clutch approximately twenty
times (five seconds on, then five seconds off). During
this procedure, set the heater-A/C control in the
Recirculation Mode, the A/C button in the on posi-
tion, the blower motor switch in the highest speed
position, and the engine speed at 1500 to 2000 rpm.
This procedure (burnishing) will seat the opposing
friction surfaces and provide a higher compressor
clutch torque capability.

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).

Fig. 3 Clutch Plate And Shim(s)


1 - COMPRESSOR SHAFT
2 - CLUTCH PLATE
3 - CLUTCH PLATE SHIM

(7) Using snap ring pliers (Special Tool C-4574 or


equivalent), remove the external snap ring that
secures the compressor clutch pulley to the front of
the compressor, then slide the pulley off of the com-
pressor (Fig. 4). Fig. 5 Clutch Coil Snap Ring
1 - SNAP RING PLIERS
2 - CLUTCH COIL
3 - SNAP RING
4 - COMPRESSOR

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.

NOTE: A new snap ring must be used to secure the


clutch coil to the compressor. The bevel side of the
snap ring must face outward.

(2) Using snap ring pliers (Special Tool C-4574 or


equivalent), install the external snap ring that
secures the clutch coil to the front cover of the com-
pressor. The bevel side of the snap ring must be fac-
ing outward and both snap ring eyelets must be
oriented to the right or left of the clutch coil dowel
pin on the compressor. Be certain that the snap ring Fig. 6 Pulley Assembly Install
is fully and properly seated in the groove. 1 - PULLEY ASSEMBLY
2 - WOOD BLOCK
CAUTION: If the snap ring is not fully seated in the
groove it will vibrate out, resulting in a clutch fail- wrench can be placed around the clutch plate to aid
ure and severe damage to the compressor front in bolt tightening. Tighten the bolt to 17.5 N·m (155
cover. in. lbs.).

(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.

DIAGNOSIS AND TESTING A/C HEATER CONTROL


A/C COMPRESSOR CLUTCH COIL DESCRIPTION
The air conditioning compressor clutch coil electri- This ATC system uses a combination of electrical
cal circuit is controlled by the ATC control module and mechanical controls. These controls provide the
which is integral to the heater-A/C control. Begin vehicle operator with a number of setting options to
testing of a suspected compressor clutch coil problem help control the climate and comfort within the vehi-
by performing the ATC Function Test using the cle.
DRBIIIt scan tool. The A/C-heater control is located on the instrument
panel inboard of the steering column and below the
PRELIMINARY CHECKS
radio (Fig. 7). The A/C-heater control contains a rota-
(1) If no diagnostic trouble codes (DTCs) are found ry-type temperature control, a rotary-type mode con-
in the A/C-heater control or the powertrain control trol, a thumbwheel-type blower motor speed control
module (PCM), go to Step 2. If any DTCs are found, and an A/C mode push button switch and indicator
repair as required. lamp. The A/C-heater control also features a push
(2) If the A/C compressor clutch still will not button switch and indicator lamp for the residual
engage, verify the refrigerant charge level (Refer to engine heat utilization (REST) function, cabin heater
24 - HEATING & AIR CONDITIONING/PLUMBING or the heater booster (as equipped).
- DIAGNOSIS AND TESTING - REFRIGERANT
SYSTEM LEAKS). If the refrigerant charge level is
OK, go to TESTS. If the refrigerant charge level is
not OK, adjust the refrigerant charge as required.

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.

(1) Disconnect and isolate the negative battery


cable.
(2) Remove the center bezel from the instrument Fig. 8 A/C-Heater Control
panel. (Refer to 23 - BODY/INSTRUMENT PANEL/ 1 - A/C-HEATER CONTROL
INSTRUMENT PANEL CENTER BEZEL - 2 - CONTROL CABLE
REMOVAL). 3 - CONTROL CABLE
4 - WIRE HARNESS CONNECTOR
(3) Remove the two screws that secure the A/C- 5 - WIRE HARNESS CONNECTOR
heater control to the instrument panel (Fig. 8). 6 - MOUNTING BRACKET (2)
(4) Pull the A/C-heater control away from the 7 - SCREW (2)
instrument panel far enough to access the connec-
tions on the back of the control. A/C PRESSURE TRANSDUCER
(5) Mark and disconnect the two control cables
from the A/C-heater control. DESCRIPTION
(6) Disconnect the two wiring harness connectors The A/C pressure transducer is installed on the liq-
from the A/C-heater control. uid line fitting located at the top of the receiver/drier.
(7) If A/C-heater control is to be replaced, remove A rubber O-ring seals the connection between the
the two mounting brackets from the A/C-heater con- transducer and the fitting. Three terminals within a
trol. molded plastic connector receptacle on the top of the
transducer connect it to the vehicle electrical system
INSTALLATION through a wire lead and connector.
(1) If removed, install the two mounting brackets The A/C pressure transducer cannot be adjusted or
to the A/C-heater control. repaired and, if faulty or damaged, it must be
(2) Connect the two wire harness connectors into replaced.
the back of the A/C-heater control.
(3) Connect the two control cables to the A/C- OPERATION
heater control. The A/C pressure transducer monitors the pres-
sures in the high side of the refrigerant system
NOTE: Install the control cable of bottom adjust- through its connection to a fitting on the liquid line.
ment lever to the front adjustment wheel of the A/C- The transducer will change its internal resistance in
heater control. response to the pressures it monitors. The ATC con-
trol module provides a five volt reference signal and
(4) Position the A/C-heater control into the instru- monitors the output voltage of the transducer on the
ment panel. transducer return circuit to determine refrigerant
(5) Install the two A/C-heater control retaining pressure. The ATC module is preprogrammed to
screws. Tighten the screws to 2 N·m (17 in. lbs.). respond to this and other sensor inputs by controlling
(6) Install the center bezel onto the instrument the operation of the air conditioning compressor
panel (Refer to 23 - BODY/INSTRUMENT PANEL/ clutch and the auxiliary radiator cooling fan to help
INSTRUMENT PANEL CENTER BEZEL - INSTAL- optimize air conditioning system performance and to
LATION). protect the system components from damage. The
(7) Reconnect the negative battery cable.
VA CONTROLS 24 - 13
A/C PRESSURE TRANSDUCER (Continued)
A/C pressure transducer input to the ATC module dures. Before testing the A/C pressure transducer, be
also prevents the A/C compressor clutch from engag- certain that the transducer wire harness connections
ing when the ambient temperature is below 0.556° C are clean of corrosion and properly connected. For
(33° F) due to the pressure/temperature relationship the air conditioning system to operate, an A/C pres-
of the refrigerant. sure transducer voltage reading between 0.7 and 4.56
The A/C pressure transducer is diagnosed by per- volts is required. Voltage outside this range indicate
forming the ATC Function Test using the DRBIIIt a low or high refrigerant system pressure condition
scan tool. Refer to Body Diagnostic Procedures. to the ATC control module. The control module is
The A/C pressure transducer cannot be adjusted or programmed to respond to a low or high refrigerant
repaired and, if faulty or damaged, it must be system pressure by suppressing operation of the com-
replaced. pressor. Refer to the A/C Pressure Transducer Volt-
age chart for the possible condition indicated by the
transducer voltage readings.
DIAGNOSIS AND TESTING
A/C PRESSURE TRANSDUCER
The A/C pressure transducer is tested using a
DRBIIIt scan tool. Refer to Body Diagnostic Proce-

A/C PRESSURE TRANSDUCER VOLTAGE

Voltage Possible Cause


0.0 1. No transducer supply voltage from ATC control module.
2. Shorted transducer circuit.
3. Faulty transducer.
0.150 to 0.450 1. Ambient temperature below 10° C (50° F).
2. Low refrigerant system pressure.
0.451 to 4.519 1. Normal refrigerant system pressure.
4.520 to 4.850 1. High refrigerant system pressure.
5.0 1. Open transducer circuit.
2. Faulty transducer.
24 - 14 CONTROLS VA
A/C PRESSURE TRANSDUCER (Continued)

REMOVAL (5) Evacuate the refrigerant system (Refer to 24 -


HEATING & AIR CONDITIONING/PLUMBING -
WARNING: REFER TO THE APPLICABLE WARN- STANDARD PROCEDURE).
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE (6) Charge the refrigerant system (Refer to 24 -
PERFORMING THE FOLLOWING OPERATION (Refer HEATING & AIR CONDITIONING/PLUMBING -
to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE).
WARNING) and (Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING - CAUTION).
AIR OUTLET TEMPERATURE
(1) Recover the refrigerant from the refrigerant SENSOR
system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - STANDARD PROCEDURE).
DESCRIPTION
(2) Disconnect and isolate the battery negative
The air outlet temperature sensor is a two-wire
cable.
temperature sensing element that detects the tem-
(3) Disconnect the wire harness connector from the
perature of the air coming out of the heater housing
A/C pressure transducer (Fig. 9).
unit. The sensor is attached to heater housing unit
(4) Using an open end wrench, remove the A/C
directly behind the ATC heater-A/C control panel.
pressure transducer from the fitting on the liquid
The thermistor will change resistance as the temper-
line.
ature changes.
(5) Remove the O-ring seal from the A/C pressure
transducer and discard.
OPERATION
The air outlet temperature sensor monitors the
temperature of the air coming out of the heater hous-
ing unit. The sensor will change its internal resis-
tance in response to the temperatures it monitors.
The ATC control module is connected to the sensor
through a sensor ground circuit and a sensor signal
circuit. As the air temperature increases, the resis-
tance of the sensor decreases and the voltage moni-
tored by the module decreases. The module uses this
monitored voltage reading to an indication of the out-
let air temperature. The ATC control module makes
adjustments to maintain the requested interior tem-
perature by cycling both the A/C compressor and
solenoid heater valve on and off.
The air outlet temperature sensor is diagnosed by
performing the ATC Function Test using the DRBIIIt
scan tool. Refer to Body Diagnostic Procedures.
The air outlet temperature sensor cannot be
adjusted or repaired, and if faulty or damaged, it
Fig. 9 A/C Pressure Transducer must be replaced.
1 - WIRE HARNESS CONNECTOR
2 - A/C PRESSURE TRANSDUCER
3 - O-RING SEAL
REMOVAL
4 - LIQUID LINE FITTING (1) Disconnect and isolate the battery negative
cable.
INSTALLATION (2) Remove the heater-A/C control from the instru-
(1) Lubricate a new O-ring seal with clean refrig- ment panel (Refer to 24 - HEATING & AIR CONDI-
erant oil and install it on the A/C pressure trans- TIONING/CONTROLS/A/C HEATER CONTROL -
ducer. REMOVAL).
(2) Using an open end wrench, install and tighten (3) Disconnect the wire harness connector from the
the A/C pressure transducer into the fitting on the air outlet temperature sensor (Fig. 10).
liquid line. Tighten the transducer to 12 N·m (106 in. (4) Remove the air outlet temperature sensor from
lbs.). the heater housing.
(3) Reconnect the wire harness connector to the
transducer.
(4) Reconnect the battery negative cable.
VA CONTROLS 24 - 15
AIR OUTLET TEMPERATURE SENSOR (Continued)
is programmed to correspond to a specific tempera-
ture.
The ambient temperature sensor is diagnosed
using the DRBIIIt scan tool. Refer to Body Diagnos-
tic Procedures.
The ambient temperature sensor cannot be
adjusted or repaired and, if faulty or damaged, it
must be replaced.

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.

