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Hold cap at eye level, right side up. The vent valve (Fig. 39) at bottom of cap should closed. A slight downward pull on the vent valve should open it. If the rubber gasket has swollen and prevents vent valve from opening, replace cap.
Hold cap at eye level, upside down. If any light can be seen between vent valve and rubber gasket, replace cap. A replacement cap must be the type
DR WATER PUMP - 5.9L (Continued)
ENGINE
7 - 63
Fig.40WaterPumpLocation—Typical
1 - WATER PUMP BYPASS HOSE 2 - FAN BLADE ASSEMBLY 3 - VISCOUS FAN DRIVE 4 - WATER PUMP AND PULLEY
REMOVAL
The water pump on all models can be removed without discharging the air conditioning system (if equipped).
The water pump on all gas powered engines is bolted directly to the engine timing chain case/cover. On the 5.9L gas powered engine, a gasket is used as a seal between the water pump and timing chain case/cover.
If water pump is replaced because of bearing/shaft damage or leaking shaft seal, the mechanical cooling fan assembly should also be inspected. Inspect for fatigue cracks, loose blades or loose rivets that could have resulted from excessive vibration. Replace fan if any of these conditions are found. Also check condi- tion of the thermal viscous fan drive (Refer to 7 - COOLING/ENGINE/FAN VISCOUS CLUTCH - DIAGNOSIS AND TESTING).
DRIVE
(1) Disconnect the negative cable. (2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
Do not waste reusable coolant. If solution is clean,
drain coolant into a clean container for reuse.
(3) Remove the radiator fan (Refer to 7 - COOL-
ING/ENGINE/RADIATOR FAN - REMOVAL)
(4) Remove accessory drive belt
(Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL) (Fig. 41).
(5) Remove the lower radiator hose and heater
hose from the water pump.
(6) Loosen the heater hose coolant return tube mounting bolt (Fig. 42) and remove the tube from the water pump. Discard the old tube O-ring.
(7) Remove the water pump mounting bolts (Fig.
43).
Fig.41BeltTensioner5.9LV-8Engine
1 - IDLER PULLEY 2 - TENSIONER 3 - FAN BLADE
Fig.42CoolantReturnTube5.9L
1 - COOLANT RETURN TUBE 2 - WATER PUMP 3 - TUBE MOUNTING BOLT 4 - O-RING
(8) Loosen the clamp at the water pump end of bypass hose (Fig. 42). Slip the bypass hose from the
ENGINE
7 - 64
WATER PUMP - 5.9L (Continued)DR
(6) Install the coolant return tube and its mount- ing bolt to the engine (Fig. 42). Be sure the slot in the tube bracket is bottomed to mounting bolt. This will properly position return tube.
(7) Connect the radiator lower hose to the water
pump.
(8) Connect the heater hose and hose clamp to the
coolant return tube.
(9) Install drive belt (Refer to 7 - COOLING/AC- CESSORY DRIVE/DRIVE BELTS - INSTALLATION) (Fig. 41).
(10) Install the fan (Refer to 7 - COOLING/EN-
GINE/RADIATOR FAN - INSTALLATION)
(11) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(12) Connect negative battery cable. (13) Start and warm the engine. Check for leaks.
WATER PUMP - 3.7L/4.7L
DESCRIPTION
DESCRIPTION—WATER PUMP
A centrifugal water pump circulates
coolant through the water jackets, passages, intake manifold, radiator core, cooling system hoses and heater core. The pump is driven from the engine crankshaft by a single serpentine drive belt.
The water pump impeller is pressed onto the rear of a shaft that rotates in bearings pressed into the housing. The housing has two small holes to allow seepage to escape. The water pump seals are lubri- cated by the antifreeze in the coolant mixture. No additional lubrication is necessary.
Both heater hoses are connected to fittings on the timing chain front cover. The water pump is also mounted directly to the timing chain cover and is equipped with a non serviceable integral pulley (Fig. 44).
DESCRIPTION—WATER PUMP BYPASS
The 3.7L and 4.7L engine uses an internal water/ coolant bypass system. The design uses galleries in the timing chain cover to circulate coolant during engine warm-up preventing the coolant from flowing through the radiator. The thermostat uses a stub shaft located at the rear of the thermostat (Fig. 45) to control flow through the bypass gallery.
OPERATION
OPERATION—WATER PUMP
A centrifugal water pump circulates
coolant through the water jackets, passages, intake manifold,
Fig.43WaterPumpBolts-5.9LV-8GasEngine-
Typical 1 - WATER PUMP MOUNTING BOLTS
water pump while removing pump from vehicle. Do not remove the clamp from the bypass hose.
(9) Discard the old gasket.
CAUTION: Do not pry the water pump at timing chain case/cover. The machined surfaces may be damaged resulting in leaks.
CLEANING
Clean gasket mating surfaces as necessary.
INSPECTION
Visually inspect the water pump and replace if it has any of the following conditions: † The body is cracked or damaged † Water leaks from the shaft seal. This is evident by traces of coolant below the vent hole † Loose or rough turning bearing. † Impeller rubbing the pump body INSTALLATION
(1) Clean the gasket mating surfaces. (2) Using a new gasket, install the water pump to the engine as follows: Guide the water pump tube into the bypass hose as the pump is being installed. Install the water pump bolts (Fig. 43). Tighten the water pump mounting bolts to 40 N·m (30 ft. lbs.) torque.
(3) Position the bypass hose clamp to the bypass
hose.
(4) Spin the water pump to be sure that the pump impeller does not rub against the timing chain case/ cover.
(5) Install a new o-ring to the heater hose coolant return tube (Fig. 42). Coat the new o-ring with anti- freeze before installation.
DR WATER PUMP - 3.7L/4.7L (Continued)
ENGINE
7 - 65
Fig.44WaterPumpandTimingChainCover
1 - INTEGRAL WATER PUMP PULLEY 2 - TIMING CHAIN COVER 3 - THERMOSTAT HOUSING 4 - HEATER HOSE FITTINGS 5 - WATER PUMP
radiator core, cooling system hoses and heater core, this coolant absorbs the heat generated when the engine is running. The pump is driven by the engine crankshaft via a drive belt.
OPERATION—WATER PUMP BYPASS
When the thermostat is in the closed position the bypass gallery is not obstructed allowing 100% flow. When the thermostat is in the open position the stub shaft enters the bypass gallery obstructing bypass coolant flow by 50%. This design allows the coolant to reach operating temperature quickly when cold, while adding extra cooling during normal tempera- ture operation.
REMOVAL
The water pump on 3.7L/4.7L engines is bolted
directly to the engine timing chain case cover.
(1) Disconnect the negative battery cable. (2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Remove fan/viscous fan drive assembly from water pump (Fig. 46) (Refer to 7 - COOLING/EN- GINE/FAN DRIVE VISCOUS CLUTCH - REMOV- AL). Do not attempt to remove fan/viscous fan drive assembly from vehicle at this time.
WARNING: CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEM HOSES.
Fig.45Water/CoolantBypassFlowandThermostat 1 - FROM HEATER AND DEGAS CONTAINER 2 - FROM RADIATOR 3 - TO WATER PUMP 4 - ENGINE BYPASS 5 - THERMOSTAT
WHEN REMOVING OR INSTALLING, USE ONLY TOOLS DESIGNED FOR SERVICING THIS TYPE OF CLAMP. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS.
CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only an original equipment clamp with matching number or letter and width.
(4) If the water pump is being replaced, do not unbolt the fan blade assembly from the thermal vis- cous fan drive.
(5) Remove the radiator fan (Refer to 7 - COOL-
ING/ENGINE/RADIATOR FAN - REMOVAL).
(6) Remove accessory drive belt (Fig. 47) (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
(7) Remove the lower radiator hose clamp and
remove the lower hose at the water pump.
(8) Remove the water pump mounting bolts.
ENGINE
7 - 66
WATER PUMP - 3.7L/4.7L (Continued)DR
(9) Remove the water pump and gasket. Discard
gasket.
CLEANING
Clean the gasket mating surface. Use caution not
to damage the gasket sealing surface.
INSPECTION
Inspect the water pump assembly for cracks in the housing, water leaks from shaft seal, worn bearing or impeller rubbing either the pump body or timing chain case/cover.
INSTALLATION
The water pump on 3.7L/4.7L engine is bolted
directly to the engine timing chain case cover.
(1) Clean the gasket mating surfaces. (2) Using a new gasket, position water pump and (Fig. 48). Tighten the
install the mounting bolts. water pump mounting bolts to 58 N·m (43 ft. lbs.).
Fig.46ViscousFanandFanDrive4.7LEngine 1 - SPECIAL TOOL 6958 SPANNER WRENCH WITH ADAPTER PINS 8346
2 - FANFig.47AutomaticBeltTensioner—4.7L
1 - AUTOMATIC TENSIONER 2 - WATER PUMP PULLEY
CAUTION: Do not pry water pump at timing chain case/cover. The machined surfaces may be dam- aged resulting in leaks.
Fig.48WaterPumpInstallation—3.7L/4.7LTypical 1 - WATER PUMP 2 - TIMING CHAIN COVER
(3) Spin the water pump to be sure that the pump impeller does not rub against the timing chain case/ cover.
(4) Connect the radiator lower hose to the water
pump.
(5) Relax the tension from the belt tensioner (Fig. 47). Install the drive belt (Refer to 7 - COOLING/AC- CESSORY DRIVE/DRIVE BELTS - INSTALLA- TION).
DR WATER PUMP - 3.7L/4.7L (Continued)
CAUTION: When installing the serpentine accessory drive belt, the belt must be routed correctly. If not, the engine may overheat due to the water pump rotating in the wrong direction. Refer to (Fig. 49) for the correct belt routing. Or, refer to the Belt Routing Label located in the engine compartment. The cor- rect belt with correct length must be used.
ENGINE
7 - 67
antifreeze in the coolant mixture. Additional lubrica- tion is not necessary.
OPERATION
The diesel engine water pump draws coolant from radiator outlet and circulates it through engine, heater core and back to radiator inlet. The crank- shaft pulley drives the water pump with a serpentine drive belt.
DIAGNOSIS AND TESTING—WATER PUMP
A quick test to determine if pump is working is to check if heater warms properly. A defective water pump will not be able to circulate heated coolant through the long heater hose to the heater core.
REMOVAL
(1) Disconnect battery negative cables. (2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Remove the accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
(4) Remove water pump mounting bolts (Fig. 50).
Fig.49BeltRouting3.7L
1 - GENERATOR PULLEY 2 - ACCESSORY DRIVE BELT 3 - POWER STEERING PUMP PULLEY 4 - CRANKSHAFT PULLEY 5 - IDLER PULLEY 6 - TENSIONER 7 - A/C COMPRESSOR PULLEY 8 - WATER PUMP PULLEY
(6) Install the radiator fan (Refer to 7 - COOLING/
ENGINE/RADIATOR FAN - INSTALLATION).
(7) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(8) Connect the negative battery cable. (9) Start and warm the engine. Check for leaks.
WATER PUMP - 5.9L DIESEL DESCRIPTION
The water pump is mounted to the front of the engine block between the automatic belt tensioner and the fan drive pulley.
The water pump impeller is pressed onto the rear of a shaft that rotates in a bearing pressed into the water pump body. The body has a small hole for ven- tilation. The water pump seals are lubricated by
Fig.50WaterPumpRemoval/Installation
1 - O-RING SEAL (SQUARE) 2 - WATER PUMP 3 - BOLT (2)
(5) Clean water pump sealing surface on cylinder
block.
CLEANING
Clean gasket mating surfaces as necessary.
DR
generator or A/C compressor from their mounting bracket is not necessary. Also, discharging the A/C system is not necessary. Do not remove any refriger- ant lines from A/C compressor.
ENGINE
7 - 68
WATER PUMP - 5.9L DIESEL (Continued) INSPECTIONVisually inspect the water pump and replace if it has any of the following conditions: † The body is cracked or damaged † Water leaks from the shaft seal. This is evident by traces of coolant below the vent hole † Loose or rough turning bearing. † Impeller rubbing the pump body INSTALLATION
(1) Install new O-ring seal
pump (Fig. 51).
in groove on water
Fig.51PumpO-ringSeal
1 - O-RING SEAL 2 - GROOVE 3 - WATER PUMP
Fig.52Generator-A/CCompressorMounting
Bracket-Typical
WARNING: THE A/C SYSTEM IS UNDER PRESSURE EVEN WITH THE ENGINE OFF. REFER TO REFRIG- ERANT WARNINGS IN SECTION 24 - HEATING AND AIR CONDITIONING.
(2) Install water pump. Tighten mounting bolts to
24 N·m (18 ft. lbs.) torque.
(3) Install accessory drive belt. Refer to procedure
in this group.
(4) Install the bolt retaining the wiring harness
near top of water pump.
System in this section.
(5) Fill cooling system. Refer to Refilling Cooling
(6) Connect both battery cables. (7) Start and warm the engine. Check for leaks.
WATER PUMP INLET TUBE - 5.9L
REMOVAL
REMOVAL - WATER PUMP BYPASS HOSE WITH AIR CONDITIONING
If equipped with A/C, the generator and A/C com- pressor along with their common mounting bracket (Fig. 52) must be partially removed. Removing the
(1) Disconnect the negative battery cable. (2) Partially drain the cooling system (Refer to 7 - COOLING - STANDARD PROCEDURE).Do not waste reusable coolant. If the solution is clean, drain the coolant into a clean container for reuse.
(3) Remove the upper radiator hose clamp at the radiator. A special clamp tool must be used to remove the constant tension clamps. Removethe hose at the radiator.
(4) Unplug the wiring harness from the A/C com-
pressor.
(5) Remove the air cleaner assembly. (6) Remove the accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
(7) The drive belt idler pulley must be removed to gain access to one of the A/C compressor/generator bracket mounting bolts. Remove the idler pulley bolt and remove idler pulley (Fig. 53).
(8) Remove the engine oil dipstick tube mounting the A/C-generator mounting
the side of
bolt at bracket.
(9) Disconnect the throttle body control cables.
DR WATER PUMP INLET TUBE - 5.9L (Continued)
ENGINE
7 - 69
(12) Remove the remaining bracket-to-engine bolts
(Fig. 55).
Fig.53IdlerPulley-5.9LV-8GasEngine
(10) Remove the heater hose coolant return tube mounting bolt (Fig. 54) (Fig. 55) and remove the tube from the engine. Discard the old tube O-ring.