DIAGNOSIS AND TESTING


BLOWER MOTOR RESISTOR BLOCK
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- Fig. 12 Blower Motor Resistor Block
LATE THE BATTERY NEGATIVE (GROUND) CABLE, 1 - BLOWER MOTOR RESISTOR
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS- 2 - ELECTRICAL CONNECTOR
3 - VENTILATION HOUSING
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
INSTALLATION
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
(1) Connect the wire harness connector to the
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
blower motor resistor block.
CAUTIONS COULD RESULT IN AN ACCIDENTAL
(2) Install the blower motor resistor into the ven-
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
tilation housing. The housing is indexed to allow
INJURY.
mounting in only one position.
For circuit descriptions and diagrams, refer to the (3) Reconnect the battery negative cable.
appropriate wiring information.
(1) Disconnect and isolate the negative battery
cable.
VA CONTROLS 24 - 17

BLOWER MOTOR SWITCH peratures it monitors. The A/C-heater control is con-


nected to the sensor through a sensor ground circuit
and a sensor signal circuit. As the evaporator tem-
DESCRIPTION
perature increases, the resistance of the sensor
The blower motor is controlled by a thumbwheel-
decreases and the voltage monitored by the A/C-
type blower motor control, mounted in the A/C-heater
heater control decreases. The A/C-heater control uses
control. The switch allows the selection of four blower
this monitored voltage reading to an indication of the
motor speeds with the ignition switch in the On posi-
evaporator temperature. The A/C-heater control is
tion.
programmed to respond to this input by cycling the
NOTE: The blower motor will operate only at the A/C compressor clutch as necessary to optimize A/C
lowest speed when the Residual Engine Heat Utili- system performance and to protect the A/C system
zation (REST) function is selected, regardless of the from evaporator freezing. The external location of the
blower speed setting on the A/C-heater control. sensor allows the sensor to be removed or installed
without disturbing the refrigerant in the A/C system.
The evaporator temperature sensor is diagnosed by
OPERATION performing the ATC Function Test using a DRBIIIt
When the ignition is turned to On, the integral scan tool. Refer to Body Diagnostic Procedures.
blower motor resistor within the ATC A/C-heater con- The evaporator temperature sensor cannot be
trol supplies power to the blower motor switch. The adjusted or repaired and, if faulty or damaged, it
switch directs power to the individual blower driver must be replaced.
circuits through the blower motor resistor block to
the blower motor and then to ground. REMOVAL
The blower motor switch cannot be adjusted or (1) Disconnect and isolate the negative battery
repaired, and if faulty or damaged, the A/C-heater cable.
control must be replaced (Refer to 24 - HEATING & (2) Remove the radio (Refer to 8 - ELECTRICAL/
AIR CONDITIONING/CONTROLS/A/C HEATER AUDIO/RADIO - REMOVAL).
CONTROL - REMOVAL). (3) Remove glove compartment.
(4) Remove cover from instrument cluster (Refer to
23 - BODY/INSTRUMENT PANEL/INSTRUMENT
DIAGNOSIS AND TESTING PANEL TOP COVER - REMOVAL).
(5) Remove the instrument cluster (Refer to 8 -
BLOWER MOTOR SWITCH ELECTRICAL/INSTRUMENT CLUSTER -
The blower motor switch can be diagnosed by using REMOVAL).
the DRBIIIt scan tool. Refer to Body Diagnostic Pro- (6) Remove passenger side airbag.
cedures. For circuit descriptions and diagrams, refer (7) Remove cover above air nozzle on passenger
to the appropriate wiring information. side.
(8) Remove speaker.
(9) Remove center section of instrument panel.
EVAPORATOR TEMPERATURE (10) Remove A/C-heater control from the instru-
SENSOR ment panel (Refer to 24 - HEATING & AIR CONDI-
TIONING/CONTROLS/A/C HEATER CONTROL -
DESCRIPTION REMOVAL).
The evaporator temperature sensor is a two-wire (11) Remove instrument panel top section.
temperature sensing element located at the coldest (12) Remove electrical connections.
point on the face of the evaporator. The sensor is (13) Remove air bezels from instrument panel.
attached to the evaporator coil fins. The evaporator (14) Disconnect the wire harness connector from
temperature sensor prevents condensation on the evaporator temperature sensor (Fig. 13).
evaporator coil from freezing and obstructing A/C (15) Remove evaporator temperature sensor from
system air flow. HVAC housing.

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.

Fig. 13 Evaporator Temperature Sensor


1 - WIRE HARNESS CONNECTOR
2 - EVAPORATOR TEMPERATURE SENSOR

INSTALLATION
(1) Install the probe of the evaporator temperature
sensor between the fins of the A/C evaporator.

NOTE: The probe must not go into the same hole


(in the A/C evaporator ) that the probe was removed
from.

(2) Install the wire harness connector to the evap-


orator temperature sensor.
(3) Install the air bezels to the instrument panel. Fig. 14 In-Car Temperature Sensor
(4) Install the electrical connections. 1 - A/C-HEATER CONTROL
(5) Install the instrument panel top section (Refer 2 - IN-CAR TEMPERATURE SENSOR
to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL TOP COVER - INSTALLATION). OPERATION
(6) Install the A/C-heater control (Refer to 24 - Air from the passenger compartment flows over the
HEATING & AIR CONDITIONING/CONTROLS/A/C thermistor of the in-car temperature sensor. The
HEATER CONTROL - INSTALLATION). thermistor changes resistance with air temperature.
(7) Install the center section of the instrument The ATC A/C-heater control measures this resistance
panel. and calculates the temperature of the air. The A/C-
(8) Install the speaker (Refer to 8 - ELECTRICAL/ heater control then makes adjustments to maintain
AUDIO/SPEAKER - INSTALLATION). the selected passenger compartment temperature.
(9) Install the cover above the air nozzle on the The in-car temperature sensor cannot be adjusted
passenger side. or repaired, and if faulty or damaged, the A/C-heater
(10) Install the passenger side airbag. control must be replaced (Refer to 24 - HEATING &
(11) Install the instrument cluster (Refer to 8 - AIR CONDITIONING/CONTROLS/A/C HEATER
ELECTRICAL/INSTRUMENT CLUSTER - INSTAL- CONTROL - REMOVAL).
LATION).
(12) Install the cover to the instrument cluster.
(13) Install glove compartment.
VA CONTROLS 24 - 19
IN-CAR TEMPERATURE SENSOR (Continued)

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.

Fig. 15 Air Distribution Control Cables


1 - AIR DISTRIBUTION CONTROL CABLES Fig. 16 Adjusting Air Distribution Control Cables
2 - ADJUSTMENT LEVERS
3 - HVAC HOUSING 1 - MODE CONTROL KNOB
2 - UPPER MODE DOOR CABLE
3 - UPPER MODE DOOR LEVER
INSTALLATION 4 - LOWER MODE DOOR LEVER
5 - LOWER MODE DOOR CABLE
(1) Connect the two control cables to the mode 6 - HEATER-A/C CONTROL
door levers (Fig. 16).
(2) Connect the two control cables to the A/C-
heater control.
24 - 20 CONTROLS VA

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 FILTER FLOOR DISTRIBUTION DUCTS


REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24
AIR OUTLETS HVAC HOUSING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 22 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 25
BLOWER MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 26
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23 INSTRUMENT PANEL DUCTS
DEFROSTER DUCTS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 28
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23

AIR FILTER INSTALLATION


(1) Install the air filter into the ventilation hous-
REMOVAL ing.
(1) Remove the insulation blanket from the venti- (2) Install the ventilation housing cover
lation housing in the engine compartment (Fig. 1). (3) Close the locking clips at the front and rear of
(2) Open the locking clips at the front and rear of the ventilation housing.
the ventilation housing.
NOTE: The locking tabs should retain the ventila-
(3) Slide the ventilation housing cover in the direc-
tion housing cover securely.
tion of the arrow shown.
(4) Remove the air filter. (4) Install the insulation blanket onto the ventila-
tion housing.

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.

Fig. 3 Instrument Panel Air Outlets


1 - SCREW (15)
2 - LH END COVER
3 - RH END COVER
4 - BRACKET
5 - PASSENGER SIDE AIR OUTLET (2)
6 - DRIVER SIDE AIR OUTLET (2)

(3) If servicing the passenger side air outlets,


install the air outlet retaining bracket to the right
side of the instrument panel. Tighten the screw to 2
N·m (17 in. lbs.).
Fig. 2 Passenger Side Air Nozzle Cover (4) If servicing the passenger side air outlets,
1 - FRONT SCREWS (2) install the passenger side air nozzle assembly by
2 - BRACKET
3 - BRACKET SCREWS
pressing the nozzle assembly firmly and evenly into
4 - NOZZLE COVER the instrument panel, until the snap features are
5 - INSTRUMENT PANEL fully engaged.
(5) If servicing the passenger side air outlets,
(6) If servicing the passenger side air outlets, install the passenger side air nozzle reinforcing plate
remove the air outlet retaining bracket from the and retaining screws. Tighten the screws to 2 N·m
right side of the instrument panel (Fig. 3). (17 in. lbs.).
(7) Remove the instrument panel end cover screws (6) If servicing the passenger side air outlets,
and the left and/or right side cover. install the passenger side airbag (Refer to 8 - ELEC-
(8) Remove the air outlet retaining screws and the TRICAL/RESTRAINTS/PASSENGER AIRBAG -
air outlets as required. INSTALLATION).
(7) If servicing the driver side air outlets, install
INSTALLATION the instrument cluster bezel (Refer to 23 - BODY/IN-
(1) Install the air outlets and retaining screws as STRUMENT PANEL/CLUSTER BEZEL - INSTAL-
required. Tighten the screws to 2 N·m (17 in. lbs.). LATION).
(2) Install the left and/or right side instrument (8) Reconnect the battery negative cable.
panel end cover and retaining screws as required.
Tighten the screws to 2 N·m (17 in. lbs.).
VA DISTRIBUTION 24 - 23

BLOWER MOTOR (4) Install the ventilation housing insulation blan-


ket.
(5) Install the engine air cleaner cover (Refer to 9 -
REMOVAL
ENGINE/AIR INTAKE SYSTEM/AIR CLEANER
(1) Disconnect and isolate the negative battery
HOUSING - INSTALLATION).
cable.
(6) Reconnect the negative battery cable.
(2) Remove the engine air cleaner housing cover
(Refer to 9 - ENGINE/AIR INTAKE SYSTEM/AIR
CLEANER ELEMENT - REMOVAL). DEFROSTER DUCTS
(3) Position the ventilation housing insulation
blanket out of the way of the blower motor assembly.
REMOVAL
(4) Disconnect the wire harness connector from the
(1) Remove the instrument panel (Refer to 23 -
blower motor (Fig. 4).
BODY/INSTRUMENT PANEL - REMOVAL).
(5) Remove the three blower motor retaining
(2) Remove the screw that secures the left and/or
screws.
right side defroster duct to the heater housing,
(6) Remove the blower motor assembly from the
depending on the duct being removed (Fig. 5).
ventilation housing.
(3) Remove the defroster duct(s) from the housing.

Fig. 5 Defroster Duct - RH Shown, LH Typical


1 - HEATER HOUSING
2 - SCREW
Fig. 4 Blower Motor Assembly 3 - DEFROSTER DUCT
1 - VENTILATION HOUSING
2
3
-
-
SCREWS (3)
WIRE HARNESS CONNECTOR
INSTALLATION
4 - BLOWER MOTOR (1) Install the left and/or right side defroster duct
5 - INSULATION BLANKET on to the heater housing.
(2) Install the screw that secures the defroster
INSTALLATION duct to the housing. Tighten the screw(s) to 2 N·m
(1) Install the blower motor assembly into the ven- (17 in. lbs.).
tilation housing. (3) Install the instrument panel (Refer to 23 -
(2) Install the three blower motor retaining BODY/INSTRUMENT PANEL - INSTALLATION).
screws. Tighten the screws to 2 N·m (17 in. lbs.).
(3) Connect the wire harness connector to the
blower motor.
24 - 24 DISTRIBUTION VA

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.

WARNING: REVIEW THE WARNINGS AND CAU-


TIONS IN PLUMBING BEFORE PERFORMING THE
FOLLOWING OPERATION. (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - WARNING) (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
CAUTION)

NOTE: The HVAC housing must be removed from


the vehicle and the two halves of the housing sep-
arated for service access of the heater core, A/C
evaporator and each of the various mode doors.
Fig. 6 Floor Distribution Duct, RH Shown, LH
Typical (1) Recover the refrigerant from the refrigerant
1 - HEATER HOUSING system. (Refer to 24 - HEATING & AIR CONDI-
2 - SCREW (1) TIONING/PLUMBING - STANDARD PROCEDURE -
3 - RH FLOOR DUCT
4 - CENTER FLOOR DUCT REFRIGERANT SYSTEM RECOVERY)
(2) Partially drain the engine cooling system
INSTALLATION (Refer to 7 - COOLING/ENGINE/COOLANT - STAN-
(1) Install the center floor distribution duct onto DARD PROCEDURE - DRAINING COOLING SYS-
the heater housing. TEM).
(2) Install the shift mechanism (Refer to 21 - (3) Disconnect and isolate the negative battery
TRANSMISSION/TRANSAXLE/AUTOMATIC - cable.
NAG1/SHIFT MECHANISM - INSTALLATION). (4) Remove the air cleaner housing (Refer to 9 -
(3) Install the left and right floor distribution ENGINE/AIR INTAKE SYSTEM/AIR CLEANER
ducts onto the center floor distribution duct. HOUSING - REMOVAL).
(4) Install the left and right floor distribution duct (5) Remove the windshield washer reservoir (Refer
retaining screws to the instrument panel support. to 8 - ELECTRICAL/WIPERS/WASHERS/WASHER
Tighten the screws to 2 N·m (17 in. lbs.). RESERVOIR - REMOVAL).
VA DISTRIBUTION 24 - 25
HVAC HOUSING (Continued)
(6) Remove the air filter from the ventilation hous- (15) Install plugs in, or tape over the opened
ing (Refer to 24 - HEATING & AIR CONDITION- refrigerant line fittings and evaporator tubes.
ING/DISTRIBUTION/AIR FILTER - REMOVAL). (16) Remove the instrument panel from the vehi-
(7) Disconnect the wire harness and vacuum con- cle(Refer to 23 - BODY/INSTRUMENT PANEL -
nectors from the recirculation door actuator (Refer to REMOVAL).
24 - HEATING & AIR CONDITIONING/CONTROLS/ (17) Remove the defroster, floor distribution and
RECIRCULATION DOOR ACTUATOR - REMOVAL). instrument panel ducts (Refer to 24 - HEATING &
(8) Disconnect the wire harness connector from the AIR CONDITIONING/DISTRIBUTION/DEFROSTER
blower motor resistor block (Refer to 24 - HEATING DUCTS - REMOVAL), (Refer to 24 - HEATING &
& AIR CONDITIONING/CONTROLS/BLOWER AIR CONDITIONING/DISTRIBUTION/FLOOR DIS-
MOTOR RESISTOR BLOCK - REMOVAL). TRIBUTION DUCTS - REMOVAL) and (Refer to 24 -
(9) Disconnect the wire harness connector from the HEATING & AIR CONDITIONING/DISTRIBUTION/
blower motor (Refer to 24 - HEATING & AIR CON- INSTRUMENT PANEL DUCTS - REMOVAL).
DITIONING/DISTRIBUTION/BLOWER MOTOR - (18) Disconnect the two bulkhead ground connec-
REMOVAL). tions near instrument cluster area.
(10) Remove the nuts and washers that secure the (19) Remove the passenger airbag bracket (Refer
ventilation housing to the body and remove the ven- to 8 - ELECTRICAL/RESTRAINTS/PASSENGER
tilation housing from the vehicle (Fig. 7). AIRBAG - REMOVAL).
(20) Disconnect the wire harness connector from
the evaporator temperature sensor and air outlet
temperature sensor (Fig. 8).
(21) Remove the wire harness from the bracket
located on the right side of the heater housing and
position the wire harness out of the way.
(22) Disconnect the A/C-heater control cables from
the mode door levers (Refer to 24 - HEATING & AIR
CONDITIONING/CONTROLS/MODE DOOR CABLE
- REMOVAL).
(23) Disconnect the evaporator drain tube from the
HVAC housing.
(24) Remove the five bolts securing the HVAC
housing to the body.