Fig.55BracketBolts-5.9LV-8Gas
1 - COOLANT TUBE MOUNTING BOLT 2 - BRACKET MOUNTING BOLTS
(13) Lift and position the generator and A/C com- pressor (along with their common mounting bracket) to gain access to the bypass hose. A block of wood may be used to hold the assembly in position.
(14) Loosen and position both hose clamps to the center of the bypass hose. A special clamp tool must be used to remove the constant tension clamps. Remove the hose from the vehicle.
REMOVAL - WATER PUMP BYPASS HOSE WITHOUT AIR CONDITIONING
A water pump bypass hose (Fig. 56)
is used between the intake manifold and water pump on all gas powered engines. To test for leaks, (Refer to 7 - COOLING - DIAGNOSIS AND TESTING).
(1) Partially drain the cooling system (Refer to 7 - COOLING - STANDARD PROCEDURE). Do not waste reusable coolant. If the solution is clean, drain the coolant into a clean container for reuse.
Fig.54CoolantReturn
1 - COOLANT RETURN TUBE 2 - WATER PUMP 3 - TUBE MOUNTING BOLT 4 - O-RING
(11) Remove the bracket-to-intake manifold bolts
(number 1 and 2 (Fig. 52).
WARNING: CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEM HOSES. WHEN REMOVING OR INSTALLING, USE ONLY TOOLS DESIGNED FOR SERVICING THIS TYPE OF CLAMP. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS.
ENGINE
7 - 70
WATER PUMP INLET TUBE - 5.9L (Continued)DR
Fig.56WaterPumpBypassHose-Typical
1 - WATER PUMP BYPASS HOSE 2 - FAN BLADE ASSEMBLY 3 - VISCOUS FAN DRIVE 4 - WATER PUMP AND PULLEY
CAUTION: A number or letter is stamped into the tongue of the constant tension clamps. If replace- ment is necessary, use only an original equipment clamp with a matching number or letter and width.
(2) Loosen both of the bypass hose clamps and
position them to the center of the hose. (3) Removethe hose from the vehicle.
INSTALLATION
INSTALLATION - WATER PUMP BYPASS HOSE WITH AIR CONDITIONING
(1) Position the bypass hose clamps to the center
of the bypass hose.
(2) Install the bypass hose to the engine. (3) Secure both of the hose clamps. (4) Install
the generator-A/C mounting bracket assembly to the engine. Tighten bolt number 1 (Fig. 53) to 41 N·m (30 ft. lbs.). Tighten bolt number 2
(Fig. 53) to 28 N·m (20 ft. lbs.). Tighten bracket mounting bolts (Fig. 53) (Fig. 53) to 40 N·m (30 ft. lbs.).(5) Install a new O-ring to the heater hose coolant return tube. Coat the new O-ring with antifreeze before installation.
(6) Install the coolant return tube and its mount-
ing bolt to the engine.
(7) Connect the throttle body control cables. (8) Install the oil dipstick mounting bolt. (9)
Install the idler pulley. Tighten the bolt to 41
N·m (30 ft. lbs.) (Fig. 57).
(10) Install the drive belt (Refer to 7 - COOLING/ ACCESSORY DRIVE/DRIVE BELTS - INSTALLA- TION).
Fig.57TensionerMounting
1 - DOWEL PIN HOLE 2 - TENSIONER MOUNTING BRACKET
CAUTION: When installing the serpentine accessory drive belt, the belt must be routed correctly. If not, the engine may overheat due to the water pump rotating in the wrong direction (Refer to 7 - COOL- ING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLA- TION). The correct belt with the correct length must be used.
(11) Install the air cleaner assembly. (12) Install the upper radiator hose to the radiator. (13) Connect the throttle cable to the clip at the
radiator fan shroud.
pressor.
(14) Connect the wiring harness to the A/C com-
(15) Fill the cooling system (Refer to 7 - COOLING
- STANDARD PROCEDURE).
(16) Start and warm the engine. Check for leaks.
INSTALLATION - WATER PUMP BYPASS HOSE WITHOUT AIR CONDITIONING
(1) Position the bypass hose clamps to the center
of the bypass hose.
(2) Install the bypass hose tothe engine. (3) Secure both of the hose clamps. (4) Fill the cooling system (Refer to 7 - COOLING
- STANDARD PROCEDURE).
(5) Start and warm the engine. Check for leaks.
WATER PUMP - 5.7L REMOVAL
(1) Disconnect negative battery cable. (2) Drain coolant. (3) Remove serpentine belt. (4) Remove fan clutch assembly. (5) Remove coolant fill bottle.
DR WATER PUMP - 5.7L (Continued)
(6) Disconnect washer bottle wiring and hose. (7) Remove fan shroud assembly. (8) Remove A/C compressor and genterator brace. (9) Remove idler pulleys. (10) Remove belt tensioner assembly. (11) Remove upper and lower radiator hoses. (12) Remove heater hoses. (13) Remove water pump mounting bolts and
remove pump.
ENGINE
7 - 71
INSTALLATION
(1) Install water pump and mounting bolts.
Tighten moubting bolts to 24 N·m (18 ft. lbs.).
(2) Install heater hoses. (3) Install upper and lower radiator hoses. (4) Install belt tensioner assembly. (5) Install idler pulleys. (6) Install A/C compressor and alternator brace.
Tighten bolt and nuts to 28 N·m (21 ft. lbs.).
(7) Install fan shroud assembly. (8) Connect washer bottle wiring and hose. (9) Install coolant fill bottle. (10) Install fan clutch assembly. (11) Install serpentine belt. (12) Connect negative battery cable. (13) Fill coolant. (14) Pressure test coolant system
7 - 72
TRANSMISSION
TRANSMISSION
TABLE OF CONTENTS
page
DR
page
TRANS COOLER DESCRIPTION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 72
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 72
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
DISASSEMBLY - 5.9L ONLY . . . . . . . . . . . . . . . 73
ASSEMBLY - 5.9L ONLY . . . . . . . . . . . . . . . . . . 73
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 73TRANS COOLER - 5.9L DIESEL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 73
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
REMOVALREMOVAL—AIR TO OIL COOLER . . . . . . . . . 74
REMOVAL—WATER TO OIL COOLER . . . . . . 74INSTALLATION
INSTALLATION—AIR TO OIL COOLER INSTALLATION
. . . . . 75
. . . . . . . . . . . . . . . . . . . . . . . 75TRANS COOLER
DESCRIPTION
DESCRIPTION
An air-to-oil transmission oil cooler is standard on all engine packages. The transmission oil cooler is mounted to the front of the radiator above the power steering cooler (Fig. 1).
DESCRIPTION
An air-to-oil transmission oil cooler is standard on all engine packages. The transmission oil cooler is mounted to the front of the radiator above the power steering cooler (Fig. 2).
OPERATION
to
the
returning
Transmission oil
is routed through the cooler where heat is removed from the transmission oil before transmission. Vehicles equipped with the 5.9L engine have an internal ther- mostat that controls fluid flow through the cooler- .When the transmission fluid is cold ( less than operating temperature) the fluid is routed through the cooler bypass. when the transmission fluid reaches operating temperatures and above, the ther- mostat closes off the bypass allowing fluid flow through the cooler. The thermostat is serviceable.
NOTE: Vehicles with the 3.7L/4.7L engines are not equipped with the oil cooler thermostat.