NOTE: Make sure that the interior is protected in


case of loss of residual fluids from the heater core
and the A/C evaporator.

(25) Remove the HVAC housing from the vehicle.

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)

Fig. 8 Heater Housing Fig. 9 HVAC Housing


1 - HEATER HOUSING 1 - SCREW (12)
2 - AIR TEMP SENSOR WIRE CONNECTOR 2 - UPPER HOUSING
3 - WIRE HARNESS 3 - A/C EVAPORATOR
4 - WIRE HARNESS CONNECTOR 4 - EVAPORATOR O-RING SEAL (2)
5 - BOLT (4) 4 - EVAPORATOR GASKET
6 - EVAP TEMP SENSOR WIRE CONNECTOR 6 - VENTILATION HOUSING GASKET
7 - EVAPORATOR DRAIN TUBE 7 - LOWER HOUSING
8 - WIRING HARNESS
9 - BOLT (3)
(8) Remove the three heater core tube retaining 10 - HEATER CORE
bolts and the heater core tube assembly from the 11 - HEATER CORE TUBE ASSEMBLY
heater core. 12 - HEATER CORE TUBE GASKET
13 - HEATER CORE TUBE O-RING SEAL (2)
(9) Remove the heater core tube seals and discard.
(10) Install plug in, or tape over the opened heater
(9) Install the gasket for the A/C evaporator and
core fittings.
heater core tube outlets and the gasket that seals the
(11) Remove the A/C evaporator from the lower
ventilation housing to the HVAC housing.
housing.
(10) Install the HVAC housing (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION/
ASSEMBLY HVAC HOUSING - INSTALLATION).
(1) Install the A/C evaporator into the lower hous-
ing.
INSTALLATION
(2) Remove the tape or plugs from the heater core
fittings. WARNING: REVIEW THE WARNINGS AND CAU-
(3) Lubricate two new rubber O-ring seals with TIONS IN PLUMBING BEFORE PERFORMING THE
clean engine coolant and install them onto the heater FOLLOWING OPERATION. (Refer to 24 - HEATING &
core fitting. AIR CONDITIONING/PLUMBING - WARNING) (Refer
(4) Connect the heater core tube assembly to the to 24 - HEATING & AIR CONDITIONING/PLUMBING -
heater core and install the three retaining bolts. CAUTION)
Tighten the bolts to 5 N·m (45 in. lbs.).
(5) Install the wire harness.
(6) Install the heater core into the lower housing. NOTE: High pressures are produced in the refriger-
(7) Install the two housing halves together. ant system when the A/C compressor is operating.
(8) Install the 12 screws that secure the two hous- Extreme care must be exercised to make sure that
ing halves together. Tighten the screws to 2 N·m (17 each of the refrigerant system connections is pres-
in. lbs.). sure-tight and leak free.
VA DISTRIBUTION 24 - 27
HVAC HOUSING (Continued)
(1) Position the HVAC housing to the dash panel. (15) Install the ventilation housing to the dash
Be certain that the evaporator condensate drain tube panel.
is positioned correctly. (16) Install the nuts and washers that secure the
(2) Install the screws that secure the HVAC hous- ventilation housing to the dash panel. Tighten the
ing to the dash panel. Tighten the screws to 4.5 N·m nuts to 5 N·m (45 in. lbs.).
(40 in. lbs.). (17) Connect the wire harness connectors to the
(3) Connect the HVAC housing wire harness con- blower motor, blower motor resistor block and the
nectors and install the wiring harness to the bracket. recirculation door actuator.
(4) Connect the A/C-heater control cables to the (18) Connect the vacuum harness connector to the
mode door levers (Refer to 24 - HEATING & AIR recirculation door actuator.
CONDITIONING/CONTROLS/MODE DOOR CABLE (19) Install the air filter into the ventilation hous-
- INSTALLATION). ing (Refer to 24 - HEATING & AIR CONDITION-
(5) Reinstall the passenger airbag bracket (Refer ING/DISTRIBUTION/AIR FILTER -
to 8 - ELECTRICAL/RESTRAINTS/PASSENGER INSTALLATION).
AIRBAG - INSTALLATION). (20) Install the windshield washer reservoir (Refer
(6) Reconnect the two bulkhead ground connection to 8 - ELECTRICAL/WIPERS/WASHERS/WASHER
near the instrument cluster area. RESERVOIR - INSTALLATION).
(7) Reinstall the defroster, floor distribution and (21) Install the air cleaner housing (Refer to 9 -
instrument panel ducts. ENGINE/AIR INTAKE SYSTEM/AIR CLEANER
(8) Reinstall the instrument panel (Refer to 23 - HOUSING - INSTALLATION).
BODY/INSTRUMENT PANEL/INSTRUMENT (22) Reconnect the negative battery cable.
PANEL ASSEMBLY - INSTALLATION). (23) Refill the engine cooling system (Refer to 7 -
(9) Unplug or remove the tape from the opened COOLING/ENGINE/COOLANT - STANDARD PRO-
refrigerant line fittings. CEDURE - COOLANT SYSTEM FILL).
(10) Lubricate two new rubber O-ring seals with (24) Evacuate the refrigerant system (Refer to 24 -
clean refrigerant oil and install them onto the evap- HEATING & AIR CONDITIONING/PLUMBING -
orator core fittings. STANDARD PROCEDURE - REFRIGERANT SYS-
(11) Connect the refrigerant line terminal block to TEM EVACUATE).
the evaporator tubes. (25) Charge the refrigerant system (Refer to 24 -
(12) Install the two bolts that secure the refriger- HEATING & AIR CONDITIONING/PLUMBING -
ant line terminal block to the A/C evaporator. STANDARD PROCEDURE - REFRIGERANT SYS-
Tighten the bolts to 5 N·m (45 in. lbs.). TEM CHARGE).
(13) Unplug or remove the tape from the heater (26) Start the engine and check for proper opera-
core hoses and tubes. tion of the heating and air conditioning systems.
(14) Connect the heater hoses to the heater core
tubes and install the heater hose clamps.
24 - 28 DISTRIBUTION VA

INSTRUMENT PANEL DUCTS


REMOVAL
(1) Remove the instrument panel (Refer to 23 -
BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL ASSEMBLY - REMOVAL).
(2) Remove the defroster ducts (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION/
DEFROSTER DUCTS - REMOVAL).
(3) Remove the floor distribution ducts (Refer to 24
- HEATING & AIR CONDITIONING/DISTRIBU-
TION/FLOOR DISTRIBUTION DUCTS -
REMOVAL).
(4) If removing the right instrument panel duct,
remove the passenger air bag module and bracket
(Refer to 8 - ELECTRICAL/RESTRAINTS/PASSEN-
GER AIRBAG - REMOVAL).
(5) Remove the screws that secure the left and/or
right instrument panel duct and remove the duct(s)
Fig. 10 Instrument Panel Duct - RH Shown, LH
as required (Fig. 10).
Typical
1 - RH DEFROSTER DUCT
INSTALLATION 2 - SCREW (2)
(1) Connect the instrument panel duct(s) to the 3 - RH INSTRUMENT PANEL DUCT
heater housing as required. 4 - RH FLOOR DISTRIBUTION DUCT
5 - CENTER FLOOR DISTRIBUTION DUCT
(2) Install the instrument panel duct retaining
screws. Tighten the screws to 2 N·m (17 in. lbs.). (5) Install the defroster ducts (Refer to 24 - HEAT-
(3) If servicing the right instrument panel duct, ING & AIR CONDITIONING/DISTRIBUTION/DE-
install the passenger air bag module and bracket FROSTER DUCTS - INSTALLATION).
(Refer to 8 - ELECTRICAL/RESTRAINTS/PASSEN- (6) Install the instrument panel (Refer to 23 -
GER AIRBAG - INSTALLATION). BODY/INSTRUMENT PANEL/INSTRUMENT
(4) Install the floor distribution ducts (Refer to 24 PANEL ASSEMBLY - INSTALLATION).
- HEATING & AIR CONDITIONING/DISTRIBU-
TION/FLOOR DISTRIBUTION DUCTS - INSTAL-
LATION).
VA PLUMBING 24 - 29

PLUMBING

TABLE OF CONTENTS
page page

PLUMBING A/C EXPANSION VALVE


DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 29 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 41
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
WARNING DIAGNOSIS AND TESTING
ENGINE COOLING SYSTEM . . . . . . . . . . . . . 30 A/C EXPANSION VALVE . . . . . . . . . . . . . . . . 41
A/C SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 30 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
CAUTION - A/C SYSTEM . . . . . . . . . . . . . . . . . 30 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 41
DIAGNOSIS AND TESTING ELECTRIC COOLANT PUMP
REFRIGERANT SYSTEM LEAKS . . . . . . . . . . 31 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 42
STANDARD PROCEDURE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
REFRIGERANT SYSTEM SERVICE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . 31 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 43
REFRIGERANT SYSTEM RECOVERY . . . . . . 32 HEATER CORE
REFRIGERANT SYSTEM EVACUATE . . . . . . 32 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 43
REFRIGERANT SYSTEM CHARGE . . . . . . . . 33 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
A/C COMPRESSOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 34 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 44
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 LIQUID LINE
DIAGNOSIS AND TESTING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
A/C COMPRESSOR NOISE . . . . . . . . . . . . . . 34 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 45
REMOVAL RECEIVER/DRIER
DENSO 7SBU16C A/C COMPRESSOR . . . . . 35 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 46
DENSO 10S17 A/C COMPRESSOR . . . . . . . . 36 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
INSTALLATION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
DENSO 7SBU16C A/C COMPRESSOR . . . . . 36 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 46
DENSO 10S17 A/C COMPRESSOR . . . . . . . . 37 REFRIGERANT
A/C CONDENSER DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 47
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 37 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 REFRIGERANT OIL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 47
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 38 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
A/C DISCHARGE LINE STANDARD PROCEDURE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 REFRIGERANT OIL LEVEL . . . . . . . . . . . . . . 47
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 39 SUCTION LINE
A/C EVAPORATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 40 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 49
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 WATER VALVE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 40 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 49

PLUMBING this vehicle. This nylon tube helps to further contain


the R-134a refrigerant, which has a smaller molecu-
lar structure than R-12 refrigerant. The ends of the
DESCRIPTION
refrigerant hoses are made from lightweight alumi-
The refrigerant lines and hoses are used to carry
num or steel, and commonly use braze-less fittings.
the refrigerant between the various air conditioning
Any kinks or sharp bends in the refrigerant plumb-
system components. A barrier hose design with a
ing will reduce the capacity of the entire air condi-
nylon tube, which is sandwiched between rubber lay-
tioning system. Kinks and sharp bends reduce the
ers, is used for the R-134a air conditioning system on
flow of refrigerant in the system. A good rule for the
24 - 30 PLUMBING VA
PLUMBING (Continued)
flexible hose refrigerant lines is to keep the radius of temperature and altitude is extremely high. As a result,
all bends at least ten times the diameter of the hose. anything that comes in contact with the refrigerant will
In addition, the flexible hose refrigerant lines should freeze. Always protect the skin or delicate objects
be routed so they are at least 80 millimeters (3 from direct contact with the refrigerant.
inches) from the exhaust manifold. The R-134a service equipment or the vehicle refriger-
ant system should not be pressure tested or leak
OPERATION tested with compressed air. Some mixtures of air and
High pressures are produced in the refrigerant sys- R-134a have been shown to be combustible at ele-
tem when the air conditioning compressor is operat- vated pressures. These mixtures are potentially dan-
ing. Extreme care must be exercised to make sure gerous, and may result in fire or explosion causing
that each of the refrigerant system connections is property damage, personal injury or death.
pressure-tight and leak free. It is a good practice to
inspect all flexible hose refrigerant lines at least once CAUTION - A/C SYSTEM
a year to make sure they are in good condition and
properly routed. CAUTION: Liquid refrigerant is corrosive to metal
The refrigerant lines and hoses cannot be repaired surfaces. Follow the operating instructions supplied
and, if faulty or damaged, they must be replaced. with the service equipment being used.
Never add R-12 to a refrigerant system designed to
use R-134a and do not use R-12 equipment or parts
WARNING on the R-134a system. They are not compatible and
damage to the refrigerant system will result.
ENGINE COOLING SYSTEM Do not overcharge the refrigerant system. Over-
charging will cause excessive compressor head
WARNING: The engine cooling system is designed pressure and can cause noise and system failure.
to develop internal pressures of 97 to 123 kilopas- Recover the refrigerant before removing any sec-
cals (14 to 18 pounds per square inch). Do not ondary retaining clips, if equipped. Recover the
remove or loosen the coolant pressure cap, cylin- refrigerant before opening any fitting or connection.
der block drain plugs, radiator drain, radiator Before disconnecting a refrigerant line or hose,
hoses, heater hoses, or hose clamps while the clean the outside of the fittings thoroughly to pre-
engine cooling system is hot and under pressure. vent contamination from entering the refrigerant
Allow the vehicle to cool for a minimum of 15 min- system. Open the fittings with caution, even after
utes before opening the cooling system for service. the system has been discharged.
Failure to observe this warning can result in seri- Do not open the refrigerant system or uncap a
ous burns from the heated engine coolant. replacement component until you are ready to ser-
vice the system. This will prevent contamination in
the system. Immediately after disconnecting a com-
A/C SYSTEM ponent from the refrigerant system, seal the open
fittings with a cap or plug.
WARNING: The A/C system contains refrigerant under
The internal parts of the A/C system will remain sta-
high pressure. Repairs should only be performed by
ble as long as moisture-free refrigerant and refrig-
qualified service personnel. Severe personal injury or
erant oil is used. Abnormal amounts of dirt,
death may result from improper service procedures.
moisture or air can upset the chemical stability.
Avoid breathing the refrigerant and refrigerant oil
This may cause operational troubles or even seri-
vapor or mist. Exposure may irritate the eyes, nose,
ous damage if present in more than very small
and/or throat. Wear eye protection when servicing the
quantities.
air conditioning refrigerant system. Serious eye injury
Refrigerant oil will absorb moisture from the atmo-
can result from direct contact with the refrigerant. If
sphere if left uncapped. Do not open a container of
eye contact occurs, seek medical attention immedi-
refrigerant oil until you are ready to use it. Replace
ately.
the cap on the oil container immediately after using.
Do not expose the refrigerant to open flame. Poison-
Store refrigerant oil only in a clean, airtight, and
ous gas is created when refrigerant is burned. An elec-
moisture-free container.
tronic leak detector is recommended.
All tools, including the refrigerant dispensing mani-
If accidental system discharge occurs, ventilate the
fold, manifold gauge set and test hoses should be
work area before resuming service. Large amounts of
kept clean and dry. Keep the work area clean. Con-
refrigerant released in a closed work area will displace
tamination of the refrigerant system must be
the oxygen and cause suffocation and death.
avoided to ensure proper A/C system operation.
The evaporation rate of R-134a refrigerant at average
VA PLUMBING 24 - 31
PLUMBING (Continued)
CAUTION: The use of A/C system sealers may DARD PROCEDURE - REFRIGERANT SYSTEM
result in damage to A/C refrigerant recovery/evacu- CHARGE)
ation/recharging equipment and/or A/C systems. (3) Position the vehicle in a wind-free work area.
Many federal, state/provincial and local regulations This will aid in detecting small leaks.
prohibit the recharge of A/C systems with known (4) With the engine not running, use a electronic
leaks. DaimlerChrysler recommends the detection R-134a leak detector and search for leaks. Because
of A/C system leaks through the use of approved R-134a refrigerant is heavier than air, the leak detec-
leak detectors and fluorescent leak detection dyes. tor probe should be moved slowly along the bottom
Vehicles found with A/C system sealers should be side of all refrigerant lines, connector fittings and
treated as contaminated and replacement of the components.
entire A/C refrigerant system is recommended. A/C (5) To inspect the evaporator coil for leaks, insert
systems found to be contaminated with A/C system the electronic leak detector probe into the center
sealers, A/C stop-leak products or seal conditioners instrument panel outlet. Set the blower motor switch
voids the warranty for the A/C system. to the lowest speed position, the A/C button in the
On position, and select the Recirculation Mode.

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)

A R-134a refrigerant recovery/recycling/charging


station that meets SAE Standard J2210 must be
used to recover the refrigerant from an R-134a refrig-
erant system. Refer to the operating instructions sup-
plied by the equipment manufacturer for the proper
care and use of this equipment.

REFRIGERANT SYSTEM EVACUATE


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) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION)

If the refrigerant system has been open to the


atmosphere, it must be evacuated before the system
can be charged. If moisture and air enters the system
Fig. 1 Manifold Gauge Set - Typical and becomes mixed with the refrigerant, the com-
1 - HIGH PRESSURE GAUGE pressor head pressure will rise above acceptable
2 - VALVE
3 - VACUUM/REFRIGERANT HOSE (YELLOW W/ BLACK STRIPE) operating levels. This will reduce the performance of
4 - HIGH PRESSURE HOSE (RED W/ BLACK STRIPE) the air conditioner and damage the compressor.
5 - LOW PRESSURE HOSE (BLUE W/ BLACK STRIPE) Evacuating the refrigerant system will remove the
6 - VALVE
7 - LOW PRESSURE GAUGE air and boil the moisture out of the system at near
room temperature. To evacuate the refrigerant sys-
MANIFOLD GAUGE SET CONNECTIONS tem, use the following procedure:
(1) Connect a R-134a refrigerant recovery/recy-
CAUTION: Do not use an R-12 manifold gauge set cling/charging station that meets SAE Standard
on an R-134a system. The refrigerants are not com- J2210 and a manifold gauge set to the refrigerant
patible and system damage will result. system of the vehicle.
(2) Open the low and high side valves and start
LOW PRESSURE GAUGE HOSE The low pressure the charging station vacuum pump. When the suc-
hose (Blue with Black stripe) attaches to the suction tion gauge reads 88 kPa (26 in. Hg.) vacuum or
service port. This port is located on the suction line greater, close all of the valves and turn off the vac-
near the dash panel. uum pump.
HIGH PRESSURE GAUGE HOSE The high pres- (a) If the refrigerant system fails to reach the
sure hose (Red with Black stripe) attaches to the dis- specified vacuum, the system has a leak that must
VA PLUMBING 24 - 33
PLUMBING (Continued)
be corrected. (Refer to 24 - HEATING & AIR CON- and outlet tube temperatures are measured. The
DITIONING/PLUMBING - DIAGNOSIS AND temperature difference is measured with a tempera-
TESTING - REFRIGERANT SYSTEM LEAKS) ture meter with one or two clamp-on thermocouple
(b) If the refrigerant system maintains the spec- probes. The difference between the evaporator inlet
ified vacuum for five minutes, restart the vacuum and outlet tube temperatures will determine the
pump, open the suction and discharge valves and amount of refrigerant needed.
evacuate the system for an additional ten minutes. Before adding a partial refrigerant charge, check
(3) Close all of the valves, and turn off the charg- for refrigerant system leaks. (Refer to 24 - HEATING
ing station vacuum pump. & AIR CONDITIONING/PLUMBING - DIAGNOSIS
(4) The refrigerant system is now ready to be AND TESTING - REFRIGERANT SYSTEM LEAKS)
charged with R-134a refrigerant. (Refer to 24 - If a leak is found, make the necessary repairs before
HEATING & AIR CONDITIONING/PLUMBING - attempting a full or partial refrigerant charge.
STANDARD PROCEDURE - REFRIGERANT SYS- (1) Attach a manifold gauge set to the refrigerant
TEM CHARGE) system service ports.
(2) Attach the two clamp-on thermocouple probes
REFRIGERANT SYSTEM CHARGE to the inlet and outlet tubes of the evaporator coil.
• If a single thermocouple probe is used, attach
WARNING: REVIEW THE WARNINGS AND CAU- the probe to the evaporator inlet tube just before the
TIONS IN THE FRONT OF THIS SECTION BEFORE collar of the refrigerant line connector fitting. The
PERFORMING THE FOLLOWING OPERATION. probe must make contact with the bottom surface of
(Refer to 24 - HEATING & AIR CONDITIONING/ the evaporator inlet tube.
PLUMBING - WARNING) (Refer to 24 - HEATING & • If dual thermocouple probes are used, attach
AIR CONDITIONING/PLUMBING - CAUTION) probe 1 to the evaporator inlet tube, and probe 2 to
the evaporator outlet tube. Attach both probes to the
evaporator tubes just before the collar of the refrig-
CAUTION: A small amount of refrigerant oil is erant line connector fittings. The probes must make
removed from the A/C system each time the refrig- contact with the bottom surfaces of the evaporator
erant system is recovered and evacuated. Before inlet and outlet tubes.
charging the A/C system, you MUST replenish any (3) Open all of the windows or doors of the passen-
oil lost during the recovery process. Refer the ger compartment.
equipment manufacturer instructions for more infor- (4) Set the A/C button on the A/C Heater controls
mation. to the on position, the temperature control knob in
the full cool position, select Recirculation Mode, and
After the refrigerant system has been tested for
place the blower motor switch in the highest speed
leaks and evacuated, a refrigerant charge can be
position.
injected into the system. (Refer to 24 - HEATING &
(5) Start the engine and hold the engine idle speed
AIR CONDITIONING/PLUMBING - SPECIFICA-
at 1,000 rpm. Allow the engine to warm up to normal
TIONS - CHARGE CAPACITY)
operating temperature.
A R-134a refrigerant recovery/recycling/charging
(6) The compressor clutch may cycle, depending
station that meets SAE Standard J2210 must be
upon ambient temperature, humidity, and the refrig-
used to charge the refrigerant system with R-134a
erant system charge level.
refrigerant. Refer to the operating instructions sup-
(7) Hold the engine idle speed at 1,000 rpm.
plied by the equipment manufacturer for proper care
(8) Allow three to five minutes for the refrigerant
and use of this equipment.
system to stabilize, then record the temperatures of
PARTIAL CHARGE METHOD the evaporator inlet and outlet tubes.
• If a single probe is used, record the temperature
WARNING: REVIEW THE WARNINGS AND CAU- of the evaporator inlet tube. Then remove the probe
TIONS IN THE FRONT OF THIS SECTION BEFORE from the inlet tube and attach it to the evaporator
PERFORMING THE FOLLOWING OPERATION. outlet tube just before the collar of the refrigerant
(Refer to 24 - HEATING & AIR CONDITIONING/ line connector fitting. The probe must make contact
PLUMBING - WARNING) (Refer to 24 - HEATING & with the bottom surface of the evaporator outlet tube.
AIR CONDITIONING/PLUMBING - CAUTION) Allow the thermocouple and meter time to stabilize,
then record the temperature of the evaporator outlet
The partial charge method is used to add a partial tube. Subtract the inlet tube temperature reading
charge to a refrigerant system that is low on refrig- from the outlet tube temperature reading.
erant. To perform this procedure the evaporator inlet
24 - 34 PLUMBING VA
PLUMBING (Continued)
• If dual probes are used, record the temperatures couple measurements. Record the temperature differ-
of both the evaporator inlet and outlet tubes. Then ence to determine if an additional charge is required.
subtract the inlet tube temperature reading from the (11) Record the compressor discharge pressure. If
outlet tube temperature reading. the reading is higher than the pressure shown in the
(9) If the measured temperature differential is Compressor Discharge Pressure Chart, the system
higher than 22° C to 26° C (40° F to 47° F), add 0.4 could be overcharged. If the reading is equal to, or
kilograms (14 ounces) of refrigerant. lower, than the pressure shown in the chart, continue
(10) Allow three to five minutes for the refrigerant with this procedure.
system to stabilize, then take a second set of thermo-

Compressor Discharge Pressure Chart


Ambient 16°C 21°C 27°C 32°C 38°C 43°C
Temperature (60°F) (70°F) (80°F) (90°F) (100°F) (110°F)
Compressor 1378 kPa 1516 kPa 1723 kPa 1930 kPa 2206 kPa 2413 kPa
Discharge (200 psi) (220 psi) (250psi) (280 psi) (320 psi) (350 psi)
Pressure

(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.