REMOVAL
(1) Disconnect the battery negative cable. (2) Place a drain pan under the oil cooler lines.
Fig.1CoolingModule—5.9LGas
1 - TRANS OIL COOLER BYPASS (5.9L only) 2 - OIL COOLER THERMOSTATIC BYPASS VALVE (5.9L only) 3 -TRANS OIL COOLER 4 - OIL COOLER MOUNTING BOLT (4) 5 - POWER STEERING COOLER 6 - POWER STEERING COOLER MOUNTING BOLT(2) 7 - TRANS OIL COOLER OUTLET 8 - TRANS OIL COOLER INLET 9 - COOLER LINE CLIP 10 - COOLER LINE CLIP 11 - RADIATOR
(3) Disconnect
the transmission oil cooler line quick-connect fitting at the cooler outlet using the quick connect release tool 6935. Plug the cooler lines to prevent oil leakage.
(4) Unsnap the transmission cooler tubes from the
radiator tank clips.
DR TRANS COOLER (Continued)
TRANSMISSION
7 - 73
Fig.3TransmissionOilCoolerThermostat
Removal/Installation
1 - THERMOSTAT HOUSING 2 - SPRING 3 - END PLUG 4 - SNAP RING 5 - THERMOSTAT
Fig.2CoolingModule-3.7L/4.7L/5.7L
1 - TRANS OIL COOLER 2 - TRANS OIL COOLER MOUNTING BOLT (3) 3 - POWER STEERING OIL COOLER 4 - POWER STEERING OIL COOLER MOUNTING BOLT 5 - TRANS OIL COOLER OUTLET 6 - TRANS OIL COOLER INLET 7 - COOLER LINE CLIP 8 - COOLER LINE CLIP 9 - RADIATOR
(5) Remove the bolts attaching the transmission
cooler to the radiator.
(6) Remove oil cooler from the vehicle. Take care not to damage the radiator core or transmission cooler tubes.
DISASSEMBLY - 5.9L ONLY
NOTE: The transmission oil cooler uses an internal thermostat to control transmission oil flow through the cooler. This thermostat is servicable.
(1) Remove the transmission oil cooler (Refer to 7 -
COOLING/TRANSMISSION/TRANS REMOVAL).
COOLER
(2) Remove the snap ring retaining the thermostat
end plug (Fig. 3).
(3) Remove the end plug, thermostat and spring
from transmission oil cooler (Fig. 3).
ASSEMBLY - 5.9L ONLY
(1) Throughly clean the thermostat bore on the
transmission oil cooler.
and snap ring.
(2) Install the new spring, thermostat, end plug
(3) Install the transmission oil cooler (Refer to 7 -
COOLING/TRANSMISSION/TRANS INSTALLATION).
COOLER
INSTALLATION
(1) Position the transmission cooler tubes to the
front of the radiator.
(2) Snap the transmission cooler tubes into the
clips on the side of the radiator tank.
(3) Install the transmission cooler attaching bolts.
Tighten the bolts to 16 N·m (140 in. lbs.).
(4) inspect the quick connect fittings for debris and install the quick connect fitting on the cooler tube until an audible “click” is heard. Pull apart the con- nection to verify proper installation and install the secondary latches.
(5) Connect the battery negative cable. (6) Start the engine and check all
fittings for
leaks.
(7) Check the fluid level in the automatic trans- mission. Refer to the appropriate transmission sec- tion(Refer to 21 - TRANSMISSION/TRANSAXLE/ AUTOMATIC - 45RFE/545RFE/FLUID - STANDARD PROCEDURE) or(Refer to 21 - TRANSMISSION/ TRANSAXLE/AUTOMATIC - 46RE/FLUID - STAN- DARD PROCEDURE).
TRANS COOLER - 5.9L DIESEL DESCRIPTION
All diesel models equipped with an automatic transmission are equipped with both a main water- to-oil cooler and a separate air-to-oil cooler. Both cool-
TRANSMISSION
7 - 74
TRANS COOLER - 5.9L DIESEL (Continued)DR
ers are supplied as standard equipment on diesel engine powered models when equipped with an auto- matic transmission.
The main water-to-oil transmission oil cooler is mounted to a bracket on the intake side of the engine (Fig. 4).
The air-to-oil cooler is located in front of and to the
left side of the radiator (Fig. 5).
Fig.5AuxiliaryTransmissionOilCooler—Diesel
Engine
1 - MOUNTING BOLTS 2 - RADIATOR 3 - QUICK-CONNECT FITTINGS 4 - TRANSMISSION OIL COOLER
Fig.4TransmissionWater-To-OilCooler—Diesel
Engine—Typical 1 - TRANSMISSION WATER-TO-OIL COOLER
OPERATION
thermostat
The transmission oil is routed through the main cooler first, then the auxiliary cooler where addi- tional heat is removed from the transmission oil before returning to the transmission. The cooler has an internal controls fluid flow through the cooler. When the transmission fluid is cold (less then operating temperature), the fluid is routed through the cooler bypass. When the trans- mission fluid reaches operating temperatures and above, the thermostat closes off the bypass allowing fluid flow through the cooler. The thermostat is ser- vicable.
that
REMOVAL
REMOVAL—AIR TO OIL COOLER
(1) Remove Charge Air Cooler (Refer to 11 - EXHAUST SYSTEM/TURBOCHARGER SYSTEM/ CHARGE AIR COOLER AND PLUMBING - REMOVAL).
(2) Place a drain pan under the oil cooler. (3) Raise the vehicle. (4) Disconnect the oil cooler quick-connect fittings
from the transmission lines.
(5) Remove the charge air cooler-to-oil cooler bolt
(Fig. 6).
(6) Remove two mounting nuts. (7) Remove the oil
cooler and line assembly towards the front of vehicle. Cooler must be rotated and tilted into position while removing.
REMOVAL—WATER TO OIL COOLER
CAUTION: If a leak should occur in the water-to-oil cooler mounted to the side of the engine block, engine coolant may become mixed with transmis- sion fluid. Transmission fluid may also enter engine cooling system. Both cooling system and transmis- sion should be drained and inspected in case of oil cooler leakage.
(1) Disconnect both battery negative cables. (2) Remove starter (Refer to 8 - ELECTRICAL/
STARTING/STARTER MOTOR - REMOVAL).
(3) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(4) Disconnect coolant lines from cooler.
DR TRANS COOLER - 5.9L DIESEL (Continued)
TRANSMISSION
7 - 75
Fig.6AuxiliaryTransmissionOilCooler—Diesel
Engine
Fig.7TransmissionWater-To-OilCooler—Diesel 1 - TRANSMISSION WATER-TO-OIL COOLER
1 - MOUNTING BOLTS 2 - RADIATOR 3 - QUICK-CONNECT FITTINGS 4 - TRANSMISSION OIL COOLER
(5) Disconnect transmission oil lines from cooler.
Plug cooler lines to prevent oil leakage.
(6) Remove cooler bracket to transmission bolt. (7) Remove two cooler bracket to cooler bolts. (8) Remove cooler assembly from vehicle. (Fig. 7)
INSTALLATION
INSTALLATION—AIR TO OIL COOLER
(1) Carefully position the oil cooler assembly to the
vehicle.
(2) Install two nuts and one bolt. Tighten to 11
N·m (95 in. lbs.) torque.
mission cooler lines.