Fig. 2 Denso 7SBU16C A/C Compressor


1 - A/C COMPRESSOR
2 - O-RING SEAL
3 - A/C SUCTION LINE
4 - BOLT
5 - RETAINING CLIP
6 - BOLT
7 - A/C DISCHARGE LINE
8 - O-RING SEAL

DENSO 10S17 A/C COMPRESSOR


WARNING: Refer to the applicable warnings and
cautions for this system before performing the fol-
lowing operation (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - WARNING - A/C Fig. 3 Denso 10S17 A/C Compressor
PLUMBING) and (Refer to 24 - HEATING & AIR CON- 1 - REFRIGERANT LINES
DITIONING/PLUMBING - CAUTION - A/C PLUMB- 2 - WIRE HARNESS CONNECTOR
ING). Failure to follow the warnings and cautions 3 - BOLTS (3)
4 - A/C COMPRESSOR
could result in possible personal injury or death.
INSTALLATION
NOTE: The A/C compressor may be removed and
repositioned without disconnecting the refrigerant DENSO 7SBU16C A/C COMPRESSOR
lines or discharging the refrigerant system. Dis-
charging is not necessary if servicing the compres- NOTE: Be certain to check the refrigerant oil level if
sor clutch, clutch coil or the engine. the A/C compressor is being replaced. See Refriger-
ant Oil Level in this group for the procedures. Use
(1) Recover the refrigerant from the refrigerant only refrigerant oil of the type recommended for the
system (Refer to 24 - HEATING & AIR CONDITION- A/C compressor in the vehicle.
ING/PLUMBING - STANDARD PROCEDURE -
REFRIGERANT SYSTEM RECOVERY). (1) Position the A/C compressor in the engine com-
(2) Disconnect and isolate the negative battery partment and loosely install the three compressor
cable. retaining bolts. Tighten the bolts using the following
(3) Raise and support the vehicle. sequence to 20 N·m (15 ft. lbs.).
• The upper bolt at the front of the compressor.
• The lower bolt at the front of the compressor.
VA PLUMBING 24 - 37
A/C COMPRESSOR (Continued)
• The bolt at the rear of the compressor. R-134a system. Use only refrigerant oil of the type
(2) If equipped with an add-on rear A/C system, recommended for the A/C compressor in the vehicle.
install the lower A/C compressor (Refer to 24 - HEAT- (4) Connect the A/C suction and discharge lines to
ING & AIR CONDITIONING/PLUMBING/A/C COM- the A/C compressor.
PRESSOR - INSTALLATION - DENSO 10S17). (5) Install the bolts that secure the A/C suction
(3) Lower the vehicle. and discharge lines to the A/C compressor. Tighten
(4) Remove the tape or plugs from the opened suc- the bolts to 23 N·m (17 ft. lbs.).
tion line fitting and the discharge line fitting and the (6) Connect the wire harness connector to the A/C
compressor ports. compressor clutch coil.
(5) Lubricate new rubber O-ring seals with clean (7) Install the accessory drive belt (Refer to 7 -
refrigerant oil and install them onto the suction and COOLING/ACCESSORY DRIVE/BELTS-DRIVE -
the discharge line fittings. Use only the specified INSTALLATION).
O-rings as they are made of a special material for the (8) Lower the vehicle.
R-134a system. Use only refrigerant oil of the type (9) Reconnect the negative battery cable.
recommended for the A/C compressor in the vehicle. (10) Evacuate the refrigerant system (Refer to 24 -
(6) Connect the A/C suction and discharge lines to HEATING & AIR CONDITIONING/PLUMBING -
the A/C compressor. STANDARD PROCEDURE - REFRIGERANT SYS-
(7) Install the bolts that secure the A/C suction TEM EVACUATE).
and discharge lines to the A/C compressor. Tighten (11) Charge the refrigerant system (Refer to 24 -
the bolts to 23 N·m (17 ft. lbs.). HEATING & AIR CONDITIONING/PLUMBING -
(8) Connect the wire harness connector to the A/C STANDARD PROCEDURE - REFRIGERANT SYS-
compressor clutch coil. TEM CHARGE).
(9) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION). A/C CONDENSER
(10) Reconnect the negative battery cable.
(11) Evacuate the refrigerant system (Refer to 24 - DESCRIPTION
HEATING & AIR CONDITIONING/PLUMBING - The condenser is located in the air flow in front of
STANDARD PROCEDURE - REFRIGERANT SYS- the engine cooling radiator. The condenser is a heat
TEM EVACUATE). exchanger that allows the high-pressure refrigerant
(12) Charge the refrigerant system (Refer to 24 - gas being discharged by the compressor to give up its
HEATING & AIR CONDITIONING/PLUMBING - heat to the air passing over the condenser fins.
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE). OPERATION
When the refrigerant gas gives up its heat, it con-
DENSO 10S17 A/C COMPRESSOR denses. When the refrigerant leaves the condenser, it
has become a high-pressure liquid refrigerant. The
NOTE: Be certain to check the refrigerant oil level if volume of air flowing over the condenser fins is crit-
the A/C compressor is being replaced. See Refriger- ical to the proper cooling performance of the air con-
ant Oil Level in this group for the procedures. Use ditioning system. Therefore, it is important that
only refrigerant oil of the type recommended for the there are no objects placed in front of the radiator
A/C compressor in the vehicle. grille openings in the front of the vehicle or foreign
material on the condenser fins that might obstruct
(1) Position the A/C compressor in the engine com- proper air flow. Also, any factory-installed air seals or
partment and loosely install the three compressor shrouds must be properly reinstalled following radia-
retaining bolts. Tighten the bolts using the following tor or condenser service.
sequence to 20 N·m (15 ft. lbs.). The condenser cannot be repaired and, if faulty or
• The upper bolt at the front of the compressor. damaged, it must be replaced.
• The lower bolt at the front of the compressor.
• The bolt at the rear of the compressor.
(2) Remove the tape or plugs from the opened suc-
tion line fitting and the discharge line fitting and the
compressor ports.
(3) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them onto the suction and
the discharge line fittings. Use only the specified
O-rings as they are made of a special material for the
24 - 38 PLUMBING VA
A/C CONDENSER (Continued)

REMOVAL
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
WARNING) and (Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING - CAUTION).

(1) Disconnect and isolate the negative battery


cable.
(2) Recover the refrigerant from the refrigerant
system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - STANDARD PROCEDURE -
REFRIGERANT SYSTEM RECOVERY).
(3) Remove the front fascia.
(4) Remove the grille (Refer to 23 - BODY/EXTE-
RIOR/GRILLE - REMOVAL).
(5) Remove the headlamps from their mounts.
(6) Remove the radiator crossmember (Refer to 23
- BODY/EXTERIOR/RADIATOR CROSSMEMBER - Fig. 4 A/C Condenser
REMOVAL). 1 - SCREW (4)
(7) Disconnect the A/C discharge and liquid lines 2 - CONDENSER
from the A/C condenser and remove and discard the 3 - LIQUID REFRIGERANT LINE
4 - COMPRESSOR DISCHARGE LINE
O-ring seals (Fig. 4). 5 - NUT (2)
(8) Install plug in, or tape over the opened liquid 6 - LOWER AUXILIARY FAN BRACKET
line fitting and the condenser ports. 7 - NUT (2)
8 - WIRE HARNESS CONNECTOR
(9) Disconnect the wire harness connector from the 9 - AUXILIARY COOLING FAN
auxiliary fan. 10 - SCREW (2)
(10) Remove the auxiliary fan and upper bracket
assembly. (6) Remove the tape or plug from the condenser
(11) Remove the auxiliary fan lower bracket ports and the opened refrigerant line fittings.
retainers and bracket. (7) Lubricate a new rubber O-ring seal with clean
(12) Remove the four condenser retaining screws. refrigerant oil and install it on the refrigerant line
(13) Carefully remove the condenser from the vehi- fittings.
cle. (8) Connect the A/C discharge and liquid lines to
the A/C condenser.
INSTALLATION (9) Install the nuts that secure the A/C discharge
and liquid lines to the A/C condenser. Tighten the
NOTE: If the A/C condenser is being replaced, add nuts to 33 N·m (24 ft. lbs.).
30 milliliters (1 fluid ounce) of refrigerant oil to the (10) Install the radiator crossmember (Refer to 23
refrigerant system. Use only refrigerant oil of the - BODY/EXTERIOR/RADIATOR CROSSMEMBER -
type recommended for the A/C compressor in the INSTALLATION).
vehicle. (11) Install the headlamps into their mounts.
(12) Install the grille (Refer to 23 - BODY/EXTE-
(1) Carefully position the A/C condenser into the RIOR/GRILLE - INSTALLATION).
engine compartment. (13) Install the front fascia.
(2) Install the four screws that secure the A/C con- (14) Reconnect the negative battery cable.
denser. Tighten the screws to 2 N·m (17 in. lbs.). (15) Evacuate the refrigerant system (Refer to 24 -
(3) Install the lower auxiliary fan bracket and HEATING & AIR CONDITIONING/PLUMBING -
retaining nuts. Tighten the nuts to 5 N·m (45 in. STANDARD PROCEDURE - REFRIGERANT SYS-
lbs.). TEM EVACUATE).
(4) Install the auxiliary fan and upper bracket (16) Recharge the refrigerant system (Refer to 24 -
assembly. Tighten the screws to 5 N·m (45 in. lbs.). HEATING & AIR CONDITIONING/PLUMBING -
(5) Connect the wire harness connector to the aux- STANDARD PROCEDURE - REFRIGERANT SYS-
iliary fan. TEM CHARGE).
VA PLUMBING 24 - 39

A/C DISCHARGE 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).

(1) Disconnect and isolate the negative battery


cable.
(2) Recover the refrigerant from the refrigerant
system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - STANDARD PROCEDURE -
REFRIGERANT RECOVERY).
(3) Remove the grille (Refer to 23 - BODY/EXTE-
RIOR/GRILLE - REMOVAL).
(4) Remove the nut that secures the discharge line
fitting to the condenser on the left side of the con-
denser.
(5) Disconnect the discharge line fitting from the Fig. 5 A/C Compressor - Refrigerant Lines
condenser inlet port. 1 - A/C COMPRESSOR
(6) Remove the seal from the discharge line fitting 2 - O-RING SEAL
3 - A/C SUCTION LINE
and discard. 4 - BOLT
(7) Install plug in, or tape over the opened dis- 5 - RETAINING CLIP
charge line fitting and the condenser inlet port. 6 - BOLT
7 - A/C DISCHARGE LINE
(8) Remove the bolt that secures the discharge line 8 - O-RING SEAL
fitting to the top of the compressor (Fig. 5).
(9) Disconnect the discharge line fitting from the (3) Lubricate a new rubber O-ring seal with clean
compressor discharge port. refrigerant oil and install it on the discharge line fit-
(10) Remove the seal from the discharge line fit- ting.
ting and discard. (4) Connect the discharge line fitting to the com-
(11) Install plug in, or tape over the opened dis- pressor discharge port on the top of the compressor.
charge line fitting and the compressor discharge port. (5) Install the bolt that secures the discharge line
(12) Disconnect the discharge line from the retain- fitting to the compressor. Tighten the bolt to 23 N·m
ing clip and remove the discharge line from the vehi- (17 ft. lbs.).
cle. (6) Remove the tape or plugs from the condenser
inlet port and the discharge line fitting.
INSTALLATION (7) Lubricate a new rubber O-ring seal with clean
Any kinks or sharp bends in the refrigerant plumb- refrigerant oil and install it on the discharge line fit-
ing will reduce the capacity of the entire air condi- ting.
tioning system. Kinks and sharp bends reduce the (8) Connect the discharge line fitting to the con-
flow of refrigerant in the system. A good rule for the denser inlet port.
flexible hose refrigerant lines is to keep the radius of (9) Install the nut that secures the discharge line
all bends at least ten times the diameter of the hose. fitting to the condenser. Tighten the nut to 33 N·m
In addition, the flexible hose refrigerant lines should (24 ft. lbs.).
be routed so they are at least 80 millimeters (3 (10) Install the grille(Refer to 23 - BODY/EXTERI-
inches) from the exhaust manifold. OR/GRILLE - INSTALLATION).
(1) Position the discharge line into the engine com- (11) Evacuate the refrigerant system. (Refer to 24 -
partment. HEATING & AIR CONDITIONING/PLUMBING -
(2) Remove the tape or plugs from the compressor STANDARD PROCEDURE - REFRIGERANT SYS-
discharge port and the discharge line fitting. TEM EVACUATE)
24 - 40 PLUMBING VA
A/C DISCHARGE LINE (Continued)
(12) Charge the refrigerant system. (Refer to 24 - (1) Remove the HVAC housing (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING - HEATING & AIR CONDITIONING/DISTRIBUTION/
STANDARD PROCEDURE - REFRIGERANT SYS- HVAC HOUSING - REMOVAL).
TEM CHARGE) (2) Disassemble the HVAC housing to access the
(13) Reconnect the negative battery cable. A/C evaporator (Refer to 24 - HEATING & AIR CON-
DITIONING/DISTRIBUTION/HVAC HOUSING -
DISASSEMBLY).
A/C EVAPORATOR (3) Lift the A/C evaporator out of the lower half of
the HVAC housing (Fig. 6).
DESCRIPTION
The evaporator is located in the heater housing,
behind the instrument panel. The evaporator is posi-
tioned in the housing so that all air that enters the
housing must pass over the fins of the evaporator
coils before it is distributed through the system ducts
and outlets. However, air passing over the evaporator
coil fins will only be conditioned when the compres-
sor is engaged and refrigerant is circulating through
the evaporator coil tubes.

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 (1) Recover the refrigerant from the A/C system-


High-pressure, high temperature liquid refrigerant (Refer to 24 - HEATING & AIR CONDITIONING/
from the liquid line passes through the expansion PLUMBING - STANDARD PROCEDURE -
valve orifice, converting it into a low-pressure, low- REFRIGERANT SYSTEM RECOVERY).
temperature mixture of liquid and gas before it (2) Disconnect and isolate the negative battery
enters the evaporator coil. A thermal sensor in the cable.
expansion valve monitors the temperature of the (3) Remove the nut that secures the suction and
refrigerant leaving the evaporator coil through the liquid line fittings to the stud on the A/C expansion
suction line, and adjusts the orifice size at the liquid valve (Fig. 7).
line to let the proper amount of refrigerant into the (4) Disconnect the suction and liquid lines from
evaporator to meet the vehicle cooling requirements. the expansion valve.
Controlling the refrigerant flow through the evapora- (5) Remove the seals from the suction and liquid
tor ensures that none of the refrigerant leaving the line fitting and discard.
evaporator is still in a liquid state, which could cause (6) Install plugs in, or tape over the opened liquid
damage to the compressor. and suction line fittings and both expansion valve
The expansion valve is factory calibrated and can- ports.
not be adjusted or repaired. If faulty or damaged, the (7) Remove the two bolts that secure the expan-
expansion valve must be replaced. sion valve to the evaporator tube tapping plate.
(8) Remove the expansion valve from the evapora-
tor tube tapping plate.
DIAGNOSIS AND TESTING (9) Remove the seals from the evaporator inlet and
outlet tube fittings and discard.
A/C EXPANSION VALVE (10) Install plugs in, or tape over the opened evap-
The A/C expansion valve is located on the engine orator inlet and outlet tube fittings and both expan-
side of the dash panel near the shock tower. sion valve ports.
The A/C expansion valve can fail in three different
positions (open, closed or restricted). INSTALLATION
In an Open Position: this will result in a noisy A/C (1) Remove the tape or plugs from the tapping
compressor or no cooling. The cause can be broken plate evaporator inlet and outlet tube fittings and
spring, broken ball or excessive moisture in the A/C both ports on the back of the A/C expansion valve.
system. If the spring or ball are found to be defective, (2) Lubricate new rubber O-ring seals with clean
replace the A/C expansion valve. If excessive mois- refrigerant oil and install them on the tapping plate
ture is found in the A/C system, recycle the refriger- evaporator inlet and outlet tube fittings.
ant. (3) Position the A/C expansion valve onto the tap-
In a Closed Position: There will be low suction ping plate evaporator inlet and outlet tube fittings.
pressure and no cooling. This may be caused by a (4) Install the two bolts that secure the A/C expan-
failed power dome or excessive moisture in the A/C sion valve to the evaporator tube tapping plate.
system. If the power dome on the A/C expansion Tighten the bolts to 5 N·m (45 in. lbs.).
valve is found to be defective replace the A/C expan- (5) Remove the tape or plugs from the liquid and
sion valve. If excessive moisture is found recycle the suction line fittings and both expansion valve ports.
refrigerant.
24 - 42 PLUMBING VA
A/C EXPANSION VALVE (Continued)

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).

ELECTRIC COOLANT PUMP Fig. 8 Electric Coolant Pump


1 - HEATER HOSE
DESCRIPTION 2 - HOSE CLAMP (2)
The electric coolant pump is used on all vehicles. 3 - HEATER HOSE
The pump is located in the left side of the engine 4 - ELECTRIC COOLANT PUMP
5 - WIRE HARNESS CONNECTOR
compartment near the battery. 6 - NUT (2)
VA PLUMBING 24 - 43
ELECTRIC COOLANT PUMP (Continued)

INSTALLATION WARNING: REVIEW THE WARNINGS AND CAU-


(1) Install the electric coolant pump and mounting TIONS IN THE FRONT OF THIS SECTION BEFORE
bracket onto the body studs. PERFORMING THE FOLLOWING OPERATION (Refer
(2) Install the two bracket retaining nuts. Tighten to 24 - HEATING & AIR CONDITIONING/PLUMBING -
the nuts to 5 N·m (45 in. lbs.). WARNING) and (Refer to 24 - HEATING & AIR CON-
(3) Using a twisting motion gently install both DITIONING/PLUMBING - CAUTION).
hoses onto the electric coolant pump.
(1) Remove the heater housing (Refer to 24 -
(4) Tighten both hose clamps securely.
HEATING & AIR CONDITIONING/DISTRIBUTION/
(5) Connect the wire harness connector to the elec-
HVAC HOUSING - REMOVAL).
tric coolant pump.
(2) Disassemble the HVAC housing to access the
(6) Reconnect the negative battery cable.
heater core (Refer to 24 - HEATING & AIR CONDI-
(7) Fill the engine cooling system (Refer to 7 -
TIONING/DISTRIBUTION/HVAC HOUSING - DIS-
COOLING/ENGINE/COOLANT - STANDARD PRO-
ASSEMBLY).
CEDURE - COOLING SYSTEM FILL).
(3) Lift the heater core out of the lower half of the
HVACr housing (Fig. 9).
HEATER CORE (4) If necessary, remove the three heater core tube
retaining bolts and the heater core tube assembly
DESCRIPTION from the heater core.
(5) Remove the heater core tube seals and discard
The heater core is located in the HVAC housing,
as required.
behind the instrument panel. It is a heat exchanger
made of rows of tubes and fins.

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).

NOTE: The A/C liquid line is serviced in two sec-


tions. The front section connects between the A/C
condenser and the receiver/drier and includes the
high side service port and the A/C pressure sensor
on the fitting for the receiver/drier. The rear section
connects between the receiver/drier and the A/C
expansion valve. Fig. 10 Receiver-Drier
1 - RECEIVER/DRIER
2 - A/C LIQUID LINE (REAR SECTION)
3 - A/C PRESSURE TRANSDUCER
FRONT SECTION 4 - A/C LIQUID LINE (FRONT SECTION)
(1) Recover the refrigerant from the refrigerant 5 - CLAMP
system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - STANDARD PROCEDURE - REAR SECTION
REFRIGERANT SYSTEM RECOVERY). (1) Recover the refrigerant from the refrigerant
(2) Disconnect and isolate they negative batter system (Refer to 24 - HEATING & AIR CONDITION-
cable. ING/PLUMBING/REFRIGERANT - STANDARD
(3) Remove the grille (Refer to 23 - BODY/EXTE- PROCEDURE - REFRIGERANT SYSTEM RECOV-
RIOR/GRILLE - REMOVAL). ERY).
(4) Remove the nut that secures the A/C liquid line (2) Disconnect and isolate the negative battery
to the A/C condenser. cable.
(5) Disconnect the A/C liquid line to the A/C con- (3) Remove the grille (Refer to 23 - BODY/EXTE-
denser and remove and discard the O-ring seal. RIOR/GRILLE - REMOVAL).
(6) Install plug in, or tape over the opened liquid (4) Remove the nut that secures the A/C suction
line fitting and the condenser outlet port. and liquid lines to the stud on the A/C expansion
valve (Fig. 11).
VA PLUMBING 24 - 45
LIQUID LINE (Continued)
(5) Disconnect the A/C suction and liquid lines section connects between the receiver/drier and the
from the A/C expansion valve and remove and dis- A/C expansion valve.
card the O-ring seals.
(6) Disengage the routing clip retainer from the FRONT SECTION
rear section of the A/C liquid line. (1) Position the front section of the A/C liquid line
into the engine compartment.
(2) Remove the tape or plugs from the liquid line
fitting and the receiver/drier inlet port.
(3) Lubricate a new rubber O-ring seal with clean
refrigerant oil and install it on the liquid line fitting.
(4) Connect the front section of the liquid line to
the receiver/drier.
(5) Install the bolt that secures the liquid line fit-
ting to the receiver/drier. Tighten the bolt to 7 N·m
(62 in. lbs.).
(6) Position the front section of the liquid line into
the routing clip and install the routing clip onto the
body stud on the left frame rail.
(7) Install the routing clip retaining nut. Tighten
the nut to 5 N·m (45 in. lbs.).
(8) Remove the tape or plugs from the condenser
outlet port and the liquid line fitting.
(9) Lubricate a new O-ring seal with clean refrig-
erant oil and install it on the liquid line fitting.
(10) Connect the liquid line fitting to the con-
denser outlet port on the right side of the condenser.
(11) Install the nut that secures the liquid line fit-
Fig. 11 A/C Expansion Valve ting to the condenser. Tighten the nut to 17 N·m (12
ft. lbs.).
1 - EVAPORATOR TUBE TAPPING PLATE
2 - O-RING SEAL (2) (12) Reinstall the A/C pressure transducer (Refer
3 - A/C EXPANSION VALVE to 24 - HEATING & AIR CONDITIONING/CON-
4 - BOLT (2) TROLS/A/C PRESSURE TRANSDUCER - INSTAL-
5 - A/C SUCTION LINE
6 - NUT LATION).
7 - A/C LIQUID LINE (13) Install the grille (Refer to 23 - BODY/EXTE-
8 - O-RING SEAL (2) RIOR/GRILLE - INSTALLATION).
(14) Reconnect the battery negative cable.
(7) Remove the bolt that secures the rear section (15) Evacuate the refrigerant system (Refer to 24 -
of the liquid line to the top of the receiver/drier (Fig. HEATING & AIR CONDITIONING/PLUMBING/RE-
10). FRIGERANT - STANDARD PROCEDURE -
(8) Disconnect the rear section of the liquid line REFRIGERANT SYSTEM EVACUATE).
from the receiver/drier. (16) Charge the refrigerant system (Refer to 24 -
(9) Remove the seal from the liquid line fitting HEATING & AIR CONDITIONING/PLUMBING/RE-
outlet port and discard. FRIGERANT - STANDARD PROCEDURE -
(10) Install plugs in, or tape over the opened liquid REFRIGERANT SYSTEM CHARGE).
and suction line fittings, both receiver/drier ports and
both expansion valve ports. REAR SECTION
(11) Remove the rear section of the liquid line from (1) Position the rear section of the A/C liquid line
the engine compartment. into the engine compartment.
(2) Remove the tape or plugs from the liquid and
INSTALLATION suction line fittings, the receiver/drier outlet port and
both expansion valve ports.
NOTE: The A/C liquid line is serviced in two sec-
(3) Lubricate new rubber O-ring seals with clean
tions. The front section connects between the A/C
refrigerant oil and install them onto the suction and
condenser and the receiver/drier and includes the
liquid line fittings for the expansion valve.
high side service port and the A/C pressure trans-
(4) Connect the liquid line and suction line fittings
ducer on the fitting for the receiver/drier. The rear
to the A/C expansion valve.
24 - 46 PLUMBING VA
LIQUID LINE (Continued)
(5) Install the nut that secures the suction line to 24 - HEATING & AIR CONDITIONING/PLUMBING -
and liquid line fittings to the stud on the A/C expan- WARNING) and (Refer to 24 - HEATING & AIR CON-
sion valve. Tighten the nut to 10 N·m (89 in. lbs.). DITIONING/PLUMBING - CAUTION).
(6) Lubricate new rubber O-ring seal with clean (1) Recover the refrigerant from the refrigerant
refrigerant oil and install it on the liquid line fitting. system(Refer to 24 - HEATING & AIR CONDITION-
(7) Connect the liquid line fitting to the receiver/ ING/PLUMBING - STANDARD PROCEDURE -
drier outlet port. REFRIGERANT SYSTEM RECOVERY).
(8) Install the bolt that secures the liquid line fit- (2) Remove the bolts that secure the front and rear
ting to the receiver/drier. Tighten the bolt to 7 N·m sections of the A/C liquid line to the top of the receiv-
(62 in. lbs.). er/drier (Fig. 12).
(9) Install the routing clip retainer to the rear sec- (3) Disconnect the liquid line fittings from the
tion of the liquid line. receiver/drier and remove and discard the O-ring
(10) Install the grille (Refer to 23 - BODY/EXTE- seals.
RIOR/GRILLE - INSTALLATION). (4) Install a plug in, or tape over the opened liquid
(11) Reconnect the negative battery cable. line fittings and the receiver/drier ports.
(12) Evacuate the refrigerant system (Refer to 24 - (5) Loosen the clamp that secures the receiver/
HEATING & AIR CONDITIONING/PLUMBING/RE- drier to the mounting bracket.
FRIGERANT - STANDARD PROCEDURE - (6) Remove the receiver/drier from the engine com-
REFRIGERANT SYSTEM EVACUATE). partment.
(13) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/RE-
FRIGERANT - STANDARD PROCEDURE -
REFRIGERANT SYSTEM CHARGE).