(3) Connect the quick-connect fittings to the trans-
(4) Install Charge Air Cooler
to 11 - EXHAUST SYSTEM/TURBOCHARGER SYSTEM/ CHARGE AIR COOLER AND PLUMBING - INSTALLATION).
(Refer
(5) Start the engine and check all
fittings for
leaks.
(6) Check the fluid level in the automatic trans- mission (Refer to 21 - TRANSMISSION/TRANS- AXLE/AUTOMATIC - 47RE/FLUID - STANDARD PROCEDURE).
INSTALLATION
(1) Position oil cooler on cylinder block. (2) Install two mounting bolts to cooler at the cyl-
inder block. Torque bolts to 77N·m (57 ft. lbs.)
(3) Install cooler bracket to transmission adapter
bolt. Tighten to 24N·M (18 ft. lbs.).
(4) Connect transmission oil lines to cooler. (5) Connect coolant hoses to cooler. (6) Install starter motor (Refer to 8 - ELECTRI- INSTALLA-
CAL/STARTING/STARTER MOTOR - TION).
(7) Connect battery negative cables. (8) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(9) Check transmission oil level and fill as neces- sary (Refer to 21 - TRANSMISSION/TRANSAXLE/ AUTOMATIC STANDARD PROCEDURE).
47RE/FLUID -
DR
AUDIO
8A - 1
AUDIO
TABLE OF CONTENTS
page
page
AUDIO
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING - AUDIO . . . . . . . . . . 2AMPLIFIER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 4ANTENNA BODY & CABLE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DIAGNOSIS AND TESTING - ANTENNA BODYAND CABLE
. . . . . . . . . . . . . . . . . . . . . . . . . . 4
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6INSTRUMENT PANEL ANTENNA CABLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7RADIO
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
AUDIO DESCRIPTION
An audio system is standard factory-installed equipment on this model. Several combinations of radio receivers and speaker systems are offered. The audio system uses an ignition switched source of bat- tery current so that the system will only operate when the ignition switch is in the RUN or ACCES- SORY positions. The audio system includes the following compo- nents:† Antenna † Power amplifier (with premium speaker system only)† Radio noise suppression components † Radio receiver † Remote radio switches (if equipped) † Speakers Certain functions and features of the audio system rely upon resources shared with other electronic modules in the vehicle over the Programmable Com- munication Interface (PCI) bus network. The data bus network allows the sharing of sensor informa- tion. For diagnosis of these electronic modules or of the data bus network, the use of a DRB IIIt scan tool
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8RADIO NOISE SUPPRESSION GROUND STRAP
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10REMOTE SWITCHES
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
DIAGNOSIS AND TESTING - REMOTESWITCHES
. . . . . . . . . . . . . . . . . . . . . . . . . . 11
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12SPEAKER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 12
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DIAGNOSIS AND TESTING - SPEAKER . . . . . . 13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15and the proper Diagnostic Procedures manual are recommended.
Refer to the appropriate wiring information for complete standard and premium audio system circuit diagrams. The wiring information includes proper wire and connector repair procedures, further details on wire harness routing and retention, as well as pin-out and location views for the various wire har- ness connectors, splices, and grounds.
OPERATION
The audio system components are designed to pro- vide audio entertainment and information through the reception, tuning and amplification of locally broadcast radio signals in both the Amplitude Modu- lating (AM) and Frequency Modulating (FM) com- mercial frequency ranges.
The audio system components operate on battery current received through a fuse in the Integrated Power Module (IPM) on a fused ignition switch out- put (run-acc) circuit so that the system will only operate when the ignition switch is in the Run or Accessory positions.
On vehicles that are equipped with the optional remote Instrument Cluster receives hard wired resistor multiplexed inputs from the remote radio switches. The programming in the
switches,
radio
the
AUDIO
8A - 2
AUDIO (Continued)Instrument Cluster allows it to process those inputs and send the proper messages to the radio receiver over the Programmable Communication Interface (PCI) bus network to control the radio volume up or down, station seek up or down, preset station advance, and mode advance functions.
Refer to the owner’s manual for more information on the features, use and operation of each of the available audio systems.
DIAGNOSIS AND TESTING - AUDIO
Any diagnosis of the Audio system should begin with the use of the DRB IIIt diagnostic tool. For information on the use of the DRB IIIt, refer to the appropriate Diagnostic Service Manual.
Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire
DR
harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds.
WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- LATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYS- TEM CAPACITOR TO DISCHARGE BEFORE PER- FORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRE- CAUTIONS COULD RESULT IN ACCIDENTAL AIR- BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
AUDIO SYSTEM DIAGNOSIS TABLE
CONDITION
POSSIBLE CAUSES
CORRECTION
NO AUDIO
1. Fuse faulty.
NO RADIO DISPLAY
2. Radio/amplifier (if equipped) connector faulty. 3. Wiring faulty.
4. Radio/amplifier (if equipped) ground faulty.
5. Radio/amplifier (if equipped) faulty. 6. Speakers faulty. 1. Fuse faulty.
2. Radio connector faulty.
3. Wiring faulty.
4. Radio ground faulty.
5. Radio faulty.
1. Check radio fuse and Ignition-Off Draw (IOD) fuse in the Integrated Power Module (IPM). Replace fuses, if required. 2. Check for loose or corroded radio/amplifier connector. Repair, if required. 3. Check for shorted or open wires. Repair wiring, if required. 4. Check for continuity between radio chassis and a known good ground. There should be continuity. Repair ground, if required. 5. Refer to appropriate Diagnostic Service Manual. 6. Replace speaker as necessary. 1. Check radio fuse and Ignition-Off Draw (IOD) fuse in Integrated Power Module (IPM). Replace fuses, if required. 2. Check for loose or corroded radio connector. Repair, if required. 3. Check for battery voltage at radio connector. Repair wiring, if required. 4. Check for continuity between radio chassis and a known good ground. There should be continuity. Repair ground, if required. 5. Refer to appropriate Diagnostic Service Manual.
DR AUDIO (Continued)
AUDIO
8A - 3
CONDITION
POSSIBLE CAUSES
CORRECTION
CLOCK WILL NOT KEEP SET TIME
1. Fuse faulty.
2. Radio connector faulty.
3. Wiring faulty.
4. Radio ground faulty.
5. Radio faulty.
POOR RADIO RECEPTION
1. Antenna faulty.
NO/POOR TAPE OPERATION
NO COMPACT DISC OPERATION
2. Radio ground faulty.
3. Radio noise suppression faulty. 4. Radio faulty.
1. Faulty tape. 2. Foreign objects behind tape door. 3. Dirty cassette tape head.
4. Faulty tape deck. 1. Faulty CD. 2. Foreign material on CD. 3. Condensation on CD or optics. 4. Faulty CD player.
1. Check Ignition-Off Draw (IOD) fuse in the Integrated Power Module (IPM). Replace fuse, if required. 2. Check for loose or corroded radio connector. Repair, if required. 3. Check for battery voltage at radio connector. Repair wiring, if required. 4. Check for continuity between radio chassis and a known good ground. There should be continuity. Repair ground, if required. 5. Refer to appropriate Diagnostic Service Manual. 1. (Refer to 8 - ELECTRICAL/AUDIO/ANTENNA BODY & CABLE - DIAGNOSIS AND TESTING). 2. Check for continuity between radio chassis and a known good ground. There should be continuity. Repair ground, if required. 3. Repair or replace ground strap as necessary.