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).

(1) Recover the refrigerant system. (Refer to 24 -


HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM RECOVERY)
(2) Disconnect and isolate the negative battery cable.
(3) Remove the routing clip retaining nut and disen-
gage the metal routing clip from the A/C suction line.
(4) Disengage the plastic routing clip located near
the A/C expansion valve from the A/C suction line.
(5) Remove the nut that secures the A/C suction
and liquid lines to the stud on the A/C expansion
valve (Fig. 13).
(6) Disconnect the A/C suction and liquid lines
from the A/C expansion valve and remove and dis-
card the O-ring seals.
(7) Install plugs in, or tape over the opened liquid
Fig. 14 A/C Compressor - Refrigerant Lines
and suction line fittings and both expansion valve ports.
(8) Remove the bolt that secures the A/C suction 1 - A/C COMPRESSOR
2 - O-RING SEAL
line to the A/C compressor (Fig. 14). 3 - A/C SUCTION LINE
(9) Disconnect the A/C suction line from the A/C 4 - BOLT
compressor and remove and discard the O-ring seal. 5 - RETAINING CLIP
6 - BOLT
(10) Install plugs in, or tape over the opened suc- 7 - A/C DISCHARGE LINE
tion line fitting and the compressor suction port. 8 - O-RING SEAL
VA PLUMBING 24 - 49
SUCTION LINE (Continued)

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 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54


DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 50 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 54
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 HEATER UNIT
DIAGNOSIS AND TESTING REMOVAL
SUPPLEMENTAL CABIN HEATER . . . . . . . . . 51 HEATER UNIT . . . . . . . . . . . . . . . . . . . . . . . . 55
EXHAUST TUBE WIRE HARNESS . . . . . . . . . . . . . . . . . . . . . . 56
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 INSTALLATION
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 52 HEATER UNIT . . . . . . . . . . . . . . . . . . . . . . . . 56
FUEL DOSING PUMP WIRE HARNESS . . . . . . . . . . . . . . . . . . . . . . 56
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 53 INLET HOSE
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 57
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 53
FUEL LINE
STANDARD PROCEDURE
CLEANING ................ . . . . . . . . . . 54

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)

DIAGNOSIS AND TESTING


SUPPLEMENTAL CABIN HEATER
Refer to the Symptoms Diagnosis table for basic
checks of the diesel fueled supplemental cabin heater.

SYMPTOMS DIAGNOSIS

Symptom Possible Causes


Smell of diesel fuel. Check cabin heater system integration in vehicle’s fuel system. Check
fuel lines for leakage, kinks or obstructions. If OK, Inspect the inlet
muffler, drain as necessary. Re-test the cabin heater and re-inspect.
Inspect the exhaust tube and cabin heater for the presence of external
fuel. If presence of external fuel is observed on the heater unit or in the
exhaust tube or after draining and testing. Remove the cabin heater
from vehicle and repair or replace components as required.
Heater does not achieve full load Check cabin heater operation with DRBIIIT scan tool and replace
operation. components as required.
Continuous white smoke from heater Check cabin heater operation with DRBIIIT scan tool and replace
exhaust during combustion operation. components as required. White smoke is typical in extreme weather
conditions.
Heater can not be switched off. Check cabin heater operation with DRBIIIT scan tool and replace
components as required.
Heater does not operate. Diagnosis cabin heater control module using the DRBIIIT scan tool and
the procedures listed in Vehicle Performance under Cabin Heater
Diagnosis in Group 18.
Loss of coolant (Leakage) or heater Inspect coolant hoses for leakage, kinks or loose hose connection.
develops smoke during combustion Inspect the exhaust tube assembly for continuous flow, if OK there is an
operation and exhaust has an internal heater leak and cabin heater should be inspected and
extremely sweet smell. components should be replaced as required.
Loss of fuel (dripping). Check cabin heater system integration in vehicles fuel system. Check
fuel line connection for leakage. If OK there is an internal leak and
cabin heater should be inspected and replaced as required.
24 - 52 CABIN HEATER VA

EXHAUST TUBE INSTALLATION


(1) Install the flexible exhaust pipe to the heater
REMOVAL unit. Tighten mounting clamp securely.
(2) Position the steel exhaust pipe to the flexible
WARNING: THERE IS A POTENTIAL DANGER OF exhaust and install and tighten the mounting clamp
SKIN BURNS AS THE HEATER AND ITS COMPO- securely.
NENTS MAY BE VERY HOT. MAKE SURE THE (3) Install the three exhaust pipe screws, adjust
HEATER IS ALLOWED TO COOL DOWN BEFORE pipe placement as needed and tighten the screws
ANY SERVICE WORK ON THE CABIN HEATER SYS- securely.
TEM IS ATTEMPTED. (4) Install the clamp to connect the steel exhaust
pipe to the flexible exhaust pipe and tighten clamp
(1) Raise and support the vehicle while taking note securely.
of the location of the flexible exhaust tube section. (5) Check exhaust pipe exhaust end placement and
(2) Remove the exhaust clamp at the flexible pipe make any final adjustments.
and steel pipe connection (Fig. 1). (6) Lower the vehicle.
(3) Remove the clamp at the flexible pipe connec-
tion and the supplemental heater housing (if
required).
(4) Remove the three screws holding the exhaust
pipe to the body.
(5) Remove the steel exhaust pipe from the vehi-
cle.
(6) Remove the flexible exhaust pipe from the
vehicle (if required).

Fig. 1 Cabin Heater Exhaust System


1 - MOUNTING SCREW (3) 4 - FLEXIBLE HEATER EXHAUST PIPE
2 - STEEL HEATER EXHAUST PIPE 5 - HEATER SHIELD
3 - EXHAUST CLAMP (2) 6 - EXHAUST PIPE MOUNTING CLIP (3)
VA CABIN HEATER 24 - 53

FUEL DOSING PUMP NOTE: Utilize an approved fuel storage container to


catch any residual fuel.
DESCRIPTION (3) Disconnect the wiring harness connector to the
The dosing pump is a combined delivery, dosing fuel pump by depressing the integral spring and pull-
and shut-off system for the fuel supply to the supple- ing the connector away from the pump.
mental cabin heater from the vehicle fuel tank. (4) Remove the dosing pump from the rubber iso-
lator.
OPERATION
The dosing pump is an electrically operated pump that INSTALLATION
receives its operation instructions from the supplemental (1) Install the dosing pump onto the rubber isola-
cabin heater control module. The pump supplies diesel tor.
fuel from the vehicle fuel tank to the cabin heater. (2) Connect the fuel lines to the dosing pump and
the cabin heater unit.
REMOVAL
NOTE: The connectors should point towards the
NOTE: The dosing pump is serviceable without cabin heater fuel line.
removing the component from the vehicle.
(3) Use aviation style clamps to attach the hose to
(1) Disconnect the rubber hose at the fuel line to the fuel pump nipples (Refer to 24 - HEATING &
heater fuel pump. Leave the rubber hose on the fuel AIR CONDITIONING/CABIN HEATER/FUEL LINE
line (Refer to 24 - HEATING & AIR CONDITIONING/ - INSTALLATION).
CABIN HEATER/FUEL LINE - REMOVAL) (Fig. 2). (4) Connect the wire harness connector to the fuel
(2) Disconnect the fuel line between the dosing pump by depressing the integral spring and pushing the
pump and the cabin heater unit. connector towards the dosing pump. Pull the connector
towards the cabin heater to verify the installation.
NOTE: Position and retain the heater fuel line to pre- (5) Verify function of the supplemental cabin
vent fuel leakage while servicing the dosing pump. heater.

Fig. 2 Cabin Heater Dosing Pump Fuel Line


1 - FUEL LINE 3 - DOSING PUMP
2 - RETAINING CLAMP 4 - HEATER AIR INTAKE PIPE
24 - 54 CABIN HEATER VA

FUEL LINE NOTE: Have an approved fuel holding device ready


to capture any diesel fuel that drains from the fuel
line or cabin heater unit.
STANDARD PROCEDURE
(2) Remove clamps on dosing pump end of fuel line
CLEANING and separate line from the pump (Fig. 3).
(3) Remove clamp from the fuel line at the fuel
(1) Remove the cabin heater fuel line (Refer to 24 -
tank connection and separate the line from the tank.
HEATING & AIR CONDITIONING/CABIN HEAT-
(4) Remove any retaining clips and remove the
ER/FUEL LINE - REMOVAL).
fuel line from vehicle.
(2) With the cabin heater fuel line removed from the
vehicle, place a shop cloth on the fuel tank end of the
fuel line to catch any residue, then apply a small INSTALLATION
amount of air pressure to the other end of the fuel line.
WARNING: DO NOT OPERATE THE DIESEL SUP-
(3) Check to see if air pressure is coming from the
PLEMENTAL CABIN HEATER IN AN ENCLOSED
tank end of the line. If pressure is flowing unre-
AREA SUCH AS A GARAGE THAT DOES NOT HAVE
stricted the line is clean.
EXHAUST VENTILATION FACILITIES. ALWAYS VENT
(4) If the fuel line shows any signs of being
THE CABIN HEATER EXHAUST WHEN OPERATING
restricted after air pressure is applied, the fuel line
THE CABIN HEATER. ALLOW THE DIESEL SUPPLE-
should be replaced.
MENTAL CABIN HEATER TO COOL BEFORE PER-
(5) Install the cabin heater fuel line (Refer to 24 -
FORMING ANY SERVICE PROCEDURES TO THE
HEATING & AIR CONDITIONING/CABIN HEAT-
CABIN HEATER. VERIFY THAT ALL DIESEL SUP-
ER/FUEL LINE - INSTALLATION).
PLEMENTAL CABIN HEATER FUEL LINES ARE
(6) Verify function of the cabin heater.
SECURELY FASTENED TO THEIR RESPECTIVE
COMPONENTS BEFORE PERFORMING ANY SER-
REMOVAL VICE PROCEDURES TO THE CABIN HEATER. FAIL-
(1) Raise and support the vehicle. Take note of the
URE TO FOLLOW THESE INSTRUCTION MAY
location of the flexible section of the cabin heater
RESULT IN PERSONAL INJURY OR DEATH.
exhaust tube.

Fig. 3 Cabin Heater Dosing Pump Fuel Line


1 - FUEL LINE 3 - DOSING PUMP
2 - RETAINING CLAMP 4 - HEATER AIR INTAKE PIPE
VA CABIN HEATER 24 - 55
FUEL LINE (Continued)
NOTE: Verify that there is more than 1/8 of a tank of THE CABIN HEATER EXHAUST WHEN OPERATING
fuel in the vehicle’s fuel tank before performing this THE CABIN HEATER. ALLOW THE DIESEL SUPPLE-
procedure. Add fuel, if necessary. MENTAL CABIN HEATER TO COOL BEFORE PER-
FORMING ANY SERVICE PROCEDURES TO THE
(1) Install the cabin heater fuel supply line into CABIN HEATER. VERIFY THAT ALL DIESEL SUP-
vehicle and fuel line retainers. PLEMENTAL CABIN HEATER FUEL LINES ARE
(2) Install the fuel line connection at the fuel tank SECURELY FASTENED TO THEIR RESPECTIVE
and tighten the connection securely. COMPONENTS BEFORE PERFORMING ANY SER-
(3) Install the fuel line at the dosing pump and VICE PROCEDURES TO THE CABIN HEATER. FAIL-
tighten the connection securely. URE TO FOLLOW THESE INSTRUCTION MAY
(4) Lower the vehicle. RESULT IN PERSONAL INJURY OR DEATH.
(1) Raise and support the vehicle. Take note of the
NOTE: Failure to prime the dosing pump after drain- location of the flexible section of the cabin heater
ing the supplemental cabin fuel line will prevent exhaust tube.
cabin heater activation during the first attempt to (2) Drain the engine cooling system (Refer to 7 -
start the cabin heater. This will also set a diagnostic COOLING - STANDARD PROCEDURE - DRAINING
trouble code (DTC) in the cabin heater control’s COOLING SYSTEM).
memory. Do not perform the Dosing Pump Priming (3) Carefully open one hose to the underbody tube
procedure if an attempt was made to start the cabin assembly and drain the remaining coolant. A salvage
heater without priming the dosing pump first. This hose is a good idea to control the residual coolant, as
will put excess fuel in the cabin heater and cause flow will occur from both the cabin heater and the
smoke to emit from the cabin heater exhaust pipe hose and tube assemblies.
when cabin heater activation occurs. (4) Remove the second hose from the underbody
hose and tube assembly.
(5) Connect the DRBIIIt scan tool to the diagnos-
(5) Loosen the hose and tube assembly from the
tic link connector.
toe-board crossmember at two locations.
(6) Turn the ignition to the ON position.
(6) Disconnect the electrical connector from the
NOTE: Do not activate the dosing pump prime more body harness near the toe-board crossmember and
than one time. This will put excess fuel in the sup- rail.
plemental cabin heater and cause smoke to emit (7) Remove the wiring harness from the toe-board
from the cabin heater exhaust pipe when cabin crossmember (Refer to 24 - HEATING & AIR CON-
heater activation occurs. DITIONING/CABIN HEATER/HEATER UNIT -
REMOVAL - WIRE HARNESS).
(8) Open the fuel filler cap. Disconnect the rubber
NOTE: A clicking noise heard coming from the dos- fuel hose between the body tube assembly and the
ing pump indicates that the pump is operational. fuel pump nipple at the body tube joint. A minimal
amount of fuel may flow from the open port.
(7) With the DRBIIIt scan tool in Cabin Heater,
select System Tests and Dosing Pump Prime. Allow NOTE: Utilize an approved fuel storage container to
the dosing pump to run for the full 45 second cycle catch any residual fuel.
time. When the 45 second cycle is complete, press
Page Back on the DRBIIIt scan tool key pad to exit (9) Loosen the two fasteners at the rail. Take care
the Dosing Pump Prime. The Dosing Pump Priming to notice that the exhaust tube bracket tab is on top
procedure is now complete. of the heater bracket and that there are two spacer
washers installed between the rubber grommets.
(10) Remove the flexible section of the cabin
HEATER UNIT heater exhaust tube from the exhaust tube by loos-
ening the clamp. Remove the hose from the exhaust
tube. Removal of the rail tube assembly may aid in
REMOVAL this service operation (Refer to 24 - HEATING & AIR
CONDITIONING/CABIN HEATER/EXHAUST TUBE
HEATER UNIT - REMOVAL).
(11) Remove seat hex nut at the heater mounting
WARNING: DO NOT OPERATE THE DIESEL SUP- flange to crossmember.
PLEMENTAL CABIN HEATER IN AN ENCLOSED (12) Loosen the remaining fasteners which mount
AREA SUCH AS A GARAGE THAT DOES NOT HAVE the exhaust tube assembly to the vehicle.
EXHAUST VENTILATION FACILITIES. ALWAYS VENT
24 - 56 CABIN HEATER VA
HEATER UNIT (Continued)
(a) Install a suitable support device under the bolt of the clamp securley. Install the hose to the
cabin heater and secure the cabin heater to the exhaust tube.
support. (8) Tighten the two M8 fasteners at the rail to 23
(13) Loosen the remaining three fasteners to the N·m (17 ft. lbs.). Taking care so that the exhaust
crossmembers. tube bracket tab is on the top of the heater bracket.
(14) Remove the loosened fasteners that support (9) Install the wiring harness (Refer to 24 - HEAT-
the cabin heater while supporting the weight of the ING & AIR CONDITIONING/CABIN HEATER/
heater. HEATER UNIT - INSTALLATION - WIRE
(15) Swing the cabin heater mounting bracket HARNESS).
from between the exhaust bracket and rail mounting (10) Tighten the hose and tube assembly to the
location. Drain any residual coolant from the cabin toe-board crossmember at two locations.
heater. (11) Install the second hose to the underbody hose
(16) Remove the cabin heater from the vehicle. and tube assembly.
(12) Connect the rubber fuel hose between the
WIRE HARNESS body tube assembly and the fuel pump nipple at the
(1) Raise and support the vehicle while taking note body tube joint. Close the fuel fill cap.
of the location of the flexible exhaust tube section. (13) Remove the cabin heater support device from
(2) Disconnect the cabin heater wire harness con- under the vehicle.
nector from the vehicle wiring harness. (14) Lower the vehicle.
(3) Disconnect the cabin heater wire harness con- (15) Fill the engine cooling system (Refer to 7 -
nector from the dosing pump. COOLING - STANDARD PROCEDURE - COOLING
(4) Disconnect the two cabin heater wire harness SYSTEM FILL).
connectors from the cabin heater controller. (16) Verify function of the heater unit.
(5) Remove two wiring harness retainers from the
underbody. WIRE HARNESS
(6) Remove two wiring harness retainers from the (1) Carefully route the cabin heater wire harness
cabin heater shield. from the left side between the heater unit and the
(7) Carefully route the cabin heater wire harness heater shield.
out the left side between the heater unit and the (2) Install the two wiring harness retainers to the
heater shield. cabin heater shield.
(3) Route the wiring harness along the underside
of the vehicle and install the two wiring harness
INSTALLATION retainers to the underbody.
(4) Connect the two cabin heater wire harness con-
HEATER UNIT nectors to the cabin heater controller.
(1) Install the cabin heater mounting bracket (5) Connect the cabin heater wire harness to the
between the exhaust bracket and the rail mounting dosing pump.
location. (6) Connect the cabin heater wire harness connec-
(2) Support the cabin heater and install the fasten- tor to the vehicle wiring harness.
ers that secure the cabin heater to the mounting (7) Lower the vehicle.
bracket. (8) Verify function of the heater unit.
(3) Install the three fasteners to the crossmem-
bers. Tighten the M6 fasteners to 7 N·m (62 in. lbs.).
(4) Position the two spacer washers between the INLET HOSE
body and the rubber grommets for the two mounting
points on the rail. REMOVAL
(5) Tighten the remaining M6 fasteners to 7 N·m
(62 in. lbs.) and the M8 fasteners to 23 N·m (17 ft. NOTE: The air intake tube for the supplemental
lbs.) which mount the exhaust tube assembly to the cabin heater is part of an assembly that includes
vehicle. the heater cooling intake and return pipes. If the
(6) Install the seat hex nut at the heater mounting cabin heater air intake tube requires removal or
flange to the crossmembers. Tighten the nut to 60 replacement the entire cabin heater assembly will
N·m (44 ft. lbs.) require removal or replacement.
(7) Install the flexible section of the cabin heater
exhaust tube to the exhaust tube. Tighten the M6 (1) Drain the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - DRAINING
COOLING STSTEM).
VA CABIN HEATER 24 - 57
INLET HOSE (Continued)
(2) Remove clamps from the cabin heater tubes at
the lower heater port and the lower EGR connector
which are located under the hood.
(3) Remove the retaining clamp at the cabin
heater air intake muffler connection (Refer to 24 -
HEATING & AIR CONDITIONING/CABIN HEAT-
ER/INLET MUFFLER - REMOVAL).
(4) Remove the clamp at the flexible tube to steel
tube connection (Fig. 4).

Fig. 5 Cabin Heater Air Intake And Heater Pipe


Assembly
1 - INTAKE TUBE AIR INTAKE
2 - INTAKE PIPE
3 - RETAINING SCREWS
4 - INTAKE HEATER LINE
5 - RETURN HEATER LINE

(2) Attach the steel tube to the flexible tube and


position and then tighten the retaining clamp
securely.
(3) Install the flexible tube to the cabin heater air
intake muffler and install and tighten the retaining
Fig. 4 Cabin Heater Flexible Air Intake Line clamp securely.
(4) Install the cabin heater tubes to the lower
1 - CABIN HEATER AND SPLASH SHIELD
2 - DOSING PUMP heater connection and the lower EGR cooler connec-
3 - DOSING PUMP FUEL LINE tion and tighten the retaining clamps.
4 - FLEXIBLE INTAKE LINE (5) Lower the vehicle.
5 - CLAMP
6 - STEEL INTAKE PIPE (6) Refill the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
(5) Remove the two retaining screws and remove SYSTEM FILL).
pipe assembly (Fig. 5). (7) Verify function of the heater unit.

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 .................1 EXHAUST GAS RECIRCULATION ............4

EVAPORATIVE EMISSIONS

TABLE OF CONTENTS
page page

CRANKCASE VENTILATION HEATER REMOVAL .............................2


REMOVAL .............................1 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CRANKCASE VENTILATION BREATHER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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

CRANKCASE VENTILATION REMOVAL


(1) Remove the engine cover.
BREATHER (2) Disconnect the breather outlet hose at the
breather (Fig. 3).
DESCRIPTION (3) Remove the breather fasteners (Fig. 3).
The crankcase ventilation breather is a three (4) Wiggle the breather free from the cylinder head
staged, filtered, oil separating breather with a oil cover (Fig. 3).
return passage into the cylinder head cover (Fig. 2).
The oil separator removes oil from the blow by gasses INSTALLATION
to reduce MAF sensor contamination. For service (1) Remove the oil fill cap, clean the oil return pas-
procedures refer to (Refer to 25 - EMISSIONS CON- sage in the cylinder head cover, then blow out with
TROL/EVAPORATIVE EMISSIONS/CCV low pressure compressed air.
RESTRICTER - REMOVAL). (2) Clean mating surfaces.
(3) Install the CCV breather and tighten fasteners
to 11 N·m (97 in.lbs.) (Fig. 3).
(4) Connect the CCV breather outlet hose (Fig. 3).
(5) Install the engine cover(Refer to 9 - ENGINE -
INSTALLATION).

Fig. 2 CCV BREATHER


VA EVAPORATIVE EMISSIONS 25 - 3
CRANKCASE VENTILATION BREATHER (Continued)

Fig. 3 CCV BREATHER


1 - FUEL RAIL 6 - CAM POSITION SENSOR
2 - FUEL RAIL PRESSURE SENSOR 7 - FUEL INJECTOR
3 - FUEL INJECTOR RETURN LINE 8 - HIGH PRESSURE FUEL INJECTOR SUPPLY LINE
4 - CCV BREATHER 9 - FUEL PRESSURE SOLENOID
5 - CYLINDER HEAD COVER 10 - FUEL RAIL SUPPLY LINE
25 - 4 EXHAUST GAS RECIRCULATION VA

EXHAUST GAS RECIRCULATION

TABLE OF CONTENTS
page page

EXHAUST GAS RECIRCULATION REMOVAL .............................6


DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
VALVE VALVE COOLER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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)

Fig. 1 EGR AND COOLER


1 - EGR VALVE 3 - COOLING FINS
2 - COOLANT PASSAGE 4 - EXHAUST GAS PASSAGE
25 - 6 EXHAUST GAS RECIRCULATION VA

VALVE The ECM evaluates this signal as well as that


from the Charge Air Pressure sensor, and outputs a
PWM signal in accordance with one of the maps
DESCRIPTION
stored in it. The signal is sent to the exhaust gas
Exhaust gas recirculation reduces the quantity of
recirculation valve. The map is formulated to keep
fresh air supplied to the cylinders per stroke without
the NOx as low as possible. The EGR valve is actu-
having to throttle the air supply. Exhaust gas is
ated by an electric positioning motor and has a self
recirculated during all engine speed and engine load
cleaning function. Every time the ignition switch is
conditions. As a result, emissions are reduced. If a
turned off, the valve rotates twice to eliminate any
quantity of exhaust gas is mixed with the air that is
carbon deposits.
to be used to burn the fuel in the cylinders, the oxy-
gen content is reduced because the exhaust gas is
low in oxygen. The result is that the combustion rate
REMOVAL
is reduced, as is the combustion temperature. This NOTE: The EGR and EGR Cooler are serviced as an
reduces the quantity of NOx that are emitted in the assembly.
exhaust gas. (Fig. 2).
The ECM power supply relay has a power off delay (1) Disconnect the negative battery cable.
feature. The relay is powered off approximately 15 (2) Partailly drain the cooling system (Refer to 7 -
seconds after the ignition switch is turned off. This COOLING/ENGINE/COOLANT - STANDARD PRO-
allows for the self-cleaning function of the EGR valve CEDURE).
and a function check of the sensors for diagnosis pur- (3) Lift up on the charge air hose retaining clip at
poses. the intake manifold and disconnect hose with seal
(4) Disconnect the electrical connector at the EGR
positioner (Fig. 3).
(5) Disconnect the EGR cooler hose.
(6) Remove the EGR fasteners and EGR with
cooler assembly (Fig. 3).

Fig. 2 EXHAUST GAS RECIRCULATION


1 - EGR VALVE
2 -CHARGE AIR PRESSURE SENSOR
3 - EXHAUST MANIFOLD
4 - EGR DUCT IN CYLINDER HEAD
5 - INTAKE MANIFOLD
Fig. 3 EGR VALVE
OPERATION 1 - EGR VALVE
The mass of the air supplied to the cylinders per 2 - INTAKE MANIFOLD
stroke is the decisive factor for determining the opti- 3 - EGR COOLER HOSE
4 - HARNESS CONNECTOR
mum quantity of exhaust gas for the operating con-
dition. This is calculated from the Mass Air Flow
sensor information.
VA EXHAUST GAS RECIRCULATION 25 - 7
VALVE (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
SERVICE MANUAL COMMENTS

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800 Chrysler Drive
CIMS 486-02-76
Auburn Hills, MI 48326-2757

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