4. Refer to appropriate Diagnostic Service Manual. 1. Insert known good tape and test operation. 2. Remove foreign objects and test operation.
3. Clean head with Mopar Cassette Head Cleaner. 4. Exchange or replace radio, if required. 1. Insert known good CD and test operation. 2. Clean CD and test operation. 3. Allow temperature of vehicle interior to stabilize and test operation. 4. Refer to appropriate Diagnostic Service Manual.
AMPLIFIER DESCRIPTION
The optional Infinity premium speaker system includes a separate Infinity audio power amplifier. The amplifier is a six channel unit and is rated at 240 total output watts. The amplifier is located behind the glove box.
OPERATION
The power amplifier electronically increases the frequency response of the normal audio signal output from the radio amplifier in order to improve the acoustic performance of the speakers. On vehicles
equipped with an amplifier, the amplifier section of the radio becomes a pre-amplifier.
The amplifier receives audio signal
inputs for speaker channels from the radio, then sends ampli- fied audio outputs through six separate channels with dedicated feed and return circuits to the indi- vidual speakers.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove glove box (Refer to 23 - BODY/IN-
STRUMENT PANEL/GLOVE BOX - REMOVAL).
AUDIO
8A - 4
AMPLIFIER (Continued)(3) Remove instrument panel center bezel (Refer to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT PANEL CENTER BEZEL - REMOVAL).
(4) Remove instrument panel
lower right center bezel (Refer to 23 - BODY/INSTRUMENT PANEL/IP LOWER RIGHT CENTER BEZEL - REMOVAL).
(5) Disconnect electrical harness connector from
amplifier (Fig. 1).
Fig.1AMPLIFIERMOUNTING
1 - INSTRUMENT PANEL 2 - AMPLIFIER 3 - MOUNTING BOLTS 4 - ELECTRICAL CONNECTOR
(6) Remove mounting bolts.
INSTALLATION
(1) Connect
electrical harness
connector
and
(2) Install mounting bolts. Tighten to 10 N·m (90
install amplifier.
in. lbs.).
(3) Install
instrument panel
lower right center bezel (Refer to 23 - BODY/INSTRUMENT PANEL/IP LOWER RIGHT CENTER BEZEL - INSTALLA- TION).
(4) Install instrument panel center bezel (Refer to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT PANEL CENTER BEZEL - INSTALLATION).
(5) Install glove box (Refer to 23 - BODY/INSTRU-
MENT PANEL/GLOVE BOX - INSTALLATION).
(6) Connect battery negative cable.
ANTENNA BODY & CABLE DESCRIPTION
The antenna body and cable is secured below the fender panel by the antenna cap nut through a mounting hole in the right front fender. The primary coaxial antenna cable is then routed beneath the fender sheet metal and through a entry hole in the
DR
right cowl side panel into the interior of the vehicle. Inside the vehicle, the primary coaxial cable is con- nected to a secondary instrument panel antenna coaxial cable with an in-line connector that is located behind the right kick panel. The secondary coaxial cable is then routed behind the instrument panel to the back of the radio.
OPERATION
by
are
that
signals
broadcast
The antenna body and cable connects the antenna mast to the radio. The radio antenna is an electro- magnetic circuit component used to capture radio fre- quency local commercial radio stations in both the Amplitude Modulating (AM) and Frequency Modulating (FM) frequency ranges. These electromagnetic radio fre- quency signals induce small electrical modulations into the antenna as they move past the mast. The antenna body transfers the weak electromagnetic radio waves induced into the rigid antenna mast into the center conductor of the flexible primary antenna coaxial the antenna coaxial cable is grounded through both the antenna body and the radio chassis, effectively shielding the radio waves as they are conducted to the radio. The radio then tunes and amplifies the weak radio signals into stronger electrical signals in order to operate the audio system speakers.
cable. The braided outer shield of
DIAGNOSIS AND TESTING - ANTENNA BODY AND CABLE
antenna with an ohmmeter:
The following four tests are used to diagnose the † Test 1 - Mast to ground test † Test 2 - Tip-of-mast to tip-of-conductor test † Test 3 - Body ground to battery ground test † Test 4 - Body ground to antenna coaxial cable
shield test.
WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- LATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYS- TEM CAPACITOR TO DISCHARGE BEFORE PER- FORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRE- CAUTIONS COULD RESULT IN ACCIDENTAL AIR- BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
The ohmmeter test lead connections for each test
are shown in the illustration (Fig. 2).
DR ANTENNA BODY & CABLE (Continued)
the primary antenna cable (integral
NOTE: This model has a two-piece antenna coaxial cable. Tests 2 and 4 must be conducted in two steps to isolate an antenna cable problem. First, test to the antenna body and cable) from the coaxial cable connector behind the right side kick panel to the antenna body. Then, test the secondary antenna cable (instrument panel antenna cable) from the coaxial cable connector behind the right side kick panel to the coaxial cable connector at the radio.
Fig.2AntennaTests-Typical
TEST 1
Test 1 determines if the antenna mast is insulated
from ground. Proceed as follows:
(1) Disconnect and isolate the antenna coaxial
cable connector behind the right side kick panel.
(2) Touch one ohmmeter test lead to the tip of the antenna mast. Touch the other test lead to known ground. Check the ohmmeter reading for continuity. (3) There should be no continuity. If OK, go to Test 2. If not OK, replace the faulty antenna body and cable.
TEST 2
Test 2 checks the antenna conductor components for an open circuit. This test should be performed first on the entire antenna circuit, from the antenna mast to the center conductor of the coaxial cable con- nector at the radio. If an open circuit is detected, each of the three antenna conductor components (antenna mast, antenna body and cable, instrument panel antenna cable) should be isolated and tested individually to locate the exact component that is the source of the open circuit. To begin this test, proceed as follows:
AUDIO
8A - 5
(1) Disconnect the instrument panel antenna cable
coaxial connector from the back of the radio.
(2) Touch one ohmmeter test lead to the tip of the antenna mast. Touch the other test lead to the center conductor pin of the instrument panel antenna cable coaxial connector for the radio. Check the ohmmeter reading for continuity.
(3) There should be continuity. The ohmmeter should register only a fraction of an ohm resistance. High or infinite resistance indicates a damaged or open antenna conductor. If OK, go to Test 3. If not OK, isolate and test each of the individual antenna conductor faulty antenna conductor component.
components. Replace
only the
TEST 3
Test 3 checks the condition of the vehicle body ground connection. To begin this test, proceed as fol- lows:
(1) This test must be performed with the battery positive cable disconnected from the battery. Discon- nect and isolate both battery cables, negative cable first.
(2) Reconnect the battery negative cable. (3) Touch one ohmmeter test lead to a good clean ground point on the vehicle fender. Touch the other test lead to the battery negative terminal post. Check the ohmmeter reading for continuity.
(4) There should be continuity. The ohmmeter should register less than one ohm resistance. High or infinite resistance indicates a loose, corroded, or damaged connection between the battery negative terminal and the vehicle body. If OK, go to Test 4. If not OK, check the battery negative cable connection to the vehicle body and the radio noise suppression ground strap connections to the engine and the vehi- cle body for being loose or corroded. Clean or tighten these connections as required.
TEST 4
Test 4 checks the condition of
the connection between the antenna coaxial cable shield and the vehicle body ground as follows:
(1) Disconnect and isolate the antenna coaxial
cable connector behind the right side kick panel.
(2) Touch one ohmmeter test lead to a good clean ground point on the vehicle fender. Touch the other test lead to the outer crimp on the antenna coaxial cable connector. Check the ohmmeter reading for con- tinuity.
(3) There should be continuity. The ohmmeter should register less than one ohm resistance. High or infinite resistance indicates a loose, corroded, or damaged connection between the antenna body and the vehicle body or between the antenna body and the antenna coaxial cable shield. If not OK, clean the
AUDIO
8A - 6
ANTENNA BODY & CABLE (Continued)antenna body to fender mating surfaces and tighten the antenna cap nut to specifications.
(4) Check the resistance again with an ohmmeter. If the resistance is still more then one ohm, replace the faulty antenna body and cable.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the right side kick panel. (3) Disconnect antenna body cable from instru-
ment panel cable.
(4) Securely tie a suitable length of cord or twine to the antenna half of the coaxial cable connector. This cord will be used to pull the cable back into position during installation.
(5) Remove the antenna mast. (6) Remove the antenna cap nut using an antenna
nut wrench (Special Tool C-4816) (Fig. 3).
DR
(6) Install the antenna cap nut. Tighten to 7 N·m
(65 in. lbs.).
(7) Install the antenna mast. (8) Connect the battery negative cable.
INSTRUMENT PANEL ANTENNA CABLE REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the glove box (Refer to 23 - BODY/IN-
STRUMENT PANEL/GLOVE BOX - REMOVAL).
(3) Remove the instrument panel center bezel (Refer to 23 - BODY/INSTRUMENT PANEL/IN- STRUMENT PANEL CENTER BEZEL - REMOVAL). (4) Remove the instrument panel lower right cen- ter bezel (Refer to 23 - BODY/INSTRUMENT PAN- EL/IP REMOVAL).
LOWER RIGHT CENTER BEZEL
(5) Remove the radio (Refer to 8 - ELECTRICAL/
AUDIO/RADIO - REMOVAL).
CAUTION: Pulling the antenna cable straight out of the radio without pulling on the locking antenna connector could damage the cable or radio.
(6) Disconnect the antenna cable by pulling the locking antenna connector away from the radio (Fig. 4)
Fig.4ANTENNATORADIO
1 - RADIO 2 - LOCKING ANTENNA CONNECTOR 3 - INSTRUMENT PANEL ANTENNA CABLE
(7) Remove antenna cable from instrument panel
by pulling on retaining fasteners (Fig. 5).
Fig.3ANTENNABODYANDCABLE
1 - NUT 2 - FENDER 3 - ANTENNA BODY AND CABLE 4 - ADAPTER
(7) Remove the antenna adapter. (8) With the right door open, pull the antenna body assembly out through the opening between the fender and body.
INSTALLATION
(1) Tie the cord that was used during the removal
procedure to the cable being installed.
(2) Using the cord, pull the antenna cable through the hole in the door opening and seat grommet into place.
(3) Connect the antenna body and cable to the
instrument panel cable.
(4) Install the right side kick panel. (5) Insert the antenna body through the hole in
the fender and install adapter.
DR INSTRUMENT PANEL ANTENNA CABLE (Continued)
AUDIO
8A - 7
(PCI) data bus network. All factory-installed receiv- ers are stereo Electronically Tuned Radios (ETR) and include an electronic digital clock function.
These radio receivers can only be serviced by an authorized radio repair station. See the latest War- ranty Policies and Procedures manual for a current listing of authorized radio repair stations.
OPERATION
The radio receiver operates on ignition switched battery current that is available only when the igni- tion switch is in the On or Accessory positions. The electronic digital clock function of the radio operates on fused battery current supplied through the IOD fuse, regardless of the ignition switch position.
For more information on the features, setting pro- cedures, and control functions for each of the avail- able factory-installed radio receivers, refer to the owner’s manual.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove center instrument panel bezel (Refer to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT PANEL CENTER BEZEL - REMOVAL).
(3) Remove radio mounting screws (Fig. 6).
Fig.5INSTRUMENTPANELANTENNACABLE
1 - INSTRUMENT PANEL ANTENNA CABLE 2 - ANTENNA BODY AND CABLE
INSTALLATION
(1) Install antenna cable to instrument panel by
pressing retaining fasteners into position.
(2) Connect instrument panel antenna cable to
antenna body and cable.
(3) Install radio (Refer to 8 - ELECTRICAL/AU-
DIO/RADIO - INSTALLATION).
(4) Install the instrument panel lower right center bezel (Refer to 23 - BODY/INSTRUMENT PANEL/IP LOWER RIGHT CENTER BEZEL - INSTALLA- TION).
(5) Install the instrument panel center bezel (Refer to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT PANEL CENTER BEZEL - INSTALLATION).
(6) Install the glove box (Refer to 23 - BODY/IN- INSTALLA-
STRUMENT PANEL/GLOVE BOX - TION).
(7) Connect the battery negative cable.
RADIO DESCRIPTION
model include:
ture (RBB sales code)
Available factory-installed radio receivers for this † AM/FM/cassette with CD changer control fea- † AM/FM/cassette/CD/graphic equalizer with CD † AM/FM/CD with CD changer control feature (RBK sales code) † AM/FM/CD with 6 CD changer (RBQ sales code) † AM/FM/cassette/CD (RBY sales code) - export only
changer control feature (RAZ sales code)
All factory-installed radio receivers can communi- cate on the Programmable Communications Interface
Fig.6RADIO
(4) Disconnect electrical harness connector.
CAUTION: Pulling the antenna cable straight out of the radio without pulling on the locking antenna connector could damage the cable or radio.
(5) Disconnect the antenna cable by pulling the locking antenna connector away from the radio (Fig. 7)
AUDIO
8A - 8
RADIO (Continued)Fig.7ANTENNATORADIO
1 - RADIO 2 - LOCKING ANTENNA CONNECTOR 3 - INSTRUMENT PANEL ANTENNA CABLE
INSTALLATION
(1) Install antenna cable to radio. (2) Connect electrical harness connector to radio. (3) Install radio to instrument panel. (4) Install instrument panel center bezel (Refer to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT PANEL CENTER BEZEL - INSTALLATION).
(5) Connect battery negative cable.
RADIO NOISE SUPPRESSION GROUND STRAP DESCRIPTION
Radio noise suppression devices are factory-in- stalled standard equipment on this vehicle. Radio Frequency Interference (RFI) and ElectroMagnetic Interference (EMI) can be produced by any on-board or external source of electromagnetic energy. These electromagnetic energy sources can radiate electro- magnetic signals through the air, or conduct them through the vehicle electrical system.
When the audio system converts RFI or EMI to an audible acoustic wave form, it is referred to as radio noise. This undesirable radio noise is generally man- ifested in the form of “buzzing,” “hissing,” “popping,” “clicking,” “crackling,” and/or “whirring” sounds. In most cases, RFI and EMI radio noise can be sup- pressed using a combination of vehicle and compo- nent grounding, filtering and shielding techniques. This vehicle is equipped with factory-installed radio noise suppression devices that were designed to min- imize exposure to typical sources of RFI and EMI; thereby, minimizing radio noise complaints.
DR
Factory-installed radio noise suppression is accom- plished primarily through circuitry or devices that are integral to the factory-installed radios, audio power amplifiers and other on-board electrical com- ponents such as generators, wiper motors, blower motors, and fuel pumps that have been found to be potential sources of RFI or EMI. External radio noise suppression devices that are used on this vehicle to control RFI or EMI, and can be serviced, include the following: † Engine-to-body ground strap - This length of braided ground strap has an eyelet terminal connec- tor crimped to each end. One end is secured to the engine cylinder head(s). The other is secured to the plenum at the exhaust heat shield forward/outer attaching stud. † Resistor-type spark plugs - This type of spark plug has an internal resistor connected in series between the spark plug terminal and the center elec- trode to help reduce the production of electromag- netic radiation that can result in radio noise.
OPERATION
There are two common strategies that can be used to suppress Radio Frequency Interference (RFI) and ElectroMagnetic Interference (EMI) radio noise. The first suppression strategy involves preventing the production of RFI and EMI electromagnetic signals at their sources. The second suppression strategy involves preventing the reception of RFI and EMI electromagnetic signals by the audio system compo- nents.
The use of braided ground straps in key locations is part of the RFI and EMI prevention strategy. These ground straps ensure adequate ground paths, particularly for high current components such as many of those found in the starting, charging, igni- tion, engine control and transmission control sys- tems. An insufficient ground path for any of these high current components may result in radio noise caused by induced voltages created as the high cur- rent seeks alternative ground paths through compo- nents or circuits intended for use by, or in close proximity to the audio system components or circuits. Preventing the reception of RFI and EMI is accom- plished by ensuring that the audio system compo- nents are correctly installed in the vehicle. Loose, corroded or improperly soldered wire harness connec- tions, improperly routed wiring and inadequate audio system component grounding can all contribute to the reception of RFI and EMI. A properly grounded antenna body and radio chassis, as well as a shielded antenna coaxial cable with clean and tight connec- tions will each help reduce the potential for reception of RFI and EMI.
DR RADIO NOISE SUPPRESSION GROUND STRAP (Continued) REMOVAL
BED TO CAB
AUDIO
8A - 9
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the attaching bolts and strap (Fig. 8).
Fig.10GROUNDSTRAPTOHEATSHIELD
1 - STUD 2 - GROUND STRAP 3 - NUT
ENGINE TO HEAT SHIELD - 4.7L AND 5.7L ENGINE (1) Disconnect and isolate the battery negative
(2) Remove the attaching bolts from the cylinder
cable.
heads (Fig. 11).
Fig.8BEDTOCABGROUNDSTRAP
1 - BED 2 - CAB 3 - GROUND STRAP 4 - MOUNTING BOLTS
ENGINE TO HEAT SHIELD - 3.7L ENGINE
(1) Disconnect and isolate the battery negative
(2) Remove the attaching bolts from the cylinder
cable.
heads (Fig. 9).
Fig.9ENGINEGROUNDSTRAP-3.7L
1 - GROUND STRAP 2 - MOUNTING BOLTS
(3) Remove nut from heat shield and remove strap
(Fig. 10).
Fig.11ENGINEGROUNDSTRAP-4.7LAND5.7L 1 - GROUND STRAP 2 - MOUNTING BOLTS
(3) Remove nut from heat shield and remove strap
(Fig. 10).
ENGINE TO HEAT SHIELD - 5.9L AND 8.0L ENGINE (1) Disconnect and isolate the battery negative
cable.
heads (Fig. 12).
(Fig. 10).
(2) Remove the attaching bolts from the cylinder
(3) Remove nut from heat shield and remove strap
AUDIO
8A - 10
RADIO NOISE SUPPRESSION GROUND STRAP (Continued)DR
Fig.12ENGINEGROUNDSTRAP-5.9L(8.0L
SIMILAR)
1 - GROUND STRAP 2 - MOUNTING BOLTS
INSTALLATION
BED TO CAB
(1) Install the ground strap and retaining bolts.
Tighten to 5 N·m (45 in. lbs.).
(2) Connect the battery negative cable.
ENGINE TO HEAT SHIELD
(1) Install the retaining nut and ground strap to
the plenum. Tighten to 8 N·m (70 in. lbs.).
(2) Install the retaining bolt and ground strap to the engine cylinder heads. Tighten to 12 N·m (106 in. lbs.).
(3) Connect the battery negative cable.
REMOTE SWITCHES DESCRIPTION
A remote radio control switch option is available on some models. Two rocker-type switches are mounted on the back (instrument panel side) of the steering wheel spokes (Fig. 13). The switch on the left spoke is the seek switch and has seek up, seek down, and preset station advance functions. The switch on the right spoke is the volume control switch and has vol- ume up, and volume down functions. The switch on the right spoke also includes a “mode” control that allows the driver to sequentially select AM radio, FM radio, cassette player, CD player or CD changer (if equipped).
Fig.13RemoteRadioSwitchOperationalView
1 - PRESET SEEK 2 - SEEK UP 3 - VOLUME UP 4 - MODE 5 - VOLUME DOWN 6 - SEEK DOWN
OPERATION
open,
are normally
The six switches in the two remote radio switch resistor multiplexed units momentary switches that are hard wired to the Inte- grated Power Module (IPM) through the clockspring. The IPM sends a five volt reference signal to both switch units on one circuit, and senses the status of all of the switches by reading the voltage drop on a second circuit.
When the IPM senses an input (voltage drop) from any one of the remote radio switches, it sends the proper switch status messages on the Programmable Communication Interface (PCI) data bus network to the radio receiver. The electronic circuitry within the radio receiver is programmed to respond to these remote radio switch status messages by adjusting the radio settings as requested. For diagnosis of the IPM or the PCI data bus, the use of a DRB IIIt scan tool and the proper Diagnostic Procedures manual are recommended.
For more information on the features and control functions for each of the remote radio switches, refer to the owner’s manual.
DR REMOTE SWITCHES (Continued) DIAGNOSIS AND TESTING - REMOTE SWITCHES
Any diagnosis of the Audio system should begin with the use of the DRB IIIt diagnostic tool. For information on the use of the DRB IIIt, refer to the appropriate Diagnostic Service Manual.
For complete circuit diagrams, refer to the appro- priate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connec- tors, splices and grounds.
WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- LATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYS- TEM CAPACITOR TO DISCHARGE BEFORE PER- FORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRE- CAUTIONS COULD RESULT IN ACCIDENTAL AIR- BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
(1) Disconnect and isolate the battery negative cable. Remove the remote radio switch(es) (Fig. 14) from the steering wheel (Refer to 8 - ELECTRICAL/ AUDIO/REMOTE SWITCHES - REMOVAL).
Fig.14RemoteRadioSwitches
1 - BLACK (LEFT) SWITCH 2 - WHITE (RIGHT) SWITCH
AUDIO
8A - 11
(2) Use an ohmmeter to check the switch resis- tances as shown in the Remote Radio Switch Test chart. If the remote radio switch resistances check OK, go to Step 3. If not OK, replace the faulty switch.
REMOTE RADIO SWITCH TEST TABLE
Switch Right (White) Right (White) Right (White)
Left
(Black)
Left
(Black)
Left
(Black)
Switch Position
